QUALITY ASSURANCE FOR SOURCED POWER MODULES Identify Hidden Quality Risks in Framed Power Modules at an Early Stage
Purchased Framed Power Modules may appear inconspicuous while still containing hidden manufacturing weaknesses. Targeted sample testing helps identify quality risks at an early stage, reduce uncertainty in supplier and module selection, and make more confident decisions when qualifying new modules, changes, or suppliers.
Hidden Quality Risks When Quality Issues Are Identified Too Late
Manufacturing-related weaknesses are not always visible or detectable through electrical testing. Standard tests also provide only limited insight into coating reliability. Critical defects may therefore remain undetected and only become apparent under humidity and high electrical stress.
At the same time, comparing the robustness of different module types or identifying changes in supplier quality at an early stage can be challenging.
The later quality issues are identified, the greater the business impact. Additional testing and approval cycles can delay releases, quarantined batches can disrupt supply, and production interruptions can affect output and delivery performance. Field failures may lead to warranty costs, customer complaints, or even recalls. Early identification therefore helps reduce operational risk, avoid avoidable cost, and support more reliable sourcing and release decisions.
The key is to identify quality risks early, before they lead to additional qualification effort, delayed release decisions, supply disruptions, or costly field failures.
Typical Failure ModesWhen Latent Defects in Power Modules Lead to Failure
These examples show how latent defects can compromise the reliability of power modules. Drawing on experience from more than 800 customer cases, we can assess anomalies in context, investigate critical root causes in greater depth, and define appropriate next steps.
Targeted Quality Assessment Revealing Hidden Defects with the CoRe Test
ZESTRON performs manufacturer-independent sample testing of selected Framed Power Modules using the Coating Reliability Test (CoRe Test) in accordance with IEC PAS 61191-10.
The modules are exposed to defined humidity and high-voltage stress. This can reveal defects that may remain undetected during standard testing.
At the same time, the CoRe Test allows the robustness of different modules to be assessed under comparable conditions. This makes it possible to identify differences between module types, suppliers, or batches.
The test itself takes around one hour, making the CoRe Test a fast and cost-effective method for quality assessment. It provides an early basis for deciding whether more extensive long-term testing is required.
Assessment From Test Results to Actionable Recommendations
Our service does not end with the CoRe Test. ZESTRON evaluates the results and interprets them in the context of the specific technical question.
No relevant anomalies identified in the sample?
The result provides an additional basis for the next quality decision.
Potential defects identified?
ZESTRON investigates the findings in greater detail, assesses their relevance, and recommends further action where appropriate.
Your Benefits More Confidence in the Quality of Sourced Power Modules
The CoRe Test provides a fast, reliable basis for assessing the quality of sourced Framed Power Modules and taking targeted action when anomalies are identified.
✓ Assess Quality Risks Earlier
Targeted sample testing helps identify hidden defects early, giving you more confidence in quality decisions and allowing you to take action before issues lead to additional testing, release delays, or field failures.
✓ Reduce Testing Effort and Costs
The short test duration provides a fast initial assessment, helping you avoid unnecessary long-term testing and the associated costs. More extensive testing can then be focused only on cases where further clarification is genuinely required.
✓ Select Modules and Suppliers Based on Better Evidence
Unterschiede in der Robustheit werden aufgezeigt. Das erleichtert die Vergleichbarkeit neuer Modultypen, Lieferanten und Second Sources.
✓ Detect Changes in Quality Early
Regular sample testing reveals changes in robustness between batches and provides a reliable basis for deciding whether supplier quality remains stable or further action is required.
✓ Make Faster, More Informed Business Decisions
ZESTRON evaluates the results and recommends appropriate next steps, helping you move more quickly from technical findings to confident business decisions.
Quality Assurance with the CoRe Test Make More Informed Decisions on Sourced Framed Power Modules
Quality issues in sourced power modules can significantly affect testing effort, procurement, production, and field reliability.
Targeted CoRe sample testing provides early insight into module robustness. ZESTRON evaluates the results and helps you determine whether action is required and which next steps are appropriate.