Comparative Study for DC-DC Converter Output Bank’s Reliability Evaluation Using Prediction Standards MIL-HDBK-217F vs. Telcordia SR-332

In the last decade, a higher level of reliability has become a compulsory demand when it comes to modern DC-DC converters. This work addresses the main reliability metrics: in many studies, the failure rate λ and MTBF of an output capacitor bank used within a high-current low-voltage buck converter have shown that the output capacitor bank is the most critical component within the converter. Many authors dealt with this issue by performing reliability predictions. The majority of studies use only one specific standard prediction to solve the problem. Herein, the calculation was performed using both the older standard, MIL-HDBK-217, and the latest one, Telcordia SR-332, providing a benchmark comparison between the two, which is a helpful tool for output capacitor selection in early-stage design. The military standard was well accepted for decades in reliability prediction, even in industrial electronics, and is still used today in a critical manner because there have been no more updates after the latest version, MIL-HDBK-217F—Notice 2, was released in 1995. Since then, newer prediction standards have appeared in the electronics reliability market. Over time, this standard was mostly used, but it does not accurately model the reliability because of a lack of taking account of the mission profile. The above-mentioned newer standard—i.e., Telcordia SR-332—also tries to compensate for the lack of the newest component technology in the older standard (which is the first standard released on the market), supplying useful design data for design engineers who use the so-called “design with reliability in mind” concept. This provides the designer of DC-DC converters with a comparison between the reliability values when the two mentioned standards are used. This paper establishes the environmental condition for the passive components by means of a point of load (PoL) buck converter that is used for both calculation methods. The influence of temperature and several specific concepts, like reference conditions, operating conditions, ripple, and internal self-heating, were taken into account in order to display the results. The temperature for the capacitor’s capsule needed in π T stress factor calculation was derived using PSPICE simulation. High-fidelity and dedicated SPICE models provided by the manufacturer were used for MOSFETs, polymer electrolytic, and MLCC capacitors that comprise the converter.