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Very fast.
Six-Step Troubleshooting
(technique used by the US Navy)
1.
2.
3.
4.
5.
6.
Symptom recognition
Symptom elaboration
Listing of probable faulty functions
Localizing the faulty function
Localizing trouble to the circuit
Failure analysis
Step #3:
Listing probable faulty functions
Step #4:
Localizing the faulty functions
Consider:
Most likely faulty functional area,
Ease of testing the functional area,
Suggestions in technical manual servicing
block diagrams, if available.
Use as reference:
Technical manual,
Known good device for comparison,
Engineering educated guess.
Step #5:
Localizing trouble to the circuit
BAD
NOT
LIT
ALSO
BAD
BAD
Step #3:
Listing of probable faulty functions
The problem is in the power supply.
For this simple example, that is the answer for Step #3.
THE PROBLEM
IS SOMEWHERE
IN THE POWER
SUPPLY
Step #4:
Localizing the faulty function
The problem is in the power supply.
For this simple example, that is also the answer for Step #4.
No additional module-level testing is required.
THE PROBLEM
IS SOMEWHERE
IN THE POWER
SUPPLY
Step #5:
Localizing trouble to the circuit
Problem most likely to left of transformer (primary side).
Ohmmeter testing confirmed this assumption. Switch SW1 was
found to be miswired.
NOT
LIT
BAD
TINY WIRE
BROKEN
Problem:
NI-DAQ & LabVIEW showed constant
+12 VDC out from this system, but should
have been 0-12 VDC proportional to load.
0-300 LB
FORCE
LOAD
CELL
OP
AMP
NI-DAQ
(DATA
ACQUISITION
UNIT)
PC RUNNING
NI LABVIEW
Solution approach:
Isolate and test one small subcircuit
at a time, beginning with the area of
most uncertainty. Since op amp was an
unproven design in this system, it was
tested first.
FUNCTION
GENERATOR:
20 mV SINE
WAVES
OP
AMP
OSCILLOSCOPE
LOAD
CELL
OP
AMP
OSCILLOSCOPE
0-300 LB
FORCE
LOAD
CELL
+/- 12 V
POWER
SUPPLY
OP
AMP
OSCILLOSCOPE
0-300 LB
FORCE
+/- 12 V
POWER
SUPPLY
10 VDC
POWER
SUPPLY
LOAD
CELL
OP
AMP
NI-DAQ
(DATA
ACQUISITION
UNIT)
PC RUNNING
NI LABVIEW
Lessons learned:
If a system does not work, test each subcircuit
thoroughly.
It is better to test each subcircuit or module
before building an entire system, and then
integrate them into the whole.
Read, understand, and trust the manufacturers
data sheets.
Lessons here:
Spring-type electrical contacts are a likely
source of intermittent problems.
Bad solder joints are also a common cause of
intermittent problems, although not the culprit
in this example.
Lessons learned:
Part-swapping with a known good unit can
save time and effort.
Careful visual inspection at the start of
troubleshooting can also save time.
Solution approach:
First, cut open the electronic toothbrush
because the base simply a charging coil
was found to be good by testing with a
known good toothbrush.
In closing,
Some General Troubleshooting Tips
Questions?