Índice de contenidos
What was the challenge or problem to be solved?
In industrial environments where electrical systems operate under demanding conditions, exposure to high temperatures can significantly compromise the integrity of components. In particular, electrical cables and electronic controllers are critical elements whose degradation can lead to functional failures, service interruptions or even safety risks.
In this context, the need arose to address a recurring problem associated with premature failures in electrical systems subjected to severe thermal conditions. These failures not only affected system performance, but also created uncertainty regarding the durability of the materials used and the suitability of the design under real operating conditions.
Electrical cable failure analysis under thermal stress in industrial environments
The problem was observed in systems where electrical cables were exposed to temperatures higher than those expected under nominal conditions. This situation is common in applications with nearby heat sources, repeated thermal cycles or environments with limited ventilation.
The occurrence of failures in these cables created a clear need to understand whether the root cause was related to insulation material, system design or operating conditions. In this context, electrical cable failure analysis was considered a key tool to identify deviations between expected and actual performance.
Uncontrolled thermal exposure can generate latent failures that remain undetected until advanced stages of the system lifecycle, increasing operational risk, which is why early analysis allows degradation to be anticipated before it leads to critical failures.
The objective was not only to detect the failure, but to understand its origin and evolution in order to anticipate similar issues in other applications. This enabled the client to reduce operational risks and improve the overall reliability of their electrical systems.
Additionally, it was necessary to evaluate the interaction between the different factors that could be contributing to the failure, including the combination of temperature, electrical load and environmental conditions. This approach made it possible to address the problem from a systemic perspective, avoiding partial analyses that could lead to incomplete conclusions.
Failure mechanisms in cables exposed to high temperatures and thermal ageing of insulation
The effect of temperature on electrical materials is one of the most critical factors in their long-term behaviour. In this case, continuous exposure to high temperatures could lead to phenomena such as accelerated insulation ageing, loss of mechanical properties or changes in conductivity.
These failures in cables exposed to high temperatures do not always appear immediately, but rather evolve progressively until they result in functional failures. This characteristic makes early detection difficult and increases the risk of unexpected failure during operation.
Thermal ageing of insulation is not a linear process, but rather cumulative and dependent on multiple operational variables, meaning that small deviations in temperature can drastically reduce cable lifetime.
The main objective of the project was to evaluate how thermal conditions were affecting the system and to determine whether there was room for improvement in terms of material selection, design or operating conditions.
Additionally, the possible influence of other phenomena such as oxidation, chemical degradation of insulation or the formation of microcracks was considered, as these can accelerate cable deterioration even in the absence of significant electrical overloads.
Characterisation of thermal degradation of electrical materials and correlation with functional failure
From a technical standpoint, one of the main challenges was to characterise the thermal degradation of electrical materials and its direct relationship with the observed failures. This type of degradation involves physical and chemical changes that are not always visible to the naked eye, but critically affect component performance.
The challenge was to differentiate between expected wear due to use and abnormal degradation that could indicate a design, material or process issue. In addition, it was necessary to correlate the results obtained with real service conditions, avoiding conclusions based solely on theoretical testing.
In this context, INFINITIA approached the project from a forensic engineering perspective, aimed at identifying the causes of failure and providing a solid technical basis for decision-making without compromising sensitive client information.
To achieve this, it was essential to integrate results from different analytical techniques, enabling cause-effect relationships to be established between the observed degradation and the functional behaviour of the system, thus allowing a more robust interpretation of the problem.
How was it addressed or what was the solution?
To address the identified problem, an approach based on comparative analysis and technical characterisation of the affected components was defined. This approach not only made it possible to identify differences between functional and defective samples, but also to establish clear relationships between operating conditions and observed failure mechanisms.
INFINITIA’s intervention focused on providing a structured understanding of the problem, combining material analysis techniques with testing aimed at reproducing service conditions.
Electrical failure analysis through OK NOK comparison and evaluation of material deviations
The project was carried out through electrical failure analysis based on the comparison between samples showing failure NOK and those with acceptable performance OK. This approach made it possible to identify key differences in the condition of materials, insulation and other critical system elements.
The comparative analysis facilitated the detection of degradation patterns associated with thermal exposure, allowing hypotheses on failure mechanisms to be established without initially relying on complex theoretical models.
From a strategic perspective, this approach proved particularly useful in narrowing down the problem and guiding subsequent analysis phases towards specific aspects of the system.
Additionally, this methodology helped reduce initial uncertainty in the project, as it provided direct evidence of differences between samples, enabling prioritisation of investigation lines and optimisation of technical resources.
Temperature testing of electrical components to simulate real service conditions
To complement the initial analysis, temperature testing of electrical components was carried out, aimed at reproducing real operating conditions. These tests made it possible to evaluate material behaviour under thermal stress and to validate the hypotheses raised during the comparative analysis.
The project team played a key role in defining test parameters, ensuring that the applied conditions were representative of the actual use environment. This aspect is essential to avoid erroneous conclusions derived from unrealistic testing conditions. Furthermore, the combination of testing and analysis made it possible to establish clear relationships between thermal exposure and failure evolution, providing an objective basis for result interpretation.
The validity of thermal testing depends directly on its ability to reproduce real operating conditions, as non-representative tests can lead to incorrect diagnoses and inefficient technical decisions.
At the same time, the reproducibility of the obtained results was evaluated, ensuring that the observed behaviours were not due to isolated variations but to consistent trends associated with the applied thermal stress.
Electrical failure diagnosis through correlation between thermal degradation and loss of functionality
As a result of the study, an electrical failure diagnosis was obtained, allowing the most probable causes of the observed problems to be identified. This diagnosis not only explained the origin of the failure, but also provided relevant information for technical decision-making.
Based on the obtained results, it was possible to achieve a deeper understanding of material behaviour under real operating conditions, particularly in relation to their response to prolonged thermal exposure. This made it possible to identify critical factors affecting system reliability that had not initially been considered in design or material selection.
Furthermore, the analysis significantly reduced uncertainty in decision-making, as a solid technical basis was available to evaluate potential improvements. This information proved key in defining actions aimed at optimising both system design and operating conditions.
Finally, the knowledge generated enabled the establishment of concrete recommendations to prevent failure recurrence, facilitating the implementation of improvements both in design phases and operating conditions, and contributing to increased system robustness and durability in thermally demanding environments.
