Hello again,
I absolutely love the passion on Chief Delphi. As most the mentors know, as long as passion is directed, patient, controlled, and utilized for the betterment of the whole, that passion will make you very successful in whatever it is you are passionate about.
Just in case you missed my posts last season, we did not ignore the fact that teams were reporting failures on Chief Delphi - hence, my repeated (almost annoying) failure updates and requests for teams to send us failed units (on our dime), shipping next day replacements, following up personally with teams that were reporting a failure on Chief Delphi but did not turn in units for FA, and sending out a Luminary Micro engineer to most every regional event (and championships) to personally check on teams, gather experience, and perform on-the-spot RMAs - most of the time, regardless of how the unit failed. I, like a lot of people, was expecting the failure rate to be horrid based on the posts I was seeing on Chief Delphi. When all was said and done, we published a report the week before Championships in order to convey our findings. (here is that thread again for your reference - with Jaguar FA report). Summary/Conclusion:
- 131 of the 136 returned units are legitimate failures.
- The total validated failure rate for MDL-BDC is 1.4% of all units sold.
- The most common issue reported was a loss of control in the forward direction (representing over 40% of all specific failure reports).
- Failure analysis of all units concluded that over 70% of units returned for examination exhibited a failure of the U6 and/or U7 gate driver, sometimes in addition to other components.
- The probable cause of the gate driver(s) failure can be attributed to a variety of factors, including inadvertent misuse (such as temporarily mis-wiring the MDL-BDC Jaguar unit or accidental swarf causing a short) and potential ESD vulnerability of the MDL-BDC design.
Some notables not included in the report was our own personal visual check on which teams were using Jaguars on their robot. Over 80% of teams across all regional and championship events were using either ALL Jaguars or were using a hybrid of Victor/Jaguar. This is important because it lessens the argument that our numbers were extremely skewed because “most teams didn’t use their Jags”. (not true, actually)
At Championships (even after submitting the report), we set up both in the pits and on the mezzanine to gather more data and more failed Jags to see if failures were consistent with what we were seeing. I brought over 100 replacement Jaguars in case there was a chance that our data was bad. (I really DO want you to be successful and I want to position you for the best chance at success - which are facts that one can sometimes lose when one experiences a failure). We did replace some more units, but several teams admitted that units being returned were due to their own fault. No problem - this was championships, so if I am at Champs and you experience a Jag failure - I am going to make sure you are equipped to compete.
All told - post champs, our failure rate was much less than 2% - which includes several misused Jaguars that we replaced onsite at Regional and Chmpionship events.
So, if right about now you are thinking that I am defending rather than learning, you’d be wrong.
As an engineer myself (yeah, imagine that - an engineer and a collegiate linebacker… and unless you are incredibly talented to make lots of money in sports, trust Dean - I am much happier/successful as a engineer than an aging, injured pro athlete - I digress)… as an engineer myself, we have taken all of our learnings and applied them to Black Jaguar. We’ve bumped suspect components (and replaced with TI Analog!), we’ve redesigned to improve ESD, we’ve changed CMs, we’ve added some new features that might be incorporated in FRC :yikes:, and we’ve finally taken your advice that you didn’t like our Pantone corporate grey color - and rebranded/shot with TI Black and Red (like I had a choice…). To specifically address that sw question I saw, we even added a way to use Black Jag to update firmware on Black and Grey Jags. So, even though I am personally glad that the failure rate seemed higher than it really was, the entire “Luminary Micro” team made a commitment to FIRST to improve the design - based on all the great feedback, returned units, and design recommendations that we received from the FRC network of engineers.
Looking forward to another successful FRC season, and I’ll be about to keep you informed.
Regards,
Scott