Failure Mode and Effect Analysis for Components of UPS in Laboratory

This study analyzed a 3kW UPS, used in a laboratory, by presenting three assemblies—an AC-DC rectifier, a DC-AC inverter, and sensors/cooling fans—and 13 constituent components. For each component, potential failure modes were derived, with their causes and effects described at the component level. Using Failure Mode and Effects Analysis (FMEA), Risk Priority Numbers (RPNs) were calculated. The RPN analysis identified two capacitors, one IGBT, one battery, and three cooling fans as key problematic components. Capacitors and cooling fans were prioritized for immediate improvement. Specifically, current aluminum electrolytic capacitors required replacement with film capacitors due to their longer lifespan and more stable performance. For cooling fans, voltage-controlled DC fans, often problematic at low speeds, necessitated replacement with PWM fans, which offer stable rotation and easy speed control. The remaining IGBT and battery components were decided to be retained as they were difficult to replace. This study's findings are broadly applicable to ensuring the safety of daily necessities, preventing industrial accidents, and enhancing school safety.