In industrial environments, reliability matters. Lighting failures can lead to safety risks, operational disruptions, and unnecessary maintenance costs.
Dialight’s industry-leading 10-year warranty is supported by disciplined engineering, extensive validation testing, and strict manufacturing controls throughout design and production.
Watch this short video highlighting Dialight’s industry-leading 10-year warranty.
Below are ten key elements that support long-term reliability and longevity in Dialight industrial LED lighting solutions.
1. Component Selection
Component ratings checked via stress analysis at the design phase. Use of long-life electrolytic capacitors.
2. Topology Selection
Use of efficient, soft-switching resonant topologies. 90-94% efficiency.
3. Reliability Predictions
MTBF and survival probability calculations consistent with 10-year warranty.
4. Accelerated Life Tests (ALT)
Practical MTBF assessment using temperature cycling and failure rate calculations. Repeated for any major change. Scheduled HALT on production samples (Quality Audit).
5. Stress Analysis
Stress on every component checked by calculation and/or measurement. Multiple temperature studies.
6. DFM and Supply Chain Analysis
Design For Manufacturing. All PCB design specifications (spacings, hole sizes, etc.) are carefully reviewed for ease of manufacturing to reduce handling and rework. Multiple component alternates are specified and tested to prevent production stoppages.
7. Quality Controls
No Tolerance Policy. 100% testing of THD, PF, and input power. Subassemblies are tested before being assembled into the final product.
8. Weak Signal Management (WSM) Data Analysis
Weak manufacturing fallout analysis. Burn-in data analysis. Comprehensive investigation for field failure mode historical data analysis. Check that failure rates remain in alignment with 10-yr life expectation.
9. Burn-in
This can include power cycling, over-voltage stressing, and thermal stressing of the final product.
10. PHM
Prognostic & Health Management. Gen 4 power supplies.
Industrial environments demand lighting that performs reliably over long operating lifetimes. Through rigorous engineering validation, testing, and quality control practices such as these, Dialight supports the long-term durability expected from its industry-leading 10-year warranty.