1)
Referring to the Capacitor crack issue, from your explanation, you should have suspect your manufacturing process because it found 5 boards with capacitor crack at the same place.
We are doing manually assembly process. If it caused by human handling problem, then it will be found component damage at different location. In this case, I believe only a auto or semi-auto process will create a same problem at the same location.
Furthermore , please refer to the attached DRIT. There are few capacitor problem that we found during IQC check before we sending for the assembly line.
This shown very clear that there must be some problem in your manufacturing process that cause same problem and your testing is not able to detect such defect.
Please look into it.
2)
Regarding the IC Burnt issue, I will revert back this to the end user and claim as invalid NCR due to overcurrent.
3)
Regarding the “PDO timeout Issue” , From my email on 23rd September 2015, I have sent you the explanation from the end user.
“PDO Timeout ==> The data lost during transmission. (Can be cause by EMC perturbation , Boards Grounding Itself)”
Your testing is to confirm the basic function of the board which the motor is able to run after you connect the motor to the board and supply input.
It is good But I believe that the board will has other control functions which you do not test during the OQC.
Can you share this with your Technical/ Engineering team to have some technical feedback from them.
Reminder that we have 2 boards have the same issue.
Let be sure the problem before you make decision to send the board back.