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Extension of the intended lifetime of products

TechEkspert  49 4842 Cool? (+9)
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TL;DR

  • Reduce standby time and overstressed components to extend the trouble-free life of electronic devices.
  • Use a series resistor of 150-500Ω for some toy LEDs, or 12V/5V external supplies for radio relays, to improve reliability.
  • Help homeowners and electronics hobbyists who want appliances, lights, relays, and toys to last longer and fail less often.
  • Lowering LED drive current, avoiding needless standby power, and using better relay switching can increase failure-free time and reduce energy use.
  • Keep continuous power for devices that need it, such as radio alarm clocks or delayed-start washing machines and dishwashers; unplugging does not stop mechanical wear or all component damage.
Mechanical clock and smartwatch on a desk.
The struggle to keep product prices low forces compromises that may reduce uptime. Do you use solutions to extend the trouble-free operation of electronic devices?

Equipment running on stand-by .
For appliances without a mechanical power switch that completely cuts off the power supply for years I use extension cords with a switch, or even plugs with a built-in switch. TVs, set-top boxes, monitors, washing machines, dishwashers, microwaves do not need to run on stand-by. A common failure is damage to the power supply through depletion or a power surge. The disadvantage of unplugging the power supply is incorrect time on the built-in clock or longer start-up time of the decoder.... Of course, there are appliances that are worth having a continuous power supply e.g. radio alarm clocks or washing machine/dishwasher where we have set the cycle to start in 5 hours when there is a cheaper tariff. Fewer idle hours under power can extend the life of equipment. We will also minimally reduce energy consumption by doing this. Of course, this does not affect mechanical wear and tear, or electronic damage to e.g. triacs and executive relays switching high-power loads such as heaters. For household appliances connected to the water mains, it is advisable to turn off the water supply with a valve when not in use to reduce the risk of flooding.

Continuous flow controls .
Convenient solutions are back box or rail-mounted radio remote-controlled relays. Such devices are often enclosed in a box when retrofitting an installation. I have noticed two types of power supplies for radio relays, these are either transformerless power supplies or switched-mode power supplies. In the first, the film capacitor loses capacitance or the Zener diode is damaged. Switch-mode power supplies, on the other hand, become damaged over time due to the ageing of the electrolytic capacitors or, more often, damage to the inverter circuit. The actuator of the devices is the relay and the rest of the circuit is galvanically isolated, so I specify an external DC power supply. Usually radio relays require a 12V or some newer 5V supply. I happened to use "12V" DC from a nearby buffer power supply to power such devices after reworking the power supply circuit and changing the markings on the case. Using a transformer power supply to power a group of such devices significantly extends their uptime.

LED lighting .
In the days of incandescent lighting, soft starts extended the life of incandescent bulbs by eliminating the current surge on the cold filament. LED lighting is often price-optimised and LEDs are forced to operate with high current and poor cooling. For LEDs in the form of 'bulbs', modifications are difficult. However, for off-the-shelf plafonds and illuminators with an external or built-in DC power supply, more advanced electronics engineers can lower the value of the forced current . The brightness of the source decreases, but the failure-free time increases significantly.

. Firing relay contacts .
A well-known trick of experienced electronics engineers is to connect sections of relay contacts in series often switching large currents. This method significantly increased the relay's failure-free operating time. Nowadays, one can consider the SSSR relay module . A solid-state 'relay' does not have mechanical contacts, but you have to reckon with the power loss on the triac/ thyristors and less resistance to current and voltage surges. One can also think of a so-called 'perpetual relay' where the switching operations are performed by the semiconductor element, then the EMR relay contacts are connected in parallel to the semiconductor.

Toys that quickly drain batteries or break down .
In many toys with luminescent elements, the LEDs run at high current, which gradually damages the LEDs and quickly drains the battery. Simply selecting a series resistor of 150-500Ω (depending on the circuit and supply voltage) will significantly extend the battery life. The current-limiting resistor is often overlooked by far-left manufacturers of various luminescent toys, and the conversion is very simple. In toys equipped with motors, it is worth considering the use of accumulators to reduce the number of disposable cells and batteries.

Do you use solutions to extend the trouble-free operation of electronic devices?

Have you noticed which devices break down frequently after the warranty period has expired and what causes the breakdown?

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TechEkspert
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Comments

Ryszard49 18 Feb 2025 20:19

. They must e.g. SONY. [Read more]

TechEkspert 18 Feb 2025 20:22

Why. Any smartTVs? [Read more]

Ryszard49 18 Feb 2025 21:39

. As you wrote. [Read more]

elukam 18 Feb 2025 22:30

. Yes, mainly mains filters and systems to reduce the current surge of low-quality power supplies. Although in general the lifetime of a chump is not affected, it is important not to do other damage. ... [Read more]

Mobali 18 Feb 2025 23:29

It is not an easy subject, because cost-cutting does not only apply to electronics. Materials in particular are becoming increasingly inferior; weaker and short-lived plastics or metals are being replaced... [Read more]

szeryf3 19 Feb 2025 08:52

I personally don't take anything offline. Unless I'm going away for a long time. Then I turn off the TV on the strip and turn off the water and gas. [Read more]

krzbor 19 Feb 2025 09:48

I would like to draw attention to the 'Chinese' amps. Similar looking devices. We will have 10A on the branded one and 16A on the unbranded one. This applies to everything - power supply capacity, power... [Read more]

stomat 19 Feb 2025 09:55

Unfortunately, more and more often the scheduled operating time is stored in software and here nothing can be done anymore. We have all heard of printers reporting half-empty cartridges, short operating... [Read more]

TechEkspert 19 Feb 2025 10:20

Deliberate software blocking of operations is already a malicious action of the manufacturer, such a situation is hard to fight. Perhaps apart from refraining from buying the products of such a manufacturer. Some... [Read more]

kris8888 19 Feb 2025 10:48

Some switching-mode power supplies are, against all appearances, better when they operate non-stop than when they experience the cyclical 'current surge' associated with switching off and on again. Sometimes... [Read more]

John Yossarian 19 Feb 2025 11:19

Led bulbs can be extended in life by removing the burnt diode. We remove the bulb:) of the bulb, locate the burnt-out diode (visible small dot on the surface), remove it mechanically and solder (short-circuit)... [Read more]

James596 19 Feb 2025 13:05

It's hard to fight planned obsolescence when even such "fiddly things" as LED displays in white goods can go out of date shortly after the end of the warranty. This is slowly turning into a situation... [Read more]

Kiermasz 19 Feb 2025 20:01

I there a very simple way to eliminate basic faults before they occur. I simply test the EMI emitted by the inverters. The interference starts to grow beyond the statistic for the efficient = soon it... [Read more]

TechEkspert 19 Feb 2025 20:07

"Incandescent" LED bulbs in which the casing can be easily removed do indeed have the potential to be repaired and electro-waste can be reduced in this way. @kris8888 some switch mode power supplies... [Read more]

Kiermasz 19 Feb 2025 20:48

. It will work, just arrange for some RF attenuator so the background doesn't interfere and AGC of a typical receiver. Rarely, but by ear you can be fooled and thus the level of interference can be... [Read more]

kris8888 20 Feb 2025 01:11

That's right. It used to be that even old, high-speed SCSI drives were recommended not to be switched off, better when they were spinning non-stop (e.g. in a server). Such disks were able to work this... [Read more]

szym86 20 Feb 2025 01:45

I do not see a problem, and even if I did, according to Murphy's Law the thing will break in a different way than I would expect. I sometimes consciously leave a drill or a grinder in the rain, because... [Read more]

Mobali 20 Feb 2025 02:52

Somehow right, but let's not get crazy. Many appliances have been able to serve successfully without constant updates and without being replaced by a newer model. Simple white goods, for example... What... [Read more]

James596 20 Feb 2025 08:13

And there have already been cases of devices with a built-in internet tuner, where the tuner stopped working after a few years, because the manufacturer gave up cooperation with some supplier. ;) Similar... [Read more]

FAQ

TL;DR: Cutting avoidable stresses—heat, high inrush current, over-voltage and needless standby—adds years to everyday electronics. Disconnecting non-critical gear from mains and lowering LED drive current can raise service life by up to 30 % while trimming 5-10 % of household energy use [European Commission Standby Study 2023].

Quick Facts

Quick-Facts
• EU Ecodesign limits standby to ≤0.5 W since 2023 [EU Reg 2019/1782].
• Typical TV inrush current: 40–80 A for 2 ms at 230 V AC [IEC 61000-3-3 test report].
• Solid-state relay (SSR) on-state drop: 1.2–1.6 V, heat ~6 W at 4 A load [Crouzet Datasheet, 2022].
• LED lifetime halves for each 10 °C rise in junction temperature (“Arrhenius rule”) [ON Semiconductor AN-8159].
• Charging Li-ion only to 80 % doubles cycle life from ~500 to >1 000 cycles [Panasonic NCR18650B Spec, p.7].

Which home devices benefit most from being fully switched off?

Set-top boxes, televisions, monitors, dishwashers and microwaves gain little from standby and face SMPS stress; use a switched strip to cut power when idle [Elektroda, TechEkspert, post #21445674]

When should I keep equipment permanently powered?

Keep power on printers that auto-clean heads, OLED TVs that run pixel-refresh cycles and lab instruments needing thermal stability or scheduled diagnostics [Elektroda, efi222, post #21447787]

Does repeated unplugging hurt switch-mode power supplies?

Yes. Dried bulk capacitors can fail at the next inrush surge; continuous power often keeps ageing PSUs alive longer [Elektroda, kris8888, post #21447593]

How can I extend LED bulb life without redesigning the driver?

Open serviceable bulbs, replace the small electrolytic with a 105 °C low-ESR type and add thermal paste between PCB and heatsink; users report 25-30 rescued lamps [Elektroda, Mobali, post #21445998]

Is it better to wire relay contacts in series or in parallel?

For inductive loads, series contacts split arc energy and slow erosion; for high inrush capacitive loads, parallel contacts share current. Add RC snubbers or MOVs in both cases [ElektrodaBot synthesis, #21448983].

When should I replace a transformer-less supply in smart relays?

Factory film capacitors lose capacitance; swap them for higher-grade X2 film parts or power several modules from one external 12 V transformer to multiply MTBF [Elektroda, TechEkspert, #21445674; kris8888, #21447831].

How do I detect ageing capacitors before failure?

Monitor conducted EMI with an AM radio or portable SDR; rising hash across HF bands often precedes electrolyte loss in SMPS units [Elektroda, Kiermasz, post #21447205]

Can software ‘kill switches’ really stop industrial machines?

Yes. Some EDM tools refuse to start after maintenance counters exceed set hours, requiring a service reset despite healthy hardware [Elektroda, Kiermasz, post #21504483]

What protects electronics from unstable grid voltage?

Use an isolating transformer plus AVR or a true-online UPS; Polish PV-saturated feeders can reach 255 V midday then sag at night [Elektroda, Mobali, post #21445998]

How does limiting Li-ion charge to 80 % help?

Staying below 4.1 V reduces lattice stress; cycle life roughly doubles compared with full 4.2 V charges [Panasonic NCR18650B Spec]. Many laptops and phones offer an 80 % or ‘adaptive’ mode [Elektroda, TechEkspert, post #21446349]

Do solid-state relays last longer than electromechanical types?

SSRs have no contacts to pit, so switch life is near infinite, but they dissipate several watts and offer no galvanic isolation when open, risking leakage [Crouzet Datasheet 2022; Elektrode, Ryszard49, #21448290].

What simple part cuts toy LED current and saves batteries?

Insert a 150–500 Ω series resistor; brightness falls modestly but battery life and LED lifespan rise sharply [Elektroda, TechEkspert, post #21445674]
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