Let me tell the story about how misreading a graph almost bankrupted a company. This is a true story.
Our chief engineer, a Tektronix veteran, designed a power amplifier called the Point Zero Three, or PZ3 (hey, I didn’t name it, OK?).
A 100-watt/channel transistor amp. It measured great, sounded so-so, but had a little fault ... it blew up without warning, and worse, took out all the power and driver transistors, scorching the circuit board as it went. Take out the circuit board, replace the power transistors (all of them), and put in a new one. Repeat as necessary.
There were days when more came back than were shipped out. Obviously, this couldn’t continue. Word was getting out, and a failure rate approaching 50% is unsustainable.
Our new engineer, Bob Sickler, looked more closely at the SOA curves for the driver transistors. Bob told me these curves are intentionally hard to read, and it usually escapes notice that both voltage and current axis are log scale. Not only that, a straight load-line is assumed by most engineers, but with real loads, that line opens into an ellipse. Once that ellipse touches the no-go line, and stays there for more than 10 milliseconds, boom!
The chief engineer, despite being an old Tek hand, had missed this tiny little detail. It turned out the driver transistors were undersized by a factor of three, so we had to parallel them in a 3-stack with individual emitter resistors to have a stable amplifier. The fix worked; but we had to recall every amplifier in the field and update the circuit board with the new driver stack. It wasn’t cheap, but it stopped them coming back, and they kept working.
This incident resulted in Bob Sickler, the new guy who saved the company, getting permission to design a new amp of his own, which became the Audionics CC-2, their most successful, reliable, and best-sounding product. They sold more than 1,000 with a failure rate of less than 0.3%, the lowest in the industry. The CC-2 was their most profitable product.
All this happened because one part, a driver transistor, had poorly understood behavior in a boundary condition. Ask for too much current for too long, go past the SOA boundary, and blooey! A scorched circuit board with mostly shorted transistors, all thanks to DC coupling propagating the single point of failure through the entire output section in less than a second. Engineers love DC coupling, but it can propagate failure very, very fast, in less time than it takes to jump across the room and turn it off.
That experience is why I am wary of dismissing boundary conditions. Poorly understood boundary conditions can destroy a product, destroy consumer trust, and take down a company. All from not reading a data sheet carefully enough.