Products must pass a series of tests to ensure readiness for mass production. Each industry utilizes a variety of test specifications to validate their products. The goal is to see whether the subjected parts will ultimately comprise a full product viz.
Automobile, aircraft or machine are strong enough to withstand the dynamics. Envitest includes various types of dynamic testing employed on various industries.
Dynamics testing types range from moderate to intense based on the endurance requirements of a given product. Envitest has some of the most extensive dynamics testing capabilities in the world. We operate Dynamics Testing facilities end to end and we have extensive experience with all product types.The goal of dynamic testing is to determine how many forces a product can withstand and still maintain its composition and functionality.
In real-life settings, excess loads of acceleration can have damaging effects on numerous commercial and industrial products. For example,
- Structural damage
- Stressed, leaky seals
- Jammed actuators
- Broken mounting pieces
- Flickering sensors
- Ruined contacts
For machines, vehicles, aircraft and electronics, vibration testing is a crucial part of the product-inspection process. The impacts of shakes and tremors can be damaging to the internal mechanisms of any product that lacks sound design. Therefore, vibration tests are performed on products before release in the military, aerospace, and automotive sectors.In order to test the vibration resistance of these various components, tests are employed with shaker tables on which parts are subject to heavy tremors.
Common test standards that require vibration testing along with a variety of commercial testing specifications are MIL STD 810, MIL-STD 202 method 213, MIL-STD-810 method 516.6, MIL-STD-750-2 method 2016.2,ISTA 3A, JSS 55555, IEC 60068-2-XX, NEBS-GR, RTCA-DO, JIS, ISO, ETSI-EN, IS etc.
Mechanical Shock Testing
Shock testing subject’s products to extreme force with respect to time. Mechanical shock testing is a sub-category of vibration testing utilizing shock with a very specific purpose of validating the fragility of a product or component. Unlike impact testing, mechanical shock tests are conducted with controlled variables for G-force (gravitational units) and are limited to a single degree of freedom. Mechanical shock testing is commonly used for fragility analysis and utilizes sudden, extreme acceleration or deceleration.
Mechanical shock testing is utilized in a variety of industries such as automotive, aerospace and defense. Common requirements for shock testing include, MIL STD 810, MIL-STD 202 method 213, MIL-STD-810 method 516.6, MIL-STD-750-2 method 2016.2, as well as other industrial testing standards.
What goes up must come down and if an object does not land as planned, it will inevitably cause some degree of impact. With drop testing, products and/or packaging is tested to determine the height from which these products can drop and remain intact after impact. Drop testing is important for products and packaging in all sectors.
Common drop test conditions consist of a freefall from various heights onto a solid surface. The drop height for each test is dependent on requirements set forth by standards such as those from MIL-STD, JSS, IEC, ISO ASTM, ISTA etc.
HALT testing, HASS testing, HATS testing
For manufacturers, it is important to know how each product is likely to endure the process of aging during its expected lifespan. The tests that employ age-accelerating processes include Highly Accelerated Life Testing (HALT), Highly Accelerated Stress Screening (HASS) and Highly Accelerated Thermal Shock (HATS) testing. HALT tests are employed to find weaknesses within a given test device. During a HALT test, heat and vibration are applied for short periods at high volumes to see how the product will weather the exposure.
Ultimately, the objective is not to see whether a product can survive the test but to determine how long and at what levels of exposure the product can function and hold its composition before failing.
The purpose of HASS testing is to see whether defects are present in a product during stages of manufacturing. While HALT testing is employed to test products in beta form, HASS tests challenge the durability of each product in revised form. Highly Accelerated Thermal Shock (HATS) testing, as the name implies, tests the durability and operability of products in the event of thermal shock.
Dynamics Testing at Envitest
Before a product is manufactured and released for use in large quantities, it is crucial to have it tested for maximum strength and durability. Whether a given part is designed for use in an aircraft, vehicle, military weapon, factory machine or commercial product, lives and property could be at stake if the product fails to perform its intended function. To put your product to a series of ultimate tests, contact NTS today to request a free quote.
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1. Challenges in Testing Radio Oscillators: A Comprehensive Examination
Radio oscillators play a pivotal role in radio communication systems, serving as the heartbeat that generates continuous radio frequency (RF) signals. These signals are the bedrock of wireless information transmission, allowing audio, video, or data to be sent and received effortlessly. At the core of radio oscillation lies a fundamental principle: feedback. By taking a fraction of its output signal and feeding it back to the input, the oscillator reinforces and sustains the signal, causing it to oscillate continuously between high and low levels and, thereby, generating the desired RF frequency.
However, testing radio oscillators for vibrations presents unique challenges for test laboratories. These challenges stem from the lack of information about the components within the test samples and the fragility of such components. This article examines into these challenges, highlights the consequences of inadequate testing, and explores potential solutions to improve the testing process.
One of the fundamental challenges we face when dealing with radio oscillators is the lack of information about the components of the test samples. These components play a critical role in the functioning of devices. As a result, when a test sample is subjected to rigorous testing, it can often yield unsatisfactory results, leading to a cascade of issues.
End customers, driven by the need to meet the stringent “Acceptance Documents” requirements, mandate thorough testing of the products. Consequently, they submit test samples to labs for evaluation. However, in many instances, if the tests yield unfavourable outcomes, much to the dismay of both the customers and the test labs.
In situations where test results are less than satisfactory, the blame game starts. Test labs are frequently the first to be criticized for issues such as incorrect setups or malfunctioning equipment. However, what often goes unnoticed is the presence of a critical components such as radio oscillator inside the test sample.
This situation is compounded when the same customer decides to approach multiple test labs, only to find that the results are consistent across the board – a failing grade. Frustration mounts as the customer seeks a pass report without delving into the intricate details of the oscillator’s functionality. Even if the customer manages to obtain a pass report, it may be rendered useless, as the end customer conducts additional assembly and testing.
The heart of the matter lies in a missed opportunity to consider testing comprehensively from the outset. A straightforward approach, such as temporarily removing the crystal oscillator during vibration testing, could have saved the entire testing process. By focusing on this critical component, test labs can enhance their testing methodologies and contribute to more accurate results. The following are approaches usually we follow:
- Component Identification: Implementing a process to identify the critical components within test samples, can help test labs better understand the complexities involved in the testing process.
- Collaboration: Test labs and customers should collaborate closely to establish clear communication channels and ensure that both parties are aware of the intricacies of the test sample.
- Component Isolation: Considering the importance of components, test labs provide options for temporarily isolating or removing critical components during specific tests to prevent interference and obtain accurate results.
- Education: Customers could have been educated about the significance of these components and the impact they can have on test results. This can help manage expectations and prevent failures.
Conclusion: Testing radio oscillators is a challenge that requires a thorough approach. The hidden nature of these critical components within test samples can lead to inaccurate results and frustration for both test labs and customers. By identifying and addressing this challenge, test labs can contribute to more accurate testing and improved outcomes. Collaboration, education, and innovative testing methods are key to meeting the demands of the ever-evolving RF technology landscape.
2. Analyzing Vibration Tests on Electric Scooters: Frequent Rear Fender Failures
The electric scooter industry has witnessed remarkable growth in recent years as urban commuters seek sustainable and efficient modes of transportation. Electric scooters (EV scooters) have become increasingly popular due to their eco-friendliness and convenience. However, like any other technology, they are not immune to challenges. One such recurring issue the customer of this product faced was failure of rear fenders due to vibrations. In this article, we analyse into the scope of vibration tests on electric scooters and understand why the rear fender was a weak point and what one can do to address this issue.
Electric scooters are designed to be nimble and lightweight, making them perfect. These very characteristics that make them agile also make them susceptible to vibrations, especially on uneven roads or during high-speed rides. Vibrations radiate from various sources, including scooter’s own motor, road irregularities, and tires. These vibrations can have a significant impact on the structural integrity of the scooter’s components. Let’s only discuss what we faced as failure – the rear fender.
So we subjected this product for vibration testing for a long duration of 100 hours. This was a proto sample and objective was Data Analysis. We were tasked to collect data to assess how vibrations affect various parts of the scooter such that we can pinpoint the area’s most vulnerable to vibration-induced stress.
During the process, we saw one component which was not behaving as intended. Every component was giving their best to withhold their component characteristics except one – ‘Rear Fender’. In this scooter, the rear fender’s main function is to protect tires and braking systems from mud or other splashes so that they are safer and more efficient, and help prevent mud, dirt, dust particles and other liquids from being thrown inside the scooter engine and passenger area when the tires are rolling. Importantly, they also hold the licence plate. When we simulate real-world scenarios by subjecting scooters to a range of vibration frequencies, amplitudes, and durations to replicate the conditions of urban roads and riders’ experiences, we expect that the fitted components behave and sustain the energy to make product reliable.
We observed failure and next was to dissect the reasons. We worked on three important aspects:
- Material Selection
- Placement and holding pattern.
- Loads acting on them.
Well, we started to check with the loads acting during the vibration test such that the material that was used has significant strength to hod such loads. Soon it was realised that the material used has density to hold such loads and does not have effects due to acting forces. Next moved to holding pattern. Here we found a significant flaw. The shear force distribution of the component. Basically, it was a design constraint. To accommodate the rear fender in the available space, the designer had to shape the fenders where it compromises its shear force distribution due to the imbalance. This design was accommodating the component to main panel chassis, but while doing so, it was losing significant amount for strength required, igniting the very resonance points at all the time.
Resonance is a physical phenomenon that occurs when force is applied which matches to natural vibration frequency, this causes component to vibrate with a higher amplitude, leading to significant consequences. So component was sent to re-engineering.
Conclusion: The rear fender failure due to vibrations was a recurring issue in the electric scooter. As electric scooters continue to run, it’s essential to invest in extensive vibration testing and develop innovative solutions to enhance their durability. By addressing these issues, the industry can provide a safer and more reliable means of sustainable transportation.
Based on 40 reviews
Envitest has been an invaluable partner in our product development process. Their dynamic and vibration testing services have helped us to identify and address potential problems early on, which has saved us time and money in the long run. Their engineers are highly knowledgeable and experienced, and they are always willing to go the extra mile to help us meet our testing goals.
We have been using Envitest’s drop testing services for several years now, and we have always been impressed with their quality and professionalism. Their equipment is state-of-the-art, and their staff is highly trained and experienced. They are always willing to work with us to develop custom test plans that meet our specific needs. We highly recommend Envitest to anyone who needs drop testing.
Envitest is our go-to lab for shock testing. They are a trusted partner that we rely on to provide us with accurate and reliable results. Their customer service is excellent, and they are always responsive to our needs.
Professional with clients and good for startups to test the product reliability.
Very nice lab with a professional and very friendly staff…
Envitest is the world’s most trusted independent test, inspection, and certification company. With state-of-art lab and the top thought leaders, Envitest provides customers with best-in-class testing services to serve a wide range of industries, including space, defense, automotive, energy, electronics, telecommunications, medical, IoT, industrial, and aviation.
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