Shock and Vibration Testing

Agenda

Shock Testing

Comparison and Selection of Methods

Comparison of Specs Rationale for Selection of Testing

Vibration Testing

Comparison and Selection of Methods

Comparison of Specs Rationale for Selection of Testing.

Vibration and Shock

Vibration and Shock

Machine
TIRA TIRA Unholz Dicke MB Corp Model C-60 Ling Thermotron Elite

Type
Vibration Vibration Vibration Vibration Vibration Vibration Package Vibration Mechanical Shock Mechanical Shock Acceleration

Range
20,000lb vector, 2 inch displacement

Range
5-2500Hz 5-2500Hz 5 2500 Hz 5 3000 Hz 5 2000 Hz 5-20,000 Hz 2 4 Hz

Capabilities
3 axis slip plate; 5 ft. x 5 ft. slip table

12,000lb vector, 2 inch displacement

17,000lb vector, 1.5 inch displacement 6000lb vector, 1 inch displacement 6000lb vector, 1 inch displacement 5 Hammer Repetitive Shock

3 axis slip plate; 30 in. x 30in . slip table

3 axis slip plate; 36 in. x 36 in. slip table 3 axis slip plate; 30 in. x 30in . slip table 3 axis slip plate; call for size limitations HALT Thermal Shock with vibration Cam operated bounce test for transportation

AVCO FF367-1
AVCO A105 Schaevitz G-6-A

300gs/20ms
30,000gs/0.02ms Limited by 3 ft. arm; Call for size

Inquire
Inquire

Sine or saw-tooth
Sine or saw-tooth

Vibration and Shock

Vibration and Shock

Heating Elements HALT Test Vibration Impactors

Vibration and Shock

HALT/HASS Chamber HALT -Highly Accelerated Life Testing Combined six-axis vibration and temperature extremes. Intentionally but systematically produces test item failures for the purpose of rapidly identifying mechanical, electrical, design and functional weak points. Design weaknesses can be analyzed, corrected, and the product design optimized. HASS -Highly Accelerated Stress Screening Overstress test to identify marginal or defective products before shipment. HASS test levels are identified during HALT and are established to compress test time without damaging the product or reducing its life.

Vibration and Shock

Elite HALT/HASS Chamber Capabilities -100C to +200C (-148F to +302F) Greater than +70C per minute product temperature change rates (heating or cooling) 30 x 30 Vibration Table, 480lbs total weight capacity for test item & fixture Workspace Dimensions 42W x 42D x 40H Vibration Frequency Range: 2Hz-10kHz; Vibration Level: Up to 50Grms Two (2) 3x8 access ports, Three (3) 20x20 viewing
windows

Vibration and Shock

Vibration Testing
Sine, Random, SOR, Field Data Replication Record actual vibration levels Import data to vibration controller Operate vibration table according to recorded profile and acceleration magnitude Run test item for endurance Mechanical Shock SRS

Vibration and Shock

Drop Shock Sawtooth, Half-Sine

Classical Shock Test Machines

Vibration and Shock

High G Mechanical Shock

Vibration and Shock

High G Constant Acceleration

Vibration and Shock

Ultimate Strength

Yield Strength

Stress

Proportional Limit

Stress

Endurance Limit

Strain

Cycles

Fatigue Crack Growth

Vibration and Shock

Sine

Vibration From rotating or oscillating machinery; electric motors, wheels, engines, gears, springs. Useful for evaluating dynamic characteristics of structures, i.e resonance Vibration More accurately represents the true environment. Excites all frequencies

Random

Most damage occurs at fundamental frequency of electronics PCB.

Vibration and Shock

Shock

High stresses causing fracture or permanent deformation High accelerations which can cause relays to chatter, potentiometers to slip, bolts to loosen. High displacement which can cause impact between adjacent circuit boards Usually not considered a fatigue failure if shock quantity less than 1,000 cycles.

Selecting a Vibration Level or a Shock Pulse

Which Shock Pulse should I Apply? How Many? Which Level? What is the vibration spectrum of interest? How long should I test for?
Follow the Contract Specifications Create Your Test Based on Existing Specifications as Guidance Make Field Measurements

1. 2. 3.

1- Follow Contract Requirements

Contract Requirements MIL-PRF-15305

Contract Requirements MIL-PRF-15305

MIL-STD-202G Method 213

2- Use Existing Specifications for Guidance

Military, Regulatory, and OEM Specs Industry Standard Test Methods

with Recommended Levels

Create Your Own Specification

Shock Test Specs & Methods

Automotive

FORD, GM SAE J1455

Handling Drop Classical Shock (Potholes & Crashes)

Classical Shock Bump Free Fall Operational and Crash Safety Shock Sustained Shock

Commercial Products

IEC 68-2-27; -29; -31

Commercial Aviation

RTCA DO 160E Section 8

Military

MIL-STD-810 Systems MIL-STD-883 Circuit Cards MIL-STD-202 Components

SRS Classical Pyroshock Ballistic Shock

Handling and Free Fall Drop Tests

Drop Surfaces

Concrete Steel Wood Sand

Package or Device

Typical Classical Shock Tests for Electronic Systems

A(Gs)
A(Gs)

Time (msec)

Time (msec)

Reference Specification MIL-STD-810F Ground Equipment ISO 16750-3 General Motors GMW 3172 General Motors GMW 3172 Ford Motor RTCA DO-160D (Operational) RTCA DO-160D (Crash Safety)

Amplitude Pulse and Duration Shape 75g-6ms Saw-tooth 50g-6ms Half-Sine 25g-15ms 100g-11ms 100g-10ms 6g-11ms 20g-11ms Half-Sine Half-Sine Half-Sine Saw-tooth Saw-tooth

Quantity 3 pulses x 3 axes x 2 Dir (18 total) 10 pulses x 3 axes x 2 Dir (60 total) 132 pulses x 3 axes x 2 Dir (792 total) 3 pulses x 3 axes x 2 Dir (18 total) 6 pulses x 3 axes x 2 Dir (32 total) 1 pulse x 3 axes x 2 Dir (6 total) 1 pulse x 3 axes x 2 Dir (6 total)

Typical Classical Shock Tests for Electronic SystemsIEC 68-2-27

Gs
15

Time
11

Wave
ST, HS, TR

Components

Equipment
General handling and transport. Land based items or items transported by road, rail or air in secured shock resistant packages Installed or tranported in a secured position on normal road or rail vehicles or in transport aircraft Items installed or transported in a secured position in full cross-counry vehicles. Items carried loose in normal road or rail vehicles for long periods. Items used in industrial areas and subjected to shock from mechanical handling equipment for example dock cranes, fork lift trucks.

30

18

ST, HS, TR

30

11

ST, HS, TR

Items in secured packages transported by wheeled vehicles, aircraft, merchant ships or light marine craft.

100

Items in secured packages transported by full cross country vehicles. Items mounted in ST, HS, TR equipment tranported by or installed in full cross country vehicles or aircraft HS Structural integrity semiconductors, microcircuits. Structural integrity semiconductors, microcircuits. tests on integrated circuits, tests on integrated circuits,

500

1500

0.5

HS

Elite Capability for Classical Shock

Large Avco (Assume 150lb load and fixture)

Short Pulse 3msec- 300Gs Long Pulse 30msec-20Gs

Small Avco (Assume 50lb load and fixture)

Short Pulse 0.3msec- 1000Gs (longer pulses up to 10kGs) Long Pulse 6msec-500gs

Tira Electro-dynamic Vibration Table (Assume 150lb load and fixture)

Short Pulse 0.5msec 150Gs Long Pulse 30msec 15Gs

Classical Shock Pulses

Advantages

Easy to specify and understand shape, tolerance, mathematics Test machinery can generate pulses Accepted methods written into many specs

Disadvantages

Not real world pulses Does not evaluate device response to shock

Classical Shock Tests

Axis1(g's) Axis2(g's) Axis3(g's)
15 10 5 0 -5 -10 -15 -20 15 10 5 0 -5 -10 -15 10 5 0 -5 -10 -15 0 20 Engine 3.sif - AccelTH@Axis3.RN_2

Engine 3.sif - AccelTH@Axis2.RN_2

Engine 3.sif - AccelTH@Axis1.RN_2

40 Time(secs)

60

80

100

Classical Shock Tests

15 10 5 TmpEdit_0004.sif - AccelTH@Axis3.RN_2

Axis3(g's)

0 -5 -10 -15 -20 0 5 10 Time(secs) 15 20

Shock Response Spectrum

Shock Response Spectrum

Input Pulse Measured Response

Shock Response Spectrum

Shock Response Spectrum

Shock Response Spectrum

Shock Response Spectrum

Preferred method for MIL-810 Describes the Peak Acceleration Response vs. Freq Develop a simple shock pulse that will generate the response function Some ED shakers have SRS capabilities Ringing plates Pyrotechnic Shock

Pyrotechnic Shock

Pyrotechnic Shock

Pyrotechnic Shock

Ballistic Shock

Custom Shock Evaluation

ASTM D3332

Damage Boundary

Response to short duration pulse is a function of velocity change. Response to long duration pulse is a function of the peak acceleration and waveform.

MIL-810 Fragility Test

Vibration and Shock Summary

1.
2.

3.

Follow the Contract Specifications Create Your Test Based on Existing Specifications as Guidance Make Field Measurements
Call us with your application needs.

4.

Thank you for this opportunity to serve you.