IEC 60068-2 is a globally recognized standard that outlines a series of tests for products, components, and equipment to assess their ability to withstand environmental conditions. By simulating the different climatic conditions and mechanical stresses a product can undergo during its lifetime, environmental testing can help manufacturers validate the ruggedness, durability, and performance of their products.

One of the key tests within this series is the shock test, which is designed to simulate the effects of sudden impacts or abrupt changes in motion that a product might encounter during its lifecycle. Specifically, the International Electrotechnical Commission (IEC) manages two well-known shock and drop-shock standards for electrical and electronic-related technologies, IEC 60068-2-27 and IEC 60068-2-31. 

• IEC 60068-2-27 Environmental testing Part 2-27: Test Ea: Shock
• IEC 60068-2-31 Environmental testing Part 2-31: Test Ec: Rough Handling Shocks

IEC 60068-2 shock testing is a critical part of product development for several reasons:

• Real-world conditions simulation: Products often encounter shocks and impacts during shipping, handling, and everyday use. IEC 60068-2 shock testing simulates these conditions to assess how well the product can withstand them.

• Identification of potential weaknesses: Shock testing can reveal design or manufacturing flaws that might cause the product to fail prematurely. Identifying these issues early in the development process can save time and money on product recalls or redesigns.

• Ensuring product reliability: For products that are used in critical applications, such as medical devices or aerospace components, shock testing is crucial to ensure they can perform reliably under all conditions.

• Worldwide recognition: IEC 60068-2 is an international standard, so products tested to this standard are accepted worldwide. This can simplify the process of selling your product in international markets.

At DES, we understand the importance of detailed and accurate shock testing. Our experienced team can guide you through the process, ensuring your product meets all relevant standards and is ready for the rigors of real-world use.

IEC 60068-2-27: A Detailed Look at the Shock Testing Standard

IEC 60068-2-27 is a specific test within the IEC 60068-2 series that focuses on shock testing. This test is designed to simulate the shock conditions that products, components, and equipment may encounter during transportation, storage, handling, or in use. The purpose of this test is to reveal mechanical deficiencies, degradation, and/or accumulate damage caused by shocks.

The IEC 60068-2-27 test is a crucial part of the product development process. It provides manufacturers with valuable insights into the potential weaknesses of their products, allowing them to make necessary improvements to enhance product durability.

The test involves subjecting the product to specified levels of shock impulses in a controlled environment. There are 3 types of shocks in IEC 60068-2-27, half-sine impulse, saw-tooth impulse, and the trapezoidal impulse.  Much of this standard defines the pulse shapes and control of the shock parameters.  Other sections cover the test severities such as the peak acceleration level, duration, and number of shocks.  The user specifies which test severities are applicable to their products.  Annex A provides guidance and examples of test severities for various applications.  Annex B gives information about shock response spectra (SRS) and the characteristics of the pulse shapes.  The product’s performance may be evaluated during the shocks or just before/after the test.

At Delserro Engineering Solutions, we have extensive experience conducting IEC 60068-2-27 shock testing. Our meticulous approach to testing ensures that your product is thoroughly evaluated for potential weaknesses, providing you with the information you need to make informed decisions about product improvements. Our commitment to quality and accuracy ensures that our testing procedures meet the highest standards of reliability and precision.

IEC 60068-2-31: Shocks Intended to Simulate Rough Handling

IEC60068-2-31 is another critical standard within the IEC 60068-2 series, focusing on simulating the effects of rough handling shocks.  Rough handling shocks are knocks, jolts, and falls typically encountered during repair work, rough handling or dropping.  IEC 60068-2-31 defines 3 types of rough handling shock tests:

• Drop and Topple is intended to assess the effects of knocks or jolts typically occurring during repair work or rough handling on a table or work-bench.  The drop tests are accomplished by raising an edge or corner of an item to a prescribed height, then releasing it allowing the face under test to drop onto a hard surface.  The topple test is performed by raising an edge slowly until instability occurs, then allowing the specimen to topple over onto an adjacent face.  The number of drops or topples is usually 4.
• Free Fall – Procedure 1 is aimed at evaluating the effects of falls from rough handling.  The entire specimen is raised to a defined height, then released allowing it to free fall onto a hard surface.  The product can be oriented to allow the impact to occur on a face, edge or corner.  Typically the number of free falls is 2.
• Free Fall – Procedure 2 is intended to reproduce repetitive shock conditions likely to occur on component-type specimens such as electrical connectors.  The test specimens are subjected to a prescribed number of falls from a specified height onto a hard surface.  The number of falls in procedure 2 typically ranges from 50 to 1,000. 

At Delserro Engineering Solutions, we use a thorough approach when conducting IEC 60068-2-27 and IEC 60068-2-31 shock testing, ensuring that the test is performed under repeatable conditions and your product is evaluated for rugged usage.

Our testing process begins with a thorough understanding of your product and its intended use. This allows us to assess the shocks and impacts your product is likely to encounter. We then subject your product to a specified level of shocks or impacts in a controlled environment. This test can reveal defects in the product’s design or construction that might not be evident.

Throughout the testing process, our team of experts will keep you informed of our findings and will deliver a detailed report upon test completion. Our goal is to help you improve your product’s reliability and durability, ultimately enhancing its market success.

Our commitment to quality and accuracy is demonstrated by our compliance with ISO/IEC 17025, a globally recognized standard for testing and calibration laboratories. Furthermore, our lab is accredited by A2LA, the country’s leading accreditation agency. This ensures that all tests conducted are technically competent, reliable, and of the highest quality. Clients can have peace of mind knowing that their products are tested with precision and accuracy, minimizing the risk of product failures in the market.

IEC 60068 2: Why Choose DES for Your Shock Testing Needs

Choosing the right partner for your shock testing needs is crucial. At Delserro Engineering Solutions, we offer a comprehensive suite of services designed to ensure your products meet the stringent IEC 60068-2 standards. Here’s why DES should be your first choice:

1. Experience: With over 30 years in the industry, we have the expertise to conduct thorough and accurate shock testing for a wide range of products. Our team has managed testing projects for clients all over the world, including renowned organizations like Adidas, Crayola, Medtronic, Rolls Royce, Boeing, Lockheed Martin, NASA and the U.S. Army.
2. Quality Assurance: Our lab is ISO/IEC 17025 compliant and A2LA accredited, ensuring the highest level of quality and reliability in our testing procedures. This commitment to quality is demonstrated in every test we conduct, providing you with confidence that your product has been thoroughly evaluated and meets all relevant standards.
3. Customized Solutions: We understand that every product is unique, so we tailor our testing methods to meet your specific needs. Our team works closely with you to understand your product and its intended use, allowing us to customize our testing process to accurately simulates the shocks and impacts your product is likely to encounter.
4. Client Satisfaction: We’ve worked with global clients and have received positive feedback on our seamless procedures, high level of service, and impressive test results. Our commitment to client satisfaction is evident in every project we undertake, and we strive to exceed your expectations at every turn.

Contact DES today to discuss your IEC 60068-2 shock testing requirements with one of our experts. We’re here to help you ensure your product’s success in the market.

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Thermal shock exposes devices to rapid temperature changes greater than 15°C/minute.  Temperature cycle testing uses a transition rate less than 15°C/minute and is usually between 1 to 10°C/minute from our experience. 

Examples of sources where thermal shock may occur are:

• Rapid changes in environment such as transfer of items between a temperature controlled environment to an outdoor extreme temperature
• Sudden change when starting equipment that was stored outside in an artic climate
• Sudden large internal power changes
• Ascent from a high temperature ground environment to high altitude

Examples of sources where slower thermal cycles may occur are:

• Powering electronics on and off in a controlled environment
• Slower daily outdoor temperature changes between night and day

The soak times at each hot and cold temperature vary greatly for different items.  The soak times are mainly dependent on the thermal masses of the larger components within each product.  Soak time can typically vary from 15 minutes to 2 hours.  Soak times are also dependent on whether the units are powered or unpowered during testing.  

Thermal shock failures could be different from temperature cycle failures.  Failures from thermal shock could be more of an overstress type.  Thermal shock failures on solder joints tend to be caused by tensile overstresses and tensile fatigue.  Thermal cycle failures on solder joints components are typically from shear creep fatigue and stress relaxation. 

Thermal shock testing is typically performed in a dual compartment chamber.  One compartment is for hot temperature and the other is for cold temperature.  Products are placed in a carriage that shuttles between the hot and cold compartments within seconds exposing the test item to thermal shock.  For large specimens, a single compartment chamber can be used that can perform rapid temperature changes. DES has both types of chambers.

Temperature cycle testing is performed in a single compartment chamber, either a chamber that controls only temperature or a temperature humidity chamber.  Most temperature humidity chambers can perform thermal cycling with or without adding controlled humidity.  DES conducts temperature cycle testing using both types of single compartment chambers. 

Typical test specifications include:

• MIL-STD-202, Method 107, Thermal Shock
• MIL-STD-810, Method 503, Temperature Shock
• MIL-STD-883, Method 1010, Temperature Cycling
• JESD22-A104, Temperature Cycling
• JESD22-A105, Power & Temperature Cycling
• IEC 60068-2-14, Change of Temperature
• RTCA/DO-160, Section 5.0 – Temperature Variation

Delserro Engineering Solutions, Inc. (DES) has many years of experience performing thermal shock and temperature cycle testing.  We can assist you with setting up a test, choosing the proper test conditions or choosing a test specification.  Please contact us or call 610.253.6637 to find out what DES can do for you!

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MIL-STD 810, Method 516, Shock Testing Overview

MIL-STD 810, Method 516, Shock Testing Procedure I – Functional Shock

MIL-STD 810, Method 516, Shock Testing Procedure II – Transportation Shock

MIL-STD 810, Method 516, Shock Testing Procedure III – Fragility

MIL-STD 810, Method 516, Shock Testing Procedure IV – Transit Drop

MIL-STD 810, Method 516, Shock Testing Procedure V – Crash Hazard Shock

Bench Handling Shocks are used to test products that may experience shocks on a work bench.  Bench handling shocks could occur when items are being repaired or when they are in the process of being packaged.  Products are tested in an unpackaged configuration and are usually non-operational during the test.  Procedure VI is appropriate for medium-to-large test items that have a maximum dimension greater than approximately 23 cm (9 inches).  Smaller products are typically tested to higher shock levels using Procedure IV, Transit Drop.

Bench Handling Shocks are performed on a solid wood bench top that is at least 4.25 cm (1.675 inches) thick.   The procedure is:

• Perform an operational and physical checkout of the unit under test before start. Configure the test item as it would be for servicing, i.e., with a service panel removed, etc.
• Using one edge as a pivot, lift the opposite edge of the product until one of the following conditions occurs (whichever occurs first). This step is shown in Figure 1 above.

1. The lifted edge of the chassis has been raised 100 mm (4 in.) above the horizontal bench top.
2. The chassis forms an angle of 45° with the horizontal bench top.
3. The lifted edge of the chassis is just below the point of perfect balance.

• Release the product and let the chassis drop back freely onto the horizontal bench top. Repeat using other practical edges of the same horizontal face as pivot points, for a total of four drops.
• Repeat Step 3 on other faces until the item has been dropped for a total of four times on any face on which it could be placed practically during servicing.
• Perform a visual inspection of the test item. Then perform a final operational and physical checkout and compare the results to step 1.

Typical failures are damaged cover protrusions, connections or even internal damage to the product.  For more information on Shock Testing or other testing services, contact DES or call 610.253.6637.

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