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Category: Test Standards

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

This is part two of a series of blog posts concerning the MIL-STD 810 Shock Section, Method 516.  This blog was written with reference to MIL-STD-810G w/Change 1 dated 15 April 2014.  DES has the experience and expertise to run your MIL-STD-810 test.  For more information, please check out our DES shock testing services page and our other MIL-STD-810 shock testing blog articles:

MIL-STD 810, Method 516, Shock Testing Overview

Shock testing according to Procedure I of MIL-STD 810, Method 516 is intended to test products while they are operating to see if any functional problems occur and to determine if they survive without damage.  The applied shocks usually represent those that may be encountered during operational service.  This article will focus on the shock test condition when measured field data is not available and the testing will use classical shock impulses.  The terminal peak sawtooth is the default classical shock pulse to be used for this condition.  Figure 516.7-10 from MIL-STD-810 shows its shape and tolerance limits.  Table 516.7-IV contains the terminal peak sawtooth default test parameters for Procedure I -Functional Test.  In limited cases a half sine shock impulse is specified.  Its shape and tolerance limits are shown in Figure 516.7-12.

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MIL-STD-810: Vibration Testing Category 8 – Aircraft – Propeller

This is part four of a series of blog posts concerning the MIL-STD 810 Vibration Section.  This blog was written with reference to MIL-STD-810G w/Change 1 dated 15 April 2014.  DES has the experience and expertise to help you determine what profiles are appropriate for your product and to run your MIL-STD-810 vibration test.  For more information, please check out our Vibration Testing services page and our other MIL-STD-810 vibration testing blog articles:

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MIL-STD-810: Vibration Testing Category 7 – Aircraft – Jet

This is part three of a series of blog posts concerning the MIL-STD 810 Vibration Section.  This blog was written with reference to MIL-STD-810G w/Change 1 dated 15 April 2014.  DES has the experience and expertise to help you determine what profiles are appropriate for your product and to run your MIL-STD-810 vibration test.  For more information, please check out our Vibration Testing services page and our other MIL-STD-810 vibration testing blog articles:

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MIL-STD-810: Shock and Vibration Testing Category 9 – Aircraft – Helicopter

This is part of a series of blog posts concerning the MIL-STD 810 Vibration Section.  This blog was written with reference to MIL-STD-810G w/Change 1 dated 15 April 2014.  DES has the experience and expertise to help you determine what profiles are appropriate for your product and to run your MIL-STD-810 vibration test. For more information, please check out our Vibration Testing services page and the other blog posts in this series,

MIL-STD-810 Vibration Testing Overview

MIL-STD-810: Vibration Testing Category 4 – Truck/Trailer – Secured Cargo

Procedure I (General Vibration), Category 9 of Method 514.7 Vibration testing details the vibration profile of cargo carried in helicopters.  This vibration profile is unique because it superimposes strong narrowband peaks of sinusoidal vibration caused by rotating components such as the main or tail rotors, over low-level wideband random vibration caused by aerodynamic flow.  This vibration profile is generally referred to as Sine on Random Vibration Testing.  Figure 1 outlines the typical vibration profile and the variables which are determined based upon the type of helicopter as well as the location on the helicopter where your product will be used or stored.  Tables 1 and 2 define the equations and properties used to determine the variables used in the Figure 1 plot.

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MIL-STD-810: Vibration Testing Category 4 – Truck/Trailer – Secured Cargo

This is part two of a series of blog posts concerning the MIL-STD 810 Vibration Section.  This blog was written with reference to MIL-STD-810G w/Change 1 dated 15 April 2014.  DES has the experience and expertise to help you determine what profiles are appropriate for your product and to run your MIL-STD-810 vibration test.  For more information, please check out Part 1 – MIL-STD-810 Vibration Testing Overview blog and our Vibration Testing services page.

Category 4 of Method 514.7 Vibration testing details the transportation random vibration environmental conditions from cargo interaction with vehicle suspension and structures with road and surface discontinuities.  “This environment may be divided into two phases, truck transportation over US highways, and mission/field transportation.  Mission/field transportation is further broken down into two-wheeled trailer and wheeled vehicles categories.”

 

Truck Transportation over US Highways Vibration Testing

This vibration test method is used when products or equipment will be transported by large trucks tractor-trailers commonly seen on US highways.  The truck transportation over US highways random vibration profile is designed to simulate 1609 km (1000 miles) on interstate highways.  The random vibration profile along each axis can be seen in the plot below in Figure 1.  The length of this profile is 60 minutes per axis for each 1000 miles of transportation.  For example to simulate 2000 highway miles, the vibration test duration would be 2 hours per axis x 3 axes = 6 hours total.

Vibration Testing MIL-STD-810G w/ Change 1
Figure 1. Figure 514.7C-2 from MIL-STD-810G w/ Change 1

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MIL-STD-810 Vibration Testing Overview

This is part one of a series of blog posts discussing MIL-STD 810 Vibration Testing.  This blog was written with reference to MIL-STD-810G w/Change 1 dated 15 April 2014.  DES has the experience and expertise to help you determine what profiles are appropriate for your product and to run your MIL-STD-810 vibration test.  Check out our vibration testing capabilities here.

MIL-STD-810 is a public military test standard that is designed to assist in the environmental engineering considerations for product design and testing.  For the purposes of this blog series we will focus on Method 514.7, titled Vibration.  This section defines the environmental vibration conditions a material or product may experience during the product life cycle and translates these conditions into replicable test procedures.  Unfortunately, unless you’re familiar with this document, this section or any section for that matter may seem a little daunting.  This blog will hopefully provide some guidance into navigating your way through it.

vibration testing standard MIL-STD-810
Figure 1. Table 514.7-I from MIL-STD-810G w/ Change 1

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Door Open/Close Accelerated Life Test Case Study

Customer Goal

A customer contacted DES, seeking to create a reliability test plan for their product based on customer usage, new features and design limits.  One of the concerns identified by the customer was the need for an accelerated life test which tested whether their “door assembly” product met the design specification for usage.  In other words, the goal was to create an automated test solution which opened and closed cabinet doors to the estimated amount they would see during a lifetime in the field.

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Rapid HALT – A Cost Effective Alternative to HALT

Rapid Highly Accelerated Life Testing or Rapid HALT is a reliability test method that is used to expose product weaknesses.  A Rapid HALT procedure is a modification of a Classical HALT procedure.  For more information about Classical HALT procedures, refer to the following blog articles:

A Rapid HALT is an abbreviated HALT, typically one day of tests, making it a great cost-effective solution for those seeking faster qualitative results.  Exposing a product to a Rapid HALT early in the design process can help reduce product development time and cost by enabling manufacturers to identify flaws or areas of improvement before it’s too late.

Rapid HALT’s are a good tool for assessing the reliability of different suppliers of components but can also be used to assess the reliability of less complicated products.  For example, DES has performed Rapid HALT’s to evaluate the reliability of different suppliers of power supplies, cooling fans, and LED’s.  DES has also performed a Rapid HALT to study different fastening methods in order to determine which was more robust.

DES Rapid HALT Profile
Figure 1. DES Rapid HALT Profile

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Qualification Testing on Aerospace Connectors

DES recently performed qualification testing on aerospace connectors which involved combined temperature and sinusoidal vibration testing, random vibration testing and shock testing.  Combined temperature and sinusoidal vibration tests were performed per EIA 364-28F.  EIA 364-28F required test conditions of 10-2000 Hz, 20G maximum acceleration sweeps at temperatures of -54°C and 200°C over the course of 4 hours per axis.  Random vibration tests were also performed per EIA 364-28F.  Random vibrations at 50-2000 Hz, 46.3 Grms were applied to the connectors for 8 hours per axis.  The random vibrations were applied at room temperature.  Finally, the connectors were subjected half sine shocks per EIA 364-27C.  The shock requirements were three shocks per polarity, per axis at 300G over the duration of 3msec.  A sample shock plot can be seen in Figure 1.

Sample Shock Testing Chart
Figure 1 – Sample Shock Test Plot

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