Motorized products must go through a series of tests to be ready for mass production. For example, parts containing an automobile are sent to dynamic test labs to withstand changing pressure, noise, vibration and other demanding forces.
The purpose of these tests is to see if each of the parts that will ultimately contain a vehicle, plane or machine is strong enough for the finished product. After each test pass, the various product parts must ensure that the vehicle or plane fulfills its expected lifetime under any intensive stress, without cracking, breaking or twisting along any point.
Dynamic test types used in the automotive and aerospace departments include:
Dynamic testing types range from medium to heavy, depending on the durability requirements of a particular product.
EUROLAB has the most comprehensive dynamic testing laboratories in the country and has extensive experience in all product types.
The purpose of the acceleration test is to examine how a product reacts to changing acceleration speeds. These tests, which move slowly and steadily between low and high acceleration, are measured at g-forces. Acceleration tests take care to exclude shock, vibration, and other types of impacts used in separate tests.
The purpose of the acceleration test is to determine how many g of a product can withstand and still maintain its strength, composition and functionality.
In real life environments, excessive acceleration loads can have detrimental effects on a large number of commercial and industrial products. For example, printed circuit boards may fail due to impact due to intense acceleration loads. Other harmful acceleration effects include:
Acceleration tests are usually performed on products manufactured for the aviation industry, such as the outer and inner parts of aircraft. To pass the test, a product must remain operational under peak loads.
Acceleration tests in EUROLAB are carried out in G-charts, from centimeters with diameters and weight capacities ranging from 1ft (0.3m) to 62m (16m), from a few grams to 7175 kg. During the test, electric slip rings are used to control and operate each device. If the tester is pneumatic or hydraulic, rotators are used to provide the required compressed air or water during the test. Swivels provide a high degree of flexibility during the testing phase.
In general, the acceleration test is carried out by various methods such as centrifuge, loop, multi-axis, thrust application and load analysis, the last of which is especially true for satellites and space probes. MIL-STD-202 is the industry standard for testing electrical components for durability in acceleration light.
The effects of acoustic noise vary between different device types. When products are manufactured for commercial or industrial use, it is very important to test the noise threshold of each device. With the acoustic noise test, manufacturers can determine how a particular device handles various degrees of sound exposure at the loudest possible settings.
Acoustic noise testing laboratories use high-tech equipment that tests the noise threshold of products before they are released. Based on these results, manufacturers can determine whether a particular product is ready for commercial, industrial or military use. If a device cannot process acoustic noise within an expected range, the product is returned for revisions.
At high altitudes and under intense speed or torque, acoustic noise can have an intense effect on motor components. Some of the harshest sources of acoustic noise include wind resistance and running motors. Therefore, parts containing the engines of aircraft and vehicles must undergo acoustic tests before they are approved for market use.
If exposed to excessive acoustic noise, a product may show some of the following symptoms:
Acoustic noise can penetrate a device, even in a closed, fixed environment. When a vehicle or airplane is in motion, acoustic noise can graze the outer surfaces of the parts.
Acoustic noise testing is applied in products used in the military, regulatory and telecommunications sectors. Noise testing is essential for defense equipment to ensure that hearing loss and enemy detection are not caused by the noise levels created by guns and artillery. Acoustic noise testing is covered by many industry standards.
One of the most unpredictable dangers for flying aircraft is the upcoming bird. Although it seems odd that such small, organic creatures might endanger something as big and relatively invincible as an airplane, collisions with birds have been the cause of considerable material damage to commercial and military aircraft. Birds are dangerous for planes due to the high effect of contrasting high speeds.
In some cases, bird strikes appear to drag passenger aircraft into mandatory landings. For example, consider US Airways Flight 1549, which crashed into the Hudson River shortly after take-off when each of the aircraft's engines were hit by geese. Both engines were heavily damaged by the impact of birds, and this event caused the plane to fall into the river.
In most engine pulses, only one engine gets stuck and the other engine is used to safely land the nearest airport. In general, bird strikes damage the planes more than $ 400 million annually. Most of these collisions occur in other parts of the plane, where birds can cause dents in metal and cracks in the windshields.
The bird crash test is performed with a crash simulator or "chicken gun" in which organic and imitation birds in a range of 2.2 to 8 kilos are released at high speeds of up to 400 mph. The aim is to test whether parts of an airplane or vehicle are strong enough to withstand high-speed impacts on birds.
Vibration testing for machines, vehicles, aircraft and electronic devices is an important part of the product review process. The effects of vibrations and vibrations can damage the internal mechanisms of any product without sound design. For this reason, vibration tests are carried out on the products before they are placed in the military, aviation and automotive sectors.
Amidst the speeds that vehicles and planes travel, the engine components that drive each vehicle and aircraft should withstand vibrations. To test the vibration resistance of these various components, shaker tables and tests are used, in which the engine parts are subjected to heavy vibrations.
During a given daily ride, any random passenger vehicle may be subject to vibration due to surface irregularities on highways and highways. Similarly, the gunner vibrates with rocket and missile launch force. Even on an airplane, wind resistance causes the wings to vibrate at high altitudes.
In the vibration test, each applicable component passes a test that mimics the type of vibration that the engine or metal part may encounter in the air, on the road, or in a fixed environment. Vibration testing helps manufacturers identify design weaknesses that can cause engine components to crack or break through their associated connections. In addition, the vibration test ensures that the released components meet the minimum vibration thresholds of the automotive and aerospace industries.
At EUROLAB, we can produce up to 70.000 force pounds in single shaker and up to 45.000 force pounds in a single shaker. It has performed more than 200 GRMS vibration tests in one band, and we can connect more than 100 data channels.
Components designed for various industries must be subjected to corrosion testing to ensure they are physically intact in corrosive environments. The problem is that corrosion can take months and sometimes years to build and spread a metal surface. In order for corrosion tests to be used effectively without continuing the production of a particular product, the parts must be subjected to an artificial environment that accelerates the corrosive process quickly.
Accelerated corrosion test With, manufacturers can get a more accurate idea of how long a particular product can withstand the corrosive effects of a medium. In EUROLAB, parts are subjected to corrosion testing and monitoring in a number of conditions that accelerate corrosive effects.
Depending on the type of environment intended for the operation of a machine or vehicle, a corrosion test may require special standards. For example, if a machine is made for use in a high acidity facility, the test will need to simulate these more extreme effects to determine whether the machine and its various parts can withstand these environmental factors during the expected life cycle.
For products intended for use in environments with average corrosive factors, a basic salt-fog test is usually applied. Various industry standards including MIL-STD-810, ASTM B117 and GM9540P are applied to the corrosion test. Corrosion tests are carried out for the aviation, automotive, military and medical industries at EUROLAB. Basic tests, such as salt spray testing, are also done on commercial products.
In the thermal shock test, the products are exposed to extreme, sudden fluctuations in temperature. The aim is to test the temperature threshold at both ends of the hot-cold spectrum to determine how these products will fly under these changes. Thermal shock testing is typically done in products manufactured for use in environments where sudden temperature changes are regular.
The shock test is also used to determine the durability of a product under sharp accelerations and deceleration pressure. In reality, the reaction of products to shock fluctuations in heat, cold and pressure is examined to see if a product is ready for mass production in its current design. The intensity of the shock test depends on which industry standard applies to the product in question.
In EUROLAB, it is used in a variety of ways, including mechanical shock testing, pyro-shock and on-board shock testing. Pyro-shock simulates the shock of an explosive connected to the test product, while the ship shock, also known as heavy shock, mimics the shock equipment on deck when the explosive is detonated in the water beneath the ship using a float. Light shock is carried out using hammering techniques in ship machinery, equipment, systems and structures. The medium-weight shock simulates body level inputs with rest products below 7.4000 lbs.
With the drop test, products or packaging are tested to determine the height at which these products can fall and remain intact after a collision and fall. The drop test is important for products and packaging in all industries.
The drop test is often used to test the durability of packaging arrangements for small consumer products. For example, testing how much a shipping box full of calculators or smartphones can withstand a 3 to 5 foot drop is an example. The height at which a product falls from the test is proportional to the fact that a product falls into a real-life situation, neglect, or the prevention of bad play. ISTA standards are the most commonly used for shipping containers, some organizations such as FedEx and Amazon have their own set of ISTA requirements for package testing.
At EUROLAB, the steepest drop tests are carried out at a height of 80 feet to determine the flexibility of the product if a real drop occurs during the transportation or transport stages. Drop towers are also used in test products to create mechanical shocks between 15.000 g and 20.000 g.
For manufacturers, it is important to know how each product can withstand the aging process over its expected life. In this way, manufacturers can make design revisions, if necessary, to make products more flexible and reduce downtime and warranty claims. To this end, tests are carried out on products to speed up the aging process.
Tests using processes that accelerate aging include High Accelerated Life Testing (HALT), High Accelerated Stress Screening (HASS) and High Accelerated Thermal Shock (HATS) tests.
HALT tests are used to find weaknesses in a particular test device. During the HALT test, heat and vibration are applied for short periods in high volumes to see how the product impairs exposure. Ultimately, the goal is not to see if a product can survive the test, but to determine how long and at what exposure levels the product can function and retain its composition before it fails.
HALT tests are carried out in five stages - high temperature stress, low temperature stress, vibration, thermal and combined environment. HALT tests for the manufacturer make it possible to make the products strong enough for maximum possible durability during the five test cycles before cracks, warping and other signs of trouble occur.
The purpose of the HASS test is to see if there is a defect in a product during the manufacturing stages. HALT testing is used to test products in beta form, while HASS tests force the durability of each product in revised form. The Highly Accelerated Thermal Shock (HATS) test, as the name implies, tests the durability and operability of products in case of thermal shock.
HALT and HASS test methods serve similar purposes to fatigue testing on industrial materials such as metal, plastic and polymer. With the fatigue test, the resistance of a material to deformation and decomposition is tested under a series of stress volumes. Fatigue testing allows manufacturers to determine the strength and flexibility of a particular material before it is used in a product.
It is very important to test a product for maximum strength and durability before it is manufactured and placed on the market for use in large quantities. Whether a particular part is designed for use in aircraft, vehicles, military weapons, factory machinery or commercial products, life and property may be at risk if the product fails to perform its intended function.
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