Accelerated & Environmental Stress Testing
Rigorous testing is conducted daily in Siemens state-of-the-art Environmental Stress Test Lab to produce reliable rugged communications equipment.
As a way to ensure superior quality and durability of the RUGGEDCOM portfolio, Siemens conducts rigorous testing in its environmental stress test lab. All Accelerated and Environmental Stress Testing is conducted in-house with specialized equipment – where controlled and incremental stressors are applied to expose latent flaws. The tests are designed to condense the time required to identify product design flaws and manufacturing errors.
Highly Accelerated Life Testing (HALT)
HALT is used during the early product research and design phase to eliminate marginally performing components and manufacturing processes. To achieve this, products will endure the HALT test for extended periods of time at extreme vibrations and temperature levels over multiple stress cycles. Siemens uses the HALT chamber to ensure that RUGGEDCOM products perform reliably throughout their intended service lives.
HALT Testing Procedure
During the HALT process, the RUGGEDCOM products are clamped down onto the vibration table; thermocouples and accelerometers are then connected to the device for monitoring. The products are exposed to ambient temperatures consisting of multiple hot and cold cycles, extreme vibrations, and rapid thermal transitions. Real time data is consistently acquired during the entire HALT process to create precise testing profiles and refine product designs.
During the HALT testing procedure the product are exposed to the following test cycles:
Vibration Cycle: Continuous 6 degrees of freedom repetitive shock vibration with a maximum
setting of 50 grms
Combined Cycle: Thermal extremes, intense thermal ramp rates, and continuous 6 degrees of freedom repetitive shock vibration
Profile time: Typically 1 to 2 weeks
Highly Accelerated Stress Screening (HASS)
HASS subjects RUGGEDCOM products to tougher conditions than they will encounter in the field. This is how the company ensures minimal early life failures and achieves industry leading field demonstrated mean-time-between-failures (MTBFs) measured in hundreds of years.
During manufacturing cycles, HASS is used to ensure that items released from our production lines have zero manufacturing errors. HASS testing simulates extreme real-world environments to help expose any latent flaws early-on that could possibly cause product failures in-the-field. If any flaw is found during the HASS testing, the product will be immediately transferred to the failure analysis team, so the root issue can be identified and corrected.
HASS Testing Procedure
During the HASS testing process, RUGGEDCOM products are loaded into the HASS chamber. The four quadrants per chamber allow for multiple products to be tested simultaneously. Modular fixtures can be fully or partially loaded with RUGGEDCOM products. Once the products are loaded, a RUGGEDCOM specific test script is launched and a scanning process is initiated to automate the monitoring process of running units. HASS testing ensures that all products leaving the factory are of the highest quality.
During the HASS testing procedure the products are exposed to the following cycles:
Heat Cycle: Starting temperature at + 30° C to maximum product operating temperature to ensure
a RUGGEDCOM product will run consistently at +85° C
Cold Cycle: Starting temperature at + 30° C to lowest product operating temperature to ensure
a RUGGEDCOM product will run consistently at -40° C
Rapid Temperature Cycle: Consecutive hot and cold cycles
Vibration Cycle: Continuous 6 degrees of freedom vibration with a maximum setting of 15 grms
Combined Cycle: Thermal extremes, intense thermal ramp rates and continuous 6 degrees
Profile time: Typically 2 hours
Temperature & Humidity Stress Screening (THSS)
The humidity chamber is an essential environmental parameter that is analyzed by the Siemens team. To further increase product reliability, a Temperature and Humidity Stress Test is performed. During the humidity testing process, water vapor is added to the chamber, intensifying the moisture penetration into the RUGGEDCOM products. Data is then collected and analyzed to ensure that RUGGEDCOM products perform beyond industry standards.