Author: Ryan League

Product Testing and Environmental Test Chambers

December 2, 2024

Ensuring your products are reliable, durable, and market-ready is essential for success. Across industries, product testing is a vital part of maintaining quality. Proper testing not only ensures that products perform as intended but also helps avoid costly recalls, protecting your brand’s reputation.

A key tool in this process are environmental test chambers, which allow manufacturers to replicate real-world conditions in a controlled setting. This article explores the importance of product testing and how environmental test chambers contribute to product success.

What is Product Testing?

Product testing is a thorough process that evaluates how well a product functions, holds up under stress, and remains safe for consumers. The primary objective is to identify and address potential flaws before the product reaches the market. By doing so, manufacturers ensure the product is both safe and effective.

There are several critical types of product testing that companies rely on, including:

  • Functional Testing: Verifies that the product performs as expected in everyday use scenarios.
  • Performance Testing: Assesses how well the product functions under specific conditions, including stress tests that simulate extreme environments.
  • Reliability Testing: Measures the product’s ability to maintain consistent performance over time.

Through these types of testing, manufacturers can detect issues early in the production process, allowing them to resolve potential problems before the product reaches consumers. This saves time, money, and — most importantly — helps avoid damage to brand reputation. For example, electronics manufacturers often perform product testing to evaluate how their devices perform in varying conditions of temperature and humidity.

The Importance of Environmental Test Chambers

An essential part of modern product testing is the use of environmental test chambers. These chambers simulate environmental conditions such as extreme temperatures, humidity, altitude, and vibrations that a product may encounter throughout its life cycle. By exposing a product to these conditions, manufacturers can observe how it performs and identify any weaknesses.

Different types of environmental chambers are available, depending on what testing is required:

  1. Temperature and Humidity Chambers: Temperature chambers expose products to extreme heat or cold to determine how they respond. Humidity chambers test the impact of moisture on a product’s internal components and materials.
  2. Thermal Shock Chambers: Assess how a product handles sudden, extreme temperature changes, such as moving from cold storage to a warm environment.
  3. AGREE Chambers: Simulate the physical stress a product might endure during transport or operation in high-vibration environments.

Using environmental test chambers in their product testing processes allows manufacturers to detect flaws that might otherwise go unnoticed. For example, automotive companies use these chambers to confirm that vehicle components can operate reliably under extreme weather conditions and during extended use.

Benefits of Environmental Test Chambers in Product Testing

Using environmental test chambers in product testing offers significant benefits, particularly when it comes to improving product reliability and compliance with regulatory standards.

Improved Reliability and Safety

Testing in controlled environments that replicate extreme conditions ensures that products can withstand the challenges they may face in the real world. This results in more reliable, safer products that are less likely to fail in customer hands. Products that pass these rigorous tests offer better protection for both consumers and brand reputation.

Early Detection of Design Flaws

Environmental test chambers allow manufacturers to identify weaknesses in product design and material choices. For instance, certain plastics may become brittle in extremely cold environments, or electronic components might overheat when exposed to high temperatures. Detecting these flaws early enables manufacturers to refine their designs and select better materials before mass production.

Cost Efficiency

Addressing design flaws early in the development process is far more cost-effective than issuing recalls or repairing products after they’ve reached the market. Preventing widespread failures or defects with environmental testing saves companies from the financial and reputational costs associated with these problems. Moreover, reducing the likelihood of product recalls helps ensure smoother production schedules and greater customer satisfaction.

Ensuring Compliance with Industry Standards

Many industries are governed by stringent safety and performance regulations. By testing products in environmental chambers, manufacturers can verify that their products meet or exceed these standards, ensuring compliance and reducing the risk of fines or product delays. This is especially important in highly regulated industries such as aerospace, automotive, and medical devices, where environmental test chambers are essential for meeting industry benchmarks.

In summary, product testing plays a critical role in the product development cycle, ensuring that products are safe, reliable, and capable of performing as expected in various conditions. The use of environmental test chambers enhances this testing by replicating real-world environments, helping manufacturers identify and address potential flaws before products reach consumers.
For companies that prioritize quality, incorporating environmental test chambers into their product testing process is a savvy investment. It boosts product reliability, reduces the risk of recalls, and ensures compliance with industry standards. Whether you’re manufacturing electronics, automotive components, or medical devices, robust product testing — particularly that using environmental test chambers — is key to delivering high-quality products that stand the test of time.

What are Thermal Cycling Chambers?

May 13, 2022

Thermal cycling testing is designed to enhance the strength, reliability, and quality of products and components. These tests generally require a quick, uniform, and reproducible change in temperature over a set number of cycles according to industry test standards. 

When you need an environmental test chamber with a high rate of temperature change, uniformity, and reproducibility, we recommend referencing your test standards against the dimensions, temperature cycling rate, and overall temperature range of the chamber to determine the best fit.

Below are a few common questions we receive regarding our temperature chambers or thermal cycling chambers.  

1. What temperature change rates are available in a thermal cycling chamber?

Many factors influence the temperature change rate in a thermal cycling chamber. The size of the chamber, the number, weight, and material composition of the samples under test, and the starting and ending temperatures are just a few to consider. 

Generally, temperature change rates of up to 15°C per minute can be produced in a mechanically cooled chamber depending on compressor size and configuration. Adding direct-injected liquid nitrogen supplemental or boost cooling can dramatically reduce cool-down and diminish temperature transition times. 

2. What size thermal cycling chambers are available? 

Like most environmental test chambers, thermal cycling chambers are available in a wide range of sizes. For example, our smallest test chamber has an 8 cu. ft. interior capacity, is equipped with reach-in shelves, and fits through a standard doorway on rolling casters. 

Larger units are available depending on the size and quantity of the test sample. Walk-in or drive-in test chambers, for example, are fully customizable to your exact specifications and requirements. An important consideration to remember, in general, the larger the interior volume of the thermal cycling chamber, the greater capacity of cooling and heating power is required to achieve and maintain rapid temperature transition. 

3. Do you offer humidity with your thermal cycling chambers? 

Some test standards do require a temperature and humidity-controlled environment. Based on your requirements and testing profile, humidity is available within a standard range of 10% to 95% RH. 

It is important to understand temperature and humidity control considerations as they relate to thermal cycling chambers. In general, the warmer the air, the more moisture it can hold within the same volume of space. Therefore it takes significantly more water vapor to elevate the relative humidity of air as it increases in temperature.

The opposite is true as the air cools. Due to this fact, 50% RH at a dry bulb temperature of 85°C is an exponentially higher moisture level than 50% RH at a dry bulb temperature of 10°C.

4. What available options do you recommend? 

Many optional features are available depending on your testing requirements. We typically recommend a few key options based on improving uniformity and reproducibility within a given test.

A compressed dry air purge is helpful to reduce the dew point of the chamber supply air. This protects moisture-sensitive test samples and also reduces condensation during rapid temperature transitions.

Liquid nitrogen boost cooling is a direct injection system used to enhance the temperature cooling rate and produce faster temperature pulldowns. 

A product temperature control thermocouple provides precise temperature measurement and control, directly at the sample. This is especially useful for providing quick temperature recovery during transitions by overshooting the temperature setpoint until the product temperature reaches the desired temperature level. 

5. What types of controllers are available? 

Our most popular and frequently used controller is the Watlow F4T, a proportional-integral-derivative (PID) color touchscreen controller capable of storing up to 40 different profiles. It conveniently offers an ethernet interface for remote monitoring and operation as well as USB ports for download and storage. 

For more robust capabilities, we offer our own russellsOne® color touchscreen controller in a 12” human-machine interface (HMI) format. Data logging is available with up to 64 analog inputs and 4 channels of PID control. With its ability to interface with other software, it is our most frequently retrofitted controller to existing and other test chamber manufacturers’ equipment. 

6. Do I have access to service and technical support after delivery?

We offer an industry-leading parts and service warranty on all our equipment, including our thermal cycling chambers. Purchasing an environmental test chamber is a significant investment. That’s why we’re proud to provide timely, friendly, and economical service to our customers.  

Our dedicated service team is available to meet your needs if and when issues arise. And because we offer a preferred service provider network across our delivery footprint, you’re not handcuffed to one vendor or having to wait for service when your test equipment is down. Whether you call our factory or reach out online, you will receive prompt and effective solutions from our dedicated staff.   

If you have questions or are interested in a thermal cycling chamber, contact us today to begin a conversation.

Combined Environmental Testing – Altitude, Temperature & Humidity

May 2, 2022

Simulating real-world conditions is critical to understanding how products react in a variety of environments. Perhaps no more important conditions exist in which to proactively test products than aerospace and military defense applications. Typically, these products and components must function properly at various altitudes, temperatures, and humidity conditions. Coupled with mechanical or electromagnetic vibration, combined testing is essential to understanding the material resistance to the effects of changing temperature and humidity environments at varying altitudes. 

Why is Combined Environmental Testing Important?

While the individual conditions on their own can be replicated, the importance of combined temperature, altitude, and humidity testing is critical in aerospace, defense, and electronics manufacturing where products and components are functioning in extreme environments. Navigational components of commercial aircraft and guidance systems for defense articles are just a few examples of critical components required to operate functionally in diverse conditions. Combined climatic testing allows manufacturers to replicate these conditions within a controlled environment to test, validate, and diagnose for potential failures in advance of their utilization. 

Most manufacturers utilize combined methods of temperature chambers, altitude testing chambers, and humidity testing chambers for engineering development, operational testing, and qualification. Many requirements involve actively powered devices or parts in operation at altitude including aircraft, missiles, and aerospace components. By synergistically combining environmental conditions, combined climatic testing simulates the effects that are likely to occur over the majority of the deployment life of the test article.

What Environmental Conditions Can Be Created?

To verify products remain operational and durable against the full range of environmental conditions to which they might be exposed, concurrently simulating temperature and altitude or altitude and humidity can help identify potential failures that may not manifest in each condition tested separately. 

MIL-STD-810 G Test Method 520.3 specifically addresses the combined effects of temperature, altitude, humidity, and vibration on airborne electronic and electromechanical components to ensure their safety, integrity, and performance during ground and flight operations. Identifying the specific profile, procedure, and step within MIL-STD-810 G will assist your test chamber manufacturer in designing the equipment to best match your requirements. 

Most altitude test chambers possess the capability to achieve altitude up to 100,000 ft. with extended ranges in some cases to 200,000 ft. The temperature range is typically offered between -70°C and +180°C, with humidity between 10% and 95% RH. Mechanical refrigeration or the use of liquid nitrogen are used to create a wide temperature environment, while rotary vane vacuum pumps of varying sizes create the ‘vacuum’ associated with high altitude conditions. Atmospheric steam generators are typically used to introduce humidity into the system bound within a maximum dry bulb temperature generally not to exceed 85°C. 

Test profiles within military and aerospace standards require the following combined environment testing conditions. Altitude with temperature is produced by cycling 5°C per minute or steady-state temperature testing between site level and 65,000 ft. Temperature and humidity are cycled between 10% and 95% RH typically at site level only. 

What to Look for in a Test Chamber?

While many manufacturers claim to make altitude test chambers, not all are created equal. Consider the following construction factors when determining which altitude chamber manufacturer is best suited for your needs. 

The chamber liner should be constructed of a minimum 16 gauge heavy-duty stainless steel material ensuring robust strength and rustproof quality. Seams should be hermetically sealed to prevent moisture migration during low-temperature operations. Consider external or internal pressure membranes in your selection process. These should be constructed of heavy-duty reinforced welded steel plates to withstand atmospheric pressures induced during testing. 

Additionally, look for a minimum 8” foam glass insulation with a 0.25 k factor to ensure strong temperature uniformity and efficiency. Finally, your manufacturer should offer reliable parts and labor warranty with start-up and service in the field available at request. 

Russells Technical Products has developed a reputation as the industry leader in altitude test chambers, specifically those used for combined temperature, altitude, and humidity testing. There is a reason many of our units are still in operation over thirty years later. Contact us today to learn more about our altitude test chambers and which solution best meets your needs. 

Lithium Ion Battery Testing: Procedure, Standards & Safety

April 15, 2022

Lithium-ion battery (Li-ion) technology is paving the way for vehicle electrification, a trend that most analysts predict will accelerate in the next decade. According to Fortune Business Insights, the global lithium-ion battery market is expected to grow from $44 billion in 2021 to $193 billion by 2028.

The majority of rechargeable technology utilized today owes its longevity to lithium-ion battery technology including laptops and cellphones, yet significant investments are being made in hybrid and electric vehicles. With the increased adoption of battery-powered vehicles across the industry coupled with declining prices of Li-ion technologies, the growing demand for BATTERY TEST CHAMBERS is sure to catalyze additional research, testing, and manufacturing of these Li-ion components. 

What is Thermal Runaway in Lithium-Ion Batteries?

While Li-ion batteries are considered relatively safe among consumers, their thermal stability can be compromised under certain conditions. A process known as thermal runaway can occur when a cell within a Li-ion battery reaches an elevated temperature due to mechanical, thermal, short-circuiting, or electrochemical failure resulting in an exponential thermal cascade and ultimate loss of stability.

The resulting thermal and electrochemical energies are subsequently released into surrounding areas producing potentially catastrophic loss through fire and toxic gas release. Abuse testing of Li-ion batteries and their components is used to simulate a thermal or mechanical failure, which often results in the exothermic decomposition known as thermal runaway. 

What is Lithium Ion Battery Testing?

The primary objective of Li-ion battery testing is to ensure proper function and safety in any environment by creating similar environmental conditions in which these batteries will operate. Any number of a series of tests are performed according to industry standards from UL, SAE, IEC, and others with specific objectives including thermal abuse, heat resistance, temperature cycling, and short-circuiting under heat.

Below are some of the common test standards for primary (non-rechargeable) and secondary (rechargeable) Li-ion battery cells or modules with corresponding testing chambers used to accomplish the requirements.

Lithium Ion Battery Testing Standards

UL 1642

The UL Standard for Safety for Lithium Batteries consists of a series of electrical, mechanical, and environmental tests for a diverse assortment of user-replaceable Li-ion batteries. The general scope of UL 1642 requirements is to reduce the risk of fire or explosion when Li-ion batteries are used in a product, while also reducing the risk of injury to persons when operating products with user-replaceable Li-ion batteries.

A reach-in temperature chamber can be used for the electrical and environmental test portions of UL 1642 including short circuit testing at 60°C, heat testing of 5°C per minute to 150°C, and temperature cycling from 70°C to 20°C to -40°C in 30-minute transitions. 

UL 2054

The UL Standard for Safety for Household and Commercial Batteries pertains to battery level tests whereas all component cell level testing is covered under UL 1642. A series of electrical, mechanical, battery enclosure, fire exposure, and environmental tests are designed to validate primary and secondary batteries. Depending on the size and quantity of batteries, a reach-in or walk-in temperature chamber can accomplish the mold stress relief test at 70°C, heating test of 5°C per minute to 150°C, and temperature cycling from 70°C to 20°C to -40°C in 30-minute transitions. 

UL 2580

The UL Standard for Batteries for Use in Electric Vehicles was developed as a pass/fail standard to qualify Li-ion batteries in electric and hybrid electric vehicles. This standard consists of a variety of mechanical and electrical tests with one environmental test involving temperature cycling. A thermal shock chamber can be used to subject a fully charged electrical storage assembly to temperature extremes from 85°C to -40°C. 

IEC 62133

The Safety Requirements for Portable Sealed Secondary Cells represent a key standard for rechargeable Li-ion batteries for use in portable electronics like phones, laptops, and cameras. Like UL, IEC standards address general, safety, and transportation specifications for Li-ion cells and batteries. A reach-in temperature chamber can accomplish test portions including short circuit testing at 55°C, mold stress relief testing at 70°C, thermal abuse testing up to 130°C at 5°C per minute, and temperature cycling from 75°C to 20°C to -20°C in 30-minute transitions. 

IEC 62660-2

Secondary Li-ion cells for the propulsion of electric road vehicles – Part 2: Reliability and abuse testing includes standard test procedures and conditions for basic characteristics of Li-ion cells for use in the propulsion of electric vehicles. A temperature chamber can accomplish a variety of test standards including a thermal test of 5°C per minute to 130°C, temperature cycling from 85°C to -40°C at 1°C per minute (or 65°C to -20°C with electrical operation), and capacity discharge tests at -20°C, 0°C, 25°C, and 45°C.  

SAE J2464

Electric and Hybrid Electric Vehicle Rechargeable Energy Storage System (RESS) Safety and Abuse Testing describes a body of tests that may be used for abuse testing of vehicle rechargeable batteries to determine the response to conditions or events which are above their normal operating range. A temperature chamber can be used for thermal stability testing by increasing temperature in 5°C increments, while a thermal shock chamber would be effective for temperature cycling from 70°C to -40°C in 15-minute transitions. 

Lithium Ion Battery Safety Testing

While Li-ion battery use becomes universal across the vehicle and consumer electronic industries, each manufacturer develops its own proprietary Li-ion chemistries to enhance reliability, longevity, and cost-efficiency. Combining the unique chemical compositions with specific abuse test standards creates a challenge for test chamber manufacturers to provide effective testing equipment that is safe for both the user and facility.

The European Council for Automotive R&D (EUCAR) has defined hazard levels to assess and predict a specific level of danger associated with handling and testing batteries according to predictable events. As batteries are exposed to various test conditions outside their normal operating range, a hazard level is assigned to describe the potential event and effect. 

As the hazard level increases, environmental test chambers must be equipped with specific safety features to protect both facility and personnel. The most common features include temperature limited sheath heaters, intrinsically safe barriers, gas monitoring, pressure relief vents, fresh air blowers, fire suppression systems, and more. For example, a temperature limited sheath heater is designed to limit the surface temperature of the heater below the auto-ignition point of potential flammable gas released during a battery event. In some extreme test-to-failure scenarios, a unique protective enclosure may be necessary to isolate an explosion or catastrophic event. 

Looking for Lithium Ion Battery Testing Equipment?

Russells Technical Products develops environmental test chambers to meet specific customer requirements for battery testing to provide temperature cycling, humidity, altitude, vibration, and other factors. Contact us today to learn more about our battery test chamber capabilities and allow us to provide the best solution for your battery testing needs.  

Electric Vehicle Battery Testing

February 11, 2022

Vehicle electrification is here to stay. The latest reports suggest electric vehicles (EV) will reach 29.5% of all vehicle sales by 2030, a significant jump from 3.4% in 2021. That estimate accounts for roughly 4.7 million EVs on the road per year by the end of the decade. Some economists suggest the consolidation to EV mass adoption had already begun by late 2021, citing factors including new technology, emissions regulations, environmental considerations, cost, and a rapidly changing market as key elements toward jettisoning petroleum vehicles. As demand increases, manufacturers are eyeing advancements in battery technology to make EVs more accessible, economical, and longer-lasting. 

What is an Electric Vehicle Battery?

Unlike internal combustion engines, EVs rely on an electric traction motor powered by an onboard electric battery pack. The traction battery pack which drives the motor must be rechargeable, and the race continues to develop lighter, longer-lasting, and more efficiently charged battery packs. Part of the initiative to advance EV adoption is eliminating range anxiety, which is the fear of being stranded between charges. Some battery manufacturers today are introducing paradigm shifts in battery charging capacities, with one company demonstrating a proof of concept battery that powered an EV 752 miles without recharging. While this type of extended range relies on dual-energy chemistry, there largely remain four types of battery technology used in EVs today. 

Lithium-Ion Batteries for EVs

By far the most widely utilized battery technology in EVs today are lithium-ion batteries. These batteries are also widely used in consumer electronics and are prized for their high energy per unit mass and high energy to weight ratio. Lithium-ion batteries have demonstrated excellent energy efficiency, strong high-temperature performance, and relatively low self-discharge. Emerging manufacturers are combining low-cost and durable lithium-ion technology with high energy density lithium-ion chemistry to produce a dramatically extended EV range. However, the battery and performance life of lithium-ion batteries are subject to high-temperature degradation, combined with high production cost, difficult recycling capacity, and currently inadequate recharging infrastructure. 

Nickel-Metal Hydride 

Nickel-metal hydride (Ni-MH) batteries represented the largest percentage of batteries in EVs and hybrid-electric vehicles (HEV) in the early 2000s. Because of their wide use, these batteries paved the way for lithium-ion technologies used today. These batteries are considered generally safe, while offering reasonable specific energy and power capabilities. With the advantages of high energy density and power, reliable operating thermal properties, and cost-effective recyclable material sourcing, Ni-MH batteries demonstrated promising capabilities. However, recent advancements in battery technology have yielded lower weight and cost alternatives, rendering Ni-MH batteries essentially obsolete in EV propulsion. 

Lead-Acid

Unlike lithium-ion and Ni-MH batteries, lead-acid batteries are commonly used to supplement other energy sources in EVs today. Valued for their low cost to power ratio, safety, and reliability, lead-acid batteries continue to hold strong advantages for specific use applications. More advanced lead acid batteries are currently in development for use in commercial electric vehicles for ancillary loads. Despite their advantages, these batteries demonstrate poor cold temperature performance coupled with a limited lifespan, rendering them largely prohibited for single-source EV battery power supply. 

Ultracapacitors

Ultracapacitors have become a viable option for automotive OEMs and Tier 1 suppliers over the last few years based on their ancillary power supply for common road encounters including hill climb acceleration and regenerative braking. The unique technology enables energy storage in a polarized liquid between an electrode and electrolyte. As the liquid surface area increases, so does the energy storage capacity. Another recent advancement is the ultracapacitor-powered active roll system which electrically controls the stiffness of roll bars, allowing efficient cornering by placing an electric motor on the vehicle axles. Ultracapacitors also offer a wide temperature performance range, generating quality performance even in cold temperatures where common batteries fail to perform. 

EV Battery Testing Procedure

As advancements in EV battery technology pace EV adoption, understanding the safety, reliability, and effectiveness of EV batteries is critical to their sustained implementation. Manufacturers continue to develop enhanced battery technologies to reduce cost, increase range, and shorten charging capacity timelines to appease customer demand. Environmental test chambers provide the means to understand and implement these enhancements while bolstering consumer confidence. EV batteries are exposed to extreme environmental conditions like heat, cold, vibration, and corrosion in battery test chambers to assess real-world conditions and validation. Industry-specific and OEM EV battery testing standards help to demonstrate EV battery safety and reliability, while also revealing potential design faults in the early developmental process.

Electric Vehicle Battery Testing Standards

ISO 16750

This international standard applies to electrical vehicle systems and components by describing potential environmental stresses and test requirements recommended for the specific mounting location in or on the vehicle.

ISO 12405

Similarly, this international standard specifies test procedures for lithium-ion traction battery packs and systems for use in electrically propelled road vehicles. These procedures specifically provide determination for performance, reliability, and abuse of lithium-ion battery packs.

LV 124

This quality and reliability standard was jointly developed by German automotive manufacturers in 2013 to test electronic components in 12V electrical systems. It is widely used by European automotive manufacturers to test and validate lithium-ion batteries and powered components.

EV Battery Safety Standards for Testing

Safe EV battery test methods are critically important as advancements in technology produce higher energy densities in lithium-ion batteries. As batteries are exposed to extreme environmental conditions and stresses, potential events include overloads, malfunctions, and thermal runaways. In some cases, events in a single cell can spread throughout other cells and destroy the entire battery. 

To better address and standardize the potential risks associated with automotive battery events, the European Council for Automotive R&D (EUCAR) has significantly invested in hazard classification resulting in specific safety levels associated with key events. These range from Hazard Level 0 resulting in no effect or functional limitation, to Hazard Level 7 resulting in complete decomposition of the battery cell. Battery test chamber manufacturers comply with EUCAR hazard safety standards by advising specific safety equipment relevant to customer-specific testing. These features vary from customer to customer and are largely dependent on the EV battery composition, quantity, energy storage capacity, and proximity of the equipment to adjacent infrastructure. 

Russells Technical Products is a trusted battery test chamber manufacturer for customers in automotive, aerospace, defense, renewable energy, and more. Our battery test chambers conform to a variety of industry standards capable of testing conditions including high and low temperature, humidity, altitude, and vibration. Contact us today to learn more about our battery test chamber capabilities in both reach-in, walk-in, and drive-in configurations. 

Tips When Considering A Custom Environmental Chamber

January 18, 2022

Environmental testing is a critical component across industries for designing and building safe and reliable products. Making products safer, stronger, and longer-lasting requires repeated exposure to extreme environmental conditions. The ability to produce those conditions within your facility provides flexibility and efficiency in delivering your products to market expediently. 

Some testing applications can be satisfied by a standard, off-the-shelf environmental chamber. These units are offered with pre-engineered dimensions, performance specifications, and features that provide effective and often economical testing capabilities. In some circumstances, the product being tested and/or the test specification requires a unique solution. These particular cases are accomplished with custom environmental chambers which can be designed to meet exact and specific test specifications and requirements. 

Determining Custom Environmental Chamber Features

When standard features and performance are insufficient, a custom chamber can be the right solution. Selecting the right equipment can be a challenge, so consider the following four features when determining whether a custom chamber might be required for your testing.

1. Performance

Performance is often the first consideration when buying an environmental test chamber. Temperature and product change rates are determined by your test specifications. Identifying your test profile will provide your manufacturer with valuable information in determining the compressor size and configuration required to achieve those defined parameters. When you need to achieve an elevated temperature ramp rate or pulldown, a more powerful compressor package might be required. 

2. Operating Conditions

The operating conditions under which your products need to be tested will dictate the level of heating and cooling customization. A typical standard environmental test chamber can operate within the range of -70°C to 180°C (-94°F to 356°F). Optimizing temperature and humidity within that range is accomplished through a circulation system designed to move conditioned air evenly across the interior workspace. A standard cooling system might incorporate a self-contained mechanical refrigeration system with an air-cooled condenser. A custom chamber that offers further temperature extremes (and temperature change rates) can be accomplished with boost cooling using liquid nitrogen (LN2) or carbon dioxide (CO2). 

3. Size

The size of the unit under test (UUT) plays a critical role in chamber selection. While a standard reach-in chamber might accommodate a wide testing variety, larger devices require a unique layout and design. Here your chamber manufacturer will help to navigate the number of products being tested at one time, the mass and materials of the UUT, the size and dimensions of the UUT, as well its fixture requirements. A custom environmental chamber can be designed to contain a unique component or sub-system, all the way up to a hangar-sized enclosure for walk-in or drive-in applications. 

4. Unique Features

Unique features and requirements can be a significant component of custom environmental chambers. Door configurations, for example, can be offered in hinged, bi-parting, or vertical lift (guillotine-style) in virtually any size. Your manufacturer can offer access ports in limitless size, configuration, and quantity, while portable or remote conditioning can be accomplished through insulated ducting. Intrinsic safety features like fire suppression, gas detection, and sheath limited heaters can be added to customize a battery test chamber.

What to Expect From Your Manufacturer?

The right environmental chamber manufacturer will walk with you through the selection process to determine the best fit for your testing operations. Because environmental chambers are used in almost every industry imaginable, the best manufacturers will have the right solution for each unique industry application. Prompt and regular communication from initial request to product selection, order, and delivery should be expected. The more complex the system, the higher level of involvement will be required through design and engineering to ensure efficient and timely delivery of a quality custom environmental chamber. 

Additional benefits of custom chamber design allow for unique building infrastructure and installation considerations where restrictions may limit normal facility access. Ultimately, a custom chamber design process is unique to each customer and application. The best custom environmental chambers are those designed and manufactured to meet your unique test requirements with reliability and longevity so your customers can count on your products with confidence.  

Russells Technical Products offers more than 50 years of experience designing, manufacturing, and supporting custom environmental chambers. Where other manufacturers cannot, Russells Technical Products can. Contact us today to learn why Fortune 500 companies and start-ups trust our team to create the right testing solution so they can deliver for their customers. 

Thermal Testing of Electronics: Types of Chambers & More

December 10, 2021

Thermal analysis is a critical component in understanding how products respond to extreme environments and provides engineering insights into product longevity and reliability. For example, thermal testing for electrical vehicle (EV) batteries is critical for their qualification and validation. Thermal test chambers bring real-world environmental conditions into the laboratory space, allowing for the safe and effective exposure of products to variable temperature conditions. Exploring some of the industry uses and applications will help you assess if a thermal chamber is appropriate for your testing requirements. 

What is Temperature Testing? Understanding Thermal Test Chambers

Thermal test chambers (or temperature test chambers) are widely used in a variety of industries and applications. Common uses include steady-state or stability testing, thermal cycling or thermal shock, and other applications for today’s testing needs. Key industry requirements define specific testing protocols and standards which are frequently updated to keep pace with the dramatically accelerating advancements in consumer technologies. Several key industries and applications include:

EV Batteries

With the increasing demand for vehicle electrification, OEMs, suppliers and manufacturers must keep pace with the changing technologies and regulatory environment. While a variety of methods and specifications exist, several key applications for EV battery test chambers include thermal cycling and thermal shock, reliability, and robustness from vibration, overcharge and discharge protection, and over-temperature protection. Thermal chambers are especially useful for simulating cold start conditions where various temperature extremes need to be verified. Several common standards for vehicle battery certification include UL 1642 (lithium cells), IEC 62660, ISO 12405, SAE J1772, and IEEE 1725.

Aerospace and Defense

Various space and defense programs rely on ground testing to ensure the proper and successful operation of components, systems, payloads, sensors, and more. Thermal shock chambers allow for thermal cycling of components to simulate the harsh environments experienced at altitude, while thermal vacuum chambers allow space components and subsystems to endure both extreme temperature and deep vacuum. Commercial, military, and aerospace industries require exact thermal temperature tolerances as defined by industry standards including MIL-STD-1540, MIL-STD-750, EIA-364-32, and more.

Electronics

Thermal testing and cycling of electronics and components is generally accomplished by exposing parts to temperatures exceeding normal operating temperature to detect for defects including solder joint and hermetic seal failure, as well as lead and marking damage. Thermal induced stress on electronics and components also helps to identify changes to the physical characteristics of components which could lessen the reliability and lifespan of those products. In other cases, thermal testing is used to produce component validation where wider temperature ranges exceeding normal operation are used to identify the maximum and minimum operating temperature for those components. Various industry standards exist, though the widely accepted eleven standards that comprise JDEC 51 specifically address thermal measurement of component packages in various environmental conditions. 

Other Industries

There are extensive industries and services which develop products that must comply with national and international standards using forms of thermal testing. Some industries and standardization bodies include building and construction materials (ASTM, ANSI, ISO), chemicals, energy commodities, consumer products, and healthcare including pharmaceutical and medical devices. 

What are the Most Important Considerations for Thermal Chambers?

While the industries and uses of thermal chambers are nearly limitless, it is important to define a few key parameters when sourcing a thermal chamber for your testing requirements. 

Performance

In order to secure the right thermal chamber, it is critical to define key performance parameters including the desired temperature range, temperature and product required change rates, and your complete test profile. Will your testing incorporate humidity as well as temperature? If so, how will this impact your product and test specification? How often will you be testing? Understanding the duration and frequency of your thermal testing will help to better define the parameters of your desired thermal chamber.

Size

Knowing the size, material composition, fixture requirements, and total mass to be tested at one time will help define the dimensions of the thermal chamber for your requirements. Benchtop and reach-in thermal chambers are designed to maximize space and efficiency in your lab, formatted with the standard performance of larger chambers, but with a condensed footprint. Larger devices under test (DUT) may require loading via a cart, pallet jack, or forklift, which generally requires a walk-in chamber to meet your specifications. Understanding your lab or facility floor space, utilities, and infrastructure is critical to ensuring the right system is selected and installed. 

Timeline

Once you have defined your performance and sizing requirements, you will want to understand the timeline and budget considerations that could impact your testing plans. Most reach-in and smaller thermal chambers are offered from various manufacturers at reduced lead times, sometimes even in stock and ready to ship. As such, these chambers are more economical than their comparable walk-in and drive-in alternatives. Lead times vary across the industry, but a general principle to apply is to give yourself a year timeline to plan, search, purchase, receive, install, and validate a walk-in or drive-in thermal chamber. 

At Russells Technical Products, we go beyond providing environmental test chambers. We’re a total partner in the industry, offering one-on-one support throughout your process, from acquisition to installation. Our primary goal is to develop a relationship based on trust and confidence so you can deliver on your objectives. Contact us today to get started. 

Temperature and Humidity Control Considerations with Environmental Test Chambers

November 22, 2021

Precise temperature and humidity control within an environmental chamber is a complex issue. To understand the nuances of humidity control, one must understand the importance of precise temperature control and the meaning of “relative” in relative humidity readings.

A good example of the importance of temperature control in relative humidity calculations is found in ASHRAE 1993: At a constant moisture content [a true measure of humidity] of a 12°C dewpoint at 23°C and 50%RH, a short-term temperature fluctuation of +1°C results in a fluctuation of relative humidity readings between 47% and 53%, even though the true moisture content in the humidity test chamber hasn’t changed.

This is the result of relative humidity being calculated by the measured moisture content of the air relative to the moisture-holding capacity of the air at any given temperature, referred to as the dry-bulb temperature. 

The warmer the air, the more moisture it can hold within the same volume of space, therefore it takes significantly more water vapor, in general, to elevate the relative humidity of air as it increases in temperature. The opposite is true as the air cools. Due to this fact, 50% relative humidity at a dry bulb temperature of 85°C is an exponentially higher moisture level than  50%  at a  dry bulb temperature of 10°C. 

At lower temperatures, the relative humidity measurement reading is affected by a change in overall moisture content of just a few grains per pound of air, whereas it may take grams of moisture to change the relative humidity reading at significantly higher temperatures.

 Stability is the Key to Humidity Control

The key then to precise humidity control in an environmental test chamber is stability. Typical environmental chamber control tolerance is +1°C and +5% relative humidity after stabilization. Stabilization is defined within the industry as the point when the chamber interior surfaces and unit under test (UUT) change temperature less than 2°C per hour, and without variations in load either external or internal (i.e., door openings or varying heat loads generated by the UUT).

Challenges exist with environmental chamber control when instability created by constant or intermittent changes in temperature and/or humidity is required within environmental testing profiles. These are commonly referred to as cycling profiles, which consist of infinitely variable combinations of “ramp” and “soak” steps in a specific sequence.

 A ramp step can change temperature, humidity, or both simultaneously in either direction up or down at linear rate over a set time period. A soak step holds a constant temperature and humidity setpoint for a set time period. In complex cycling profiles, the chamber heating, cooling, humidification, and dehumidification systems work together, essentially chasing the elusive ever-moving setpoints.

It is during cyclical profiles that maintaining typical stability tolerances can become all but impossible because instability is intentionally introduced. Setpoint changes across a short-range and/or time period create less instability compared to wide-ranging changes over shorter periods of time, which further impact the chamber’s ability to precisely control the ever-changing variables. This often results in short-term oscillations of temperature and/or humidity beyond the limits of stabilized control tolerances.

 Other Considerations for Precise Humidity Control

Temperature and humidity control can be further upset when chamber mechanical systems change from one state to another. For instance, a ramp step might require a chamber that is operating at a high temperature/low humidity to simultaneously change to a low temperature/high humidity within a span of “x” minutes. 

Contrary to what one might think, “cooling” and “humidifying” systems may not be initially required to operate, but instead the chamber control system simply reduces heating and dehumidification outputs, allowing the chamber to do a controlled drift which follows the moving setpoints of temperature and humidity. 

However, at some point during that ramp step, reducing heating and/or dehumidification fails to provide the response necessary to chase the setpoint, and the controller energizes the chamber cooling and humidification systems by requiring small but steady increasing outputs of cooling and humidification. During these changeover periods, it is also common to see short-term oscillations in temperature or humidity control.

There can also be situations where a cyclical profile has ramping requirements that exceed the capability of the chamber being used, but these are typically related to chamber capacity and not control.

Chamber Capability is Dependent on the Desired Profile

In summary, short-term oscillations that extend beyond normal stabilized control tolerances are common and expected with cyclical profiles. Considerations must be given to the ranges, ramp rates, and complexity of cyclical profiles. 

Except in very rare cases, these short-term oscillations have no negative impact on the quality or legitimacy of the overall test sequence, providing that the final setpoint conditions for temperature and humidity are fully achieved and are not beyond the capability of the chamber being used.

Russells Technical Products is your subject matter expert for thermal cycling chambers and humidity chambers. Our team of application engineers will walk with you through the process of understanding your testing specifications and applying the right solution to meet your requirements. Contact us to learn more today.

What Is An Altitude Chamber?

November 12, 2021

Pressure or altitude testing is essential for aerospace, industrial, and consumer applications where products or components need to function or be transported in low-pressure environments or withstand rapid decompression in combination with climate control. If your products encounter these environments, or you need to conform to a military or aviation test standard including but not limited to MIL-STD-810 or RTCA DO-160, an altitude test chamber may be the solution you need.

What are the Primary Uses for Altitude Chambers?

Unlike hypobaric chambers used to study the effects of high terrestrial altitude and hypoxia on human physiology, industrial altitude chambers create far more extreme and combined environments including altitude, temperature, humidity, icing, and in some cases, vibration. By combining multiple environments, your products can undergo the qualification testing necessary to simulate real-world conditions. Here are some considerations as you consider investing in an altitude chamber.

Altitude (Vacuum/Pressure)

By utilizing vacuum pumps of various types and sizes, most altitude chambers are capable of standard vacuum conditions replicating 100,000 ft. with extended ranges available to 200,000 ft. To simulate sudden loss of cabin pressure, some altitude testing chambers can simulate rapid decompression by quickly and dramatically reducing pressure in 15 seconds or less. Alternately, using compressed air or inert gas, altitude chambers can be pressurized to simulate sub-sea or sub-site level altitude.

Temperature

Using either single-stage or cascade refrigeration, most altitude chambers are designed to provide combined altitude and temperature simulation up to 65,000 ft., allowing for a wide range of combined temperature and altitude profiles. Additionally, altitude chambers can be dual-purposed as temperature-only chambers with temperature ranges of -73°C (-100°F) to 180°C (356°F).

Humidity/Icing

The ability to simulate humidity at ground level in conjunction with temperature/altitude in a cyclical profile is essential in testing the durability and longevity of many critical flight components. In special cases like icing tests, combined environment testing must include control of temperature, humidity, and altitude simultaneously. Most combined environment altitude chambers can be dual-purposed as temperature and humidity chambers, providing ranges of 5% to 95% relative humidity (RH) within the bounds of an 85°C (185°F) maximum dry bulb and a 4°C (40°F) minimum dewpoint.

Vibration

Under unique circumstances, vibration compatibility with an electrodynamic or mechanical vibration system can integrate with altitude, temperature, and humidity chambers. Real-world applications require unique qualification testing for aerospace and avionics equipment.

Industry Requirements for Altitude Chambers

There are limitless altitude tests that can be tailored for consumer products and packaging, but for military and aerospace applications there are two primary sources of specifications and guidelines, which are often updated to reflect agreed-upon protocol changes and enhancements to ensure products meet the rigorous demands of the industry. Key industry requirements utilizing altitude testing include:

  • MIL-STD-810 – The United States DoD released the updated revision H, a successor to MIL-STD-810G, in January 2019. A MIL-STD is simply a list of testing guidelines and standards that ensure commonality in military applications. While MIL-STD-810H covers a wide range of testing methodologies, and several “Methods” within MIL-STD-810H specifically address altitude and/or combined environment testing.
  • RTCA DO-160 – This international standard, established in 1958 and most recently updated in 2011(DO-160G), is defined as the Environmental Conditions and Test Procedures for Airborne Equipment. The objectives of the standard are to demonstrate the performance characteristics of devices and equipment subjected to environmental conditions present in airborne equipment. Much like MIL-STD-810H, RTCA DO-160G covers a wide range of testing methodologies, including several “Sections” which specifically address altitude and/or combined environment testing.

Both standards make allowances for tailoring tests based on unique or specific products and/or flight or mission profiles, but in most cases test profiles are developed around four main procedural guidelines:

  • Storage – Tests materials and/or packaging transported or stored at high or low altitudes, with or without combined environment testing.
  • Operation – Evaluates performance of products or equipment at high or low altitudes, with or without combined environment testing.
  • Rapid Decompression – Evaluates the potential impact to personnel, products, or equipment resulting from rapid depressurization.
  • Explosive Decompression – Similar to Rapid Decompression, but simulating instantaneous decompression, such as when a pressurized aircraft cockpit becomes compromised.

Other Considerations for Altitude Chambers

With any purchase of environmental test equipment, there are several additional considerations for altitude chambers.

  • Chamber Dimensions – How large is your unit under test (UUT)? What quantity will you need to test at one time? Do you have move-in restrictions to your facility, or building infrastructure constraints for getting the chamber to its final place of performance?
  • Cooling and Heating Capacity – What is the temperature range requirement for your product? Does your product generate any heat under test? How quickly do you need to heat or cool the chamber? Will your testing capabilities expand in the future?
  • Altitude – What is the altitude range requirement for your product? How quickly do you need to change the altitude for your testing? Does your product discharge air or gas into the chamber during altitude tests?
  • Humidity – What is the humidity vs temperature testing range requirement for your product? Is humidity required in conjunction with altitude testing? Does your product discharge or remove moisture inside the chamber during tests?
  • Combined Environment – Is humidity, icing, and/or vibration required?   

The best altitude test chambers are designed and manufactured to meet your exacting specifications. The more information you can provide our Application Engineers, the better the outcome in meeting your requirements, both for now and the future. No two altitude chambers are exactly alike, which makes a collaborative effort between the customer and the manufacturer early in the development process critical.

Russells Technical Products understands altitude test chambers and has the solution to match your requirements. We provide one-on-one attention to our customers to make sure that from start to finish, you stay involved in the process and communicate with a single point of contact at the factory. That’s why we’ve been trusted to design and build some of the most complex altitude systems ever created. Contact us today to start a conversation and learn for yourself why we’ve been supplying superior altitude test chambers for over 50 years. 

Automotive Environmental Testing: Standards and Methods

October 26, 2021

Advancements in automotive technology are accelerating at an increasing rate. Combustion automobile engines have persevered and adapted through generations, although the emphasis on reduction in fuel consumption and elimination of greenhouse emissions has paved the way for their electric successors. In fact, a recent executive order calls for half of new cars to be electric or hybrid plug-ins by 2030. Automotive manufacturers have since doubled down on these regulations, hedging their futures on a fully electric infrastructure to support their products. For example, Toyota recently announced plans to invest $13.5 Billion by 2030 to develop batteries and the underlying supply chain, while Volvo has committed to putting 1 million electric vehicles on the road by 2025, some 50% of its total car sales. 

With the shift toward vehicle electrification, the demand for autonomous vehicles continues to grow. As this technology develops, we can anticipate the number and complexity of electronic sub-systems to keep pace with consumer demand. These components have long been subject to environmental simulation and reliability testing in the consumer automotive space, and automotive manufacturers must follow specific testing mandates to ensure product safety and reliability certification before their wider application in the consumer market.

Test Standards for Today’s Demands

Environmental simulation mimics the conditions which a product or sub-system may experience over its normal life cycle. In a ‘test to pass’ method, products are exposed to a variety of temperature, humidity, and vibration simulations which generally don’t exceed the conditions of their intended use, and are considered safe for consumer markets once the simulation is passed. Some of the more common automotive tests, their standards, and equipment include:

Temperature and Humidity Cycling

These tests can be conducted on either complete vehicles or vehicle sub-systems, including electronic systems, to identify the adverse effects of temperature and humidity extremes. Examples include rapidly changing temperature tests for electronics enclosures to prevent cracking or warping or moisture condensation in circuits or sensors which could invalidate or undermine performance. Various standards for temperature and humidity testing include:

Rapid temperature and humidity cycling can be accomplished using a variety of equipment including reach-in chambers and thermal shock chambers. Applications for larger components or full vehicle systems can also be accommodated in walk-in or drive-in temperature and humidity chambers. Key indicators for consideration include temperature uniformity and effective airflow to facilitate heat transfer from the chamber to the product under test. Typical temperature range and rates for these systems are -70°C to 180°C with temperature change rates of 5°C to 15°C per minute. 

Vibration Compatible Testing

Combined vibration and environmental simulation testing yield important qualification insights for product structural and total reliability. Users can combine temperature, humidity, and sine or random vibration using both mechanical and electrodynamic shakers to simulate road vibration or sudden impact from a pothole. Several common standards for vibration testing include:

  • SAE J1211 (robustness validation of electric modules)
  • GM 3172 (environmental durability for electrical components)
  • ISO 16750 (environmental conditions and testing for road vehicles)

AGREE chambers were originally developed for military and aerospace applications requiring temperature, humidity, and vibration simulation. The technology has since been adapted to conform to automotive industry standards to perform reliability and qualification testing. A vibration compatible chamber can be designed to seamlessly integrate with an existing shaker to perform simultaneous temperature, humidity, and vibration with thermal change rates as high as 30°C per minute. 

Testing for the Future, Today

While emerging battery and autonomous vehicle technologies gain traction over the next decade, properly working components are as critical as ever. As the automotive industry adapts, and consumers increase dependence on electrified vehicles, the complexities and number of electrical components and systems will continue to grow. Battery testing and environmental simulation of these products will not only ensure their effectiveness, but moreover pave the way toward a safe, reliable, and autonomous driving infrastructure of the future. 

Russells Technical Products has the environmental test chamber to fit your automotive testing needs. Contact us today to start a conversation. Our products are designed and built with your products in mind, for over 50 years in Holland, MI.