Background​

Thanehall has built a reputation for designing and developing highly specialised test fixtures to meet the varied needs of its clients. These fixtures have been integrated into test racks, operated externally, and used as standalone units. With applications spanning military-grade systems and advanced electronics testing, Thanehall consistently delivers solutions tailored to unique client challenges.

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Challenges​​

The clients faced demands for versatile and reliable test fixtures capable of addressing operational and environmental challenges. These ranged from military applications requiring specialist connectors and precise cooling systems to advanced electronics testing that demanded compact, integrated solutions. Additional challenges included achieving high-performance RF testing, simplifying complex testing processes, and offering economical options for smaller-scale applications.

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Solutions Delivered​

Thanehall developed military-grade fixtures equipped with air cooling systems and specialised connectors, such as Hypertac, designed to meet stringent performance requirements. A standout innovation involved creating an air cooling system to simulate the exact airflow and temperature conditions present in the Eurofighter Typhoon avionics bay, ensuring accurate environmental testing for critical components.

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For advanced electronics testing, Thanehall manufactured a sophisticated "Bed of Nails" test fixture. This all-inclusive fixture required only a PC, a power supply, and a Vector Network Analyser, integrating features like a firmware programmer, a multichannel analogue and digital data acquisition unit (NI-DAQ™), RF switching, and a bespoke communication device. It supported firmware programming, digital and analogue switching, and RF testing from DC to 6 GHz. The use of innovative RF connections, such as pogo pins with 3D-printed standoffs and custom coupling PCBAs, ensured excellent RF performance and reliability.

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For clients with more straightforward requirements, Thanehall designed economical fixtures for securing the Unit Under Test (UUT) during programming and bring-up phases. These simple yet effective solutions often incorporated basic fan cooling and provided reliable functionality at a lower cost.

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Outcome​

Thanehall’s solutions have delivered significant benefits across diverse industries. Military clients have relied on the precise simulation capabilities of the advanced cooling systems to ensure accurate testing in demanding environments. The all-inclusive Bed of Nails fixture streamlined testing processes, reducing complexity and offering comprehensive RF, analogue, and digital testing in a compact design. The economical fixtures have enabled smaller-scale clients to achieve reliable programming and bring-up functionality within budget constraints.

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Conclusion​

By addressing a wide range of testing challenges with tailored, innovative designs, Thanehall has reinforced its position as a trusted provider of test fixtures. The ability to meet stringent requirements while delivering reliable and cost-effective solutions demonstrates the company’s commitment to excellence and client satisfaction.​

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