Advanced Test Racks and Systems for Environmental Stress Testing
Background
Thanehall developed sophisticated test racks and systems for Electronic Stress Screening (ESS) and related environmental testing, adhering to stringent military standards. These systems were designed to test and validate the reliability of critical components, including units from the Eurofighter Typhoon program, under extreme environmental conditions.
Challenges
The testing required precise control of environmental conditions, including temperature cycling and vibration, in accordance with Mil. Std. 4370 and Mil. Std. 810. The systems needed to support multiple units and temperature chambers, ensure synchronisation across devices, and enable remote monitoring when testing occurred offsite. For High Temperature Operating Life (HTOL) testing, portability and ease of use were also key considerations.
Solutions Delivered
Thanehall designed a comprehensive ESS test rack to control Eurofighter Typhoon units during chamber cycling between -40°C and +70°C over multiple cycles. This included managing vibration periods to simulate real-world stress conditions. The system supported multiple units and chambers, with synchronisation achieved through TCP/IP using UDP protocols. Custom software, developed in NI LabWindows / CVI™, ensured precise control and monitoring throughout the testing process.
For HTOL testing, Thanehall provided a portable test harness that used a laptop for control and data collection, ensuring flexibility and ease of deployment. Additionally, a simplified end-of-line ESS system was developed for clients needing a compact solution. This system housed multiple units in an enclosure, with the heat generated by the units themselves driving the temperature cycles, complemented by extractor fans for regulation.
To meet the needs of clients conducting Mil. Std. 810 testing, Thanehall enabled remote monitoring of the equipment while it underwent testing at a dedicated test house. This solution provided real-time data access and ensured that testing adhered to rigorous standards without requiring the physical presence of engineers.
Outcome
Thanehall’s solutions enabled clients to conduct reliable and precise environmental testing for critical systems. The ESS test rack ensured compliance with military standards while delivering synchronised and controlled testing for multiple units and chambers. The HTOL test harness provided a portable and efficient testing method, while the end-of-line ESS system offered a cost-effective solution for less complex requirements. Remote monitoring capabilities for Mil. Std. 810 testing improved oversight and convenience, ensuring seamless testing even at external facilities.
Conclusion
Through innovative designs and tailored solutions, Thanehall provided advanced environmental stress testing systems that met stringent military requirements. These systems have proven to be reliable, efficient, and adaptable, supporting clients in achieving their testing objectives with precision and ease.
