PRODUCT & PACKAGE VIBRATION TESTING

PRODUCT & PACKAGE TESTING

VIBRATION & SHOCK

Herb Schueneman
Herb Schueneman
Chairman, WESTPAK, Inc.
Founder, Chairman
WESTPAK, INC. March
Dec 20152016
What’s This All About?

• Why, how, and when do we mechanically

test products and package systems?
• What do we learn from this?
• What do we do with the information?

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Agenda
• Background, terminology, etc.
• Vibration Dynamics
– Spring/Mass Models; Forces vs. Free Response
– Types of Excitation; Sine, Random, Acoustic,
Sources of input
– Resonance, Transmissibility, Damping, Fatigue
– Package Cushioning (springs), A/A plots
– Design for Vibration

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Dynamics
• The study of mass that is moving in a flexible
environment
• “Flexibility” implies springs so the study of
dynamics starts with a thorough understanding
of “Spring/Mass Systems”

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SDOF Spring/Mass System

MASS

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SDOF Spring/Mass System
AN INPUT APPLIED HERE
RESULTS IN “FREE
VIBRATION” OF THE MASS

MASS

AN INPUT APPLIED HERE

RESULTS IN “FORCED
VIBRATION” OF THE MASS

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SDOF Spring/Mass System

Maximum strain energy

MASS

Maximum velocity

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Spring Mode Doesn’t Matter
Tension

Compression

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Natural Frequency

1 K K 1
f n

2 M
 3.13
M
 3.13


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Natural or Resonant Frequency
As earlier noted, excitation of
the mass results in motion we
call free vibration or “Natural
Frequency”, fn.

Excitation of the base results in

“forced vibration” of the mass.
When the forcing frequency = fn,
the mass response is max and is
said to be in resonance.

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 SDOF vs. MDOF
“Normal” products are pretty complex. A multiple
degree of freedom (MDOF) model is more appropriate
however much more complex and difficult to analyze.

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Spring Types
Almost all products or product/package systems
can be analyzed and modeled as complex
spring/mass systems.

But maybe not “Linear Springs”…..

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Spring Types

Linear Spring
k=F/D
F ∆=W/k
D A p = Fn X V

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Spring Types

Non-Linear / Hardening Spring

2kd  (def)
SPRING FORCE = tan
 2d
k
d

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Spring Types

Non-Linear / Softening Spring

k
1
def
SPRING FORCE =kd tanh
F d

DEFLECTION

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Spring Types
• SDOF models assume linear springs
• Most flexibility in systems is non-linear
(Printed Circuit Boards)

• However, most systems can be analyzed in a “near linear” portion

of their deflection range so that’s why we use the linear model

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Coupling
Coupled vs. Uncoupled Motion
F
2
• The mass is a homogenous
rigid block with center of
M
gravity (cg) at point A.
• The response of the block to
F1 is pure vertical motion.
F3
A B

• The response of the block to

F2 is pure rotational motion.
F1 • The response of the block to
F3 is pure horizontal motion.

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Coupling
Coupled vs. Uncoupled Motion
F
2
• If (cg) is at point B, F1
produces both vertical
M
and rotational motion
of the block. In this
F3
A B case, the motion is
said to be coupled.
• With (cg) at point B, F3
F1 produces uncoupled
horizontal motion.

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Time for Questions !

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Resonance
Resonance occurs when a component or
system is forced at its fn.

• Spring/Mass response is
amplified at resonance.
• This is where damage, fatigue,
etc. is most likely to happen.

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 Resonance
Transmissibility Plot
Ar

Ai
f

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How the Test is Conducted
Example

Vibration Machine Types of Equipment

• Electrodynamic shaker
• Hydraulic shaker
• Single or multi-axis
• Acoustic (reverberant) chamber
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Types of Mechanical Excitation
All Spring/Mass systems respond at their natural
frequencies because they can’t do anything else.
Excitation can be:
• Sinusoidal
• Random or pseudo-random
• Acoustic
• Other

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 Excitation: the Good & the Bad
Type Positive
Sinusoidal • Easy to understand
• Good visual feedback
• Grandfathered tried & true
Random • Quicker
• Less fatigue potential
• Realistic
• Matches “real life”
Acoustic • Usable for heavy systems
• Good high frequency
Not-So-Positive
• Gives false amplification values
• Over-test for fatigue potential
• Doesn’t account for constructive and
destructive interferences between
systems
• More complex
• Requires a specific controller
• Very expensive
• Requires large chamber & analytical
capability
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Damping

Damping (Rc) is
expressed as a
ratio of observed
damping to
“Critical Damping”
in a system.

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Damping
“Critical Damping” is where the mass
returns to its initial position in the minimum
time without overshoot.

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Mechanical Fatigue
Fatigue is the weakening of a
material caused by repeatedly
applied loads. It is the
progressive and localized
structural damage that occurs
when a material is subjected to
cyclic loading. Resonance is the
prime contributor. Non-critical
damping is a factor.

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Sources of Vibration Input
Sources of input include:
• Operation
– Rotating equipment (cooling fans, motors, etc.)
– Nearby influences
– Strong air currents
– Earthquakes
• Non-Operating
– Transportation, shipping (the biggest), logistics
– Normal movement within intended environment

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Typical Test Procedures
• Sine search & dwell is still used (problems..)
• Random dwell is more common
• Margin test (to failure) has gained wide acceptance
(HALT)
• Imposed by third party
• Attempt to duplicate the in-use environment (military
vehicles & weapons)
• Lots of creativity in test procedures…. (be VERY careful
here….)

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 Common Test Specs
• ASTM D3580 (doesn’t say much)
• IEC 60068-2-6, -47 (similar)
• Federal Std 101-C (very dated)
• ISO – various standards
• JIS - Japanese Industrial Standards
• MIL STD 167, 810
• Telcordia GR-63 CORE (Bell System origin; POTS – Plain Old
Telephone System)

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Establishing the Test Plan
• Design of Experiment (DoE)
• Characterize environments EUT will see
• Define test inputs to cover all environments
• Consider Combined Environments
• Remember shipping / distribution (severe!)
• Determine acceptance criteria / inspections
• Quantitative when possible
• Cosmetic, functional, safety

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Establishing the Test Plan
• Start Small
• First: Test temperature and basic
mechanical vibration
• Second: Comprehensive testing (single
environment)
• Third: Combined Environment testing
(as applicable)

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Combined Environment Test Inputs
• Every product will see different environments
• Sample EUT: Ruggedized Laptop Computer
• Test inputs discussed
• Temperature + Vibration
• Impact Testing + Temperature Extremes
• Freefall Drop Testing + Temperature Extremes
• Mechanical Cycling + Temperature Extremes
• Temperature + Pressure
• Fluid Submersion + Temperature + Pressure
• Thermal Shock
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 Temperature + Vibration
• Background of “AGREE” Testing
• Typical Test
• Cyclic functional operation
• Temperature by application
• X, Y, Z axis in single direction
• Random frequency domain by application
• Transport (1Hz – 300Hz)
• Bare Product (5Hz – 2,000Hz)
• Test Standards
• MIL-STD-883, MIL-HDBK-781
• Variations of Testing
• Common Issues / Results
• Unsupported / surface mount component failure
• Permanent failure to operate correctly
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 End Result
• Ruggedized product
• Free of latent mechanical defects
• Good to great reliability out of the box
• A prioritized list of improvements to be made
• Verification for meeting a spec requirement

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 How About the Package Cushion?
• One of the functions of a cushion system is to
dampen vibration input at those frequencies where
the product is sensitive.
• In essence, we need to know the dynamic spring rate
of the cushion.
• Now we know the PRODUCT vibration sensitivity.
• Now we need to determine the CUSHION vibration
characteristics so that an optimum package system
can be designed.

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 Vibration Cushion Dynamics
• “Vibration Cushion Curves” (called
“Amplification/Attenuation Plots”) are developed
by loading a cushion, shaking it, and measuring
the response.
Guided Test
Block
Method

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Vibration Cushion Dynamics
T-C MODEL C-C MODEL

Alternate CUSHION
CUSHION

Method RESPONSE
ACCELEROMETER MASS
MASS
INPUT
CUSHION ACCELEROMETER CUSHION
CUSHION

VIBRATION TABLE VIBRATION TABLE

MASS ADHERED TO FOAM MASS ISOLATED BETWEEN

SO THAT THE “SPRING” TWO “SPRINGS”

(CUSHION) WORKS IN BOTH (CUSHIONS) THAT WORK

TENSION AND COMPRESSION IN COMPRESSION ONLY

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Vibration Cushion Dynamics

CUSHION TEST SAMPLE

CUSHION TEST
SAMPLE

ELECTRODYNAMIC
SHAKER

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 Vibration Cushion Dynamics
For either method, the S/M system is excited
(random or sine vibration) and the response/input
ratio is plotted as a function of frequency.

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 Vibration Cushion Dynamics
The important points on this plot are identified here:

B C

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 Vibration Cushion Dynamics
The mass on the cushion is changed and the
process (transmissibility plot) is repeated.
After 5 (min) plots, the data might look like this:

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 Vibration Cushion Dynamics
The data is then transferred to the
Amplification/Attenuation plot

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 Vibration Cushion Dynamics
Here’s how the data is used:

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Time for Questions !

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 About WESTPAK, INC.

Two Locations:

San Jose Laboratory San Diego Laboratory

83 Great Oaks Boulevard 10326 Roselle Street
San Jose, CA 95119 San Diego, CA 92121
408-224-1300 858-623-8100
www.westpak.com

Contact Us

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 THANK YOU !
Please Contact Us with any questions or testing
assistance needs. We are here to help you!

Herb Schueneman
Founder, Chairman
WESTPAK, INC.

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