“Did I forget something?” It’s that nagging feeling every engineer has when their project is about to be deployed – it may be a product about to be ramped into production, a low volume product, or even a one off like a microsatellite. If you have the time and a few prototypes to spare though, there are ways to alleviate these worries. The key is a test method which has been used in aerospace, military, and other industries for years – Highly Accelerated Life Testing (HALT).
How to HALT
The idea behind HALT testing can be summed up in a couple of sentences:
- Beat your product to death.
- Figure out what broke.
- Fix it, and fix the design.
Sounds barbaric, and in many cases it is. HALT testing is often associated with giant test chambers which are literally designed to torture anything inside them. Liquid nitrogen shock cools the chamber as low as -100°C. The Device Under Test (DUT) can soak at that temperature for hours. Powerful heaters then blast the chamber, causing temperature rises of up to 90°C per minute, topping off at up to 200°C. Pneumatic hammers beat on the chamber table causing vibrations at up to 90 Grms and 10 KHz. Corrosive sprays simulate years of rain and humidity. These chambers are literally hell on earth for any device unlucky enough to be placed inside them. It’s easy to see why this sort of testing is often referred to as “Shake and Bake”.