The Art of Accelerated Testing: Hanse Environmental HALT/HASS Chambers

In product development, ensuring the reliability and robustness of a product is paramount. One of the key tools employed to achieve this is the HALT/HASS chamber, a technology that has revolutionised product testing. In this technical blog, we explore the specific stresses applied during these tests, like extreme temperatures and vibrations, and explain how they reveal weaknesses in product design and manufacturing. We take a specific look at Hanse Environmental HALT/HASS chambers, available in the UK from CentraTEQ.

Understanding HALT/HASS Chambers

HALT stands for “Highly Accelerated Life Testing,” and HASS stands for “Highly Accelerated Stress Screening.” HALT/HASS chambers are designed to expose products to extreme environmental conditions and operational stresses to identify vulnerabilities, defects, or weaknesses in their design or manufacturing. Hanse Environmental is a renowned manufacturer of these chambers, providing state-of-the-art technology to industries worldwide.

When to Use HALT/HASS Chambers

HALT (Highly Accelerated Life Testing)

HALT is typically conducted during the early stages of product development, often in the prototype phase. During the HALT process, a product is subjected to increasing stress levels of temperature and vibration (independently and in combination), rapid thermal transitions, and other stresses customised for the unique functionalities and expected usage conditions of the product being tested. These stresses are designed to mimic the real-world environments and operational scenarios that the product is likely to encounter during its intended use. This ensures that the product is thoroughly tested under conditions relevant to its intended application, increasing the accuracy and reliability of the testing process. It serves several critical purposes:

Vulnerability Identification: HALT helps identify weaknesses or design flaws in a product under extreme conditions. This information is invaluable for improving product reliability. It determines functional operating limits and functional destruct limits, the point at which it ceases to function properly or sustainably.

Design Optimisation: By exposing a product to extreme conditions, HALT reveals areas where design improvements are necessary. These insights allow engineers to enhance the product’s robustness.

Accelerated Testing: HALT accelerates the testing process helping to uncover defects more quickly than traditional testing methods, and getting the product into production and subsequently to market quicker than would be otherwise possible.

 HASS (Highly Accelerated Stress Screening)

Once the design phase of a product is complete and it has been ruggedised, it moves into production. HASS is then employed during the manufacturing phase of a product and is a form of ongoing quality assurance. It is used to find defects and flaws in production to monitor the quality and consistency of your manufacturing processes.

Defect Detection: HASS focuses on identifying defects in products as they are being manufactured. It helps ensure that only reliable and defect-free products reach the market.

Improved Product Reliability: By systematically subjecting products to stress screening, HASS improves product reliability and reduces the likelihood of field failures.

 Conclusion

Hanse Environmental HALT/HASS  systems  are indispensable tools for industries that prioritise product reliability and quality. They offer a unique approach to identifying weaknesses and defects, allowing for design improvements and defect prevention.

Their latest chambers are capable of temperature change rates of 70°C per minute with a temperature range from -100 to 200° c. The integrated vibration systems consist of a specially designed table with pneumatic actuators underneath. The systems can generate up to 100 Grms over a frequency range of 5 to 10,000 Hz in three axes and rotational about each axis. Hanse now also offer humidity stress as an option to its complete line of eight standard HALT/HASS models, all of which can be customised to meet customers specific requirements.

Whether it’s electronics, automotive, aerospace, healthcare, or other sectors, these chambers play a vital role in enhancing the reliability and durability of products, ultimately delivering better and safer products to consumers.

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