A batch of The G-BEE25/100 (25A, 100V) Elmo’s Ultra small servo drive, passed successfully the HALT (Highly Accelerated Life Testing), during the test the NANO drives were exposed to environmental condition exceeding by far the specifies and designed limits. The drives were pulled down to -75°C (STD = -40°C), up to +110°C (STD= 70°C), vibrated to over 30GRMS (STD= 12GRMS), and cycles from -75°C to +110°C at 40°C per minute.
What is HALT?
HALT is a part of the verification process to insure the reliability of the designed product.
HALT is a product reliability test performed during the design process (preferably in the pilot pre-production phase) to discover any product's weaknesses prior to the design completion, and progressing to full production phase.
The HALT philosophy is: "A chain is only as strong as its weakest link"
Therefore HALT's purpose is to discover and correct product’s "weak link/s". This is accomplished by "exposing" the product to operate at environmental conditions well beyond its specified and design limits.
By revealing these "weak link" failures during the HALT, and then correcting them, the product reliability is established and significantly improved.
In addition, the HALT is also used to predict the product MTBF. This is a more complex process, requiring considerable testing and measurements during the HALT process.
The "HALT MTBF" of the G-BEE will be published upon analysis completion of the collected data.
HALT type of tests:
What are HALT failures?
A typical mistake is to look for components wear out / fatigue due to being exposed to extreme environmental conditions. But, Electronic components failure contributes negligibly to the unreliability.
Most malfunctions occur during the initial operating months and are caused by inadequate design and/or a flawed production, both of which are detected during the HALT process.
The highly accelerated life test conditions are such that the product is expected to break, eventually. The "successful" HALT test is one in which the product fails as the designer expects under the expected conditions of the product design. By finding the failure points for each critical component/ failure a better product emerges.
The HALT of the G-BEE25/100
Electrical HALT set up
GOLD BEES In the HALT Chamber (Temperature cycling + Mechanical vibrations)
The HALT was executed under full electrical load of 85VDC and peaking at 50A with 20ARMS.
All the drives were connected in a network with 70% -80% communication load.
GOLD BEE Endures the Extreme
All the G-BEE25/100 successfully passed the HALT. No failure occurred during the 48 hours test!
With ZERO failures, no weak links detected, and thus Nothing to correct, was the testing successful?
It was very successful testing, as it was a real "prove of design" and the verification of the high quality NPI (New Product Introduction) process and a demonstration of the High Technology of Elmo’s production capabilities.
The STD operating conditions of the G-BEE series are :
The HALT raised the G-BEE significantly above the STD operating conditions, proving that there are very large safety margins which ensure reliable operation at the STD designed operating conditions.
Note: It was impossible to extend the test conditions further as the limits of the equipment were reached.
Question: Can the G-BEE be implemented in a -55°C application even though the specification allows only -40°C?
Answer: Absolutely NO! The G-BEE was designed to operate down to -40°C. The fact that it withstands -75°C proves that there are "generous" safety margins. Operating at ambient temperature that is lower than -40°C is not within the design and not guaranteed.
Note: Consult factory For any need to exceed the STD operating environmental conditions.