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Vibration Testing, Condition Monitoring, & Structural Testing Technology

Aerospace Environmental Testing

Flight Testing

To simulate and analyze vibration responses during different flight conditions.

Modal Analysis

Determining the natural frequencies, damping ratios, and mode shapes of aerospace structures to understand their dynamic behavior.

Structural Health Monitoring

Continuous monitoring of aircraft structures to detect and assess vibrations that could indicate potential structural issues.

Ground Testing

Testing aerospace components and assemblies on the ground to ensure they can withstand vibrations encountered during flight.

Rotor Dynamics

Analyzing vibrations in helicopter rotors and other rotating components to optimize performance and reduce fatigue.

Satellite Deployment

Controlling vibrations during satellite deployment from launch vehicles to avoid damage to onboard equipment

Propulsion Systems

Monitoring and controlling vibrations in aircraft engines and rocket propulsion systems to enhance reliability and safety.

Spacecraft Launch

Assessing and mitigating vibrations during spacecraft launch to protect sensitive payloads and ensure mission success.

Aircraft Interiors

Minimizing passenger discomfort by controlling vibrations in aircraft interiors caused by engines and air turbulence.

Avionics Testing

Evaluating vibrations on avionics equipment to ensure reliability and functionality under dynamic conditions.

 

Automotive Environmental Testing

Vehicle Durability Testing

Assessing the durability of vehicle components and structures by subjecting them to controlled vibration conditions simulating real-world road conditions.

Engine Testing

Analyzing vibrations in engines to optimize performance, reduce noise, and ensure durability.

Chassis Testing

Evaluating the structural integrity and performance of vehicle chassis under different vibration frequencies and amplitudes.

Suspension System Optimization

Tuning and testing vehicle suspension systems to enhance ride comfort, handling, and stability under various vibration scenarios.

Noise, Vibration, and Harshness (NVH) Testing

Characterizing and mitigating noise, vibration, and harshness levels in vehicles to improve overall comfort and refinement.

Electrical and Electronic Components Testing

Evaluating vibrations on electronic components, such as sensors and control units, to ensure reliability and functionality.

Tire and Wheel Testing

Testing tires and wheels to ensure they can withstand vibration loads and provide safe and comfortable driving experiences.

Seat Comfort Testing

Assessing seat designs and materials to minimize vibrations transmitted to occupants and enhance comfort during driving.

Crash Testing

Simulating crash scenarios to assess the response of vehicle structures and safety systems to vibrations and impact forces.

CAN-Bus Integration

Software offers direct CAN-Bus integration to communicate with other devices.

 

Battery Environmental Testing

Battery Pack Assembly

Ensuring controlled vibrations during the assembly of battery packs to prevent damage to battery cells and optimize the packing density for electric vehicles (EVs).

Impact Testing

Simulating vibrations and impacts on battery packs to evaluate their resilience and safety in the event of accidents or collisions.

Environmental Testing

Testing batteries under controlled vibration conditions to assess their performance and lifespan in harsh environmental conditions, such as extreme temperatures and vibrations.

Transportation Testing

Subjecting battery packs to controlled vibrations during transportation simulations to assess their durability and reliability under various road conditions.

Endurance Testing

Performing long-term vibration tests on battery packs to evaluate their structural integrity and electrical performance over extended periods of use.

Fault Diagnosis

Using signal analyzers to detect and diagnose abnormalities in battery cells or packs based on electrical signals, such as voltage spikes or irregular current patterns.

Cycle Life Testing

Analyzing signals to assess the cycle life and degradation of batteries through repeated charge-discharge cycles under controlled conditions.

Battery Performance Analysis

Analyzing signals to monitor and optimize the performance of vehicle batteries, including voltage, current, and temperature profiles.

Battery Management System (BMS) Calibration

Using signal analyzers to calibrate and optimize the BMS parameters based on real-time battery performance data.

Regulatory Compliance

Analyzing signals to ensure vehicle batteries comply with regulatory standards for safety, performance, and environmental impact.

 

Consumer Goods Testing

Appliances Testing

Controlling vibrations in household appliances such as washing machines, refrigerators, and dishwashers to ensure durability, performance, and noise reduction.

Packaging Testing

Subjecting product packaging to controlled vibrations to ensure it can withstand transportation and handling without damaging the enclosed goods.

Furniture Testing

Controlling vibrations in furniture items such as chairs, tables, and beds to assess comfort, stability, and durability.

Electronics Testing

Testing and optimizing vibrations in consumer electronics like smartphones, tablets, and laptops to improve reliability and user experience.

Sporting Goods Testing

Testing vibrations in sporting equipment such as tennis rackets, golf clubs, and bicycles to optimize performance and user comfort.

Durability Testing

Analyzing signals to assess the durability and longevity of consumer goods under various stress and usage conditions.

Noise and Vibration Analysis

Analyzing signals to study and optimize noise and vibration levels in consumer products to enhance user comfort and satisfaction.

Quality Control

Analyzing signals from production lines to ensure consumer goods meet quality standards and specifications.

Performance Optimization

Using signal analyzers to monitor and optimize the performance of consumer goods, such as energy efficiency in appliances or responsiveness in electronics.

Product Development

Analyzing signals during product development stages to refine designs, improve functionality, and address performance issues before market release.

 

Education and Research

Structural Dynamics Experiments

Teaching and studying the fundamental principles of structural dynamics by exciting and analyzing vibrations in model structures.

Vibration Control Systems

Studying the principles and implementation of vibration control algorithms and systems for damping vibrations in structures.

Modal Analysis

Performing modal testing and analysis to determine the natural frequencies, mode shapes, and damping ratios of structures in educational and research settings.

Mechanical Vibrations Courses

Supporting hands-on learning in mechanical engineering courses focused on vibrations, including theoretical concepts and practical applications.

Aerospace and Automotive Engineering Research

Investigating vibrations in aerospace and automotive structures, components, and systems to improve design, performance, and reliability.

Civil Engineering and Earthquake Engineering

Studying vibrations in civil engineering structures, bridges, and buildings to assess structural integrity and resilience to seismic events.

Biomechanics and Biomedical Engineering

Researching vibrations in biological systems, such as studying bone fractures or prosthetic limbs, to understand biomechanical behavior and improve medical devices.

Materials Testing

Evaluating the vibration characteristics of materials and composites to understand their mechanical properties and behavior under dynamic loads.

Environmental Vibrations

Monitoring and analyzing vibrations in environmental studies, such as assessing the impact of vibrations from transportation or industrial activities on ecosystems or buildings.

Advanced Research in Control Systems

Developing and testing advanced control algorithms for vibration suppression, active vibration isolation, or adaptive vibration control in various applications.

 

Electronics Environmental Testing

PCB Testing

Controlling vibrations during printed circuit board (PCB) testing to ensure reliability and functionality of electronic components.

Electromechanical Devices

Testing and optimizing vibrations in electromechanical devices such as hard drives and optical disc drives to improve performance and reduce noise.

Automated Assembly

Using vibration controllers to simulate and optimize assembly line conditions, ensuring electronic components are not adversely affected by assembly-related vibrations.

Component Testing

Testing vibrations on electronic components like capacitors, resistors, and ICs to ensure they meet durability and performance standards.

Environmental Testing

Subjecting electronic devices to controlled vibrations to simulate real-world transportation and operational conditions, ensuring robustness and reliability.

Quality Control

Analyzing signals to ensure electronic components and devices meet specified performance criteria and quality standards.

Failure Analysis

Using signal analyzers to diagnose and analyze vibrations and signals from malfunctioning electronic devices to determine the root cause of failures.

Power Analysis

Analyzing signals to monitor and optimize power consumption and efficiency in electronic devices and systems.

Energy Industrial Maintenance

Power Quality Analysis

Monitoring and analyzing electrical signals to assess power quality, including voltage fluctuations, harmonic distortions, and frequency variations in power distribution systems.

Fault Detection and Diagnosis

Recording and analyzing signals to detect anomalies and diagnose faults in electrical grids, substations, and power generation equipment.

Condition Monitoring of Equipment

Using data recorders and signal analyzers to monitor vibrations, temperatures, and other parameters to assess the condition of rotating machinery such as turbines, generators, and pumps.

Energy Efficiency Audits

Conducting energy audits by recording and analyzing data from various energy-consuming systems and equipment to identify opportunities for improving energy efficiency.

Renewable Energy Integration

Monitoring and analyzing signals from renewable energy sources such as solar panels and wind turbines to optimize integration into the grid, manage variability, and ensure stability.

Gas Turbines

Controlling vibrations in gas turbines to optimize performance, reliability, and longevity. Vibration controllers help mitigate vibrations that can lead to mechanical failures and downtime.

Hydroelectric Power Plants

Using vibration controllers to monitor and control vibrations in hydroelectric turbines, generators, and other equipment to ensure smooth operation and prevent damage.

Wind Turbines

Managing vibrations in wind turbine blades, gearboxes, and towers to improve efficiency, reliability, and safety. Vibration control helps minimize fatigue and structural damage.

Pumps and Compressors

Employing vibration controllers to monitor and adjust vibrations in pumps and compressors used in oil and gas pipelines, refineries, and petrochemical plants to enhance performance and prevent breakdowns.

Transmission and Distribution Lines

Using vibration controllers to monitor vibrations in transmission towers and distribution lines to detect faults, prevent failures, and ensure the reliability of the electrical grid.

 

Medical Equipment Testing

Ensuring Equipment Durability

Medical equipment often undergoes rigorous handling during transportation and use. Vibration testing simulates these real-world conditions to ensure that the equipment can withstand mechanical stresses without failure. This is crucial for maintaining operational reliability and patient safety.

Verifying Compliance with Standards

Medical devices must adhere to various industry standards and regulations, such as ISO 13485 or IEC 60601. Vibration testing helps confirm that the equipment meets these standards, ensuring it is safe and effective for clinical use. Compliance with these standards is necessary for regulatory approval and market access.

Preventing Malfunctions in Critical Systems

Many medical devices, such as infusion pumps or imaging equipment, contain sensitive components that could malfunction if subjected to vibrations. Testing helps identify potential issues with components like connectors, screens, or sensors, preventing failures that could impact patient care.

Improving Device Longevity

Regular vibration testing during the design and manufacturing phases can help identify weaknesses and design flaws. By addressing these issues early, manufacturers can enhance the durability and lifespan of the equipment, reducing maintenance costs and the need for repairs.

Enhancing Patient Safety

Vibration testing helps ensure that medical devices remain operational and accurate despite being exposed to vibrations during normal use or transportation. This is especially critical for devices that monitor vital signs or administer treatments, as malfunctions or inaccuracies could directly impact patient safety.

 

Military and Defense Equipment Testing

Weapon Systems

Controlling vibrations in firearms, cannons, and missile systems to ensure accuracy, reliability, and minimize wear and tear.

Aircraft

Managing vibrations in aircraft structures, engines, and avionics systems to enhance safety, performance, and mission effectiveness.

Military Vehicles

Controlling vibrations in tanks, armored vehicles, and personnel carriers to improve ride comfort, equipment reliability, and reduce fatigue.

Naval Vessels

Minimizing vibrations in ship hulls, propulsion systems, and onboard equipment to enhance stealth, operational efficiency, and crew comfort.

Satellite Systems

Controlling vibrations in satellite components and payloads to ensure stability, functionality, and longevity in space missions.

Weapon System Testing and Calibration

Application: DAQ systems collect and analyze data from weapon systems during testing, including firing accuracy, recoil forces, and system performance metrics.

Reason: Ensures that weapon systems operate within specified parameters and meet accuracy and reliability standards, which is critical for operational effectiveness and safety.

Vehicle and Aircraft Performance Monitoring

Application: DAQ systems monitor various parameters of military vehicles and aircraft, such as engine performance, structural loads, and environmental conditions.

Reason: Provides real-time data to assess and optimize performance, diagnose issues, and ensure the reliability of these critical assets under operational conditions.

Explosive Testing

Application: DAQ systems are used to capture data during explosive tests, including pressure waves, blast effects, and material responses.

Reason: Helps in understanding the impact of explosives on materials and structures, which is vital for developing effective protective measures and ensuring safety.

Environmental Testing of Military Equipment

Application: DAQ systems are used to test military equipment under extreme environmental conditions, including temperature variations, humidity, and vibration.

Reason: Ensures that equipment can withstand harsh conditions encountered in various operational environments, thus improving reliability and performance.

Ballistic Testing

Application: Signal analyzers measure and analyze the acoustic signatures of military equipment, such as submarines or aircraft, to assess detectability and stealth capabilities.

Reason: Helps in optimizing designs to reduce detectability and improve stealth, which is crucial for maintaining operational security and effectiveness.

 

Additional Resources

Packaging and Transportation Environmental Testing

Package Testing

Simulating transportation vibrations to test the durability and integrity of product packaging, ensuring products arrive at their destination undamaged.

Shock Testing

Controlling vibrations to simulate shocks and impacts that packages may experience during handling and transportation, ensuring they withstand rough handling.

Container Testing

Testing vibrations on shipping containers and cargo holds to ensure they can withstand the vibrations encountered during transportation by road, rail, sea, or air.

Pallet Load Testing

Testing vibrations on palletized loads to optimize stacking configurations and ensure stability during transportation and storage.

Automotive Parts Packaging

Controlling vibrations during the packaging of automotive parts to prevent damage and ensure parts arrive in optimal condition to assembly lines or customers.

International Safe Transit Association (ISTA) Standards

Analyzing vibrations and shocks to ensure compliance with ISTA packaging standards, which specify test methods for shipping containers and palletized loads.

ASTM D4728 Standard

Analyzing vibrations and impacts on packages and products to comply with ASTM D4728 standard, which specifies test methods for mechanical handling and transportation simulation.

ISO 13355 Standard

Analyzing vibrations and shocks to comply with ISO 13355 standard, which provides guidelines for the measurement and evaluation of mechanical vibrations and shocks on goods in transit.

Environmental Testing

Analyzing vibrations and impacts on electronic devices, sensitive equipment, and pharmaceuticals during transportation to ensure compliance with regulatory requirements and industry standards.

Quality Control

Analyzing vibrations and shocks on products during transportation to ensure they meet quality control standards and customer expectations for product integrity upon delivery.

 

Space Environmental Testing

Satellite Testing

Controlling vibrations during the testing of satellites to simulate launch and operational conditions, ensuring structural integrity and functionality in space.

Rocket Payloads

Managing vibrations in rocket payloads to ensure their stability and functionality during launch and space travel.

Spacecraft Components

Testing and optimizing vibrations in spacecraft components such as antennas, solar panels, and propulsion systems to enhance reliability and performance in space.

Microgravity Research

Using vibration controllers to simulate microgravity conditions for experiments and research aboard spacecraft or in ground-based laboratories.

Lunar and Planetary Missions

Controlling vibrations during the testing of landers, rovers, and exploration vehicles destined for lunar, planetary, or asteroid missions to ensure mission success and data collection reliability.

Environmental Testing Standards (ESA/ECSS)

Analyzing vibrations and shocks to meet European Space Agency (ESA) and European Cooperation for Space Standardization (ECSS) standards for environmental testing of space hardware.

NASA Standards

Analyzing vibrations and signals to meet National Aeronautics and Space Administration (NASA) standards such as NASA-STD-7001 for vibration and acoustic testing of aerospace and flight hardware.

ASTM E606 Standard

Analyzing vibrations and signals to meet ASTM E606 standard for measuring vibration damping properties and compliance testing of materials used in aerospace applications.

Spacecraft Instrumentation

Using signal analyzers to monitor and analyze signals from scientific instruments aboard spacecraft to collect data on celestial bodies and space environments.

Communication Systems

Analyzing signals from spacecraft communication systems to ensure reliable transmission of data between Earth and spacecraft, adhering to international space communication standards.

 

Structural Engineering

Structural Health Monitoring

Signal analyzers and DAQ systems are used to monitor vibrations and acoustic emissions in structures like bridges, buildings, and dams. By measuring acceleration and acoustic signals, engineers can detect signs of deterioration or damage, such as cracks or stress fractures, and perform timely maintenance to ensure structural integrity and safety.

Dynamic Testing of Structures

To understand how structures respond to dynamic loads (e.g., wind, seismic activity, or traffic), engineers use signal analyzers to measure the acceleration and vibrations of the structure. This helps in assessing the dynamic behavior, natural frequencies, and mode shapes of the structure, which are essential for designing structures that can withstand environmental forces.

Vibration Analysis for Design Optimization

During the design and testing phases, signal analyzers and DAQ systems measure vibrations to evaluate the performance of structural components. This data helps in optimizing the design by identifying resonant frequencies and ensuring that the structure will perform as expected under operational conditions, preventing issues like excessive vibrations or resonance

Acoustic Emission Testing

Acoustic emission testing involves listening to high-frequency sound waves generated by the structure under stress. Signal analyzers can capture these acoustic signals to detect early signs of material failure, such as cracks or delamination, which might not be visible through conventional inspection methods. This non-destructive testing method enhances the ability to identify potential issues before they become critical.

Noise and Vibration Control

In structures subjected to significant external noise or vibration sources (e.g., industrial facilities, transportation infrastructure), signal analyzers and DAQ systems help in assessing the impact of these disturbances on the structural components. By measuring and analyzing these effects, engineers can design and implement control measures, such as vibration isolation or noise reduction solutions, to improve comfort and reduce potential damage.

 

Testing Lab Solutions

Product Reliability Testing

Application: Vibration controllers simulate real-world operational and transportation vibrations on consumer electronics, automotive parts, and other products to test their reliability and durability.

Reason: Ensures products can withstand typical usage and handling conditions, reducing the risk of failure and improving customer satisfaction.

Compliance Testing for Standards

Application: Vibration controllers are used to test products against industry standards such as MIL-STD, ISO, or ASTM. This includes testing electronic devices, machinery, and automotive components.

Reason: Validates that products meet regulatory and industry-specific standards, ensuring they are safe and reliable for market release.

Packaging Design Evaluation

Application: Vibration controllers assess the effectiveness of packaging materials and designs by simulating the vibrations experienced during shipping and handling.

Reason: Helps in designing packaging solutions that protect products from damage during transport, minimizing returns and enhancing customer satisfaction.

Pre-Shipment Testing

Application: Before products are shipped to customers, vibration controllers simulate transport conditions to ensure they arrive in proper working condition.

Reason: Reduces the likelihood of product failures due to shipping-induced vibrations, ensuring that products are delivered in optimal condition.

Fatigue and Lifecycle Testing

Application: Vibration controllers apply repetitive loads to test the fatigue resistance of materials and components over extended periods.

Reason: Provides insights into the longevity and performance of products under continuous or cyclic stress, helping to predict and enhance their lifespan.

Vibration and Acoustic Analysis

Application: Signal analyzers measure and analyze vibrations and acoustic emissions in products and structures to detect issues such as resonance, noise, and mechanical faults.

Reason: Identifies performance issues and potential defects, ensuring products and structures operate efficiently and quietly.

Frequency Response Testing

Application: Signal analyzers are used to assess the frequency response of systems, such as audio equipment or mechanical structures, to evaluate their performance across various frequencies.

Reason: Ensures that systems perform correctly and meet design specifications by providing detailed frequency response data.

Modal Analysis for Structural Testing

Application: Signal analyzers perform modal analysis by capturing data on a structure's response to dynamic excitation, helping to determine its natural frequencies and mode shapes.

Reason: Facilitates the understanding of structural dynamics, aiding in the design and optimization of structures to prevent issues like resonance.

Noise Emission Testing

Application: Signal analyzers measure and analyze noise levels produced by products or machinery to ensure they comply with noise regulations and standards.

Reason: Helps in managing noise pollution, ensuring compliance with legal requirements, and improving user comfort.

System Performance Evaluation

Application: Signal analyzers are employed to assess the performance of complex systems, such as HVAC systems or automotive engines, by analyzing signals from various sensors.

Reason: Provides detailed performance data, aiding in system optimization, troubleshooting, and ensuring that systems function as intended.

 

Angular Acceleration Control

Angular acceleration control is a technique used in vibration control systems to manage and mitigate unwanted rotational movements in mechanical systems. This type of control is particularly relevant in systems where rotational dynamics play a significant role, such as in spinning machinery, robotics, or aerospace applications. Angular acceleration refers to the rate of change of angular velocity, and controlling it involves adjusting the torque applied to the system to manage how quickly its rotational speed changes. By regulating angular acceleration, engineers can reduce the impact of vibrations that arise from rapid changes in rotational speed or from disturbances in the system.

In vibration control, angular acceleration control helps in stabilizing systems and reducing the amplitude of vibrations that can lead to mechanical wear, noise, or even failure. By applying control strategies that adjust the torque based on the desired angular acceleration, the system can be tuned to dampen vibrations and achieve smoother operation. This approach enhances the system's performance.

Customized Reporting

Crystal Instrument’s EDM software includes an advanced reporting tool to easily and efficiently generate documents containing import information regarding the test run. Information that can be reported on includes: all Saved Results; Plots and Graphs, Active Signal Windows, Run Logs, Test Parameters, Test Profiles, System Configuration Properties, Software Screenshots, External Video Captures, and more. The reports can be generated in three different formats: Open XML, PDF, and MS-Office.

Customized Report Templates can be created to configure exactly what details you want to include in your report. In addition to information regarding the test, the templates can also be configured to control the format of the report. Aspects such as Company Logo, Header & Footer Sections, Font Settings, and Plot/Graph Formatting can all be edited and customized. This process makes it very easy and intuitive to create documentation.

Seismic Floor Vibration

Seismic measurements (very low frequency) require extremely low noise A/D converters. This is due to the low frequency sensors used. To measure BBN criterion E effectively requires a noise floor of > -50 dB

When measuring the different criterion if the noise floor of the A/D is unknown then the measurements can be erroneous. Start by understanding the sensor’s sensitivity and noise floor and then determine the measurement system’s noise floor and dynamic range. An example is the PCB XYZ with a frequency range of .1 Hz to 1000 Hz, sensitivity of 1000 mV/mG and a noise floor of -45 dB. The measurement system must have a lower noise floor or it can introduce noise into the measurement. Crystal Instruments Spider-80X series and the CoCo series noise floor is -70 dB well below the sensor noise floor so seismic measurements can be made with confidence in the accuracy. The dynamic range is important since the levels may vary from .1 mG to 10 G’s. This large range can be measured by the Crystal Instruments dual 24 bit A/D design resulting in a total of 124 dB dynamic range.

The vibration environment of facilities used for research, photolithography, microelectronics manufacture, and similar activities has a significant effect on the performance of the equipment used within. As the dimensional requirements of today’s equipment and processes become more demanding, their sensitivity to external vibration increases. When designing such facilities, the stiffness of the floors and supporting structure must be such that the vibration levels are kept below that which causes problems for the equipment.

Crystal Instruments provides solutions to conduct testing according to the associated IEST, ISO and NIST-A criteria. The CoCo portable signal analyzer is equipped to take the 1/3 octave vibration measurements that are needed.  The CoCo also contains pre-configured modules to make it simple and easy to perform the tests according to the standards. For larger environments, the Spider series of hardware can be used to measure up to 512 channels.

Applications
Seismic Floor Vibration
Building Vibration
Clean Room Floor Vibration Surveys
Sensitive Equipment Facilities
Water Fabrication Floor Survey
Chip Manufacturing
Microelectronics Manufacturing
Features
1/3 Octave Band Analysis
Vibration Criteria (VC) Curve Comparison
Linear and Peak Hold Average Modes
Compliant with IEST, ISO, NIST-A Criteria and Guidelines
Products
CoCo-80X/90X
Spider-20
Spider-80X