Date and Time
October 9-11, 2012
8 am - 4 pm
Location
National Technical Systems - NTS
20970 Centre Pointe Parkway
Santa Clarita, California 91350
Teacher
Wayne Tustin
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(approx. 700K)
Course Description
We’ll commence by reviewing (slowly if first-timers are present) basic vibrations, sources and causes. Then we’ll explore vibration measurements, analysis and calibration. Our discussion is supported by projected visuals and video clips. We’ll compare sinusoidal vs. random vibration with emphasis on testing systems, specifications, standards and procedures. We’ll discuss ESS, HALT and HASS. We’ll emphasize vibration and shock test fixture design, fabrication, experimental evaluation and usage. Also shock measurement, shock response spectrum (SRS) and classical shock testing. We’ll review modal testing. Throughout, we emphasize topics you will use immediately.
We will visit the onsite NTS environmental test laboratory, where we will view, hear and touch (hearing and feeling the differences between sine and random vibration) one of NTS’s shakers. We will perform a resonance demonstration, using first sine and then random vibration. We will demonstrate shock testing, using both a shaker and a shock test machine. Many participants have commented that this visit was a high point of the course.
Many participants protectively install commercial-off-the-shelf (COTS) equipment in flight, land vehicles and shipboard locations subject to severe vibration and shock. Many participants laboratory test that protected equipment (1) to assure twenty years equipment survival and possible combat, also (2) to meet commercial test standards, IEC documents, DO-160G, military standards such as STANAG, MIL-STD-810G, etc. Few if any engineering schools teach about such protection or such testing. Thus we offer this specialized course.
Register to this Fundamentals of Random Vibration and Shock Testing course and also to Safely Operate Electrodynamic Shaker Systems at the same time and save $$$!!! See more under Fee/Registration.
Objectives
After this short course, you will be able to
- measure vibration and shock,
- calibrate vibration and shock measurement systems,
- convert field measured data into a test program,
- interpret vibration and shock test requirements,
- supervise vibration and shock tests,
- specify and experimentally evaluate vibration and shock test fixtures,
- perform ESS, HALT and HASS.
When you visit a lab or review a test program, you will have a good understanding of the requirements and execution of dynamics tests and will be able to ask meaningful questions and understand lab people’s responses.
For whom intended
I need practical knowledge about mechanical vibration and mechanical shock test, measurement, analysis, designing for dynamics also calibration and/or control because:
- I instrument land, sea and air vehicles as well as fixed-based equipment, in order to measure mechanical vibration and/or shock in service and during transport.
- I analyze dynamic responses to mechanical vibration and shock inputs during normal and abnormal transport.
- My title may be mechanical engineer, mechanical designer or packaging engineer. I design (ruggedize) products that must withstand factory handling + transport + normal and abnormal usage. I design products to dynamic requirements, which I don't fully understand. Then I send a prototype to our lab for testing. I really don't understand what our lab does. I'd better find out.
- I write contracts for procuring high-reliability equipment. I need to understand HALT, ESS and HASS. When do these acronyms apply? How do I insure that potential contractors will appropriately implement the random vibration requirements of these acronyms? What is g2/Hz?
- I work in an environmental test lab. We perform vibration and shock tests on prototype hardware. These tests may be part of developing a new product, of determining vibration levels for future production ESS (environmental stress screening) or production tests, or of investigating in-service or transport failures.
- I calibrate various vibration and shock sensors (including accelerometers) and analyze vibration and/or shock.
- I design to control (reduce, protect) the intensity of vibration and/or shock, which otherwise may damage delicate equipment.
- I maintain machinery whose vibration signature can warn of approaching failure.
If you thought, "aha - that's what I'm supposed to do" to any of the job descriptions listed above, then the instructor says, "This course is intended for you." It will help you move up your own "learning curve."
A smaller group, for whom the instructor also intends this course: supervisors of any of the above listed activities. Perhaps you were thrust into this responsibility without adequate training. Maybe your predecessor had no opportunity to alert you to potential difficulties. You certainly need to know what your people are talking about. Possibly you had no formal training for your present responsibilities. You need to explain your department's activities to your superiors in the technically correct language. Perhaps you need to decide between "in house" and "outside" testing.
Course Outline
Introduction for management and participants
- Purpose of environmental testing, particularly vibration and shock
- Purpose of environmental stress screening (ESS), nowadays HALT & HASS
- Types of vibration tests: resonance search/dwell, fatigue, specification
Quiz for evaluation of attendee prior knowledge
Classical sinusoidal vibration never observed in service; useful concept
- Introduction: terminology, structural resonant behavior, passive and active isolation
- Sinusoidal vibration measurements: units, sensors, readouts, errors
- Calibration of sensors and systems; traceability to NIST
Introduction to spectrum analysis via machinery vibration
Sinusoidal vibration testing
- Electrohydraulic and electrodynamic shakers; theory, tradeoffs, limits
- Power amplifier theory, operation, limitations, distortion effects
- Controls for sinusoidal vibration testing
- Sinusoidal vibration test practice
- Interpretation of standards; e.g. MIL-STD-810, DO-160G
- Controversial test methodology: tracking filters, switching and averaging among sensors
Introduction to random vibration
- Sources of random vibration in service and transportation
- No possible equivalence to sinusoidal vibration
- Terminology and definitions
- Spectral density measurement and analysis - the frequency domain. What is g2/Hz?
- Probability density - the time domain
Random vibration test practice
- Interpreting and implementing standards, e.g. MIL-STD-810G
- Equalization before testing; methods and limits
- Controls
- Electronic protection for test items and shaker system
- Simultaneous multaxis vibration testing fixed spelling
- Intense acoustic noise testing
Combined environment (CERT) testing; reliability tests, e.g. MIL-STD-781
Environmental stress screening (ESS) of electronics hardware production
- 1979-era need for ESS
- Early ESS techniques
Highly accelerated life testing (HALT), environmental stress screening (ESS) and highly accelerated stress screening (HASS) of electronics hardware production.
- Single vs. multi-axis vibration.
- Pneumatic repetitive-shock (RS) machines.
- Acoustic excitation of printed wiring boards (PWB).
Vibration and shock test fixtures; fixtures for stress screening
- Recommended designs, materials, fabrication methods
- Experimental evaluation before use
- Practical limits: transverse motion; specimen size and weight
Accommodating oversized loads
- Table expanders
- Slip plates and alternatives
Instrumentation for measuring shock in service and during tests
- Sensors, readouts, errors
- Calibration
Shock spectrum analysis; shock response spectrum
Shock testing standards and methods
Modal testing
Witnessing of tests
Course summary; optional final examination; award of certificates
Text Materials
Each participant receives a copy of Wayne's text 'A minimal-mathematics Introduction to the Fundamentals of Random Vibration and Shock Testing, HALT, ESS & HASS, also Measurements, Analysis & Calibration' (ISBN 0-9741466-0-9), including a CD containing a number of video clips pertaining to sine and random vibration and shock behavior and testing.
Location
National Technical Systems - NTS
20970 Centre Pointe Parkway
Santa Clarita, California 91350
Phone: (661) 259-8184
For map and directions, please visit Google Maps.
Suggestion for Accommodation
Embassy Suites Valencia, CA
28508 Westinghouse Place
Valencia, CA 91355
Phone: 661-257-3111
Toll Free: (800) EMBASSY
This hotel offers a promo rate of $109 per night for NTS. Follow this step by step to book your room and take advantage of this rate.
Fee/Registration
Fee is US$2,995 per student. Payment in advance via check, VISA or Mastercard preferred credit cards or bank transfer (ask for transfer details).
Early-bird Registration:
For registration and payment received one month prior to course, deduct $100. For three or more participants from an organization and payment received one month prior to course, deduct $200 each.
To start your registration click on the button to enroll online. If you do not wish to pay via credit card you can call our office at (805) 564-1260 to inform an alternative payment method after filling out the registration form.
