Vibrationstest

Vibration and Shock Test

Vibration tests are used to qualitatively check the strength of components (short-term vibration tests) or for life tests.

Structural weak points in components by means of time acceleration can therefore be detected.

We perform transport simulations with vibration profiles (road transport, rail transport or air transport) as well as the generation of short-term mechanical shocks, which can occur, for example, when driving over stones in the terrain or when lifting and dropping a transport item. In the automotive field, vibration, which is driven sinusoidally or with a stochastic noise profile, is usually driven with high and / or low temperatures superimposed. Here, tests of the most extreme type with the superimposition of sine over sine are also used in order to be able to drive high amplitudes through superimposed waveforms and thus shorten the test time.

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Vibration
Vibration and Shock Test  Normen

  • DIN EN 2591-403
  • DIN EN 60068-2-6
  • DIN EN 60068-2-64
  • DIN EN 60721-3-2
  • DIN EN 61373
  • DIN SPEC 79009
  • MIL-STD-810H Method 514→ Case Study
  • RTCA DO-160G Section 7→ Case Study
  • automotive standards (e.g. VW and BMW standards)
We also offer the following tests, among others:
noxious gas
according to the following standards, among others:

  • ASTM D1149
  • BMW GS 95003
  • IEC 60068-2-42
  • JDQ 53.3
  • NEMA 250
  • VW 80000

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Noxious Gas Tests
icing
according to the following standards, among others:

  • MIL-STD 810H
  • NEMA 250
  • RTCA DO-160G

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Icing Tests
chemical
according to the following standards, among others:

  • RTCA DO-160G
  • DIN ISO 16750-5
  • MIL-STD-810G
  • VW 50180
  • Airbus ABD0100.1.6
  • BMW GS 95003-5

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Chemical Resistance
Explanation of the vibration test(click to open)arrow right

Vibration tests are used to check the stability and anchorage of a wide variety of products from a wide range of industries and applications. They serve both to increase product comfort - by helping to eliminate unpleasant noise such as squeaking, for example - and to extend product service life, such as fundamental product safety and thus the safety of the user. They simulate as realistically as possible all the conditions under which the respective products are used. This allows the stability of structures and the reliability of connections between components to be checked.
The test objects are vibrated with the aid of a shaker. The vibrator usually consists of a platform on which the object is fixed.
The vibrations can be transmitted to the object in two ways, either as "random" ones, where different frequencies are involved at the same time, or as "sinusoidal" ones, which show a continuous, frequency-wise progression (increasing/decreasing curve). Accordingly, a distinction is made between "random vibration tests" and "sinusoidal vibration tests".
"Random vibration tests" usually depict the actual conditions of use of the products somewhat more realistically. A product often has more than one resonant frequency. Random tests with several simultaneous frequencies can quickly provide analyses that allow statements about service life and susceptibility to repair.
In the "sine vibration test", a frequency spectrum is run through. The so-called sine sweeps can be used to determine the frequencies at which the product shows the strongest response behavior.
Both test methods can also be combined to form "mixed mode vibration tests". Here the random oscillations are merged with resonance dwell times of a sine test.

Exemplary areas of application for vibration tests

Automotive

The vibrations caused by the road surface are significant for the automobile (and the occupants). In the tests, they are usually simulated by random vibration profiles that include smooth road surfaces as well as potholes, thresholds or even the behavior during braking.Opening and closing doors and hoods should also be included.

Aeronautics and astronautics

Aircraft must meet particularly stringent requirements because they can be subjected to particularly severe conditions and the safety and possibly the lives of their occupants depend on their reliability. Vibrations occur primarily during takeoff and landing as well as during weather-related turbulence.
Even stronger vibration stresses are encountered in space travel. Especially during the launch phase of a rocket, the load on systems and components can be as high as 20 G for about two minutes. But also during re-entry and eventual landing of the objects the vibration loads are enormously high.
In both cases, mixed-mode test procedures are appropriate.

Vibration testing of consumer goods

Consumer goods are also frequently exposed to vibrations in everyday life, which can be simulated by tests in order to increase the resistance and service life of the products. Kitchen appliances and furniture are just one example. In addition, many products have to undergo vibration tests to obtain certifications (e.g. CE). And last but not least, the transport routes - from the manufacturer to the dealer and finally to the consumer - contain many sources of vibration exposure. Packaging tests are necessary to ensure safety here.

Military vibration testing

Especially for military equipment, which is often exposed to high vibration stress, demanding tests have to be performed, for which our laboratory is specifically equipped. Here, according to military standards (see below), we are almost always talking about mixed-mode test executions.

Standards

Aeronautics and astronautics

RTCA-DO-160 is one of the most widely used test standards here.

Military sector

Here, the most commonly requested is MIL-STD-810, as well as MIL-STD 202 next to it. Part 1 of Standard-810 requires testing at a vibration frequency of 25 Hz and above. This standard also covers the effects of multiple events that may occur simultaneously. These include temperature, humidity and altitude in combination with vibrations.

Case Study

Structural Reliability of Avionics Electronics

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Vibration Testing according to RTCA/DO-160G Section 8
Structural Reliability of Avionics Electronics

The Challenge

Aircraft structures are continuously subjected to vibration during operation. Sources of vibration include:
  • engine operation
  • aerodynamic loads
  • turbulence during flight
  • landing gear impact during takeoff and landing
  • structural resonance within the aircraft fuselage
Avionics equipment installed in aircraft must withstand these mechanical stresses throughout the entire service life of the aircraft. Continuous vibration may lead to:
  • fatigue of mechanical structures
  • loosening of fasteners
  • failure of solder joints on electronic assemblies
  • connector degradation
  • intermittent electrical malfunction
To ensure long-term reliability, airborne equipment must be tested under realistic vibration conditions. Environmental qualification according to RTCA/DO-160G includes detailed vibration test procedures that simulate the mechanical environment encountered in aircraft.
This case study presents the vibration qualification testing of a sealed avionics control module used in a passenger aircraft system.

Device Under Test (DUT)

The tested device was an electronic control unit (ECU) responsible for controlling auxiliary aircraft systems.
The electronics are housed in a robust aluminum enclosure designed to provide mechanical protection and thermal dissipation.
Key characteristics of the DUT:
Parameter
Description
Product Type
Avionics control electronics
Application
Passenger aircraft systems
Housing
Aluminum enclosure
Cooling concept
Passive heat dissipation via housing
Connectors
Circular aviation connectors
Internal electronics
Multi-layer PCB assemblies
Installation location
Aircraft avionics compartment
Although avionics bays provide some structural protection, the manufacturer required vibration qualification testing to verify the mechanical robustness of the device under aircraft vibration conditions.

Test Objective

The vibration test evaluates the ability of airborne equipment to withstand mechanical vibration without structural damage or functional degradation.
The test verifies that:
  • the enclosure structure remains mechanically stable
  • connectors and fasteners remain secure
  • electronic components and solder joints withstand vibration loads
  • the device maintains full functionality during vibration exposure
The DUT was powered and monitored during portions of the test, ensuring that any intermittent electrical failures could be detected.

Test Setup

Testing was conducted using a multi-axis vibration shaker system capable of reproducing vibration profiles specified in the aerospace standard.
The DUT was mounted on the vibration table using a fixture that reproduced its installation orientation inside the aircraft.
The vibration shaker generated controlled vibration profiles covering the frequency ranges and acceleration levels defined in the standard.

Test Conditions

Testing was performed according to RTCA/DO-160G Section 8 – Vibration.
Typical parameters included:
Parameter
Typical Test Condition
Frequency range
low to high vibration spectrum
Vibration profile
aircraft vibration environment
Acceleration levels
defined by aircraft installation category
Test axes
three orthogonal axes
Exposure duration
extended vibration cycles
These conditions simulate the mechanical stresses experienced by avionics equipment during aircraft operation.

Test Procedure

The test program followed the procedure defined in the environmental qualification standard.
  1. Pre-Test Inspection
    Prior to vibration exposure, the DUT underwent:
    • visual inspection
    • verification of mechanical integrity
    • functional electrical testing
  2. Vibration Exposure
    The DUT was mounted on the vibration shaker and exposed to controlled vibration profiles.
    The vibration was applied sequentially in three orthogonal axes to simulate realistic aircraft vibration conditions.
  3. Operational Monitoring
    During selected phases of the test, the DUT remained powered to detect any intermittent electrical faults caused by vibration.
  4. Post-Test Inspection
    After completion of the vibration exposure, the DUT was removed from the shaker for detailed inspection and functional verification.

Post-Test Inspection

Following vibration testing, the device underwent comprehensive inspection and evaluation.
Inspection activities included:
  • examination of enclosure integrity
  • inspection of connectors and mounting hardware
  • verification of internal electronic assemblies
  • electrical functional testing

Results

The avionics control unit successfully completed the vibration qualification test.
Key observation:
Evaluation
Result
Structural integrity
No damage observed
Connector stability
No loosening detected
Internal components
No mechanical failures
Electrical functionality
Fully operational
Intermittent faults
None detected
The aluminum enclosure and internal electronics demonstrated strong resistance to mechanical vibration.

Conclusion

The tested avionics control module successfully passed the vibration qualification according to RTCA/DO-160G Section 8.
The test confirmed that:
  • the enclosure structure withstands aircraft vibration loads
  • connectors and mounting elements remain secure
  • internal electronics maintain reliable operation under vibration exposure
These results demonstrate the suitability of the device for long-term operation in aircraft environments where continuous vibration is present.

Why Vibration Testing Matters

Vibration testing plays a critical role in ensuring the mechanical reliability of airborne equipment.
Environmental qualification according to DO-160 helps manufacturers:
  • detect structural weaknesses early in development
  • validate mechanical design of avionics equipment
  • ensure long-term operational reliability
  • support certification of airborne electronics
By reproducing realistic aircraft vibration environments in the laboratory, manufacturers can verify that avionics systems remain reliable throughout their operational life.

Case Study

Vibration Resistance of an Electronic Control Unit for a Military Vehicle

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Environmental Qualification according to MIL-STD-810H – Method 514.8 (Vibration)
Vibration Resistance of an Electronic Control Unit for a Military Vehicle

Background

Military ground vehicles are exposed to extreme vibration environments during operation. These vibrations originate from multiple sources, including:
  • engine and drivetrain operation
  • rough terrain and off-road mobility
  • track or wheel impacts
  • weapon firing and recoil
  • transport by aircraft or rail
Electronic and mechanical subsystems installed inside these vehicles must withstand continuous vibration loads without functional degradation. One critical component is the electronic control unit (ECU) responsible for monitoring and controlling vehicle subsystems such as:
  • turret stabilization
  • sensor interfaces
  • auxiliary power systems
  • vehicle communication networks
Continuous vibration can cause:
  • loosening of connectors
  • fatigue of solder joints
  • failure of electronic components
  • degradation of mounting structures
To ensure operational reliability, such components must be tested according to MIL-STD-810H Method 514.8 (Vibration).

Test Objective

The objective of the test was to evaluate the structural integrity and operational performance of a vehicle electronic control unit when exposed to vibration profiles representative of military vehicle operation.
The test focused on:
  • mechanical robustness of the enclosure
  • resistance of internal electronics to vibration stress
  • stability of connectors and mounting interfaces
  • operational functionality during and after vibration exposure

Device Under Test (DUT)

Equipment:
Vehicle electronic control unit (ECU).
Application:
Subsystem controller installed inside a military armored vehicle.
Construction:
Component
Description
Housing
Aluminum alloy rugged enclosure
Internal electronics
Multi-layer PCB with surface-mounted components
Connectors
Military sealed circular connectors
Mounting system
Four-point vibration-damped mounting
Dimensions
240 × 180 × 70 mm
The ECU was mounted to a representative vehicle mounting frame to replicate its installation inside the vehicle hull.

Test Setup

Testing was conducted using a multi-axis electrodynamic vibration shaker system capable of reproducing complex vibration profiles encountered in military vehicles.
The DUT was securely mounted on the shaker table using its standard mounting brackets. Accelerometers were installed to monitor vibration levels during testing.

Test Conditions

Testing followed MIL-STD-810H Method 514.8 – Vibration.
A vibration profile representative of tracked armored vehicle operation was applied.
Parameter
Value
Frequency range
10 Hz – 500 Hz
Acceleration level
up to 5 g RMS
Vibration type
Random vibration
Test duration
1 hour per axis
Axes tested
X, Y, Z
The ECU remained powered and operational during the test, allowing continuous monitoring of functionality.

Monitoring and Inspection

During the test, system performance was continuously monitored to detect any functional anomalies.
Inspection methods included:
  • electrical performance monitoring
  • connector stability inspection
  • vibration response measurement via accelerometers
  • visual inspection of mounting hardware
After the test, the ECU was disassembled to inspect internal components.

Post-Test Inspection

Detailed inspection was performed on the DUT to identify any mechanical or electrical degradation.
Inspection included:
  • examination of PCB solder joints
  • inspection of connectors and cable interfaces
  • housing integrity verification
  • operational functional test

Test Results

Evaluation Parameter
Result
Mechanical deformation
None observed
Connector stability
No loosening detected/div>
PCB integrity
No cracks or component detachment
Functional performance
Fully operational
Mounting system
Intact
The ECU remained fully operational throughout the vibration test.

Engineering Assessment

The successful vibration resistance of the unit was attributed to several design features:
  • rugged aluminum enclosure providing structural rigidity
  • conformal coating protecting electronic components
  • reinforced PCB mounting points
  • vibration-damped mounting brackets reducing transmitted loads
These measures effectively protected the internal electronics from vibration-induced damage.

Conclusion

The electronic control unit successfully met the environmental qualification requirements of MIL-STD-810H Method 514.8 (Vibration).
The system demonstrated excellent resistance to vibration environments representative of military vehicle operation, maintaining full functional capability throughout the test.
This confirms the suitability of the component for deployment in high-mobility military ground vehicles operating under severe vibration conditions.

Marketing Summary

Engineered for reliability under extreme vibration.
Environmental qualification testing according to MIL-STD-810H Vibration demonstrates that mission-critical vehicle electronics maintain operational performance even under the intense vibration conditions encountered in military ground vehicles.
Through rugged design, reinforced mounting structures, and vibration-resistant electronics, manufacturers can ensure long-term reliability of critical vehicle systems in demanding operational environments.