This is a quick video to show vibration testing of the Modular ECUs.
As you may have seen, the Modular ECUs have modules inside which plug in to a main board. We haven’t had problems in the field so far but just to put our and your minds at rest we decided to have them professionally tested by Austest.
We tested them to MIL-STD-202G, which is a military specification, and it involves placing the device on a table which vibrates up and down. The frequency is swept from 10 Hz to 55 Hz and back down again, and this is done over a period of 2 hours. The camera here doesn’t really do it justice because the camera shutter speed is only 30 frames per second so all we see is aliasing. At the highest frequency it peaks at 7.5 G up and down and the drive coil takes over a kilowatt of electrical power. I can tell you from actually looking at accelerometer data from cars recorded on race cars that they see nothing like this in the real world!
The ECU was powered up during the test and ran special firmware which allows us to see from the outside if any of the boards works loose inside, and then if so, we would know how long it took. But the lights showed that everything was still connected at the end of the 2 hours, and a physical inspection showed all the boards still properly seated after this rigorous test.
So for anyone who’s never seen vibration testing before, I hope that was interesting!