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Elite Helps Steer Automotive EMC Standards Development

An Interview with Elite’s EMC Lab Manager and “CISPR-D” US Technical Advisor, Craig Fanning. Learn more from Craig at the upcoming Automotive EMC Standards Seminars in Detroit and Chicago.

By Stacey Klouda Cosentino

Stacey (SKC)-   So Craig, you’ve really grown a passion for helping to write and maintain automotive EMC standards. What’s your story, and tell us about these standards and committees you lead?

Craig-  Okay I’ll admit it I’ve become a standards nerd, but after 20 years of participation on tech committees, I really come to recognize standards are essential in any industry that’s successful and sustaining.  The automotive industry is 3% to 4% of our total GDP so we take pride here at Elite in contributing to this important segment of the US economy. Automotive EMC is also a big part of Elite’s brand and as the leader in automotive EMC testing, we need to be a significant voice in test technology.  

Currently, I’m the US Technical Advisor to CISPR D, Convener of CISPR D/WG2, and the Convener of CISPR D/A JTF on Chamber Validation. I am also in the process of being nominated to be Vice-Chair of CISPR D. CISPR is part of the International Electrotechnical Commission (IEC) and the various CISPR subcommittees prepare standards for different industry segments. CISPR D addresses RF emissions standards for vehicles. I am also on the SAE EMC committee and the ISO/TC22/SC32/WG3 committee. The WG3 committee is responsible for developing and maintaining the immunity standards used in the automobile industry worldwide.

SKC-   What’s involved as a committee member and leader and why is this important?

Craig-  As the US Technical Advisor, my responsibility is to provide technical input for the US on standards at an international level. We have a team of about 20 experts from US-based OEMs, suppliers, and laboratories that make up the CISPR D USTAG. Each National Committee is allowed to have just a few key individuals that can attend the international standards meetings. It is our delegation’s job to make sure the interests of US manufacturers/suppliers and test labs are well represented when developing and maintaining international standards.

Quite honestly…as a leader, I am just the organizer of a committee. We have a phenomenal team of very knowledgeable experts who have been involved with automotive EMC (and standards development) for many years. We have one expert on the USTAG who was an integral part of drafting CISPR 25 Ed.1. He basically wrote the first revision of the standard we are still using today and he still contributes to the evolution of the standard. OEM experts work on actual vehicle issues every day. They are the ones who really know what performance is needed at the module level in order to have acceptable EMC performance at the vehicle level. As an EMC laboratory expert, I provide help with test and standards development from a practical standpoint. This is definitely a team effort…and we all work together well to get the job done.   

A big part of what we do is to make sure the standards are continuously improving, relevant, and adapting to changing technology and innovation. As a committee, we specify test processes by consensus of experts and in that way capture best practices and ensure consistent and repeatable measurement results.

Our efforts to standardize methodologies reduce the cost and variety of test equipment, software, and unique expertise.  The physics of EMC is the same for each OEM, supplier, and lab, so if we can write a single test method that can be shared by all players then the evaluation process for the entire industry becomes more efficient.

SKC-   As you mention the physics of EMC has not changed and for sure automotive EMC standards have been around for many years, so why is it important to have new or revised automotive EMC standards?

Craig-  You’re right our standards have been around for years, but these documents were the best work at the time they were released.  Our work efforts now are to improve the existing specs and make them more clear, concise, and unambiguous. We include improvements on definitions, setup details, and special test cases for new technology.  

SKC-   What new technology is driving your committee work?

Craig-  Electric and hybrid vehicle electronics are a major one.  With all the plug-in and Wireless Power Transfer (WPT) charging systems vehicle electronics need to consider an entirely different EMC environment. In this area we incorporate the work from the AC mains connected CISPR/ISO/IEC committees and adapt their technical input to the vehicle environment. I am also involved with the ANSI C63.30 committee working on a procedure for the testing of WPT products (including WPT devices for vehicles).

Autonomous driving is also a big leap in vehicle technology. Autonomous vehicles have many high-frequency transmitters and include wireless connectivity. There are a greater number and variety of vehicular wireless devices with a broad range of applications, frequencies, and power levels. We will have a lot of interesting work to do from a standards development standpoint to address this new technology and connectivity.    

The receive bandwidth and sensitivity of wireless devices depend on the type of device – for example, TPMS, GPS, WiFi, or cellular.  Our committee has to consider the level of protection these devices need and then develop vehicle and component standards that will limit interference from vehicle electronics and motors. We have to balance specifying limits that protect receivers with the design constraints for vehicle electronic and motor manufacturers. After all, it’s not economical to specify requirements that dictate vehicle systems to be designed with shielded enclosures, harnesses, and connectors so we have to write practical documents.

SKC–  How are advancements in testing instrumentation and software changing standards?

Craig-  There are really important changes in our standards as a result of time-domain FFT-based receivers. We’re already seeing the benefits of FFT technology especially when testing GNSS receivers where the RBW is only 9kHz. This is an exhaustively long measurement with a swept or stepped receiver when compared to an FFT receiver. We are implementing FFT into the OEM measurements which allow FFT. Elite also does testing for the Military, Aerospace, and Commercial Electronics industries. FFT is finding its way into those standards and we will be implementing that technology into those tests whenever possible.

SKC- How has your standards work helped you personally?

Craig–  I’ve had the opportunity to meet many brilliant people in our industry from the US and around the world. I have been privileged to be able to know many of them on a professional and personal level. I’ve come to recognize that we all have a common focus of contributing our knowledge to the industry (no matter where you live or work geographically).

Being a part of these standards committees has really helped Elite be the leader in automotive EMC testing. I’ve been able to gain insight into the standards like never before so that when we test at Elite, we have a rock-solid understanding of what’s right or wrong about our processes.  It builds tremendous confidence internally and with our clients when we set up and run our tests. No matter how concise we try to make the standard, something always comes up for interpretation. Being involved with the standard development, I know what the intent of the standard was and how to correctly interpret the standards whenever there is a question or the need for engineering judgment.  

SKC-  How has Elite supported your participation?

Craig–   Elite has always been an ardent supporter of industry organizations, like the IEEE EMC Society, SAE, IEST, and other professional groups.  Industry organization support was a core belief of Elite’s founder Jim Klouda and he stressed that Elite’s employees should be active in our industry and contribute time and resources. That same belief and commitment continue today with our current company leaders Ray, Tom, and Joe Klouda.  At Elite I’m involved with CISPR, ISO, and SAE for automotive EMC, but we also have Tom Klouda leading aviation lightning standards development and Pat Hall participating in HIRF standards development in the SAE aviation committees.  Plus on the wireless regulatory testing side, Dan Crowder works in commercial wireless testing standards. Seems at times like we’ve got our hands in everything. 

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Elite’s New CTIA-Compliant Wireless Test Chamber Is On-Line

Elite is proud to announce the addition of our new CTIA-compliant antenna test chamber at the core of our Midwest Wireless Test Center. With this new capability, Elite RF engineers can perform Over the Air (OTA) measurements of Total Radiated Power (TRP), Total Isotropic Sensitivity (TIS), and Received Signal Strength Indication (RSSI).

These measurements are key performance tests for cellular, WiFi, and other wireless transmitter systems. In addition, the chamber and instruments are configured to measure antenna gain with 2D and 3D graphic renderings along with S-Parameters, Efficiency, and Directivity.

Download Elite’s Guide to Antenna Tests and OTA Measurements

The chamber is fully equipped with the latest state-of-the-art technology from Rohde & Schwarz and our system configuration is optimized for measurement accuracy and speed. Elite selected the R&S TS8991 OTA Performance Test System with a 1.4m range length and test range from 400MHz to 6GHz.

Also, joining Elite to head up this new antenna and wireless testing capability is Firass Badaruzzaman. Firass comes to Elite with years of experience in the cellular industry with Motorola, RIM, and Wistron. Elite has assembled all the pieces to provide end-to-end conformity assessment services including regulatory compliance, network operator requirements, as well as design and development assistance.

Elite’s team is ready to collaborate with your engineers to optimize wireless performance and achieve regulatory compliance for your product – stay tuned for more updates regarding our wireless testing capabilities.

Contact us today to learn more about our full spectrum of wireless product development services in one location, including antenna design, testing, and complete regulatory compliance. 

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Elite’s Photometry Lab Achieves ISO 17025 Accreditation

Elite is proud to announce that it has received ISO 17025 accreditation for Photometric Testing from the American Association for Laboratory Accreditation (A2LA, Certificate 1786.02). This is a major milestone for our photometric testing team since launching this new service in 2017. Combined with our existing scopes of accreditation for EMC/EMI TestingEnvironmental Stress Testing, and Product Certification, this achievement demonstrates our commitment to delivering high-quality testing services for the lighting industry in one location. And our customers can be confident that our test results will be accepted around the world. Elite is also an approved laboratory for the DesignLights Consortium (DLC) qualification program, including IES LM-79 luminous flux and color measurements.

Our scope covers a wide range of test methods for automotive exterior, aerospace, and general lighting products – including FMVSS 108, SAE, FAA, ICAO, and IES specifications. Our laboratory is equipped with a 2-meter integrating sphere system and Type A goniophotometer for accurate measurements of luminous flux (lumens), luminous intensity (candela), flash energy, optical power, and color for lamps and luminaires up to 48” wide. Please visit our Quality Assurance page to download our full scope of accreditation.

In July 2018, we hosted our second Photometry Workshop covering test preparation for steady and flashing lights. It was a great opportunity to learn from our photometric test team and Bob Czajkowski, a lighting industry expert from Federal Signal and SAE Standards Committee chair, as well as gain hands-on experience in our photometry lab. We’re looking forward to planning our next workshop for 2019.

Contact us today to discuss the testing requirements for your lighting product and how we can help you succeed with accredited test results.

Third-party ISO 17025 accreditation with A2LA is an internationally-recognized quality assurance process that verifies the technical competence, facilities, management systems, and personnel qualifications of a testing laboratory. Since 1986, Elite has been continuously accredited and our scope has steadily expanded along with our facilities and testing services.

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Future Bridge Builders Tour Elite

This spring, Elite hosted a group of high school students from the state of Oregon for a tour of Elite’s Downers Grove laboratory. The students and their chaperones were in Chicago to participate in the 2018 International Bridge Building Contest held at the Illinois Institute of Technology (IIT).

The mission of the IIT Bridge Building Contest is to promote the study and application of physics fundamentals in high school through a hands-on wooden bridge building project. The competition provides students an opportunity to experience the type of analytical thinking required of engineers. It is a hands-on design challenge to a set of specifications. Students develop their design, build it, and then test for scores. At stake are school pride, personal accomplishment, and a full tuition scholarship to the Illinois Institute of Technology.

Elite’s Oregon student visitors qualified to compete and represent the state against 52 other nationwide qualifiers. All performed incredibly well and finished in the top third of all contestants. Henry O’Scannlain-Miller finished in 2nd and Josh Seals 3rd overall.

During the tour of Elite students were able to view the type of work electrical and EMC engineers perform and learned about the significance of EMC for all types of products and applications.

Since the student bridge-builders were particularly interested in mechanical testing, Elite’s Environmental Testing team took time from their day to demonstrate the type of testing that is important to structural design.

Elite’s environmental test engineer, Eric Lindberg, set up and demonstrated a vibration resonance test. The test was configured to run a vibration resonance search on a flat aluminum cantilevered plate, the results of which were used to compare to calculated results that predicted the fundamental resonance and its harmonics.

Elite’s material test engineer, Nella Grandback, demonstrated our Materials Testing capabilities by setting up and completing a live impact strength test using Elite’s large MTS E22 Pendulum Impact Test System. This machine is capable of maximum impact energies up to 450J. Nella also ran a tensile strength test on a sample of aluminum using Elite’s 55,000lb MTS universal test machine.

The demonstrations helped students connect with the fact that the strength of materials can be stated in terms of several unique properties.

Thanks to all Elite staff for helping to inspire these future engineers!

In case you’re wondering why Elite hosted students all the way from Oregon, it turns out that Elite is “Linkedin” with Nestucca High School by way of Elite’s Sales and Marketing Manager, Steve Laya, and his daughter Sydney who is a teacher at the school. Nestucca High School is in the beautiful coastal town of Cloverdale, Oregon.

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Employee Spotlight: Todd Bruhl from Elite’s Machining, Automation, and Controls (MAC) Team

For over 40 years, a small company in the western suburbs of Chicago called Linear Kinetics Inc (LKI) provided area manufacturers with custom-built factory automation systems. These LKI systems helped companies speed up their processes, increase output, and deliver higher quality manufactured goods. 

Along the way, Linear Kinetics also began developing automated testing systems for Elite and its clients. The relationship between Elite and LKI became more strategic with each test automation project and with the growth of Elite’s environmental testing services. Not only was Elite using LKI services to a greater extent, but from the perspective of LKI, the majority of projects devoted to Elite were becoming a key segment of their operations.  

So in December 2016, it made perfect sense that Elite and LKI to join forces in a strategic and formal way. By April 2017 the entire LKI operation was officially moved into the newly-opened North Annex to launch Elite’s new Machining, Automation, and Controls (MAC) services.   

Heading up Elite’s MAC team is Todd Bruhl, Sr. Mechanical and Controls Engineer. Todd was the principal at LKI and now brings end-to-end automation engineering expertise to Elite clients along with a customer-service-oriented “whatever it takes” attitude. Todd was asked to describe the benefits of having MAC integrated with Elite’s testing services.  

Todd: “We have all the equipment, ability, knowledge, and expertise in place to provide test automation and fixturing of all kinds to Elite clients. How about a quick tour of the Elite MAC center to look at our key machining resources?”

Todd: “The Fadal CNC milling machine and Burgmaster CNC milling machine centers make our metalworking processes incredibly efficient. We’re able to take a Solidworks CAD model to the machine center and with a few additional steps get completed parts in minutes. Plus we machine right here at Elite and save clients the task of having to develop fixturing on their own. When our work is done the fixturing and support gear are all here ready for testing. It’s a great time saver and very convenient for customers.” 

Todd: “We also have manually operated machines such as our Induma knee mill, a Clausing gap bed lathe, and Cincinnati radial arm drill press for quick turn machined parts when the CNC machine is not necessary. These are standard machine shop systems, but they’re here to offer quick response metal working to customer needs.”   

Todd: “Our Flexarm pneumatic tapping rig gives us the ability to quickly tap holes on the fly. We use this tool often to fit custom-tapped holes to vibration and shock fixtures”.

Todd: “Our 3D printer is just awesome. It’s used nearly every day to create the small and intricate shapes that we need to adapt our test gear to customers’ test items. It also frees up time on our CNC machines to perform large-scale metalworking tasks”.

Todd is also skilled at developing controls and automation for unique tests that require mechanical cycling of switches, levers, buttons, and just about any other product that needs kinematic or dynamic motion. Using electric actuators, pneumatic, or hydraulics, Todd and his team can create a full range of forces, torques, speeds, and other conditions for cyclic or production validation testing.  

Todd: “We start with customer requirements and test item specs to come up with an automation concept. From there we bring it to a finished installed system in a reasonably quick turnaround time. We have all the expertise, great control suppliers, along with an in-house machining center. All the key parts are right here at Elite to streamline our automation development and get final test results to clients in the shortest time possible. For sure, test automation systems are demanding engineering projects, but as engineers, we love the technical challenge and feed on the pride of seeing our hard work delivered on time, on-test, and performing per spec.” 

Do you have a manufacturing or testing process that would benefit from automation? Send us your requirements and our MAC team will collaborate with you to design and build a solution.

For more information about Elite’s MAC services, contact Todd Bruhl or Mike Cosentino.

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Elite’s New Wireless Testing Capabilities

Elite is expanding in a significant way to bring enhanced wireless testing services to manufacturers who are integrating wireless connectivity with their products. Our new Wireless and Antenna Testing capabilities include a fully-anechoic CTIA-compliant chamber that will measure the Over-The-Air (OTA) performance of cellular, WiFi, and Bluetooth transceivers. Download our “Guide to Antenna and OTA Measurements” for everything you need to know about key antenna performance metrics.

Why does a manufacturer need to test in a CTIA-compliant OTA chamber? 

Here are a few ways this new resource can help make a better wireless or IoT product:

First of all, in order to have a good wireless device, you need a good antenna. If your antenna is not designed efficiently then the transmitter has to deliver higher power to the antenna terminals to achieve the range and distance for the application. Driving the transmitter at higher power means more draw on the system power supply which in turn increases the heating of components and reduces the battery life for portable devices. With Elite’s new OTA chamber, engineers can easily visualize the antenna radiation in 3D and then design antenna elements and placement within the end product to achieve optimal performance. 

A wireless device’s receiver relies on the antenna to capture very weak RF radiated signals and then convert them into voltages at the receiver front end. Improperly placing the antenna in a manner that couples noise to the receiver will dampen the receiver sensitivity and negatively impact wireless communications. Elite’s OTA chamber provides the tools to optimize the placement of the antenna relative to the enclosure and the supporting digital circuitry to maximize the receiver’s sensitivity. Highly sensitive receivers extend the transmission ranges, enable higher data throughput, and provide greater communication reliability. 

The Elite OTA chamber is also used to evaluate Total Radiated Power (TRP), Total Isotropic Sensitivity (TIS), and Relative Sensitivity on Intermediate Channels (RSIC). These measurements are key performance metrics for cellular industry network operators such as ATT, T-Mobile, Sprint, and Verizon. With this new fully-anechoic antenna chamber, Elite clients integrating cellular radios can save time and cost by testing their devices in advance of formal compliance at a certified CATL Lab.

Contact us today to learn more about our new Wireless EMC and Antenna Testing capabilities that can help optimize your antenna performance.

Stay tuned for more as we install our OTA chamber and bring together our design, test, and regulatory specialists to provide complete wireless compliance services in one location.

EBook: Guide to Antenna Tests and OTA Measurements

Antenna performance for a wireless transmitter is critical for optimizing range, throughput, and power consumption. This guide provides an overview of basic antenna concepts and the processes to evaluate antenna performance and transceiver operations. Once an antenna has been configured to a wireless device, measuring its performance can provide numerous benefits.

Everything You Need to Know About Antenna Tests & OTA Measurements

This e-book provides information on:

  • An overview of antennas and the importance of measuring
  • Antenna design basics, fundamentals, and measurements
  • Overview and summary of important antenna parameters
  • Information on Passive and Active antenna testing

​Readers will also learn how to apply that knowledge to:

  • Benchmark your antenna design through testing
  • Optimize integrated antenna-transceiver performance
  • Achieve greater success with network operator certifications

Download Guide to Antenna Tests and OTA Measurements

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Employee Spotlight: Rick King & Mark Longinotti on 20 Years of Compliance Testing

Rick King and Mark Longinotti are two key members of Elite’s regulatory compliance team. They perform testing and complete certifications of transmitters for Elite clients who want to sell their products in the US, Canada, European Union, and globally. Recently, Elite’s Stacey Klouda sat down for an interview with Mark and Rick to ask them how their jobs have changed in the 20 years that each has been at Elite.

Stacey K: So between you two guys, you have a combined 40 years of experience, and your whole time here you’ve dealt exclusively with government EMC regulations. That’s a lot of time spent reading FCC regulations…I assume you sleep well after pouring through regulations every day?

Mark L: EMC regulations are definitely not on the New York Times best sellers list. They’re not on any best-of list…

Rick K: For sure it’s one of the toughest parts of the job, staying current with all the changes. And every country has a unique rule that we have to understand. Some country regulations look alike; some are slightly or completely different, whether it’s FCC, Canada, or the EU. They’re also constantly changing and often written rules don’t provide a clear answer, which means we have to look for guidance documents, precedence, and good engineering judgments to apply the right test.

Mark L: Our job can seem a bit like putting a puzzle together in that you read the regulations then look in another procedure or linked document for more guidance, then look at how it applies to the product, followed by talking to the customer about how this would apply to their device. Repeat…rinse…repeat…etc. In a profession where we strive to give pass-fail results and answers, dealing with the occasional uncertainty about rules and regulations is a real challenge.

Rick K: I’d say this job can seem more like a crime scene investigation [laughing]

Mark L: Huh…”CSI.” Are you talking about dealing with the FCC/EU standards or are you trying to tell me what’s in store for me after working with you for so long?

Stacey K: What was your impression when you first joined Elite?

Mark L: Well, since that was 21 years ago I was a lot younger than I am now. I recall being excited about the new opportunity but slightly overwhelmed with the amount of expertise that’s required to be a good regulatory test engineer. We had several older EMC engineers “curmudgeons” who seemed to know everything. I guess I’m one of those curmudgeons now.    

Rick K: The Company was a big mystery to me. I had no experience with EMC testing and did not really know what it was, but was curious about the measurements and equipment and recognized the potential for my role and career with Elite.  

Mark L: I remember that there was a lot of “stuff” on the shelves. It was kind of like the TV show “American Pickers” where there were just racks and racks of old stuff packed up to the ceiling. But all that has been moved out and now every available square inch of space is used for actual testing. The place looks so much different than when I started. Even with all the changes, we could still use more space. I could also use a well-appointed corner office with a skyscraper view of Lake Michigan…

Stacey K: What’s the biggest change in your work seen since you started?

Rick K: There’s no question about it; transmitters are everywhere and in everything now. Nearly all products we see in our lab have some kind of wireless connectivity.

Mark L: When I started we were testing transmitters but they were more simple devices like garage door openers or remote call buttons type devices. For sure we tested licensed radios, Part 90 devices, and Part 68 devices, but still compared to today those test items were relatively straightforward.

Rick K: Technology is constantly changing. Our challenge is trying to stay current.  It seems like every year there’s something different in our lab.   We’re seeing a wide range of transmitter types like Bluetooth, Zigbee, WiFi, NFC, and LoRA, and each of them has its own unique modulation schemes, spread spectrum or wide band spread, channel configurations, and so on. 

Mark L: As an EMC engineer in this group, you have to think on your feet, and quickly.  When products come to us for testing we have to switch gears from our last project and instantly be familiar with the next product, next application, and next regulation.  It’s not a “cookie-cutter” kind of EMC test job. You really have to multi-task and quickly switch your brain to the next set of standards and technologies.   

Rick K: Our test equipment is much more advanced than ever, and we use it to be efficient and competitive.  But we still have to perform many of our measurements manually.   Sometimes we have to confirm readings using calculations and be able to spot results that don’t appear accurate.  It’s important to leverage the speed and efficiency of our test equipment and automation but still, we have to make sure we’re getting correct results.

Stacey K: What’s next for Mark and Rick?

Mark L: I’m hoping to be more of a mentor and teacher of our newer engineers. If they can tolerate me. [laughing]

Rick K: I’m pretty eager to learn more about our new wireless testing capabilities.  With our new fully anechoic CTIA complaint chamber there are measurements for TIR, TRP, and antenna pattern mapping that I would like to learn and broaden my range of knowledge.  I’ve wanted to pick up more background on this aspect of wireless measurements because I’m hearing more about the importance of these measurements with respect to regulatory compliance.  So I’m ready to dig in when the time comes.

Mark L: There’s definitely an air of excitement here at Elite with the changes and new services coming online. I’m pretty keyed up to seeing it all come together and being a part of something new and significant for our company.  

Rick K: You’re such the company guy Mark. [laughing]

Contact Rick King or Mark Longinotti to learn more about Elite’s FCC, Canada, and CE Mark testing services and get your compliance testing program started.

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Optimizing Vibration Fixtures with Simulation

At Elite, every product tested for vibration or mechanical shock has to be properly secured, or “fixtured,” to a vibration or shock machine. The easiest way to fixture is using bars, threaded rods, clamps, or other tools that can grip the test item and secure it to the table. The preferred way is to create a custom assembly, called a “fixture,” which provides a mounting surface and tapped holes for holding the Device Under Test (DUT). The base of the fixture also has attachment points that connect to the vibe/shock machine surface.

A custom-made fixture is especially important for devices that have complex shapes which do not allow for a simple clamping solution. A fixture is also helpful when the DUT must be held in a particular orientation for all axes of testing and to hold multiple samples for a single test run.

Generally speaking, there are two types of fixtures; those that “simulate” the mounting conditions, and those that “stimulate” vibration into the DUT. 

Simulate-style fixtures are intended to replicate the actual DUT mounting bracket or mounting surfaces. They are unique structures with their own mechanical response. A simulated bracket fixture will likely alter the characteristics of the vibration/shock dynamics when passing from the machine through the fixture and into the DUT. In some cases, this is desirable, for example when the goal of the test is to provide fatigue input representative of how the DUT is mounted in the actual end-use environment. The simulated fixture will have its own mechanical resonant characteristic which may amplify the input vibration and create a more severe vibration environment for the DUT. 

Stimulate-style fixtures tend to be designed with thicker more robust elements and structural members. They are arranged to provide stiffness while being lightweight. Stimulate-style fixtures are intended to transfer the applied vibration/shock input from the table directly into the DUT. A perfect stimulate-type fixture has input transmissibility that is very flat, meaning that the frequency range, amplitude, and phase of the vibration environment are applied directly to the part with no modification to the input vibration environment. 

The design of a fixture should first account for being a simulate vs. stimulate purpose. However, the design should also be lightweight to achieve maximum vibration test levels and should allow access to the DUT mounting points in order to easily attach the test item. The design needs to consider future modifications and re-tooling. It also has to balance performance with cost.

Elite engineers take all of these parameters into consideration when developing fixtures for client testing. They have the benefit of years of expertise through hands-on testing and vibration fixture development but are also able to apply the latest CAD and vibration simulation tools, like those from Solidworks.

Once a test item CAD design file is received from a client, it can be loaded into Elite’s Solidworks tool and the fixture structural design can begin. Engineers create the initial design taking into account all the particular details of the test item shape, mounting configuration, attachment and accessibility, and cost.

The next step is to run a full dynamic simulation using the vibration modeling features of Solidworks. From the simulation, we can visually and quantitatively evaluate areas of the fixture that are resonant and redesign the fixture to reduce the resonance magnitude or even shift the resonant frequency beyond the test range.  

It is critical to reduce fixture resonant frequencies that coincide with the vibration input profile. When vibration is applied at the fixture resonance conditions large displacements and accelerations (high G levels) are produced and test items can be overstressed. Similarly, when the input vibration and response align out of phase the applied vibration can result in “null” acceleration conditions and under-test the DUT.

Elite’s Steps to Vibration Fixture Optimization

1. Develop an initial fixture design considering the following:

  • Fixture purpose: Stimulate or Simulate style fixture.
  • Single or multiple samples
  • DUT orientation
  • Accessibility for DUT mounting and table mounting
  • Weight, length, width height considerations
  • Single-use fixtures or future adaptations

2. Run the simulation and identify the following:

  • Identify natural resonant frequencies, mode shapes, and relative resonance magnitude. 
  • Consider options for reduction of resonance, weight, stiffening elements, and moment of inertia (length, width, height).
  • Repeat simulation and optimize results for performance, machinability, and least cost.

When you are ready to experience the Elite advantage and put our comprehensive capabilities and proven experts to work for you, please contact us with your questions or request a quote.

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6 Steps to Certification for the “Internet of Things”

Here at Elite, we’re seeing many of our clients take steps to enable wireless connectivity in their products. Some of these firms have internal processes to get their products through regulatory and industry tests and certifications. However, others need conformity assessment expertise and administrative assistance due to limited internal resources or time constraints.

At Elite, we’re expanding our wireless test, engineering, and support services to ease the burden on our clients and help them get their Internet of Things (IoT) and wireless products to market successfully. Elite regulatory specialists and experienced test engineers can guide clients through the technical and administrative processes to complete testing and achieve certification when necessary.

1. Review and Analyze the Product and Requirements

We request that our clients provide all the available information on the radios and receivers, host device, intended applications, and target markets. Next, we review and analyze the information to create a compliance test and certification plan that will ensure all applicable government and industry requirements are addressed.

2. Prepare, Test, and Report

Since wireless tests require specific compliance configurations, Elite will schedule a pre-test meeting to confirm test plan details, review transmitter operations, and identify information and documentation required for testing and/or certification.  With two 3-meter chambers, qualified EMC engineers, and a full-service Environmental Stress lab, Elite provides a full suite of services including related partner-provided services such as safety, SAR testing, protocol-interoperability qualifications, and RoHS/REACH. Elite can also support antenna development and Over-The-Air (OTA) testing with our new CTIA-compliant chamber and instrumentation.

3. Prepare Documentation

Elite provides compliance templates for labeling, manuals, DoC, and technical file structure. We can also prepare RF exposure assessments, and safety evaluations, and can assist manufacturers with documenting the “Risk Assessment” – now a formal documentation requirement as stated in the European Union Directives and supporting guides.

4. Certify as Necessary

Some devices need to be certified for regulatory compliance. Elite is a certification body for the United States (FCC), and Canada (ISED), and a notified body for the European Union. 

5. Go Global

Beyond North America and Europe, Elite can obtain global certifications in nearly every market. Provide Elite with a list of target global markets and we can provide a plan and budgetary estimate of service fees.

6. Stay Current

When certified products change with new and updated features or when new regulations are published, Elite can signal the significance of these changes to your products.

Contact us today to learn more about how Elite can streamline your IoT and wireless product certification process.

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New Employee Spotlight: Javier Cardenas

Here’s a little bit about a new addition to the Elite team, Javier Cardenas:

Title: EMC Test Engineer

Year Started at Elite: 2018

Area(s) of expertise: Solid State Physics

Education: M.S. in Physics (Illinois Institute of Technology, 2017)

Any unique hobbies, talents, skills, experiences, etc.:  Worked at the Center for Nanoscale Materials at Argonne National Laboratories as well as at the Advanced Photon Source in the same facility.

Proudest moment in life so far:

Graduating from the Illinois Institute of Technology

What would you consider to be your passion outside of work? How did you get started in it? Any advice for someone looking to try this activity?

Driving around with no particular destination and taking in the scenery.

How did you get involved with EMC/ENV testing?

A referral from a friend.

Why did you choose to work at Elite?

The employees were all friendly and welcoming.

What is something that customers/colleagues might find surprising about you?

I don’t like chocolate.

If you had a personal motto, what would it be?

Take any learning experience that comes your way.

If you could be paid something other than money, what would you choose?

Computer hardware

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3 Advantages of 3D Printed Fixtures

Elite’s Machining, Automation, and Controls team have been experimenting with 3D printing as an alternative to machined aluminum fixtures. “3D printing” is a type of additive manufacturing that precisely layers plastics, composites, or polymers into a final object, and it is most widely used for rapid prototyping. While aluminum remains the best material choice for most testing applications, it certainly has limitations when complex shapes are involved.

What advantages does 3D printing offer for test and automation systems?

Todd Bruhl, Elite’s lead mechanical designer, set out to answer that question. He has been designing and fabricating aluminum parts and automation systems for more than 10 years and wanted to determine how 3D printed parts matched up. After researching several types of 3D printers, Todd found a desktop system that could produce parts with high-strength materials to withstand harsh test environments and repetitive motion.

As part of a recent Electrical Connector Testing project, Todd investigated both aluminum and 3D-printed holding fixtures for insertion force and torque testing. The results were clear – and they demonstrated the three key advantages of 3D printing:

1. Lower cost to produce

Material and labor are the main costs for traditional machining and 3D printing reduces both. Todd noted that “unlike traditional machining, you only pay for the material you use with 3D printing – none of it ends up as scraps on the floor.” Moreover, the 3D printer uses fewer resources and can operate unattended. For our sample project, the manufacturing cost of the 3D-printed fixture was 97% less than its aluminum counterpart and it weighed 93% less. Most importantly, the 3D-printed fixture demonstrated equivalent performance for our application.

2. Faster delivery

“Creating a solid model in CAD is typically the first step to design a fixture – with 3D printing, that is the only step,” according to Todd. Once created, the solid model is uploaded directly to the 3D printer eliminating the detailed drawings, print reviews, and CNC programming that are necessary for aluminum machining. The 3D printer can also run unattended once it is started to deliver new parts overnight.

3. Tighter tolerances without special tooling or processes

“What made this project unique was the small radius on the inside corner of the through-hole, which required Laser or Waterjet cutting,” Todd explained. Intricate features require specialized tooling and processes to achieve with aluminum – adding significant cost and machining time. Depending on the material, our 3D printer produces precise small-radius corners without any special considerations. Todd also noted that the additive process allows “blind” internal features that would be impossible using traditional machine methods.

3D printing is quickly proving its value at Elite by reducing fixture costs and delivery times for our customers. We are continuing to discover other applications throughout the lab, including low dielectric constant fixtures for EMC testing, low-mass fixtures to facilitate rapid temperature transitions, and complex part interfaces for shock and vibration testing.

This is the latest example of Elite’s drive to apply new technology to help our customers succeed. Our goal is to meet all of our customer’s needs in one location to shorten test schedules, streamline their supply chains, and deliver dependable test results that get their products to market quickly.

When you are ready to experience the Elite advantage and put our comprehensive capabilities and proven experts to work for you, please contact us to schedule a tour or request a quote.

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Elite Expands Cable, Connector, and Harness Testing

The recent addition of Elite’s new North Annex has paved the way for expanded Electrical Connector Testing for manufacturers of connectors, cables, and harnesses used in automotive, aerospace, and industrial applications.  

Elite can now perform a full scope of connector tests in line with common industry and OEM standards, such as USCAR2, GMW 3191, MIL-STD-1344A (now EIA-364), IEC 60512, and many others. Our unique capabilities include:  

  • Current cycling up to 2,000 Amps (12VDC). Current cycling tests evaluate the temperature rise, voltage drop, and resistance change over time for the cable/connector interface.
  • Connector Insertion/Retention/Deflection Testing. Mating and un-mating connector assemblies can provide data to evaluate connector lifetime and failure modes.  
  • Terminal Pull and Peel Testing. Our universal test machine load frames can apply tensile tests to measure the strength of the terminal-to-wire in an axial or radial pull test.   
  • Cross Section and Analysis. Elite can provide cross-sectional post-test inspections with magnification. 
  • RF Connector and Cable Testing. Elite’s RF engineers can configure the fixturing and instrumentation to measure insertion loss, VSWR, and shielding effectiveness.
  • Custom Fixture and Tool Fabrication. Our Machining, Automation, and Controls team can design and build custom fixtures that conform to force application and cyclic testing specifications. 

When you are ready to experience the Elite advantage and put our comprehensive capabilities and proven experts to work for you, please contact us to learn more or request a quote.

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Employee Spotlight: Robert Bugielski Earns MBA Degree

Elite congratulates Robert Bugielski on completing his advanced studies and earning a Master of Business Administration (MBA) degree from the Keller Graduate School of Management (DeVry University).

Robert Bugielski has been a member of Elite’s technical staff for over 12 years. Having graduated from DeVry University with an electronics engineering degree in 2006, he connected with Elite to begin his career as an EMC engineer. His test experience focused on automotive EMC projects with some work in military testing. In 2013, Robert became an iNARTE Certified EMC engineer. 

Robert has since transitioned to the sales team where he now helps Elite clients navigate the full range of testing and compliance work performed at Elite. This includes all EMC services as well as environmental stress testing, and photometric.

We asked Robert to share a few comments about his MBA experience:  

What fueled your interest in pursuing an MBA degree?

After obtaining experience in testing and sales at Elite, starting my MBA program felt like the next step in my career development. An everlasting impression that Mr. Klouda, the founder of Elite, left on me when he hired me, was when he told me that it was ok to make mistakes as long as I learned something new every day. 

What was the most challenging part of achieving your degree?

I wouldn’t say there is one aspect that stands out more, but a few parts that were equally difficult. The first was adapting to education again. You don’t realize how primed you were after high school to attend college, until taking 12 years off and having to write research papers or take exams. Another challenge was commitment. I decided to take two graduate classes per session instead of one so I could finish in 1.5 years. It takes a lot of motivation to work full time and complete the required coursework week in and week out. The other challenging part was the self-reflection required during the coursework. One of the key parts of my studies as you have to learn how to analyze and improve your own deficiencies before critiquing others through management.  

How do an engineering degree and advanced business degree help you?

I believe they help me see the bigger picture when it comes to the operations of a company. I can relate to the importance of procedures, policy, education, and problem-solving in engineering. Then I am able to tie that in with key business factors such as cost, profits, brand, and culture.  

What advice can you offer to others having an interest in graduate-level education?

Prepare yourself for the commitment and recognize that sacrifices will have to be made. Then when you start, make sure you put forth the required effort. Don’t just go through the motions or fake it until you make it. 

How did your family support you through the process?

My amazing wife Lacy was very supportive and helpful through the whole process. There were many weekends I spent in front of my laptop screen. Quite a few weekdays working at Elite during the day and eating dinner with the laptop at night. She was always reassuring when I felt guilty for the lack of involvement in social life during my studies. She too has a Master’s in education and understands the work that goes into graduate studies. Instead of extravagant weekend getaways, she was helping me proofread 15-page research papers. For that, I’ll always be indebted to her.

Which course or materials made a lasting connection with you?

The two main management classes I learned a great deal in. They were “Leadership and Behavior Organization” and “Leadership in the 21st century.” The classes were great for applying Maslow’s hierarchy of needs to today’s workforce. I’ll never forget the lessons about building high-performing teams, the importance of business culture, and how the business landscape is changing from hierarchy models to collaboration.

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What is HALT HASS Testing?

Watch our webinar to learn about HALT and HASS Testing and when to consider it for your products.


What are HALT and HASS?

Highly Accelerated Life Testing (HALT) is a process that utilizes a stepped stress approach in exposing your product to diverse accelerated stresses to discover the physical limitations of a design and product reliability. Manufacturers can discover their products’ failure modes and determine their failure mechanisms.

Highly Accelerated Stress Screening (HASS) is a production quality assessment to quickly and efficiently identify any weaknesses that the product may have inadvertently developed during the manufacturing stage.

Both are “Test, Analyze, Verify, and Fix” approaches – with Root Cause Analysis along the way!

Why should you perform HALT/HASS?

Highly accelerated life tests find weaknesses and flaws early in the design phase by testing to failure, while highly accelerated stress screening (HASS) catches manufacturing defects on production parts prior to installation without reducing the part’s life. HALT also provides valuable data for reliability metrics at the component level. The test results benefit customers, protect the manufacturer’s reputation, and prevent costly re-design later in the product development cycle.

What is unique about a test chamber?

Unlike other environmental simulation chambers, HALT and HASS chambers offer fast temperature ramp rates (up to 60C per minute) and combine thermal, vibration, and shock simulation in a single apparatus. As with other types of Vibration and Shock Testing, the test items require mounting fixtures to simulate the intended orientation and transmit vibratory energy without interference.

Vibration levels up to 50 Grms can be applied simultaneously in three linear axes (X, Y, and Z) and three rotational axes (pitch, roll, yaw).

How do you specify a HALT/HASS test?

HALT and HASS profiles are composed of several segments defined by the product’s intended end-use environment:

  • Cold Step Stress and Hot Step Stress: Incrementally decreasing or increasing the temperature to identify product limitations. Select start and end points based on the end-use environment for the product reliability and physical limitations of the components.
  • Vibration Step Stress: Incrementally increase the vibration levels while pausing on the way up to see how your product responds. Begin at a set Grms level, dwell for a specified duration, then increase to a higher amplitude and repeat the cycle to initiate failures.
  • Rapid Thermal Transitions (or Thermal Shock): Subjecting your product to pre-defined maximum and minimum temperatures and rapidly cycling between them.
  • Combined Environment: Simulating real-world conditions where your product will be exposed to multiple random environments simultaneously.

Here are some common HALT/HASS acronyms used to specify test profiles:

  • “Grms” – Vibrational G’s in the root mean square, where “G” is the acceleration due to gravity.
  • “PSD” – Power Spectral Density – In a random vibration spectrum, it is the measurement of the amplitude and frequency.
  • “LOL” and “LDL” – In the cold temp step stress stage, they are the “Lower Operating Limit” and “Lower Destructive Limit” 
  • “UOL” and “UDL” – The “Upper Operating Limit” and “Upper Destruct Limit ” occur in the hot temp step stress stage.

Why choose Elite for environmental testing?

Our team of experts can support your test needs from planning stages to testing, and failure analysis.

Elite’s in-house machine shop and design experts allow us to design and fabricate any custom fixture or automation solutions to meet your specific product requirements.

Request a quote now to start your HALT/HASS plan.

Visit our HALT/HASS Testing page or watch our webinar for more information.

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Employee Spotlight: Jeremy Rutnicki

Here’s a little bit about a new addition to our EMC testing department, Jeremy Rutnicki:

Title: EMC Technician

Year Started at Elite: 2017

Education: AS of Science, DeVry University

Industry Certification: ASE, VMWare Certified, Trimble Technology (GCS, SCS, BC-HSE)

Any unique hobbies, talents, skills, experiences, etc.: 

I build household electronics that most people think are weird.

Proudest moment in life so far:

The Cubs won the World Series!

If you had a personal motto, what would it be?

Bigger, better, best

If you could be paid something other than money, what would you choose?

Ice cream, grilled Reubens, or my mom’s meatloaf.

What is something that customers/colleagues would find interesting about you? 

John Wayne is my 3rd cousin. I’ve gone to 10+ cubs games a year for as long as I can remember

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IEEE James C. Klouda Memorial Scholarship

The IEEE James C. Klouda Memorial Scholarship was established in memory of James C. Klouda and his professional career in the field of electromagnetic compatibility. The Scholarship Fund awards, on an annual basis, a scholarship to a qualified undergraduate student seeking an electrical engineering degree with an emphasis in the field of EMC or a related discipline, from an accredited U.S. university or college. We hope that friends and relatives of our customers might benefit from this award as well so please inquire. Contact us for more details on the scholarship and how to apply (or see info below).

Administration:  IEEE EMC Society (EMC-S) will serve as administrator of the IEEE JCK Memorial Scholarship Selection Committee.

Eligibility:  The Scholarship Candidate must:

  • Be a U.S. citizen
  • Be enrolled as a full-time student in electrical engineering at an accredited university or college and inside the U.S. (no distance learning or online course students are eligible)
  • Have completed freshman year in an electrical engineering program at an accredited university or college in the U.S.
  • Hold a GPA of 3.0 or above on a 4.0 scale
  • Have completed college coursework in electromagnetic compatibility or in a related discipline

Prize Items:  The Scholarship Fund will be used to fund on an annual basis the following annual expenses:

  • A maximum of US$1,000 for one student for school expenses (tuition, books, students fees)
  • EMC-S Student Membership for 12 months to one student
  • Presented to the awardee at the annual IEEE EMC Symposium

The basis for Judging:

  • Evidence of maintaining a cumulative GPA of at least 3.0 on a 4.0 scale
  • One referral letter from an individual who is qualified to evaluate the applicant’s academic accomplishments (e.g., professor, administrator, employer, internship organization)
  • Additional consideration will be afforded to scholarship applicants that reside in IEEE Region 4

Application Deadline: January 31st, 2018

APPLY NOW

Labels: EMC Scholarship; JCK Memorial Scholarship; IEEE EMC

More Access to Elite’s EMC/EMI Testing

Earlier this year, we relocated and expanded our Environmental Stress TestingPhotometric Testing, and Fixture Fabrication services at our new North Annex. This made room for two more EMC/EMI test chambers at our main laboratory which is now fully operational.

Room #31 is an absorber-lined shielded enclosure (ALSE) meeting the requirements of Automotive EMC Testing per CISPR 25, ISO 11452-2, and ISO 11452-9, and is suitable for Commercial Aviation and Military EMC/EMI Testing per MIL-STD-461 and RTCA DO-160. The chamber utilizes a mixture of foam and hybrid (ferrite/foam) absorbers strategically placed behind the ground plane connection and on the ceiling to maximize antenna and absorber separation.

Room #32 is also an ALSE but is designed primarily for Commercial Aviation and Military EMC/EMI Testing per MIL-STD-461 and RTCA DO-160. The chamber is equipped with high-current, 3-phase, 400Hz filters for testing commercial and military aerospace products. Hybrid (ferrite/foam) absorber supplements the fully-lined ferrite structure for improved high-frequency performance. The ability to configure this chamber for Automotive EMC radiated immunity testing per ISO 11452-2 and ISO 11452-9 allows additional scheduling flexibility.

Both chambers are also equipped with High Voltage/High Current DC filters for testing of 48VDC “Orange Wire” automotive systems.

“These new chambers will improve throughput for AutomotiveCommercial Aviation, and Military EMC Testing that requires an ALSE,” according to Craig Fanning, Elite’s EMC Laboratory Manager. “Growing capacity to reduce backlogs has been a priority for Elite, and we design our setups to rapidly adapt to our customer’s technical and schedule requirements. Paired with our skilled test engineers, these new chambers demonstrate our commitment to deliver quick access to our high-quality facilities AND our trusted team.”

Elite’s success depends on helping our customers succeed. Our goal is to increase our EMC/EMI and Environmental Stress testing capacity and add new, complementary services to meet all of our customer’s needs in one location. This gives our customers an advantage over their competition by shortening test schedules, streamlining their supply chains, and delivering dependable test results that get their products to market quickly.

When you are ready to experience the Elite advantage and put our comprehensive capabilities and proven experts to work for you, please contact us to schedule a tour or request a quote.

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Employee Spotlight: Michael Cosentino

Title: Technical Sales Engineer

Year Started at Elite: 2017

Areas of Expertise/Interest: Environmental Stress, Military & Automotive EMC. Technical Sales.

Education:

Illinois State University – B.S., Business Administration & Organizational Leadership 

Any unique hobbies, talents, skills, experiences, etc.: 

– Hobbies: Fitness (HIIT Workouts), Hiking, Camping, Snowboarding, Scuba Diving, Traveling, 
– Talents/Skills:  I can walk on my hands pretty well.

– Experiences:

  • Hiking a “14ner” (what a 14,000 ft. mountain is called in Colorado)
  • Completed two Tough Mudder Obstacle Course Events.  (10 Miles, 20+ Obstacles & the highest elevation courses).
  • I lived in west England for a summer with a host family.
  • Recently traveled to Costa Rica and stayed on the beach, in a tree house in the cloud/rainforest forest, and in the jungle by a volcano.

What would you consider to be your passion outside of work? How did you get started in it? Any advice for anyone looking to try this activity?

Hiking!  I love being outside, in the wilderness, and exploring new places.

Get some waterproof hiking boots (with good ankle support), a hat, a small backpack that includes: a light jacket, sunscreen, sunglasses, snacks that are at least 100 calories each (cliff bars and almonds are my favorites), and a hydration reservoir filled with at least 2L of water.  Make sure to google hiking trails near you or download the “All Trails App” which lists the trails near you) and get out there and explore!

Proudest moment in life so far:

When I married the love of my life this past July in the beautiful Colorado mountains.

How did you get involved with EMC/ENV testing?

I have always wondered how all the electronics in our world get along.  For example, when the pilot says, “Please put your phones in Air Plane mode…” Also, the science behind how things are made to work within different environments. My new family might have something to do with it too ;).

Why did you choose to work at Elite?

Elite is a great company made up of awesome people with good values.

What is something that customers/colleagues might find surprising about you?

I go to get Acupuncture done and I’m sneaky-good at estimating.

If you could be paid something other than money, what would you choose? 

Laughs

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Regulation Compliance: A Testing Laboratory’s Role

Most standards and regulations rely on testing and measurement to demonstrate compliance with their requirements. These standards have requirements for the test facilities to be used when testing products for compliance. In order to properly evaluate any product, tests and measurements must be performed in a well-equipped laboratory and under conditions described and specified in the standards. The staff must be well trained and have experience with particular measurement techniques. For example, for radiated emission measurements, a large absorber-lined shielded enclosure (ALSE) or Open Area Test Site (OATS) is required. The test site must be designed and built to meet rigorous site attenuation requirements. The measurement receiver should be equipped with specified bandwidths and detector functions. Measurement antennas are listed and must be characterized for the frequency range. The equipment must be maintained and calibrated with traceability to a national standard. A properly equipped and staffed laboratory is essential for demonstrating that a product is compliant with the standards and regulations.

Manufacturers may choose to have their own internal laboratory or use one of the many independent laboratories for their compliance testing. In either case, to ensure the quality of the test, the laboratory will need to be accredited. Typically, these laboratories are required to be accredited according to the ISO/IEC 17025 standard, which specifies the general requirements for the competence of testing laboratories. These laboratories can be expensive to build and maintain, so many manufacturers will rely on independent third-party laboratories to meet their needs. Test lab trade organizations such as the American Council of Independent Laboratories (ACIL) would be a good source to contact for such third-party testing options. Sometimes a manufacturer will have what is known as a “pre-compliance” laboratory inside its facilities and use an outside third-party laboratory for official measurements. A pre-compliance laboratory might not be accredited nor meet the rigorous requirements in the standard but will be useful for experimenting with the product in its development stage so that it will likely meet the requirements when presented to the compliance laboratory for official tests.


Raymond J. Klouda has been with Elite Electronic Engineering, Inc., since 1981 and serves as President and Senior EMC Engineer. Mr. Klouda has been active in the related fields of electromagnetic compatibility (EMC) and RF shielding design since 1981. He is proficient with military and commercial EMC specifications, including Mil-Std-461, RTCA-DO160, FCC rules, Canadian regulations, CE marking, and international compliance, including CISPR and IEC/ISO specifications. As a technical reviewer, he evaluates and approves radio devices under the Telecommunication Certification Body program. In addition, he leads the team responsible for the administration of Elite’s ISO 17025 quality system and ISO 17065 certification systems. Ray lives in Lisle, IL, USA. He enjoys gardening and traveling. Mr. Klouda received his electrical engineering degree from the University of Illinois at Champaign-Urbana B.S.E.E. (1981) and graduated with honors (Tau Beta Pi and Eta Kappa Nu honor societies). He is an iNARTE-certified EMC engineer and a licensed professional engineer in the state of Illinois. He is an active member of the IEEE EMC Society and the IEEE EMC Chicago Chapter and has served on the Executive Committee since 1989 in various roles (secretary, chair, and member). He was also Technical Program Chair for both the 1994 and 2005 International EMC symposiums held in Chicago, IL, USA.

Posted via: https://www.standardsuniversity.org/e-magazine/september-2017/test-laboratories-compliance-testing/

Click here to look at compliance demo videos and other articles from this September’s Introduction to Conformity Assessment and Compliance Issue of the IEEE Standards University e-magazine

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Can Reliability Be Tested and Measured?

At Elite, we’re often asked this reliability question and the answer, of course, is “yes… but it depends”. It depends on the complexity of the product, the design and manufacturing robustness of prototypes, the availability of samples, and many other related factors.

Reliability metrics are widely used in the electric power industry, railroads, and airlines where operators collect information on their equipment for usage, uptime, and performance. They use this information to develop statistics that can help them anticipate product lifetimes and plan for maintenance and replacement of parts and critical systems. The reliability statistics are used for systems already operating in the field and whose conditions can be tracked. But it’s a bit more challenging to generate reliability metrics when the information is based solely on testing prototypes in a lab and especially on complicated electronic products.

At Elite, the more common reliability programs are success-run tests on electronic modules, test-to-failure for simple components, and accelerated test-to-failure for mechanical parts. These test programs are performed to determine life-on-test. Then, based on this information, metrics are calculated that express expected reliability over time. The reliability performance is generally stated in terms of parameters such as “parts per million,” FITs, or MTTF, or R(t) connected to a relevant life distribution.

In the automotive industry, the design validation phase for electronic modules includes over-stress testing, time-based endurance tests, and fatigue tests. The overstress tests are mechanical shockwater sprayESD, along with others. These tests are applied to simulate field conditions or high, short duration stresses which confirm that the products are capable of handling occasional extreme environments. Cumulative damage tests such as those associated with temperature and vibration stresses are run at levels below the over-stress amplitudes but above endurance limits. These temp and vibe tests accelerate failure mechanisms that degrade product performance over time. When an electronic module completes an automotive success-run program it will have demonstrated reliability metric “R” with an associated confidence interval (C) – for example, reliability 97% (R97) with a confidence interval of 50% (C50).

Mechanical components such as motor-driven actuators, levers, doors, knobs, or push buttons can accumulate years of operation and many cycles of repetitive stress. These components may be exposed to rotational motions or linear displacements that apply wear, fatigue, or other time-based degradation conditions. Accelerated testing for mechanical products involves applying stresses at one or more high levels until failure occurs. Based on failures from accelerated testing, a stress-life curve can be drawn and analytical tools such as Weibull analysis can be used to extrapolate the life of the product under test to live at normal conditions.

What can Elite do to support clients with reliability testing?

We work with clients from start-to-finish to quantify reliability using accelerated testing and we help clients generate a metric that will predict life with statistical confidence.

For mechanical reliability evaluations the Elite process begins with analyzing the product, its environment, and the anticipated life stresses including those applied in shipping, handling, and operational use. From there a Failure Modes and Effects Analysis (FMEA) is prepared to define the failure conditions, failure mechanism, and relevant stresses to be applied. Next a reliability test plan is created to identify the sample size, applied stresses, and test duration. The reliability test plan also provides instructions for dealing with minor faults and end-of-life failures.

Next, Elite’s Machining, Automation, and Controls team creates the mechanical or electrical cycling rig that will produce the motions and stresses that the product will experience throughout its life. Elite test engineers work alongside our Machining, Automation, and Controls team to ensure the life stresses are applied properly and that the automation equipment operates reliably throughout the entire duration of the program.

The results from our life testing are captured by Elite test engineers and the test items are evaluated by our failure analysis partners. The analytical results confirm the failure modes and mechanisms. These data, along with test duration for each part, are entered into calculations that establish the life distribution.

At the conclusion of testing, the output from the reliability tools (i.e. Weibull analysis) along with the failure analysis findings provide manufacturers a comprehensive assessment of reliability and a meaningful metric to support contractual requirements for reliability demonstration. The information can be used to validate designs, or to target design modifications that will improve life in the field and ultimately reduce warranty returns and manufacturing costs.

If you are an equipment manufacturer and your contractual requirements or corporate quality system specifies a quantifiable reliability metric, then contact Elite today. Our engineers can provide turn-key solutions for test planning, automation, test execution, and analysis. 

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Now Open: Elite’s New Photometric Lab

In an effort to provide lighting manufacturers with a way to validate every aspect of their product in one location, we’re excited to announce the opening of our new photometric testing lab—a state-of-the-art addition that now complements our EMC and environmental testing services.

Since everyone loves a good time-lapse video, here’s one showcasing the construction of the new addition.

More Complex Lighting Systems Call for More Complex Testing
Due to the growing complexity of today’s lighting systems, producing accurate test results has become equally as complex. Lighting innovations have extended product life, reduced energy consumption, and enhanced illumination, an in turn has increased the scope of compliance testing that’s needed. For example, compliance with FCC emission limitsCE Mark Directives, and water/dust Ingress Production (IP) may all be necessary for lighting products produced today.

State-of-the-Art Photometric Testing Equipment
Our new photometry lab is equipped with state-of-the-art measurement equipment (more on that below) to help achieve compliance with these directives by ensuring precise, repeatable results for practically any application, including the automotive and aerospace industries.

This advanced equipment includes a Type A goniophotometer for automotive exterior lighting and other forms of directed light sources. The goniophotometer also simulates Type C for accurate LM-79 measurements. We’ve also equipped the lab with high-precision spectrometers with NIST-traceable calibration sources, as well as an integrated power supply and analyzer with software control. Every application is provided with custom mounting fixtures for those difficult-to-fasten products.

If you are in need of testing for your automotive, aerospace, airport, or even general lighting products, please contact us today.

Labels: Photometric Testing

Partner Spotlight: Carrie Watson

Here’s a little bit about the front desk maven in the new North Annex, Carrie Watson:

Title: Administrative Assistant

Year Started at Elite: 2013

Any unique hobbies, talents, skills, experiences, etc.: 

My grandmother taught me how to crochet when I was young. As I got older, I taught myself to read patterns and do more intricate pieces. My new passion is knitting. I’ve been learning how to knit socks-something I’ve wanted to do for a long time.

What would you consider to be your passion outside of work? How did you get started in it? Any advice for anyone looking to try this activity?

About 15 years ago, I discovered working out at Jazzercise. The ever-changing music and routines never get boring. I have also made some wonderful friendships over the years– another added bonus. 

Proudest moment in life so far:

My husband and I have raised three wonderful children.

Why did you choose to work at Elite?

I had an opportunity to fill in at the front desk during others’ vacations.

What is something that customers/colleagues might find surprising about you?

I can speak Polish. My grandparents lived with us when I was young and Polish was their primary language.

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Elite’s New North Annex Nearly Complete

The final pieces of Elite’s new North Annex are coming together and it will be fully operational in the coming weeks. The Fixture Fabrication machine shop is running at full capacity with the addition of a large CNC mill that accommodates plates up to four feet wide. 

Three new Thermal Shock chambers are online and existing Temperature, Humidity, and Altitude chambers have been set in place. The Material and Connector testing machines are operational and our new Charpy Impact setup is ready for service. For our new Photometry Lab, the goniophotometer is installed and our 2-meter integrating sphere will be installed and calibrated next week. In the new space created by relocating additional environmental test chambers from our main building, we will be constructed two new EMC test chambers to meet automotive and military/aerospace requirements.

While we dedicated most of the new space at our North Annex for testing services, we also carved out a new Training Room to host seminars and other events for up to 20 participants. Technical experts from Elite and other industry leaders will lead classroom instruction and provide hands-on training in our lab. Please check our News and Events for more details as we begin scheduling events this fall.

Elite’s success depends on helping our customers succeed. Our goal with the North Annex is to increase our EMC and Environmental testing capacity and add new, complementary services to meet all of our customer’s needs in one location. This gives our customers an advantage over their competition by shortening test schedules, streamlining their supply chains, and delivering dependable test results that get their products to market quickly.

Stay tuned for more on our new EMC test chambers over the next few months. If you have questions about our North Annex or would like to schedule a tour, please contact us today. And if you are ready to capitalize on our new capabilities, please request a quote to experience the Elite advantage.

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Radio Equipment Directive – Deadline June 13th!

The compliance deadline for the European Union’s Radio Equipment Directive (RE-D) 2014/53/EU is June 13th, 2017.  After this date, all wireless communications transmitters and receivers being placed on the European market must be compliant with the RE-D.   Products that have been previously assessed to the R&TTE Directive 199/5/EC and continue to be placed on the market must meet the RE Directive.   

Contact Elite today and review the RE-D compliance steps for your product.  Steve Laya, 630-495-9770 x 119 or Dan Crowder at 630-495-9770 x 101.

Labels: Radio Equipment Directive (RE-D)

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Elite Notified Body Designation for Radio Equipment Directive (RE-D)

Elite Electronic Engineering is now a Notified Body for the European Union Radio Equipment Directive. With this credential, Elite regulatory experts can review a manufacturer’s technical documentation and then issue a type approval certificate to support a declaration of compliance for wireless products marketed in Europe.

A notified body assessment and type certificate are generally required for a wireless device conformity assessment when a harmonized spectrum standard (Article 3.2 or 3.3) for the device is not published in the Official Journal of the European Union. 

For more information on Elite’s Radio Equipment Directive (RE-D) notified body type approval services contact Steve Laya, at 630-495-9770 x 119 or Dan Crowder at 630-495-9770 x 101.

Labels: Radio Equipment Directive (RED)

New Photometry Lab Open Soon

One of the most exciting additions at Elite’s new North Annex is a completely new service – Photometric Testing. It is the perfect complement to our proven EMC and Environmental testing services that we currently perform on lighting products and we are committed to delivering it with the same scheduling flexibility and customer service that you expect from Elite.

Recent innovations such as LEDs and wireless connectivity for IoT (Internet of Things) applications have increased the electrical complexity of lighting products with digital controls, power electronics, and transmitters. While those innovations dramatically reduce energy consumption, extend product life, and enhance illumination, they also increase the scope of compliance testing beyond the photometric performance of the luminaire. Today’s lighting products may require compliance with FCC emission limits, various CE Mark Directives, and water/dust Ingress Protection (IP). Elite can help you navigate the maze of compliance requirements to qualify your products and get them to market faster.

Starting in June, Elite will serve the complete compliance testing needs of lighting product manufacturers – covering EMC/EMI, electrical, environmental, and photometric requirements – in one location. Our new Photometry Lab is designed for automotive and aerospace lighting applications with the flexibility to accommodate most types of consumer and industrial applications as well. It is equipped with a state-of-the-art Type A goniophotometer and a 2-meter integrating sphere with enough room for even the largest luminaires. For LED testing per IES LM-79, our Type A goniophotometer can accurately simulate Type C geometry.

Elite’s Photometry Lab will be open in June, so contact us today to find out how we can complete all of your lighting product compliance testings in one location. Stay tuned next month for more on the final preparations of our new North Annex and how it will improve our ability to serve our customers’ needs with more testing capabilities, greater capacity, and shorter lead times.

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EBook: Guide to CE Marking & RE Directives for Low-Power Wireless Transmitters

The CE Mark is a label placed on manufactured goods declaring their compliance with essential health and safety requirements for European citizens. Likewise, the Radio Equipment Directive (RED) is the compliance requirement in Europe for wireless transmitters. These two labels—and the regulatory infrastructure behind them—comprise the product conformity laws for the 28 European Union nations along with the EFTA countries of Iceland, Liechtenstein, and Norway and are adopted by Switzerland and Turkey through separate trade agreements.

Everything You Need to Know About the CE Mark & RE Directive

This e-book provides information on:

  • An overview of tests for output power, spurious emissions, transmitter and receiver functions, bandwidth usage, and adaptivity
  • Testing for EMC
  • Tests/Analysis for Electrical Safety
  • How to receive the Declaration of Conformity
  • Overview on transitioning to the RED

Download Guide to CE Marking & RE Directives for Low-Power Wireless Transmitters

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EBook: Everything You Need to Know About Marine EMC

(EMC) addresses two concerns; first, the ability of a device to limit its radio frequency emissions so it doesn’t interfere with other nearby devices (in particular radio receivers); and second, the ability of a device to operate as required in the presence of electrical and electromagnetic interference and other electrical threats.

This guide describes the EMC and wireless device regulations that apply to marine equipment and systems.

What You’ll Find in This EBook:

  1. Overview of the marine EMC environment
  2. Recreational craft regulations
  3. Commercial ship regulations
  4. Conformity assessment
  5. How to Prepare for marine equipment EMC testing

Download Everything You Need to Know About Marine EMC

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Thermal Shock Testing Expands at Elite

Elite is growing its Thermal Shock testing capability by adding dual and multi-zone chambers to its lineup of environmental resources. Three new thermal shock chambers have now been brought online to provide clients with better scheduling options and test start/completion dates. Our end goal with the expansion is to ensure shorter time-to-market services for Elite customers, and provisioning these chambers will certainly help.

With this additional capacity, Elite can now offer a total of six air-to-air thermal chambers and two single-zone chambers capable of temperature change rates between 30-50C/minute. Our new chambers also have very large test volumes capable of handling big samples or large part quantities. With a wide range of chamber sizes, Elite can more precisely match the customer project requirements to the chamber size. This helps us perform the test efficiently and by using a chamber sized to perform the test at the least cost.

John Lindberg, Environmental Department Manager (pictured), identifies Elite’s largest thermal shock chamber as “a three-zone system configured to test double the normal quantity of samples in the same time as a dual-zone chamber”. This chamber has a test volume of 39” x 23” x 23” making it the largest of Elite’s thermal shock chambers.

Two of Elite’s dual-chamber thermal shock chambers have test volumes of 25” x 15” x 13”’ and 25” x 27” x 27”. For smaller parts and low quantity testing, we have three more economical chambers each with volumes of 14” x 19” x 14”.

Elite’s existing Highly-Accelerated Life Testing (HALT) chamber and our new Environmental Stress Screening (ESS) chambers are single-zone heating/cooling systems that circulate air volumes at high rates and at extreme hot and cold temperatures. The HALT and ESS units can each achieve temperature change rates between 30-50C/minute.

For more information about Thermal Shock and other Environmental Stress Testing, contact Elite to learn about capabilities, scheduling, and for a proposal.

Labels: Thermal Shock Testing

New Fixture Fabrication Shop Open for Business

Elite’s new North Annex houses a complete machining and fabrication shop to deliver high-quality, customized fixtures and automation solutions with shorter lead times. This new addition builds upon Elite’s proven Fixture, Automation, and Life-Cycling capabilities by bringing the entire process on-site and fully integrating it with our testing services. The shop includes two CNC mills that accommodate plates up to 4 feet wide and is staffed by an experienced mechanical designer and a full-time machinist ready to serve you.

Fixtures are an integral part of the Environmental Stress Testing that we perform every day at Elite. Well-designed fixtures seamlessly transmit vibration and shock forces to products under test and accurately simulate their installed configuration. They also add efficiency to the testing process by accommodating multiple samples for simultaneous testing and easing the transition between axis orientations.

In addition to fixtures, Elite can engineer systems that automate repetitive motion or mechanical manipulation to support life-cycling and fatigue testing. Automation improves efficiency to accelerate test schedules and reduces uncertainty through repeatability.

Why trust Elite for your Fixturing and Automation Solutions?

  1. Elite’s decades of testing experience combined with material selection, mechanical design, and analysis ensure dependable solutions that are tailored to your technical and schedule requirements.
  2. Stay on schedule knowing that your fixtures will be completed and available on your start date. We can also quickly modify fixtures as necessary throughout testing.
  3. Guarantee compatibility with Elite’s test equipment and data acquisition systems and reuse for future testing projects. Even if you are not planning to test with Elite, we can also create solutions for your internal use.
  4. Streamline your supply chain with a single point of contact for design, fabrication, and testing.

Elite’s fabrication shop is now open for business, so contact us today to find out how we can deliver custom fixtures and automation solutions on time and within budget. Stay tuned next month for more on our new Photometric Testing capabilities that provide complete qualification testing services for your automotive and aerospace lighting products in one location.

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Employee Spotlight: Edwin Casas

Here’s a little bit about a new addition to our testing sales department, Edwin Casas:

Title: Technical Sales Engineer

Year Started at Elite: 2017

Education: B.S. Electrical Engineering, Northern Illinois University

Any unique hobbies, talents, skills, experiences, etc.: 

Gaming, personal electronics, and cars are my main hobbies.

What would you consider to be your passion outside of work? How did you get started in it? Any advice for anyone looking to try this activity?

Personal electronics. Ever since I was young, I loved electronics. I remember taking apart my mom’s old Nokia phone and disassembling it out of curiosity. 

Proudest moment in life so far:

Being the first in my entire family to earn a college degree. 

Why did you choose to work at Elite?

It was such a nice and welcoming environment when I first walked in. Everyone seemed so friendly with one another.

What is something that customers/colleagues might find surprising about you?

I can’t swim even though I’ve tried learning many, many times.

If you had a personal motto, what would it be?

It is never too late to pursue your goals.

If you could be paid something other than money, what would you choose?

Taco Bell, pizza, or cheeseburgers.

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