This sample report shows the results of the most relevant cable-related test protocols found in MIL-Std-810. The results are taken from actual tests done on a representative sample of a C&M Mil-Grade COTS assembly. The tests were performed by C&M, or by an authorized testing laboratory.
Performance tests include:
- Temperature cycling.
- Dust and water ingress.
- Tension @ angles.
- Flex bend and torsion.
- High and low temperature performance.
|Test Name||Test Description||Test Criteria||Min Acceptable Value||Ultimate Tested Value||Test Temp||Includes Post Test Ingress Testing||Pass/Fail||Comment|
|Base Electrical||Primary test to ensure correct manufacture of cable assembly to functional design required||Pass full set of Continuity, Isolation and Hi-Pot tests||
|Meets Requirements||+25°C||No||Pass||Passed test profile programmed into Cirris tester per design requirement|
|IP6X||Temporary immersion in Category 1 dust chamber, with fine Talcum powder for 2 hours||No ingress of Talcum||
|+25°C||-||Pass||No Talcum powder was observed in sealed areas|
|IPX8||Temporary immersion in water at a depth of >1 meter for 12 hours||No ingress of Water||12 Hrs
|+25°C||-||Pass||No Water was observed in sealed areas|
|Temp Range Short Term||Ensures cables withstand short term exposure to temp extremes||Continuously cycle between min and max temp limits||Pass Electrical||Meets Requirements||-55/105° C||Water - IPX8||Pass||Passed visual inspection and test profile programmed into Cirris tester per design requirement|
|Temp Range Operational||Ensures cables withstand long term exposure to temp extremes||Continuously cycle between min and max temp limits||Pass Electrical||Meets Requirements||-40/85° C||Water - IPX8||Pass|
|Large Radius TIC-TOC (1)||Test to continuously flex cable back and forth a foot from Bend Relief to test BR and cable||Continuously cycle unweighted cable between left and right bends||500 Cycles||>1600 Cycles||-40°C||Water - IPX8||Pass|
|Small Radius TIC-TOC (2)||Test to continuously flex cable back and forth close to end of Bend Relief to isolate BR||Continuously cycle weighted cable between left and right bends||5 Pounds
|> 20,000 Cycles||+25°C||Water - IPX8||Pass|
|Fixed Bend||Test to flex cable back and forth a foot from Bend Relief at temp extremes to test BR and cable||2 x 360 Deg||Pass Electrical||Meets Requirements||-40°C / +85°C||Water - IPX8||Pass|
|Tension on Axis||Straight cable pull to ensure proper strain relief||Pull to loss of electrical integrity||50 Pounds||120 Pounds||+25°C||No||Pass||Ultimate value was greater than 2X minimum criteria, negating need for tests at temp extreme|
|Tension @ 45t:||Offset cable pull to ensure proper strain and bend relief||Pull to loss of electrical integrity||40 Pounds||234 Pounds||+25°C||No||Pass|
|Tension @ 90t:||Right angle cable pull to ensure proper strain and bend relief||Pull to loss of electrical integrity||30 Pounds||114 Pounds||+25°C||No||Pass|
|Compress on Axis||Crush force applied to ensure cable can withstand being run over by vehicles||Crush to loss of electrical integrity||30 Pounds||>1100 Pounds||+25°C||No||Pass|
|Torsion||+/- 180 degree twisting force applied to ensure proper seal, strain and bend relief||Pass Continuity and Hi-Pot after immersion||1,000 Cycles||> 1040 Cycles||+25°C||Water - IPX8||Pass||Test halted due to no discernable impact on cable after 1000 cycles|
|Transit Shock||Drop test to ensure cable can withstand shipment with no impact on performance||MIL-STD-810; Method 516||Pass Electrical||Meets Requirements||+25°C||Water - IPX8||Pass||Passed visual inspection and test profile programmed into Cirris tester per design requirement|
|Vibration||Test to ensure cables withstand operational vibrations with no impact on performance||MIL-STD-810; Method 514||Pass Electrical||Meets Requirements||+25°C||Water - IPX8||Pass|
|Corrosion / Chemical / Fungus||Tests to ensure cables withstand various environments with no impact on performance||MIL-STD-810; Method 504/509||Meets Spec||Meets Requirements||N/A||N/A||Pass||Material Vendor Test Data used in lieu of Assembly Test|
|UV Resistance||Test to ensure cables withstand prolonged sunlight with no impact on performance||NEC 310-8 (d) MIL-STD-810; Method 505||Meets Spec||Meets Requirements||N/A||N/A||Pass|
|Flame Resistance||Test to ensure cables withstand provide minimum level of flame resistance||V-0 per UL -94||Meets Spec||Meets Requirements||N/A||N/A||Pass|