Environmental Testing for Electronics Sensors

Sensors are the foundation of smart systems across industries. From MEMS accelerometers in electric vehicles to IoT temperature sensors in smart buildings, from LIDAR systems in autonomous robots to biosensors in wearable medical devices – these sophisticated components must perform reliably across a wide range of environmental conditions. When sensors fail, the consequences can be severe, making environmental testing an essential step in sensor development and qualification.

Modern applications demand increasingly complex sensor systems. Electric and autonomous vehicles, as well as aircraft and spacecraft, depend on dozens of sensor types – battery temperature sensors, current sensors, proximity sensors, and inertial measurement units (IMUs) – all of which must maintain accuracy in extreme conditions.

These sensors face numerous environmental challenges in real-world applications. They must withstand temperature cycling from arctic to desert conditions, often experiencing extreme shifts within short periods. Humidity conditions can range from arid to tropical, mechanical shock and vibration constantly stress sensor components and connections, and atmospheric pressure changes can affect sensor calibration and performance. Often, these factors work in combination, creating complex stress scenarios that sensors must withstand. Testing under controlled conditions helps identify potential failure modes before deployment.

Environmental Tests for Sensor Validation

• Temperature cycling and thermal shock testing assess how sensors respond to rapid temperature changes. For example, sensors in electric vehicles must reliably withstand the thermal stresses encountered during charging or rapid environmental shifts. Failures due to thermal shock can lead to immediate operational issues, while cumulative damage from temperature cycling can significantly reduce a sensor's lifespan.
• Humidity testing evaluates sensor performance under varying moisture conditions, which is essential for maintaining accuracy and functionality across a range of relative humidity levels.
• Altitude testing simulates the low-pressure environments encountered at high altitudes, affecting sensor performance and reliability. This is especially vital for aerospace applications, where components must function correctly at cruising altitudes of commercial aircraft or in space. Sensors qualified to operate at altitudes up to 100,000 feet while withstanding extreme cold temperatures are essential for ensuring that they will not fail due to pressure changes or temperature extremes during flight.
• Vibration testing simulates the mechanical stresses that sensors may experience during operation, including impacts and vibrations from machinery or vehicles. In automotive applications, for example, sensors are subjected to constant vibrations from the engine and road conditions. Testing helps identify potential failure modes due to mechanical stress, ensuring that sensors remain operational even under challenging conditions.

As sensors become increasingly critical in modern systems, environmental testing plays a vital role in ensuring reliability and performance throughout their operational life.

Contact our team to discuss your specific testing needs or explore our complete range of environmental test solutions.