To ensure the absolute reliability of our ISR payloads, all models are evaluated using vigorous testing procedures - Highly Accelerated Life Testing (HALT) and Highly Accelerated Stress Screening (HASS). Compared to other tests, this methodology reveals product weaknesses in a very short amount of time: within days or, in some cases, even hours.
Unlike traditional vibration test methods or thermal-only methods, during HALT/HASS testing, the product is put under stress: repetitive shock/vibration and rapid thermal change rates by treating the unit to various minimum/maximum temperatures with the help of liquid nitrogen (the product is rapidly frozen/overheated). In HALT/HASS testing, stresses are applied in a controlled and incremental way while the gimbal undergoing the test has all sensors working and is continuously monitored for failures.
Highly Accelerated Life Testing (HALT) is a testing methodology used during the R&D stage which allows us to determine the lower and upper operational limits, as well as the lower and upper destruct limits. The goal of HALT testing is to discover and identify and weaknesses in the product design and address them. HALT testing is performed until the unit is destroyed and cannot be fixed/repaired anymore. This testing methodology provides our engineers enough information to improve gimbal design and to increase its durability.
The Highly Accelerated Stress Screening (HASS) method is performed on every unit produced and exposes any possible manufacturing defects (“infant failures”) that would cause a failure in normal field environments. Once the weaknesses of the gimbal are uncovered and corrective actions taken, the limits of the product are clearly understood, and the operating margins can be extended as far as possible. If during HASS testing weaknesses of the equipment are uncovered - corrective actions are taken, to ensure reliable operation of the payloads delivered to the customers.
HALT/HASS testing methodology is the key to produce extremely reliable and powerful ISR payloads.