Nanjing Elephant-Med instrument Co. , Ltd.
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Detailed Explanation of IEC 62506 International Standard – Active Aging Test
Standard Overview
IEC 62506:2023 (latest edition) is a general standard for product accelerated testing issued by the International Electrotechnical Commission (IEC). It provides a systematic method to evaluate and improve product reliability within a compressed time period.
This standard specifies the technical framework for accelerating product aging by applying more stringent stresses (such as temperature, humidity, and voltage) than normal operating conditions, so as to quickly identify potential failure modes or verify product reliability.
Corresponding Chinese standard: GB/T 34986-2017 Methods for accelerated testing of products, which is identically adopted from IEC 62506:2013.
Core Principle of Active Aging Test
Active aging test is applicable to devices driven by electric energy or other energy sources not directly generated by the human body (e.g., medical devices and electronic equipment). It simulates the effects of long-term service by applying accelerated stress, with the core objectives as follows:
• Reliability evaluation: Predict the service life of products under normal use conditions within a short period.• Design optimization: Identify potential failure modes and optimize product design.• Service life verification: Confirm the safety and effectiveness of products within the claimed shelf life.
Classification of Accelerated Testing (IEC 62506:2023)
Type
| Main Purpose
| Applicable Phase
| Typical Method
|
Type A Qualitative Accelerated Testing | Identify potential failure modes | Design and development phase | HALT (Highly Accelerated Life Test)
HAST (Highly Accelerated Stress Test) |
Type B Quantitative Accelerated Testing | Quantitative evaluation of reliability | Verification and validation phase | Arrhenius model, Inverse Power Law model |
Type C Time-event Compression Testing | Accelerated life verification | Production certification phase | Time compression (C1) Event compression (C2) |
Implementation Process of Active Aging Test
1. Pre-test Preparation
- • Sample selection: Normally no less than 2 representative products with intact functions.
- • Failure mode analysis: Determine critical failure mechanisms via FMEA, such as electronic component degradation, mechanical wear and insulation aging.
- • Test parameter definition: Clarify performance indicators, safety requirements and failure judgment criteria.
2. Acceleration Factor Calculation (Core Step)
Arrhenius Model (Applicable to temperature-related failures):
AF = exp[(Ea/k)(1/T_use - 1/T_test)]
Humidity Acceleration Factor (Combined with Temperature):
AH = (RH_test/RH_use)^h × exp[Ea/k(1/T_use - 1/T_test)]
: Humidity exponent (approx. 2.66 for insulating materials)
Inverse Power Law Model (Applicable to voltage and mechanical stress):
AF = (S_test/S_use)^m
- •: Stress value (voltage, mechanical load, etc.)
- •: Material constant (e.g., for capacitors; for polyethylene insulation)
3. Test Scheme Design
Select one or more of the following stress types according to product characteristics:
Stress Type | Typical Conditions | Applicable Failure Mechanism |
Temperature Aging | 50~85°C, 48~96 h | Material degradation, solder joint fatigue |
Humidity Aging | 45~95%RH, 48~96 h | Insulation failure, corrosion |
Voltage Aging | 1.1~1.5 times rated voltage, 72h | Insulation breakdown, electromigration |
Load Aging | 100~120% of rated load, 96 h | Mechanical wear, thermal overload |
Typical Test Scheme for Active Medical Devices
- • Operating Mode: The device is powered on, placed under the environmental condition of 45°C / 85% RH for approximately 1100 hours (46 days), with performance testing conducted once a week.
- • Storage Mode: The device is powered off, placed under the environmental condition of 60°C / 93% RH for approximately 336 hours (14 days), with performance testing conducted once a week.
4. Test Implementation Procedures
• Place the samples into an environmental test chamber (constant temperature and humidity chamber, vibration table, etc.).
• Apply predetermined stress conditions and keep continuous operation.
• Suspend the test periodically (e.g., once a week), restore to room temperature, and conduct functional and safety tests.
• Record performance data and evaluate whether any failure occurs.
• Terminate the test when the predetermined duration is reached or a failure occurs.
5. Result Evaluation and Judgment
• Acceptance Criteria: The changes of key performance indicators after aging are within the allowable range (e.g., luminous flux attenuation ≤ 30%, leakage current complies with relevant standards).
• Failure Definition: Loss of basic functions or exceeding the limit of safety indicators.
• Life Prediction: Calculate the reliable service life under normal use conditions by means of acceleration factors.
Application Case: Service Life Verification of Active Medical Devices
Case Background: A certain medical monitor claims a service life of 10 years, which needs to be verified by accelerated aging test.
Key Procedures:
1.Acceleration Model Selection: Adopt the comprehensive temperature-humidity acceleration model (considering both operating and storage conditions).
2.Parameter Determination:
• Operating mode: 45°C / 85% RH (maximum endurance of the device)
• Storage mode: 60°C / 93% RH (upper limit of storage conditions)
3.Acceleration Factor Calculation:
Operating mode AF ≈ 7; Storage mode AF ≈ 191
4.Test Duration:
• Operating mode: 29224 h (10-year operating time) / 7 ≈ 1102 h (46 days)
• Storage mode: 58448 h (10-year storage time) / 191 ≈ 336 h (14 days)
Implementation Result: Two prototype units completed all tests. All performance and safety indicators meet the requirements, verifying that the service life can reach 10 years.
Notes and Limitations
1.Consistency of failure mechanism: Excessively high stress may introduce abnormal failure modes, which shall be verified by preliminary tests.
2.Combined multi-stress: The actual service environment is complex; it is recommended to conduct comprehensive tests with combined multiple stresses.
3.Sample size: For high-risk products (such as medical devices), it is recommended to increase the number of samples (≥ 3 units).
4.Statistical confidence: Statistical analysis shall be performed on the results to ensure the credibility of reliability evaluation.
Summary
The active aging test specified in the IEC 62506 standard is an efficient tool for evaluating the reliability of active products. By adopting scientific acceleration models and rigorous test design, it can verify the performance and safety of products under long-term service conditions within a short period.
For products with high reliability requirements such as active medical devices, this method has become a standard approach for service life verification, providing a scientific basis for product design optimization and market access.
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