100% Thermal Cycling for Reed Relays

Environmental testing and cycling are essential for ensuring the reliability of equipment used in extreme conditions. The expansion and contraction caused by temperature fluctuations can damage PCBs and components, leading to costly field failures. While it’s unusual for reed relay manufacturers to apply thermal cycling to every device they produce, high-end manufacturers understand its importance and make it a standard part of their process.

The Cost of Compromise

Low-cost manufacturers often skip comprehensive thermal cycling to keep prices down. However, this short-term saving can lead to significant long-term costs for the end user. A field failure can result in expenses far beyond the cost of the component itself, including:

Repair Costs: Returning equipment for repair can cost thousands of dollars.
Downtime: Equipment downtime can disrupt operations and lead to substantial losses.
Service Costs: Sending an engineer to repair equipment on-site adds to the expense.
Reputation Damage: Frequent failures can damage the user’s reputation and reliability.

The initial savings on a cheaper component are insignificant compared to these potential costs.

Commitment to Quality

High-end reed relay manufacturers, like Pickering, prioritize quality and reliability over cost-cutting measures. By applying 100% thermal cycling to all products, they ensure that only the best products reach their customers.

Efficient Thermal Cycling Process

The method of applying the thermal cycle is crucial. Using an environmental chamber that heats and cools the same space can result in longer cycle times and less effective testing. A more efficient method involves physically moving parts between separate hot and cold chambers. This approach creates a more severe thermal shock, stressing any potential weak points in the components. This process:

Detects Weaknesses Early: Faster transitions between temperatures can reveal and eliminate flaws in the fine coil winding wire or internal connections before the products are shipped.
Improves Reliability: By simulating more extreme conditions than the part might encounter in actual use, manufacturers can ensure higher reliability.

Setting Appropriate Temperature Ranges

Choosing the right temperature ranges for thermal cycling is critical. While a broader range can reveal more potential failures, setting the temperatures too extreme can cause unnecessary failures. Manufacturers typically select temperature ranges based on standard operating conditions for their components and equipment.

Conclusion

At Pickering, we understand the immense value of 100% thermal cycling in producing reliable reed relays. By investing in thorough environmental testing, we ensure our products meet the highest standards of durability and performance. This commitment to quality helps prevent costly field failures and maintains the trust and satisfaction of our customers. While the initial cost of such rigorous testing might be higher, the long-term benefits far outweigh these costs, providing greater value and peace of mind for our users.