Mechanical Shock – UL 2580

What Is Mechanical Shock — UL 2580?

The mechanical shock test is a test in which short-duration, high-acceleration shocks are applied to the specimen, evaluating structural strength and continuity of function. It is defined by shock amplitude (g) and duration (ms).

Purpose of Mechanical Shock — UL 2580

The purpose is to verify that sudden shocks arising during transport, handling and service do not damage the product.

Which Products Is Mechanical Shock — UL 2580 Applied To?

Battery cells, modules and packages
Electronic units
Aerospace and defense equipment
Rail and marine equipment

In Which Sectors Is Mechanical Shock — UL 2580 Used?

AutomotiveAerospaceDefenceDemiryoluLogistics

Standards Related to Mechanical Shock — UL 2580

UL 2580Safety in electric vehicle batteries test

Mechanical Shock — UL 2580 Conditions

Shock profile: Half-sine, sawtooth or trapezoidal
Amplitude and duration: Acceleration (g) and shock duration (ms) defined in the specification
Number of shocks: A defined number of repetitions in each axis and direction
Axes: In three perpendicular axes, in both directions

Equipment for Mechanical Shock — UL 2580

Shock test machine
Accelerometer and shock control system
Mounting fixture
Explosion-proof device (battery)
Function-monitoring rig

Sample Requirements for Mechanical Shock — UL 2580

The specimen must be mounted with a fixture representing the actual installation method
The fixture must be rigid enough not to distort the shock
The specimen must be fully charged in battery tests
Function must be checked before the test

Duration of Mechanical Shock — UL 2580

It depends on the number of shocks and axis combination; a typical programme is completed in half a working day to one full day.

Mechanical Shock — UL 2580 Procedure

1The specimen is mounted on the fixture and the accelerometer is placed.
2The shock profile, amplitude and duration are set.
3Profile verification is performed with the empty fixture.
4The defined number of shocks is applied in each axis and direction.
5Function and physical condition are monitored.

Mechanical Shock — UL 2580 Acceptance Criteria

The acceptance criterion is defined in the specification: no structural damage and continuity of function. In battery tests, the absence of leakage, fire and explosion is required.

Evaluation of Results

The measured shock profile must be within the specification tolerance. Whether any loss of function is temporary or permanent is recorded.

Mechanical Shock — UL 2580 Report

Applied standard and shock profile
Amplitude, duration and number of shocks
Axis and direction information
Measured shock curves
Function status and visual inspection

Accreditation

EUROLAB holds internationally recognised accreditation obtained from accreditation bodies party to the IAF and ILAC multilateral recognition arrangements, under ISO/IEC 17025 for laboratory testing, ISO/IEC 17020 for inspection and surveillance, and ISO/IEC 17021-1 and ISO/IEC 17065 for system and product certification. This chain ensures the reports and certificates issued are accepted worldwide.

Whether this test can be offered within accredited scope depends on your product and the standard applied; since accreditation is method-based, the scope is confirmed in writing at the quotation stage.

Scope and authorisations

Related Regulations

UN 38.3 (battery transport)
UNECE R100
Aerospace and rail equipment requirements

Vibration and Shock — What Does This Testing Field Cover?

The section below describes the field that the Mechanical Shock test belongs to; the conditions and acceptance criteria of this particular test are given in the sections above. The scope specific to your product is confirmed in writing at the quotation stage.

Vibration and shock testing shows whether a product withstands mechanical dynamic loads. The two phenomena are distinct: vibration is a continuous and repeated loading, while shock is a single instantaneous impact at high acceleration. They produce different failure modes and are required separately.

The failure produced by vibration is FATIGUE: a solder joint cracks, a cable sheath abrades, a screw loosens, a connector loses contact. The failure produced by shock is FRACTURE: a brittle component shatters, a bracket breaks, a board comes out of its holder. Testing a product under vibration therefore does not show that it also withstands shock.

Vibration is applied in three forms, each giving different information. Sine vibration sweeps at a single frequency; it is used to find the resonant frequencies of the product and is very valuable at the design stage. Random vibration represents the broadband nature of the real environment and is preferred as evidence of durability. Sine-on-random and random-on-random profiles simulate together the broadband noise superimposed on dominant frequencies from engines and rotors — this is necessary in helicopter and turboprop applications.

RESONANCE is the concept at the centre of the field. Every structure has its own natural frequencies; as the excitation frequency approaches one of them the amplitude grows and the product is exposed to an acceleration many times the input level. A resonance search is therefore carried out before the test, and a design change often takes the form of shifting the resonance rather than lowering the level.

In this family the FIXTURE is part of the result, and this is the most frequently overlooked point. How the specimen is attached to the shaker directly changes the energy transmitted and the resonance behaviour. A poorly designed fixture brings its own resonances into play and imposes a load the product would not otherwise see, or conversely damps the real load and protects the product. Results obtained with different fixtures cannot be compared.

The choice of measurement point also determines the result. The control accelerometer is placed on the fixture and monitoring accelerometers at critical points of the product; the report must document these positions. Accelerations measured at different points in the same test can differ markedly.

Profiles are divided by application area: transport vibration (packaging and shipping), vehicle vibration (by mounting location), rail (EN 61373 categories), aviation (DO-160 sections), military (MIL-STD-810 methods) and battery transport (UN 38.3 T3). The same product passes through different profiles under different programmes.

Method groups in this field

Sine vibration
Determining resonances by frequency sweep and withstand at defined frequencies; the most informative test at the design stage.
Random vibration
Durability with a broadband power spectral density profile; the approach that best represents the real environment.
Combined profiles
Sine-on-random and random-on-random; for dominant frequencies arising from rotating machinery.
Classical shock
Defined acceleration and duration with half-sine, sawtooth and trapezoidal pulse shapes.
Free fall and toppling
Realistic drop scenarios arising from handling; decisive for portable products.
Resonance search and monitoring
Detection of structural change (cracking, loosening) by sweeps before and after the test.

Commonly confused in this field

Shock and vibration are not the same test; one produces fracture and the other fatigue, and they are required separately.
A report that does not document the fixture cannot be compared; a fixture can bring its own resonance into play.
Levels come from the product standard or the programme specification; the standard does not define a single universal level.
Without a resonance sweep before and after the test, structural damage can go unnoticed; the product may appear to work while being cracked internally.
The position of the measurement point must be reported; accelerations measured at different points in the same test differ markedly.
If the product is not operated during the test, intermittent loss of contact remains invisible.

Which decisions these results support

Verification of transport and in-use durability
Transport and vehicle vibration conformity for batteries
Rail, aviation and defence qualification files
Root cause analysis of solder, connector and joint failures
The decision to shift a resonance through a design change

Related Tests

Frequently Asked Questions About Mechanical Shock — UL 2580

According to which standard is Mechanical Shock made?

Mechanical Shock is executed in scope IEC 60068-2-27, UN 38.3 T.4, MIL-STD-810 Method 516, RTCA DO-160 Section 7, IEC 61373 and UL 2580. The limit values and acceptance criteria to be applied are defined in the product standard; The version valid for your product is confirmed in writing at the offer stage.

Which products does Mechanical Shock apply to?

Mainly applied to Battery cells, modules and packages, Electronic units, Aerospace and defense equipment and Rail and marine equipment. Whether your product is included in the scope is determined by examining its technical specifications and intended use.

Under what conditions is Mechanical Shock done?

The determining parameters are: Shock profile — Half-sine, sawtooth or trapezoidal, Amplitude and duration — Acceleration (g) and shock duration (ms) defined in the specification and Number of shocks — A defined number of repetitions in each axis and direction. The full terms are in the "Test Conditions" section on the page and vary depending on the product standard.

What kind of sample is needed for Mechanical Shock?

The specimen must be mounted with a fixture representing the actual installation method, The fixture must be rigid enough not to distort the shock and The specimen must be fully charged in battery tests. The number of samples is determined according to the product standard and the scope to be reported.

How long does Mechanical Shock take?

It depends on the number of shocks and axis combination; a typical programme is completed in half a working day to one full day. This duration belongs to the experiment itself; sample preparation, queuing and reporting are also evaluated. A realistic schedule for your product is given in the offer.

What is the Mechanical Shock result called "appropriate"?

The acceptance criterion is defined in the specification: no structural damage and continuity of function. In battery tests, the absence of leakage, fire and explosion is required.