Temperature Controller Life Test: Test Procedures and Equipment Guidelines

Temperature Controller Life Test: Test Procedures and Equipment Guidelines

As a core component for temperature control in home appliances, the lifespan of a temperature controller directly affects the safety and performance of the device. From laboratory testing to production line applications, a standardized test procedure and specialized equipment are essential for accurately evaluating the long-term stability of temperature controllers. This article details the implementation process of temperature controller life testing, covering both the test procedures and the necessary equipment.

1. Test Preparation: Defining Standards and Sample Pre-treatment

Before conducting the formal test, it is necessary to define the test standards and the condition of the test samples. Based on the International Electrotechnical Commission (IEC) or national standards (GB), specific performance requirements for different types of thermostats must be determined—for example, an electric water heater thermostat should withstand 50,000 on/off cycles without failure, while a refrigerator thermostat should have a low-temperature operating life of 100,000 cycles. The test samples must undergo pre-treatment: they should be kept at 25°C and 50% humidity for 24 hours to ensure a stable initial state, thus avoiding any interference to the test results due to environmental factors during transportation or storage.

2. Mechanical Life Cycle Test: Cyclic On/Off Operation and Parameter Monitoring

The mechanical life cycle test is a crucial step in verifying the durability of the core structure of the temperature controller. This test is performed using a dedicated temperature controller life test rig. Taking an electric oven temperature controller as an example, the test procedure is as follows:

Mount the temperature controller on the test rig and connect the temperature sensor and the operation recording device;

Set the temperature cycling range (e.g., from room temperature to 250°C);

The system automatically counts each completed cycle of "opening at the set temperature → closing at the reset temperature";

After 50,000 cycles, stop the test and inspect: observe the contact wear under a microscope, and measure the elasticity of the metal spring using a force gauge (the decrease in elasticity should not exceed 20% of the initial value).

3. Electrical Load Test: Stability Verification under Current Surge

The electrical load test simulates the current surge that occurs during actual operation using an electrical load testing system. The procedure is as follows:

Set the test current to 1.25 times the rated current of the thermostat (e.g., 20A for a 16A rated thermostat), while maintaining a voltage of 220V ±10%.

The control relay and the thermostat are synchronized, and one on-off cycle is completed according to the test requirements. After 10,000 cycles:

The test verifies whether the thermostat can withstand this operating condition under load. This requires a thermostat life test device that supports live-load testing to simulate the application scenario.