Aerospace ZY-2 Touchscreen-Controlled Needle Flame Test Apparatus

Overview

The Aerospace ZY-2 Touchscreen-Controlled Needle Flame Test Apparatus is a precision-engineered combustion testing instrument designed to evaluate the fire hazard potential of solid non-metallic materials—particularly insulating components in electrical and electronic equipment—under simulated fault-induced small-flame conditions. It operates in strict accordance with the needle flame test methodology defined in IEC 60695-11-5, GB/T 5169.5-2008, and GB 4706.1-2005. The apparatus generates a standardized, reproducible flame using a calibrated stainless-steel needle burner with precisely controlled geometry (inner diameter 0.5 mm ± 0.1 mm; outer diameter ≤ 0.9 mm; length ≥ 35 mm), delivering a 12 mm ± 1 mm high flame fueled by 95% butane gas. Unlike manual or semi-automated alternatives, the ZY-2 integrates full electromechanical actuation of burner positioning, eliminating operator-dependent timing errors and ensuring consistent flame application distance, angle (adjustable 0–45°), and dwell time. Its core function is to assess whether a specimen sustains flaming combustion (afterflame time) or propagates ignition following exposure to a defined thermal stress, thereby supporting compliance with safety-critical product certification requirements.

Key Features

• Integrated 7-inch full-color touchscreen HMI with intuitive icon-based navigation—enabling one-touch control of burner movement, ignition, timing, ventilation, lighting, and data saving.
• PLC-driven motorized specimen holder with programmable X/Y/Z translation—ensuring repeatable positioning without manual intervention.
• Fully automated flame cycle: burner advances to preset specimen distance upon “Start”, initiates timing, retracts automatically at end-of-application, and optionally shuts off gas supply.
• Precision digital timer with ±0.1 s resolution for both flame application duration (0–999.9 s) and afterflame measurement (0–999.9 s), including manual pause/resume capability.
• Adjustable burner tilt mechanism (0–45°) with locking vernier scale—facilitating angular flame impingement per standard-specific test configurations.
• Modular combustion chamber (>0.5 m³ internal volume; 900 × 590 × 1050 mm L×W×H) with matte black interior finish and background illumination ≤20 lux—optimized for unambiguous flame observation and photographic documentation.
• Independent exhaust system with flow-regulated fume extraction—maintaining stable chamber pressure and preventing backdraft during repeated cycles.
• Gas flow regulation via calibrated needle valve—ensuring stable flame geometry and thermal output across operational life.

Sample Compatibility & Compliance

The ZY-2 accommodates rigid and semi-rigid solid specimens up to 150 mm × 150 mm × 20 mm (custom fixtures available), including printed circuit board substrates, housing plastics, gaskets, and wire insulation. All mechanical and thermal parameters—including burner geometry, flame height, application time, and post-exposure observation protocol—are traceable to the metrological requirements of IEC 60695-11-5 Annex A and GB/T 5169.5-2008 Clause 6. The apparatus supports full auditability for GLP and GMP environments: test logs include timestamped event sequences (ignition, burner advance, flame extinction, afterflame termination), operator ID (if networked), and parameter settings—all stored internally with export capability (USB). Optional flame temperature calibration kit (K-type thermocouple, 0–1000 °C; copper calibration block Ø4.0 × 6.0 mm) enables periodic verification per IEC 60695-11-5 Clause 9.2, ensuring ongoing conformance to the 100 °C ± 2 °C → 700 °C ± 3 °C rise-time specification (23.5 s ± 1 s).

Software & Data Management

The embedded control firmware implements deterministic real-time task scheduling for flame sequencing, sensor polling, and HMI updates. Test records are stored in CSV format on internal flash memory (≥10,000 cycles) and exportable via USB port. Each record contains: test ID, date/time, operator input, applied flame duration, measured afterflame time, pass/fail status per GB/T 5169.5 pass criteria (no sustained flaming >30 s; no ignition of surgical cotton), and system diagnostic flags (gas pressure OK, burner position confirmed, exhaust flow within range). While not FDA 21 CFR Part 11 compliant out-of-the-box, the architecture supports future integration with validated LIMS platforms via RS-232 or Ethernet (optional module), enabling electronic signature, audit trail, and role-based access control deployment where required for regulated product development.

Applications

• Pre-certification fire testing of enclosures, connectors, and insulators for household appliances (IEC/EN 60335 series).
• Qualification of PCB laminates and solder mask materials per IPC-4101D flammability requirements.
• R&D evaluation of halogen-free flame-retardant polymers (e.g., phosphorus- or nitrogen-based additives) under standardized thermal insult.
• Production line incoming inspection of molded plastic components for IT equipment (IEC/EN 60950-1 / IEC/EN 62368-1).
• Root-cause analysis of field failures involving thermal runaway in power supplies or battery management systems.

FAQ

What standards does the ZY-2 fully support?
The ZY-2 meets all mechanical, dimensional, and procedural requirements of GB/T 5169.5-2008, GB 4706.1-2005, and IEC 60695-11-5. It is also suitable for test execution aligned with UL 746A, EN 60695-11-5, and CSA C22.2 No. 0.3.
Is external gas supply included?
No. Users must provide certified 95% butane gas (or LPG) with appropriate pressure regulator and CGA 510 or equivalent fitting. Gas purity and delivery stability directly impact flame repeatability.
Can the chamber be customized for larger specimens?
Yes. Aerospace offers optional stainless-steel chamber variants in 0.75 m³ and 1.0 m³ volumes, with reinforced structural framing and extended vertical travel for oversized samples.
How is flame temperature verified?
An optional calibration kit includes a K-type thermocouple (insulated, Ø0.5 mm), copper calibration block, and digital thermometer—enabling users to validate the 100 °C → 700 °C ramp rate per IEC 60695-11-5 Clause 9.2.
Does the system support remote monitoring?
Standard configuration includes RS-232 serial interface for basic command/control. Ethernet and Modbus TCP modules are available as factory-installed options for SCADA or MES integration.