Toughbook Universe

Panasonic Toughbook® mobile computers must endure torturous tests at Panasonic R&D and quality assurance facilities on a daily basis. These rigorous tests have been ongoing for more than a decade as Panasonic technicians continue their quest for even higher levels of computer reliability and performance under the harshest conditions. The technicians are so demanding that more than 1,000 Toughbook mobile computers are deliberately damaged every year, just to determine how tough they really are.

The testing program helps ensure that all newly manufactured Toughbook computers meet Panasonic’s high quality standards. In addition, testing seeks to reveal any product weaknesses so that engineers can then design even greater durability and reliability into future Toughbook models.

To ensure that Toughbook computers exceed MIL-STD requirements, technicians subject the computers to a battery of factory tests. For example, the hinges on all Toughbook models are factory tested to survive 50,000 cycles, and keyboards must last for 25 million keystrokes. Panasonic’s commitment to quality—at both the component and finished goods level—results in a total of more than 500 checks and tests before, during and after production, on every unit built.

The full rugged Toughbook line has been designed using MIL-STD-810F test procedures to measure levels of environmental reliability. Created by the U.S. government, the MIL-STD-810F specifications cover a broad range of tests that measure the durability of equipment used under harsh conditions. From the MIL-STD-810F test menu, Panasonic selected those that most closely reflect the challenges that mobile professionals face in the field, on the road, and in the office. These tests include drop-, shock-, moisture-, dust- and vibration-resistance, exposure to extremely low and high temperatures, and many others.

Drop and Shock Resistance

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Dropped computers are a common cause of hard disk failures and broken LCD displays. Toughbook® mobile computers are tested to ensure they can survive falls as well as sudden high-force impacts to any part of the product’s casing.

Drop tests are performed in accordance with MIL-STD-810F, Method 516.5, Procedure IV (Transit Drop Test). The Toughbook mobile computer is sequentially dropped in non-operating mode, onto each face, edge and corner for a total of 26 drops. The drop surface is two-inch-thick plywood over a steel plate over concrete. After each drop, Toughbook computers are visually inspected and a functional check (boot-up into Windows) is performed.

Business-rugged Panasonic Toughbook laptops are tested to 12” drops (for both the unit and hard drive), and 30” when it lands flat on its bottom side, where it needs protection the most. Fully-rugged Toughbook computers are MIL-STD-810F-rated to 36” drops (for both the unit and the hard drive). The ultra-mobile-rugged Toughbook U1 is MIL-STD-810F-rated to 72” drops. Panasonic’s internal testing process goes beyond MIL-STD requirements. Technicians subject Toughbook computers to drop tests while the units are operating. Moreover, the units are dropped onto a harder surface than what is used for MIL-STD tests.

Liquid Resistance

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Mobile computers are inevitably exposed to spills and splashes—not just from water, juice and coffee, but also from oils and certain chemicals. Testing measures the ability of Toughbook® mobile computers to survive such spills as well as rainfall.

Panasonic technicians perform water resistance tests in accordance with MIL-STD-810F, Method 506.4 (Spray). The test items are subjected to this test with the LCD open and the unit operating, but with ports closed. Rugged Toughbook computers are then tested and inspected for water intrusion. Unlike some computer manufacturers, Panasonic does not shorten the duration of liquid resistance tests. Toughbook fully-rugged computers are tested for a full 40 minutes.

Different Toughbook models have different levels of water resistance. All Toughbook computers can survive six ounces poured on a keyboard. In addition to IP65* compliance, fully-rugged and ultra-mobile-rugged Toughbook U1 models can keep running even when subjected to 12 hours of continuous spraying—the equivalent of half a day in pouring rain.

Vibration Resistance

High levels of vibration can wreak havoc with ordinary mobile computers, especially those used regularly in vehicles. Even in stationary environments, such as shops and factories, computers need protection from vibrations. Panasonic tests fully-rugged Toughbook computers to assure they can keep performing in these environments.

The vibration test is performed in accordance with MIL-STD-810F, Method 514, Procedure I, Category 24 (Minimum Integrity Test) for the non-operational condition and Category 20 (Ground Vehicles) for the operational condition. Clamped to an aluminum plate to approximate rigid mounting, a fully-rugged Toughbook laptop is subjected to the following levels of vibration:

• Non-Operational (from Figure 514.5C-17 of MIL-STD-810F) 0.04 g2 /Hz at 20-1000 Hz, -6 dB/Octave at 1000-2000 Hz, 1 hour/axis duration.

• Operational (Figure 514.5C-1 of MIL-STD-810F) 0.001 g2 /Hz at 12.5 Hz, 0.034 g2 /Hz at 20~40 Hz 5.70E-06 g2 /Hz at 200 Hz, 1 hour/axis duration simulating 1000 miles of transportation.

Panasonic’s vibration test goes beyond MIL-STD requirements. During the operational test, while the hard disk drive is spinning and being accessed to play a video, the Toughbook computer is subjected to continuous vibration.

Particle Resistance

Dust and dirt are ubiquitous in the field and have a way of invading the exposed areas of mobile computers, potentially slowing key functions and damaging components. Panasonic tests the ability of Toughbook® computers to withstand dust, sand and other airborne particles.

The Dust Resistance test for fully-rugged and ultra-mobile-rugged Toughbook U1 computers is performed in accordance with MIL-STD-810F, Method 510.4, Procedure I (Dust). An operating temperature of 140°F is used for this test. The upper non-operating temperature of 140°F is incorporated into the test as this is the “default” temperature given by the MIL-STD-810F guidelines. To conduct the most stringent tests, Panasonic uses silica flour, the smallest particle available for particle resistance testing.

To pass the test, a Toughbook computer must continue to operate with no binding or blockage of moving parts and no malfunctioning contacts or relays. In addition, fully-rugged and ultra-mobile-rugged Toughbook computers comply with IP65* standards for dust ingress and are also subjected to rigorous factory testing for dust resistance.

Temperature Resistance

To assure that Toughbook® mobile computers can handle wild temperature swings, Panasonic subjects them to a battery of tests. Fully-rugged and the ultra-mobile-rugged Toughbook U1 are MIL-STD tested as follows:

High Temperature and Low Temperature tests are conducted in accordance with MIL-STD-810F, Method 501.4 and Method 502.4, Procedures I (Storage) and Procedure II (Operation). For the High Temperature test, Panasonic sets the operating temperature at 140°F and the non-operating temperature at 160°F. For the Low Temperature test, the operating temperature is set at -20°F and the non-operating temperature is set at -60°F. To pass both series of tests, Toughbook mobile computers must continue to operate during the operational test and to boot and operate following the non-operational test. Panasonic’s internal tests go beyond MIL-STD tests by testing the units at even higher and lower temperatures. Furthermore, Highly Accelerated Life Tests (HALT), a stress testing methodology used to obtain product reliability information, are conducted during this stage. By subjecting Toughbook computers through hot and cold temperature cycles over a several week period, Panasonic engineers can observe the units’ performance over its projected, full life cycle. If any of the unit’s components fail, the problems can be addressed before manufacturing begins.

The Thermal Shock test is performed in accordance with MIL-STD-810F, Method 503.4. Panasonic sets the high temperature non-operating temperature at 205°F and the low temperature non-operating temperature at -60°F. Three cycles are performed (high to low = one cycle). To pass, Toughbook computers must continue to boot up and operate following the test exposure cycles of thermal shock from 205°F to -60°F.

Pressure Resistance

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Toughbook® mobile computers are tested for two types of pressure: atmospheric and physical.

Fully-rugged, vehicle-mounted-rugged and the ultra-mobile-rugged Toughbook® U1 products must endure the effects of atmospheric pressure. The altitude test is performed in accordance with MIL-STD-810F, Method 500.4, Procedure I (Storage) and II (Operation). The altitude level used for both procedures is 15,000 feet (highest equivalent altitude given within MIL-STD-810F for cargo pressures of military aircraft).

In addition, Panasonic technicians test the ability of the full line of Toughbook mobile computers to withstand tremendous forces of physical pressure exerted on their casing. The all-magnesium casing is 20 times stronger than ABS plastic making it an ideal material for protecting the LCD screen, a critical and expensive component. Furthermore, the cases are specially designed to absorb tremendous amounts of physical pressure. Business-rugged Toughbook laptops are compression-tested to withstand 220 lbs. of pressure; fully-rugged and Toughbook U1 models are tested to withstand 300 lbs. of pressure.

Panasonic’s internal pressure resistance testing of the casing goes significantly beyond MIL-STD requirements, which specify that pressures are to be applied only in one place. Panasonic uses robotics to systematically apply the specified pressures to many areas on the casing. This involves applying pressure to areas that are more prone to cracks and breakage, ensuring that the entire casing is free of weak spots.

Humidity Resistance

Many of the same features that make Toughbook® mobile computers liquid resistant also help prevent damage from high humidity. In addition to liquid resistance testing, Panasonic also performs rigorous testing on fully-rugged and Toughbook U1 computers in highly humid conditions.

The Humidity test is performed in accordance with MIL-STD-810F, Method 507.4 (Aggravated). Toughbook computers are tested for operation near the conclusion of the fifth and tenth cycles. Each cycle is one day (24 hours) and the entire test is performed over ten days. The temperature is cycled between 86°F and 140°F with the relative humidity at 95% constant.

Panasonic’s humidity testing ensures that computer keyboard contact points and other electrical components are less vulnerable to shorting or corrosion from extreme humidity. In addition, Panasonic technicians conduct an internal test that intermittently checks the units to make sure they are operational. MIL-STD requirements do not require intermittent checks.

EMI and EMC Testing

Unwanted electromagnetic energy can disrupt the operation of electronic devices, such as computers. To prevent such disruptions and ensure compatibility between devices operating in the same vicinity, Panasonic Toughbook mobile computers are designed to comply with MIL-STD-461E for both, electromagnetic emission and susceptibility. This standard establishes requirements for the control of electromagnetic interference (EMI) and electromagnetic compatibility (EMC) of electronic, electrical and electromechanical equipment and subsystems for use by the Department of Defense.

Because electromagnetic radiation crosses many frequency ranges and can affect multiple applications, Panasonic and third-party testing is conducted on fully-rugged Toughbook mobile computer models to verify EMI and EMC compliance across a wide range of samples. Ten different tests, listed below, are conducted on Toughbook fully-rugged computers to comply with MIL-STD-461E electromagnetic tolerances when operating in their intended environment.

IP65 Testing

Mobile computers are rated according to international standards for ingress protection (IP). IP Codes classify the degrees of protection provided by electrical enclosures from dust, water and impact.

As part of MIL-STD-810F particle resistance and liquid resistance testing, Toughbook fully-rugged and ultra-mobile-rugged computers have achieved an IP65* rating. The first digit (6) of IP65 indicates resistance to dust. The computer is not completely impervious to dust but any dust which does enter will not have any harmful effect on the equipment. The second digit (5) describes the level of protection from liquids. Water sprayed on the computer from all directions will have no harmful effect. Higher numbers indicate a higher tolerance to dust and water. For example, a unit with an IP65 certification will withstand exposure to dust and water better than a unit with an IP54 certification.