How to Test Automotive Switches

How far do you want to go with this "project"?

The basics start with "operational durability" testing. On-off-on-off over and over switching the designed load (or some factor of it).

Then start to apply various environmental factors while doing this. Like hot and cold cycle testing (automotive is typically -40DegC to 80DegC with 20% of cycles at each extreme and the rest done at "ambient".)

Then a bit more environmental stuff with humidity cycling, vibration testing and other mechanical stuff.

Then add in the more exotic stuff like "splash" testing and "spill" testing using items like water, beer, chocolate milkshakes, hot coffee and so on. We used to get some strange looks asking for re-imbursement when the lab bought the beer, drinks and various flavoured salts.

You could then add in the electromagnetic testing for transients coming from other devices and then monitor the emitted radio and transient motions from your device.

By the way a data logger at 5Mhz or better is required on your switch I/O lines to make sure that there are no transients.

Then there are the other tests to make sure that spare parts arrive in good condition. Drop tests (unprotected) onto concrete surfaces from 1m (at least 3 times in each axis x,y,z) for 12 samples. No parts break off, must function correctly when finished, storage tests at -60 Deg C through to 120 Deg C to simulate possible transport and storage scenarios.

Hey if you get all this done, can I have the diploma?

Seriously, if you want some help then let me know.