Over 20 Must-Have Standard Product Reliability Tests before You launch Mobile Chargers in the Market.


First of all, what is product reliability tests? It is manufacturer or brander use different equipment or measurement to test a product , which supposed to work as intended under a certain usage and environment for a certain time period.


AoHai is producing products from various catalogs. Let’s take mobile chargers for a deeper look! Normally, our customers will provide their own test standard, below are some standards used by AOHAI team.

  1. Input Inrush Current. At cold start; 25℃;DC output rated loading;264Vac input conditions, when input power is applied to the power supply, peak inrush current shall be limited to 100 A, Repetitive ON/OFF cycling of the input voltage will not damage the adapter. What is input inrush current? Check wikipedia
  2. Input Output Characteristic: The output voltage and input current shall be meet spec as requested.
  3. Standby Power Measurement:The EUT will be warmed up for 30 minutes at the input voltage of 115Vac/60Hz with the nameplate load of 3A under the ambient temperature of 25°C before the test, then the efficiency & standby power consumption is measured at the rated input voltages of 115Vac/60Hz and 230Vac/50Hz with 100%, 75%, 50% and 25% of nameplate load of 3A、5A、2A、1.5A respectively. What is standby power? Check Wikipedia.
  4. Efficiency Measurement:The average efficiency shall be at least ≥39% for 5V3A, ≥86.62% for 9V3A,86.95% for 12V2.5A,86.95% for 15V2A,86.95% for 20V1.5A,output.
  5. Load Regulation: The Load regulation shall not exceed the values given as requested.
  6. Output Voltage Over Shoot:The output overshoot voltage shall not exceed 10% at turn-on condition.
  7. Output Voltage Rise Time: The voltage rise time shall ≤30mS
  8. Output Voltage Fall Time:The voltage fall time shall ≤20mS
  9. Output Ripple Voltage Measurement: It is measured with 20MHz bandwidth oscilloscope and connected the capacitors 0.1uF & 10uF in parallel at .the cable end under temperature of 25°C, The output ripple voltage shall be less than 200mVp-p.
  10. Over Current Protection:The output current is increased by adjusting the electrical load connected to the output terminal of EUT at the input voltage of 90Vac and record down the maximum output current available from the EUT. Repeat the test at the input voltage of 264Vac.
  11. Short Circuited Protection Test:The charger is designed to withstand continuous current of short circuit on output. charger under continuous output short shall not cause permanent failures or danger for user, normal operation shall be recovered after removed short circuit condition.
  12. Over Voltage Protection Test :Output voltage protection range is less than 150% of the rated voltage output, when overpressure condition removed can return to normal working condition.
  13. Hi-Pot & Insulation Resistance:Primary to Secondary: 3000VAC, 1 minute and leakage current shall less than 5mA.  |  Primary to Secondary: Insulation resistance >100MΩ@500Vdc.
  14. Common Mode Interference: The test setup required a vertical and a horizontal ground reference plane which size at least 2mx2m and bonded together. The EUT shall be connected to a LISN powered by AC mains. Then the test is performed according to IEC 62684 standard. EUT switching frequency component: the peak-to-peak voltage measured in the frequency range of 1kHz to 100kHz shall not exceed 2Vp-p
  15. Dynamic Load Response: Output load changed from 10% load to 90% load, duration time 5mS each load and 0.1A/uS slew rate at the input voltage of 115Vac and 230Vac. Output voltage within 4.4~6Vdc(for 5V) ,7.92~10.08Vdc(for 9V) , 10.56~13.44Vdc(for 12V),2~18Vdc(for 15V) ,17.6~24Vdc(for 20V)  during the transient condition.
  16. Turn On Time :The maximum turn on delay time shall be less than 3S at the input voltage of 100V.
  17. Hold-Up Time:The minimum hold-up time shall be more than 5ms at 115VAC and 230VAC.
  18. Thermal Test: as requested.
  19. AC Power ON/OFF Test:The EUT must be designed to withstand 5,000 mains connections with 3S ON and 3S OFF at input voltage of 90Vac and264Vac with the rated load under the ambient temperature of 25°C
  20. Burn-in:Typical input voltage and typical load current,40℃,aging in certain hours.
  21. Leakage Current Test:Leakage current is less than 50uA at 264Vac.
  22. Line Regulation:The input voltage varies in the range of 100VAC / 240VAC, and the output voltage regulation rate is less than 1% in full load .
  23. Adapter output port compatibility: test chargers’availability of appointed mobile list by customers.

The above Product Reliability Tests are least but not the last tests. They are the most standard. Contact us for your target products’ reliablility tests.!