DR - Atomizer Microphone Test Instrument (Computer Version)

The electronic cigarette microphone test instrument uses a programmable power supply to simulate battery power supply and a piston pump to draw out the suction tube to simulate manual suction for testing. Based on the principle of introducing the output load in the microphone test process, it can achieve microphone sensitivity detection, over-suction protection test, short-circuit protection test, low-voltage protection test, charging current test and static current test. This device is equipped with an embedded intelligent PC monitoring system, which can conduct laboratory analysis based on test curves and test data, and also supports cyclic microphone fatigue testing. This test instrument is suitable for electronic cigarette finished product manufacturing enterprises, electronic cigarette microphone PCB board manufacturing enterprises, electronic cigarette microphone manufacturing enterprises, etc., for testing and calibrating products, thereby optimizing the production test line. 

Product Functions and Features

1. It can test static current, detecting the static current of the microphone when powered but not in use, with an accuracy of ±0.1μA.

2. It can test load current, measuring the current when a load is connected during the microphone's suction process, with an accuracy of ±0.01A.

3. It can test the microphone's sensitivity, detecting the trigger negative pressure when the microphone starts to output voltage, with an accuracy of ±10Pa.

4. The accuracy of the voltage value when the microphone is working is ±0.01V.

5. It can test the release pressure of the microphone, which is the pressure value at which the microphone closes when the pressure drops.

6. The microphone connector can provide two sets of outputs, with a wiring terminal capable of reaching 30A.

7. It supports four working modes for electronic cigarette microphones: OUT1 independent output / OUT2 independent output / OUT1/OUT2 alternating output / OUT1/OUT2 simultaneous output.

8. It can test the load voltage, with a 200Ω gold resistor added to the load (the OUT1/OUT2 external load interfaces are independent, allowing for connection to one or two loads simultaneously).

9. During testing, it can monitor the microphone's static current, output voltage, start pressure, release pressure, input current, and input voltage in real time, and generate real-time analysis curves. It can also generate fatigue analysis curves for the microphone's sensitivity during cyclic testing.

10. It has the function of storing and exporting test data, and can export to generate Excel data tables or data analysis reports.

11. It has RS232 and RS485 communication functions (optional).

12. It provides an embedded intelligent PC monitoring system.

13. The power supply is DC10V 30A, and it supports voltage regulation.

Instrument parameters

Core Technology Highlights and Functional Design

✅ Dual-Dimension Simulation: Replicating Real-World Conditions for More Credible Testing

✦ Battery Power Simulation System:

Utilizing a programmable DC power supply (output range: 2.5V–5.5V, accuracy ±0.01V; current 0–3A, accuracy ±0.001A), it can simulate the full cycle of voltage and current changes of an e-cigarette battery, such as "full charge - low charge - charging" (e.g., 3.7V normal power supply, 3.2V low voltage warning, 5V charging mode);

Supports custom power supply curves (e.g., "3.7V constant voltage → drop to 3.5V after 2 hours → trigger low voltage protection"), accurately recreating the power supply environment of the microphone during actual use.

✦ Bionic Piston Pump Suction System:

A precision piston pump (flow rate range: 5–30ml/s, accuracy ±0.5ml/s) simulates human suction actions, supporting multiple flow rate settings such as "light suction (10ml/s)", "deep suction (25ml/s)", and "rapid suction (30ml/s)";

The suction frequency is adjustable (0.5 times/second – 2 times/second), replicating users' real-world usage habits of "normal suction - continuous rapid suction - intermittent suction". 

✅ Six core tests: Covering all performance dimensions, ensuring no blind spots in quality control

✦ Microphone sensitivity test:

Automatically adjust the suction flow rate (5ml/s → 30ml/s), record the minimum flow rate value at which the microphone triggers a signal (i.e., the "trigger threshold"), and evaluate the microphone's response to weak airflows (qualified range: 8–12ml/s, accuracy ±0.2ml/s).

✦ Over-suction protection test:

Simulate a user's "continuous rapid suction" (flow rate 30ml/s, lasting 5 seconds), and check if the microphone triggers "over-suction protection" (i.e., stops outputting signals to prevent the atomizer core from overheating), and verify the protection response time (≤0.3 seconds).

✦ Short-circuit protection test:

Actively simulate a short circuit at the microphone output end (resistance < 0.1Ω), and check if the device triggers "short-circuit protection" (cuts off power supply to prevent battery overcurrent), and verify the protection response time (≤0.1 seconds).

✦ Low voltage protection test:

Gradually reduce the power supply voltage (3.7V → 3.2V → 2.8V), and check the microphone's operating status under low voltage (such as whether it reduces sensitivity at 3.2V and completely shuts down at 2.8V), and evaluate the reliability of the protection logic.

✦ Charging current test:

Under the "charging while in use" scenario (power supply 5V/1A), detect the fluctuation of the charging current when the microphone is in operation (normal range: 0.8–1.2A), to prevent battery overheating due to abnormal current.

✦ Static current test:

Simulate the "standby state" of the microphone (no suction action), and detect its static power consumption (normal range: ≤5μA), to assess whether the low-power design meets the standard (traditional devices have an error > 2μA). 

✅ Embedded intelligent monitoring system: Data visualization + in-depth analysis

✦ 10-inch industrial-grade touch screen:

Simultaneously display real-time data (voltage/current/flow/trigger threshold) and dynamic curves (pressure-time, current-voltage) of 6 test stations on the same screen;

Supports "one-click switch" mode (production line mode: only display pass/fail; R&D mode: display full parameter curves).

✦ Laboratory-level data analysis:

Built-in algorithms automatically mark abnormal points (such as high trigger threshold, delayed protection response), generate "yield analysis report" (including abnormal type proportion, batch defect trend);

Supports "historical data comparison" (such as sensitivity changes of the same model of microphone in 3 months), assisting in predicting aging risks. 

✅ Cyclic Fatigue Testing: Predicting Lifespan and Reducing After-sales Risks

✦ Million-cycle Testing:

The "continuous suction - standby" cycle can be set (e.g., 1 suction per second for 24 hours), simulating the "3-year lifespan" of the microphone (based on an average of 200 suction operations per day); 

During the cycle, the "trigger threshold drift" (normal ≤ 1 ml/s) and "static current increment" (normal ≤ 1 μA) are recorded in real time to assess the durability of the microphone (traditional equipment can only test up to 50,000 cycles).

✦ Automatic Shutdown Protection:

If "overcurrent/overvoltage/temperature exceeds limit" (chamber temperature > 50°C) is triggered during the test, the equipment automatically shuts down and alarms (with sound, light, and SMS notification) to prevent testing accidents. 

Application scenarios and customer value

✅ Electronic cigarette finished product factory: Full line inspection, yield rate increased by 30%

✦ Line compatibility:

Matches the assembly line rhythm (single piece detection < 30 seconds), supports 6-station synchronous testing, and detects ≥ 120 pieces per hour;

Full parameter coverage detection, reducing the related defect rate of the microphone from 2.5% (manual spot check) to 0.2% (such as the after-sales complaint caused by the undetected "low voltage does not shut down" issue). 

✅ Microphone PCB Board Factory: Process Control, Cost Reduction and Efficiency Enhancement

✦ Process Optimization Support:

Real-time monitoring of PCB board soldering quality (such as abnormal static current caused by cold soldering), identifying defective processes (such as soldering temperature deviation);

Batch test data can be used to guide process adjustments in reverse (such as optimizing capacitor selection to reduce static power consumption), reducing material waste by 15%. 

✅ Original manufacturer of microphone: Research and development verification, accelerating iteration

✦ Comparative testing of multiple solutions:

Simultaneously test 6 different designs of microphones (such as different diaphragm materials, ASIC chip solutions);

Output "sensitivity-life" and "power consumption-cost" correlation curves to assist the R&D team in quickly locking in the optimal solution (traditional testing requires 6 repetitions, reducing the time by 80%). 

Reliability and Maintenance

✅ Structural Durability:

✦ The lifespan of the piston pump is ≥ 5 million strokes (equivalent to continuous testing of 100,000 microphones);

✦ The power supply module has undergone 100,000 voltage switching tests (with no voltage drop or abnormal temperature rise). 

✅ Easy-to-maintain design:

✦ The sensor module supports "plug and play" (replacement can be completed within 5 minutes without calibration);

✦ Annual calibration only takes 1 hour (original factory standard flow generator + power calibration kit provided);

✦ Self-diagnostic function for faults (displaying error codes such as "flow deviation" and "unstable power supply"), guiding quick maintenance. 

✅ Operation Process (5 Steps for Immediate Learning and Application)

✦ Parameter Setting → Select the test mode (full inspection on production line / R&D testing / fatigue testing), and set parameters such as power supply voltage, suction flow rate, and cycle times;

✦ Sample Clamping → Fix the microphone/PCB board onto the 6-station fixture (elastic contacts automatically connect the power supply and signal interfaces);

✦ Start Testing → Click the "Start" button, and the device automatically completes power supply simulation, suction action, and parameter collection (each station test takes ≤ 30 seconds);

✦ Result Output → Qualified samples are marked with a "green label" (all parameters meet the standards), and unqualified products are marked with a "red label" and display specific defects (such as "trigger threshold too high"), with data automatically stored/uploaded to the MES system. 

Manufacturer and Customization Services and Precautions

Services and Certifications

✦ 1-year full machine warranty: Lifetime technical support for key components (cylinder/sealing ring);

✦ Compliance with standards: Meets the requirements of "Technical Conditions for Centralized Lubrication Systems" JB/T 5000.10 and the oil injection accuracy requirements for electronic cigarettes;

✦ Customization services: Supports customization of oil cylinder capacity (such as 30ml×2), oil outlet direction (left/right/double ports) as per requirements;

✦ Manufacturer information: According to search results, such equipment is usually provided by professional testing equipment manufacturers (such as Zhongzhou Measurement and Control), supporting customization of the number of workstations, suction parameters, and structural dimensions;

✦ Calibration traceability: Optional NIST-certified calibration certificate;

✦ Military-grade reliability: MTBF ≥ 50,000 hours, adaptable to temperature and humidity fluctuations;

✦ Lifetime technical support: Remote software upgrades, modular hardware replacement. Notes to be Observed

✦ Operating Specifications: One-click start for testing after sample installation. Automatic alarm and machine stop in case of abnormality.

✦ The detection mechanism ensures stable data and is compatible with the environment of CMA-certified laboratories. 

Multi-dimensional simulation, precise monitoring - with data-driven detection, the safety of every e-cigarette battery becomes a "reliable promise". 

Full-condition simulation · Multi-dimensional parameter monitoring · Intelligent safety protection