Technical Analysis of Design Features and Applications of Needle Flame Test Apparatus

The needle flame test apparatus is a core device for fire safety testing in the electrical and electronic, household appliance, lighting and other industries, mainly used to simulate small flames generated by internal equipment faults and evaluate the flame resistance of materials and products. Taking the LISUN ZY-3 needle flame test apparatus as the research object, this paper analyzes its technical design features from five dimensions: modular design, integration of core functions, adherence to standard parameters, optimization of operation modes and adaptability to test samples. Combined with the equipment specifications and industry application scenarios, it expounds the technical advantages and practical value of the needle flame test apparatus in product fire protection testing, providing a reference for the selection and application of fire safety testing equipment in relevant industries.

1. Introduction

In the electrical and electronic, information technology, automotive electronics and other industries, faults such as internal circuit short circuits and component overheating of equipment are prone to generate small flames. If the flame resistance of materials is insufficient, fire accidents are highly likely to occur. Therefore, the fire safety testing of relevant products has become a key link in industry quality control and market access. As a professional testing device for simulating the ignition scenario of small fire sources, the testing accuracy, operational convenience and standard compliance of the needle flame test apparatus directly determine the reliability of test data. Aiming at the industry’s testing needs, the LISUN ZY-3 needle flame test apparatus adopts a modular design concept, integrates a number of core testing functions, strictly controls key test parameters in accordance with international and domestic standards, and optimizes the operation mode and improves the sample adaptability. It has become an important equipment for electrical and electronic manufacturers, testing institutions and research institutes to carry out fire protection testing. Its design features and technical performance are of great significance for improving the efficiency and accuracy of industrial fire protection testing.

2. Modular Design System of the Needle Flame Test Apparatus

The modular design of the LISUN ZY-3 needle flame test apparatus is one of its core technical features, which breaks the limitations of low functional integration and high maintenance difficulty of traditional testing equipment. The apparatus is divided into independent functional units such as combustion control module, temperature detection module, data recording module and operation control module. All modules are connected through standard interfaces to realize flexible combination of functions and independent operation and maintenance.

As the core unit, the combustion control module integrates a needle burner, a gas supply system and an angle adjustment mechanism, which can accurately control the combustion direction, combustion time and gas flow to meet the combustion requirements in different test scenarios; the temperature detection module is equipped with a high-precision thermocouple and a temperature acquisition circuit to realize real-time detection and feedback of flame temperature and sample temperature; the data recording module independently stores all data during the test process and supports data export and traceability; the operation control module integrates the signal processing units of the touch screen and remote control operation to ensure the accurate transmission of operation instructions.

The modular design not only makes the function expansion of the needle flame test apparatus more convenient. For example, an electronic gas flow meter can be optional according to testing needs to improve gas control accuracy, but also greatly reduces the maintenance cost of the equipment. If a certain module fails, the unit can be directly replaced without shutting down the whole machine, adapting to the continuous quality inspection needs of enterprises. It is especially suitable for the batch ex-factory testing of electrical and electronic manufacturers and the continuous testing of multiple samples in testing institutions.

3. Integration of Core Functions and Control of Testing Accuracy

The testing accuracy of the needle flame test apparatus directly determines the accuracy of flame resistance evaluation. The LISUN ZY-3 needle flame test apparatus integrates three core functions: precision temperature control, automatic timing and data recording, realizing the automation and precision of the test process and effectively avoiding errors caused by manual operation.

The precision temperature control function is realized by relying on a Φ0.5mm K-type thermocouple and an intelligent temperature control algorithm. The temperature measurement range covers 0~1000℃, which can capture the change of flame temperature in real time and strictly control the flame temperature rise rate in accordance with standard requirements. The time consumed to rise from 100℃±2℃ to 700℃±3℃ is accurately controlled within 23.5s±1s, ensuring that the flame temperature is highly consistent with the temperature characteristics of the actual fault small fire source. The automatic timing function supports the accurate recording of combustion time and afterflame time. The combustion time can be custom-set within the range of 0~999.9s (±0.1s), and the standard combustion time of 30s can be called with one key. The afterflame time is also accurate to 0.1s, and supports automatic marking and manual pause, which can completely record the combustion state of the sample after it is separated from the flame. The data recording function realizes the real-time storage of all parameters in the whole test process, including flame height, combustion time, afterflame time, flame temperature, etc. The data cannot be tampered with, providing true and traceable original data for product test reports and third-party certification, meeting the data retention requirements for product research and development and market access.

The in-depth integration of the three core functions enables the needle flame test apparatus to realize the integrated and automatic operation of “combustion-testing-recording” without real-time manual intervention, which not only improves the testing efficiency, but also makes the accuracy of test data meet the requirements of international and domestic standards, providing a scientific and quantitative basis for flame resistance evaluation.

4. Standard-Compliant Design of Key Parameters

The core of the needle flame test is to simulate real fault scenarios through standardized test parameters. Therefore, the key parameters of the needle flame test apparatus must strictly follow relevant standards. The LISUN ZY-3 needle flame test apparatus is fully compliant with international and domestic standards such as GB/T 5169.5-2020 and IEC 60695-11-5:2016, and accurately controls key parameters such as flame height, burner angle and combustion gas to ensure the authority and comparability of test results.

As a core parameter, the flame height is accurately controlled at 12mm±1mm, which is completely consistent with the flame height of small fire sources required by the standard. Double calibration through a scale and an automatic adjustment mechanism avoids the distortion of test results caused by the deviation of flame height; the burner angle adopts an adjustable design, maintaining a 45° inclination during the test to form a standard contact angle with the sample, and adjusted to vertical during flame height calibration to ensure calibration accuracy, complying with the angle operation specifications of the needle flame test; the combustion gas uses high-purity butane with a purity of ≥95% to ensure the stability of flame combustion without interference from impurity gases. At the same time, an electronic gas flow meter can be optional to realize the precise control of gas flow and further improve the stability of the flame.

In addition, the equipment supports the parameter setting of single/multiple continuous combustion, and can carry out continuous combustion tests in accordance with IEC 62368-1:2023 Annex S S.1, meeting the standard testing requirements of different products. The design of all key parameters is centered on the standards, making the test results of the needle flame test apparatus recognized by domestic and foreign testing institutions, and helping enterprises’ products pass domestic and foreign safety certifications such as CCC and CE smoothly.

5. Dual-Mode Operation Design and Operational Safety Assurance

Operational convenience and safety are important considerations for the needle flame test apparatus in practical applications. The LISUN ZY-3 needle flame test apparatus innovatively adopts a dual-mode design of self-developed large LCD touch screen + remote control operation, which not only simplifies the test process, but also fundamentally guarantees the safety of operators.

The LCD touch screen adopts an intuitive graphical operation interface, integrating functions such as test parameter setting, process start and data viewing on the screen. Parameter setting can be selected with one key, and the test process is displayed in real time. Operation can be completed without professional technical training, which greatly reduces the operation threshold and improves the testing efficiency; the remote control operation mode realizes the physical isolation between the operator and the test area. During the high-temperature combustion test, the operator can complete all operations such as start, pause and stop through the remote control, avoiding scald risks caused by high flame temperature and dripping from sample combustion. It is especially suitable for the needle flame test of flammable materials, eliminating safety accidents from the operation level.

At the same time, the equipment body is made of high-temperature spray steel structure, which has the characteristics of high temperature resistance and corrosion resistance, can adapt to the long-term high-temperature test environment, avoid operation failures caused by high-temperature aging of the equipment, and further improve the safety of the operation process. The dual-mode operation design makes the needle flame test apparatus give priority to operational safety while taking into account operational convenience, adapting to different operating environments such as laboratories and production workshops.

6. Adaptable Design for Test Samples of Sizes

Test samples in different industries vary greatly in size, shape and material, such as small terminal blocks of electrical and electronic products, large drive housings of lighting equipment, and wire harness insulation layers of automotive electronics. The sample adaptability of the needle flame test apparatus directly determines its application scope. Through flexible fixture design and test space layout, the LISUN ZY-3 needle flame test apparatus realizes the adaptation to the testing needs of test samples of different sizes, greatly improving the versatility of the equipment.

The equipment is equipped with adjustable fixtures, which can adjust the clamping position and angle according to the size and shape of the sample. Whether it is small electronic component housings (such as USB interfaces, relay housings) or large lamp heat sinks and charging pile insulation parts, stable clamping can be achieved to ensure the standard contact position between the flame and the sample; the dual-model design of the boxed version (ZY-3) and the unboxed version (ZY-3S) further adapts to different test space requirements. The boxed version has an independent test cavity, suitable for the testing of flammable samples with drips, while the unboxed version is more suitable for the testing of large samples and only weighs 40kg, which can be moved flexibly to meet the needs of on-site testing.

The adaptable design for test samples of sizes makes the needle flame test apparatus break through the limitation of single sample testing, and can be widely used in electrical and electronic, information technology, lighting equipment, automotive electronics, material research and development and other fields. One device can meet the fire protection testing needs of various enterprise products, reducing the equipment procurement cost of enterprises.

7. Key Specifications of the Needle Flame Test Apparatus

Parameter Name	Technical Index
Model Classification	ZY-3 (boxed), ZY-3S (unboxed)
Burner Angle	Adjustable, 45° inclination during testing, vertical during calibration
Combustion Time	0~999.9s (±0.1s), 30s recommended for regular use
Afterflame Time Recording	0~999.9s (±0.1s), automatic marking + manual pause
Flame Height	12mm±1mm
Combustion Gas	Butane ≥95%, electronic gas flow meter optional
Temperature Measurement Range	0~1000℃
Flame Temperature Rise Rate	100℃±2℃ to 700℃±3℃, time consumed 23.5s±1s
Temperature Detection Component	Φ0.5mm K-type thermocouple
Combustion Times	Single/multiple continuous combustion optional
Operation Mode	Self-developed large LCD touch screen + remote control operation
Body Material	High-temperature spray steel structure
Overall Weight	ZY-3: 180kg; ZY-3S: 40kg

8. Conclusion and Prospect

As a core device for fire safety testing, the technical design of the needle flame test apparatus directly affects the efficiency and accuracy of industrial fire protection testing. Based on modular design, the LISUN ZY-3 needle flame test apparatus realizes the automation and precision of the test process through the integration of core functions of precision temperature control, automatic timing and data recording; it ensures the high consistency of test parameters with international and domestic standards through strict standard-compliant design, making the test results authoritative and comparable; it simplifies the test process and fundamentally guarantees operational safety through the dual-mode design of touch screen + remote control operation; it greatly improves the application scope of the equipment through the adaptable design for test samples of sizes, meeting the fire protection testing needs of multiple industries.

With the rapid development of emerging industries such as new energy and artificial intelligence, the miniaturization and integration of electrical and electronic products are becoming increasingly obvious, and the requirements for the accuracy and efficiency of fire protection testing for small fire sources will be further improved. In the future, the design of the needle flame test apparatus should move towards the direction of intellectualization, digitalization and integration, such as integrating the Internet of Things technology to realize remote monitoring and data sharing of the equipment, combining artificial intelligence algorithms to realize automatic analysis and evaluation of test results, further improving the flexibility of modular design, and enabling the equipment to adapt to the testing needs of more new materials and products.

The design features and technical performance of the LISUN ZY-3 needle flame test apparatus provide a reference direction for the technical upgrading of the needle flame test apparatus, and also provide a reliable equipment support for fire safety testing in various industries. With the continuous improvement of industry standards and the continuous innovation of testing technology, the needle flame test apparatus will play a more important role in ensuring product fire safety, avoiding fire accidents and promoting the high-quality development of the industry.

Tags：ZY-3