IEC 60745-2-5 Figure 105 Test Probe ‘a’

The IEC 60745-2-5 Figure 105 Test Probe ‘a’ (12mm Dia, 50mm Length) is a specialized safety tool for verifying accessibility to hazardous parts (e.g., rotating gears, blade housings) in handheld motor-operated tools—specifically rotary tools like drills, impact drivers, and angle grinders. It features a rigid 12mm-diameter stainless steel probe (50mm working length) to mimic small objects or finger contact, paired with an insulated PA handle for operator safety. Built to strict dimensional tolerances, it applies controlled force to check if dangerous components are reachable during normal use. Critical for tool manufacturers, it ensures compliance with global safety standards, reducing injury risks from moving parts.

Specifications:
Tool Type: Test Probe A (IEC 60745-2-5 Figure 105; for hazardous part accessibility testing in handheld rotary tools)
Probe Material: 304 stainless steel (high rigidity; no bending under test force; corrosion-resistant for workshop use)
Handle Material: Polyamide (PA) – insulated (resistance ≥ 100MΩ); heat-resistant up to 120°C; non-slip grip for oily/wet conditions
Key Dimensions:
|- Probe Diameter: 12mm ± 0.1mm (critical for simulating small object access)
– Working Length (Probe Tip to Handle): 50mm ± 0.2mm
– Total Length (Probe + Handle): Typical 150mm ± 0.5mm (ergonomic for tool testing)
– Tip Shape: Flat (no sharp edges; prevents artificial damage to tool casings)
Applied Force: 10N ± 0.5N (simulates accidental contact force; aligns with IEC 60745-2-5 safety criteria)
Core Function: Tests if rotary tool hazardous parts (gears, blades) are reachable; validates casing barrier effectiveness; ensures compliance with global tool safety standards

Test Procedures:
1. Inspect the probe for bent sections, cracked handles, or diameter deviations; confirm 12mm ± 0.1mm with a caliper.
2. Power on the handheld rotary tool under test (EUT, e.g., cordless drill) and set it to normal operating mode.
3. Hold the PA handle, align the 12mm probe tip with EUT gaps (gear cover seams, chuck housing slots).
4. Apply steady 10N thrust—stop if resistance blocks insertion or the probe touches the EUT’s outer casing.
5. Check if the probe contacts hazardous moving parts (e.g., rotating gears) or live components.
6. Record results: Pass if no access to hazards; Fail if the probe reaches dangerous parts.

Applications:
1. Testing gear cover gaps in cordless drills (per IEC 60745-2-5:2020 Figure 105) to prevent finger contact with rotating gears.
2. Verifying angle grinder blade housing openings (compliant with EN 60745-2-5:2020) to block access to spinning blades.
3. Safety checks for impact driver chuck slots (per ANSI/UL 60745-2-5:2021) to avoid exposure to internal moving parts.
4. Quality control for rotary tool manufacturers, ensuring casings meet IEC 60745-2-5 hazardous part isolation rules.
5. Post-production testing of small rotary sanders to validate compliance with global handheld tool safety standards.

IEC60745-2-5:2010 Figure 105