How do we test & verify cable assembly?

To professionally test and verify the quality of a cable harness, consider the following methods:

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1. Visual Inspection:

   • Examine the cable harness for physical defects, such as frayed wires, poor insulation, and incorrect terminations.

   • Ensure that strain relief is adequate at connection points.

2. Continuity Testing:

   • Use a multimeter to check for continuity in each wire, ensuring there are no breaks.

   • Confirm that each wire is properly connected to its respective terminals.

3. Wire Mapping:

   • Employ a cable tester to verify that the pin configuration matches the design specifications.

   • Check for cross-wiring or miswiring issues.

4. Insulation Resistance Testing:

   • Measure the insulation resistance between conductors and from conductors to ground to ensure no leakage paths exist.

5. High-Pot Testing:

   • Perform high-potential (high-pot) testing to assess the dielectric strength of the insulation by applying a high voltage.

6. Signal Testing:

   • Test the cable harness with the intended signals (e.g., data, power) to ensure proper transmission without significant loss or interference.

7. Load Testing:

   • Apply a load to the harness to ensure it can handle the specified current and voltage levels without overheating or degradation.

8. Environmental Testing:

   • If applicable, test the harness under extreme conditions (temperature, humidity, vibration) to ensure it meets environmental specifications.

9. Documentation and Compliance:

   • Maintain thorough records of all tests performed, including results and any corrective actions taken.

   • Ensure compliance with relevant industry standards (e.g., IPC/WHMA-A-620 for wire harness assemblies).

 

These methods help ensure the reliability, safety, and performance of cable harnesses in their intended applications.