Testing of automotive power connectors
A power connector in automotive electronics is a component for connecting the power supply to an electrical circuit and serves to transmit high currents between components.
Key factors in evaluating power connectors are their maximum voltage and current carrying capacity . The insulation between the connector contacts is also a crucial test parameter, with particularly high demands placed on leakage current .
Furthermore, the mechanical connection between the plug and socket in power connectors is very precisely manufactured. To prevent damage during repeated mating and unmating, reliable mating cycle and power load tests are necessary.
Solution details
Test requirements:
1. Functional test
- Electrical continuity testing under normal operating conditions
2. Overcurrent test
- Performing current cycle tests at several defined test points according to the requirements
- Checking the voltage drop at both ends of the line within the specified range.
- Simultaneous monitoring for breakthrough or arcing on the product
3. Impulse test
- After more than 10 plug-in and unplug cycles between the product and the cable harness connector, the components are reconnected.
- Testing with a required current in the form of a half-sine pulse
- Assessment of whether deformations or cracks occur on the product surface
4. High and low temperature aging test
- Placement of the product in a temperature chamber
- Load with the required current according to test specifications
- Temperature cycling within the defined temperature range over 24 hours
- Inspection for deformation or cracking on the product surface
List of instruments
- TH6680 Series