Testing of vehicle wiring harnesses and connectors
Automotive wiring harnesses and connectors are found in almost every area of a vehicle. They connect various electrical components and electronic systems within the vehicle and transmit electrical signals.
The quality of the contact connections of vehicle wiring harnesses and connectors has a direct impact on the reliable function of the vehicle as well as on the safety of the driver and passengers.
With the continuous development of automotive electronics, the demands on connectors are also increasing. They must be more flexible, offer higher insulation performance, and ensure optimal conditions for signal transmission within the wiring harness.
Testing requirements for automotive wiring harnesses and connectors
Vehicle wiring harnesses and connectors must be checked for the following parameters:
- passage
- Open Circuit
- Short circuit
- Cross connections / incorrect wiring
- Intermittent Testing
- Dielectric strength
- isolation
In addition, certain cable harness components must also be checked for the following component properties:
- Inductors
- Resistors
- Capacitors
- Light-emitting diodes (LEDs)
Solution details
On-off test
The following properties are checked using high-precision voltage and current sources as well as appropriate measurement methods:
- Short circuit or interruption
- Faulty connections or intersections
- Incorrect connection assignment
Instantaneous On-Off Test
During production and testing, vehicle wiring harnesses can be briefly interrupted by frequent movements or vibrations.
These intermittent interruptions must be reliably detected. This requires an extremely high sampling rate . 
Dielectric strength and insulation testing
With the increasing prevalence of electric vehicles (EVs) and the further development of high-voltage technology, battery systems of modern vehicles reach voltages of over 1000 V.
Therefore, safety and reliability are crucial factors in automotive wiring harnesses and connectors.
Cable harnesses and connectors must therefore be regularly checked for the following properties:
- Dielectric strength
- Insulation resistance
- 1 × TH8601