How Are Cable Assemblies Tested to Ensure Proper Quality?

Manufacturing of cable assemblies and wire harnesses has grown more technical over the years. While the highest quality materials are used during the manufacturing process how can businesses be sure they will function as designed? Through testing. That is right. All custom cable assembly manufacturers perform exhaustive tests on their products. It is Perhaps the most vital step in the entire manufacturing process. Testing entails the product will meet or exceed industry specifications and the needs of the application. Testing involves putting the final product through the motions looking at the following factors:

  • Strength
  • Performance
  • Function

What Testing Procedures Are Used in Testing Cable Testing?

All custom cable assembly manufacturers perform the various testing procedures listed below to make sure all manufactured cable assemblies are suited for use. All tests are performed in accordance to IPC and WHMA guidelines. While the tests listed below are by no means exhaustive, they are the most important.

  • Electrical Testing
  • Visual Testing
  • Environmental Testing
  • Mechanical Testing

Electrical Testing

The entire assembly needs to be checked for conductivity. There cannot be any shorts, incorrect wiring, or opens. The electrical testing method involves attaching the assembly’s connectors to mating connectors. Once connected, then a fixture is used. The fixture is the component which checks the assembly for open wiring or short circuits between both shields and conductors. The fixture can also check to make sure the pins are in their proper placement.

Visual Testing

This is the lowest level of testing, but in many ways, the most important. The cable is visually inspected by staff, looking for deformities and defects. The types of components tested include the following:

  • Connectors
  • Markings
  • Sockets
  • Design
  • Constructions
  • Finishes

A dimension inspection is also performed to ensure the cable exceeds specifications

Environmental Testing

For those cables utilized in the elements, such as a battery cable assembly, it is important they remain functional regardless of weather. They need to function without their performance suffering. The cable is put through various tests including the following:

  • Thermal Shocks
  • High Humidity Levels
  • Vibrations
  • Salt Sprays for Corrosion Testing
  • Both Elevated and Decreased Temperatures

Mechanical Testing

This focuses on the cable connectors and the durability of the cable itself.

Whether testing a battery cable assembly or RF cable assemblies, Star Engineering can ensure the quality of your cabling product. Reach out to Star Engineering today.

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