One of the most critical elements of producing any cable assembly or harness is the amount of cable assemblies testing that is done when the product is completed in manufacturing. There are many methods and levels for testing cable assemblies, but all testing has one goal – to ensure that the product meets or exceeds its specifications.

Cable assemblies can be built to one or multiple specifications. For example, an assembly may be produced to a customer specification with regards to the color of the jacket and over mold material used, among other customer centric requirements, but from an electrical standpoint the assembly may be required to meet an industry standard. Based on the specifications and standards the assembly was produced to, a final test plan is constructed that the assembly will be tested to. The test plan states the pass/fail criteria and the assembly is deemed serviceable if it meets, at a minimum, the pass criteria.

Cable Assembly Electrical Testing

At a bare minimum, cable assembly testing must include complete electrical tests for shorts, opens, or incorrect wiring. The proper method to electrically test an assembly is to attach the connector at each end of the assembly to a mating connector. The mating connector will be attached to a fixture that will check for opens in the assembly, shorts between the conductors or the conductors and shields if any are present, and the proper pin placement for all the components of the assembly. This setup puts the assembly into a test situation that fully replicates the installation that the assembly was built for.

Additional Cable Assembly Tests

Additional testing may be considered from a visual, environmental, mechanical, and signal integrity standpoint. The use of EIA Standard 364, IPC/WHMA-A-620B, and any other relevant industry standards documents should be used as guidelines for this testing. These additional tests may not be necessary on all assemblies and the below information is presented as guidelines to consider. Cable Assembly Signal Integrity Analysis

Visual Testing

Environmental Testing

Mechanical Testing

Signal Integrity Test

The above list is by no means meant to be totally inclusive of the testing that is to be considered for cable assemblies. Additional testing such as insulation resistance tests, Hi-Pot testing, Safety certifications, and numerous other customer and industry requirements should be considered as potential testing areas.

Cable assemblies and wire harness production should be entrusted to reputable cable manufacturers that have the means to do a complete testing plan and perform all tests documented within the plan. As you can see, the list of testing can be quite extensive, all of which is designed to deliver the best possible product to customers.

Topics: Cable Assemblies, Wire Harnesses

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