Electrical Connector and Cable Testing

The reliability of electrical connectors and cables decides the fate of any given equipment. These components, found in various applications such as automotive, aerospace, military, medical, and telecom, must withstand rigorous stresses to ensure optimal performance.

In this blog, we’ll explore the significance of electrical connector and cable testing, shedding light on the potential challenges and the comprehensive testing methods employed by experts like DES.

Understanding the Importance of Testing

Electrical connectors and cables play a crucial role in the functionality of electronic systems. Failures, whether due to broken solder joints, crimped leads, or intermittent discontinuities during usage, can lead to system faults. Additionally, issues like cracking, wear, and fretting fatigue can compromise the reliability of these components. To guarantee their resilience, thorough evaluation of both mechanical and electrical properties is essential, especially in environments characterized by vibration, shock, and climatic variations.

Envitest Lab: Your Trusted Partner in Testing

Envitest Lab possesses the expertise and state-of-the-art equipment required for accurate and repeatable cable testing and connectors testing. Operating within a controlled, world-class accredited laboratory, Envitest Lab is well-equipped to handle diverse testing requirements. Whether your needs are conventional or unique, the team excels in designing and fabricating customized setups and fixtures.

A Multifaceted Approach to Testing

Envitest Lab conducts an array of electrical connector and cable tests to ensure comprehensive evaluation. Some of the key testing methods include:

Environmental & Climatic Testing:

  • Altitude (Pressure)
  • Salt Spray (Fog)
  • Temperature and Humidity
  • Thermal Aging and Temperature Life
  • Temperature Cycling and Thermal Shock

Mechanical Testing:

  • Connector Mating/Un-mating Force
  • Contact Retention, Insertion/Removal Forces
  • Life Cycle Testing
  • Cable Pulling and Flexing
  • Crimp Tensile Strength
  • Terminal Pull Strength
  • Cable Flexing

Electrical Testing:

  • Dielectric Withstand
  • Continuity
  • Low Level Contact Resistance (LLCR)
  • Insulation Resistance
  • Discontinuity/Event Detection
  • Adherence to Industry Standards

Envitest Lab aligns its testing methodologies with industry-recognized standards to ensure robust evaluations. Some of the prominent standards include:

  1. EIA-364 – Electrical Connector Performance Test Standards
  2. GMW 3191 – Automotive Connector Test and Validation Specification
  3. IEC 60512 – Connectors For Electrical And Electronic Equipment, Tests And Measurements
  4. MIL-STD-1344A – Military Standard, Test Methods For Electrical Connectors
  5. SAE USCAR2 – Performance Specification For Automotive Electrical Connector Systems
  6. SAE USCAR21 – Performance Specification For Cable-To-Terminal Electrical Crimps

For cable testing, Envitest Lab refers to standards such as IEC 60068-2, MIL-STD-810, and RTCA/DO-160, providing a comprehensive evaluation of the components in varied environmental conditions.

In the ever-evolving landscape of electronic technology, ensuring the reliability of electrical connectors and cables is non-negotiable. With Envitest Lab at the forefront of accurate and repeatable testing, the electronic industry can thrive with confidence, knowing that their components are rigorously evaluated and proven to withstand the harshest conditions. As technology advances, the commitment to robust testing remains a cornerstone in the pursuit of resilient and dependable electronic systems.