Automotive wiring harness high-speed current impact test

As electrification and intelligence become the mainstream trend of future automobile development, the use of single-vehicle wiring harnesses will continue to grow. According to relevant data statistics, the use of single-vehicle wiring harnesses will increase from 1.5 kilometers in 2000 to 4.5 kilometers in 2025. The automotive wiring harness is the "blood vessel" and "nerve" of the car, playing the role of energy and information transmission of the whole vehicle. The quality of the wiring harness directly affects the performance of the vehicle. Therefore, wiring harness manufacturing, vehicle manufacturing, third-party testing and other institutions usually need to conduct electrical performance, physical performance, environmental adaptability and electromagnetic shielding tests on the wiring harness in important links such as R&D design, production and manufacturing, and incoming material testing.

● Customer Cases.

A well-known global manufacturer of automotive wiring harnesses and connectors is a high-tech enterprise that specializes in providing interconnection solutions for electric vehicles, new energy storage, aerospace and other industries. The company needs to perform current impact, temperature rise and other performance tests on high-voltage wiring harnesses of electric vehicles.
Test requirements:
01 Current range: 0~2000A
02 Current accuracy: ≤0.5%
03 Current response time: ≤0.01s/500A
04 Support customised current-time series import
05 Support wiring harness temperature measurement, with a measurement error of ≤1℃.
Previously, the company mainly used traditional test power supplies for current impact tests, and the current response speed could not meet the test requirements; in addition, it was necessary to synchronously collect multi-point temperatures of the wiring harness while loading the current, which put forward higher requirements on the synchronous acquisition and control performance of the system software.

● NGI high-performance solution

NGI has deeply understood the customer application scenarios and developed a high-precision and fast-response current impact test system for high-voltage wiring harnesses for electric vehicles. The system includes a precision programmable low-voltage and high-current DC power supply, a multi-channel temperature measurement modular instruments, a standard cabinet, and a host computer software. The host computer software communicates and controls each device through a high-speed Ethernet interface, and can monitor important parameters such as current and temperature in real time. The system hardware and software are all independently developed by NGI, which can realize current impact, temperature rise and other tests of automotive wiring harnesses.
Main features:
01 Fast response: current response time ≤0.01s/500A
02 Efficient testing: supports customised current-time series import, and supports current, temperature, time data export, and the minimum import and export time is 0.1s
03 Ultra-wide range: supports 0~2000A programmable output, and the setting resolution is up to 100mA
04 Ultra-high precision: current accuracy 0.1%+0.1%F.S.
05 Support wiring harness temperature measurement, with a measurement error of ≤1℃.
06 Flexible configuration: power supply and temperature measurement and control modular instrument can be configured as needed to meet the needs of larger current (such as energy storage power station wiring harness) and more channel temperature testing.