NGI solution - automotive wiring harness connector test

The rapid development of the new energy vehicle industry has also driven the development of automobiles in the direction of electrification and intelligence, which has led to a continuous increase in the demand for wiring harnesses for a single vehicle. According to relevant statistics, the average use of wiring harnesses for a single vehicle will increase from 1.5 kilometers in 2000 to 4.5 kilometers in 2025. The increase in the use of automotive wiring harnesses has put forward higher requirements for the reliability and durability of connectors. On the one hand, the aging of the wiring harness and other factors such as bumps during driving may cause the connection terminals to loosen, causing instantaneous power failure or short circuit, which will affect the safety of the entire vehicle to a certain extent. On the other hand, the rise of high-power electric vehicle fast charging technology and other on-board power systems is also affecting the service life of high-voltage wiring harnesses. Therefore, it is very necessary to evaluate the performance of wiring harnesses and terminal blocks for related performance tests such as instantaneous disconnection, aging, and instantaneous shorting.
Next, we will present three major customer application cases of NGI in automotive wiring harness terminal testing.

High-speed modular instantaneous disconnection test system helps company A to conduct efficient testing

Customer background
A is a global leading automotive parts company with 126 major production bases and 15 major technical centers in 44 countries/regions around the world, with 140,000 employees. Its main businesses include sensing, wiring harnesses, software, signal and power transmission architecture, etc. It has established cooperative relationships with global leading automakers such as Mercedes-Benz, BMW, Audi, and Volkswagen.
Customer needs
The customer needs to monitor the instantaneous disconnection of the wiring harness that may occur in microseconds. This short disconnection may cause the automotive electronic system to lose key communication data, causing loss of control and accidents:
Requirements for test channels: minimum support for 10 channels and maximum support for 50 channels;
Requirements for sampling speed: Since the instantaneous disconnection test standard is that the contact resistance exceeds 7Ω continuously for ≤1μs, the sampling speed is required to be ≥5MS/s;
Requirements for automotive standards: It must meet the requirements of mainstream automotive standards such as USCAR-2 and QC/T 1067.1.
NGI Solution
Our test system complies with the requirements of global mainstream standards such as QC/T-1067.1-2017 and USCAR2-7;
· High integration: 3U 19CH, the space required for the same number of channels is only half of that of traditional transient testers;
· High-speed sampling: maximum sampling rate 10MS/s, maximum sampling of 10 million points per second;
· Efficient testing: configured with dedicated host computer software, supporting real-time display of resistance curve and data storage.

High current aging test requirements of B company

Customer background
B is a world-renowned solution provider in the fields of electrical connection and electronic interface, and industrial automation.
Customer demand
With the rapid development of electric vehicle fast charging technology, shortening charging time has become the key point to improve the user experience of electric vehicles. At present, the maximum working current of charging harness and interface has increased from 250A to 800A. The main demand of customers is to perform aging tests on charging cables under high current working conditions.
NGI Solution
N3600 wide-range programmable DC power supply can meet the test requirements of high power and wide-range current. The deviation of test stability within 24 hours after 30 minutes of warm-up is less than 0.01%.

High-speed multi-channel transient short test system helps C company to test efficiently

Customer background
C is a world-renowned leader in high and low voltage wiring harnesses, power transmission protection devices and smart charging in the field of transportation. Its main products include automotive high and low voltage wiring harnesses, charging guns, charging seats, charging boxes, etc. It is currently a first-tier supplier for vehicle companies such as Volkswagen, Toyota, BMW, Geely, and BYD.
Customer demand
The main demand of this customer is to monitor the connection status of the fuse at high speed, and perform vibration testing by loading a 5V/1mA electrical signal to the fuse. When the voltage drops below 3.5V and lasts for more than 10μs, it is recorded as a transient short circuit. Microsecond instantaneous short circuits have an important impact on the operation of the entire vehicle. Therefore, it is necessary to sample and record the voltage value of the fuse when it is powered on for a long time at high speed, and refer to the test standard to determine whether the wiring harness is short-circuited. The customer's specific test requirements are as follows:
Sampling speed: μs level voltage signal acquisition is required;
Number of channels: 70+ channel tests are required;
Host computer software: must support customized settings such as voltage of each channel and test duration.
NGI solution
The transient short circuit test system we provide to customers has the following features:
·Efficient testing: supports 1.25MS/s input total sampling rate;
·High integration: 19-inch 2U space supports 24 channels;
·Flexible software functions: supports customization of all channel voltages, test durations, test judgment conditions, etc., and supports export of test data and reports.