What are the Reliability Tests of Terminal Wire Harness?

Terminal wire testing generally involves the following items: insertion force test, durability test, insulation resistance test, vibration test, mechanical shock test, thermal shock test, mixed gas corrosion test, etc.
1. Insertion force test
Purpose: To verify whether the insertion force of the terminal wire meets the product specification requirements.
Principle: Completely insert or pull out the terminal wire at a specified rate, and record the corresponding force value.
2. Durability test
Purpose: To evaluate the influence of repeated insertion and removal on the terminal wire, and to simulate the insertion and removal of the terminal wire in actual use.
Principle: Continuously plug and unplug the terminal wire at the specified rate until the specified number of times is reached.
3.Insulation resistance test
Purpose: To verify whether the insulation performance of the terminal wire meets the requirements of the circuit design or whether its resistance value meets the requirements of the relevant technical conditions when subjected to environmental stress such as high temperature and humidity.
Principle: The resistance value presented by applying a voltage to the insulating part of the terminal wire, so that leakage current occurs on the surface or inside of the insulating part.
4. Withstand voltage test
Purpose: To verify whether the terminal wire can work safely under the rated voltage and whether it can withstand over-potential, so as to evaluate whether the insulation material or insulation gap of the terminal wire is suitable.
Principle: Apply a specified voltage between the terminal wire contact piece and the contact piece, and between the contact piece and the shell for a specified time, and observe whether the sample has breakdown or discharge.
5. Contact resistance test
Purpose: To verify the resistance value that occurs when current flows through the contact surfaces of the contacts.
Principle: The resistance value is obtained by passing a specified current to the terminal line and measuring the voltage drop across the terminal line.
6. Vibration test
Purpose: To verify the effect of vibration on the performance of the terminal wire and its components.
Vibration type: random vibration, sinusoidal vibration.
7.Mechanical Shock Test
Purpose: To verify the impact resistance of the terminal wire and its components or to assess the firmness of its structure.
Test waveform: half sine wave, square wave.
8.Thermal shock test
Objective: To evaluate the influence of terminal wire on its functional quality under the rapid and large temperature difference change.
9.Temperature and humidity combined cycle test
Objective: To evaluate the influence of the terminal wire on the performance of the terminal wire after being stored in a high temperature and high humidity environment.
10. High temperature test
Purpose: To evaluate whether the performance of terminals and insulators changes after the terminal wire is exposed to high temperature environment for a specified time.
11. Salt spray test
Purpose: To evaluate the resistance to salt spray corrosion of terminal wires, terminals, and coatings.
12. Mixed gas corrosion test
Objective: To evaluate the corrosion resistance of terminal wires exposed to mixed gases of different concentrations and the effect on their performance.
13. Wire swing test
Purpose: To evaluate the shaking, swaying, and movement of the terminal wire and its impact on its performance.
Although the Wire Harness production and processing process is cumbersome, every process must be done well to ensure the quality of the wire harness. As a manufacturer specializing in high-end customized Wiring Harness, we have always put quality first. We not only have our own factory, but also our own wire harness testing laboratory. For our Industrial Cable Assembly, Medical Cable Assembly, communication wiring harness, etc., as well as normalized new energy wiring harness, they are all delivered to customers after our tests, and customers can use them with confidence. An excellent wire harness manufacturer may not necessarily win the trust of customers by price, but must be able to rely on quality.