Test Solutions for High Voltage Automotive Wirings and Components

High voltage and high current testing of cable harnesses for Hybrids and electric vehicles.

Cable harnesses for hybrids or electric vehicles can carry voltages of up to 1000 V and currents up to 700 A. They connect the high-voltage battery with the power distribution unit (PDU), together with the electric motor and components such as the air-conditioning compressor, the battery anode heater or the electrical steering system.

Malfunction of wiring connections or degraded insulation may lead to catastrophic failure with such high power being available.  So, to ensure that only accurate and fully-functional cables can be installed into vehicles, the wiring of the hybrid cable harness are tested with up to 6,000 VDC / 5000 VAC for insulation and electric strength. A vast number of new materials, tools and processes are to be implemented and mastered to ensure the required quality and productivity.

For the automated electrical, end-of-line testing of high voltage wiring assemblies, CTS in partnership with adaptronic Prueftechnik GmbH, provides customised turn-key solutions, which are setting standards in respect of functionality, work safety and operating efficiency. Customers benefit from more than 30 years of experience in the design, manufacturing and servicing of high voltage test systems including the customised adapters for every application.

The modular test systems can cover the following test requirements:

  • Test voltages up to 6,000 VDC / 5,000 VAC
  • Test current up to 25 A
  • Continuity, short circuit and component test
  • Insulation and dielectric strength tests
  • Electrical and functional testing of shielded wires and cables
  • Interfacing via robust, safe and high voltage resistant adaptor systems with various functions, (checking for correct coding, presence, leak tightness, colour, etc.)
  • Light curtain protected test cage with safety loop and two hand operation
  • Human engineering and ergonomics in hardware and software ensure short training time for supervisors and operators
  • Turn key solutions including initial review, definition of test specifications, implementation, training and remote diagnosis and maintenance