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 VAC / 3,600 VDC for insulation and electric strength.

Test solutions from CTS are often delivered with an end of line style harness test table that is designed to not only hold and test the plugs of the hybrid cable harness, but ensure the correct fitment of plugs, seals, gates and clips. Firstly, there is a low voltage continuity and insulation test where the DUT is accessible for the operator. Following successful completion of those tests, the test for insulation and dielectric strength with up to 6,000 VDC / 3,600 v AC is carried out.  But as soon as an operator enters the safety area, usually protected by a photoelectric barrier or a sliding door, the high-voltage unit disconnects the high-voltage circuit almost instantaneously and discharges the DUT from any residual voltage, making it safe.  This enables EN-13849-1-conformity, ensuring operator safety without decreasing efficiency.