1. Test objects

Low voltage connectors, high voltage connectors, high speed and high frequency connectors, charging and battery swap connectors (charging guns), automotive terminals, automotive cables and wires, and connector materials.

2. Test capabilities

Normal force testing. An in-house developed normal force versus contact resistance test system, equipped with a high precision micro-ohm resistance meter and a load tester with 1 micron displacement resolution, allowing small displacement normal force testing of various terminals.

Fretting wear. An independently developed fretting corrosion test system using a high precision displacement drive system, with synchronous monitoring of contact resistance changes and dedicated test software.

Temperature rise and current carrying capability. Four dedicated temperature rise test rooms, AC and DC power supplies of various ratings up to 2,000 A and 1,000 V, meeting the high current temperature rise testing needs of new energy applications.

Monitoring and data acquisition equipment. Intermittent contact detectors, data loggers and infrared thermometers.

High voltage connector shielding effectiveness. Line injection, tube-in-tube and triaxial methods are used to evaluate the shielding effectiveness of in-vehicle communication cables such as USB, FAKRA, HSD and Ethernet, high speed and high frequency connectors, and high voltage harnesses and connectors.

Signal integrity of high speed cables and connectors. Insertion loss, return loss, voltage standing wave ratio, crosstalk, impedance and eye diagram, with in-house design and fabrication of all kinds of signal integrity fixtures.

3. Scope of testing services

Environmental stress testing. Low temperature, high temperature, temperature change, temperature and humidity cycling, thermal shock, neutral and alternating salt mist, mixed flowing gas, ammonia fuming, chemical solution resistance, dust testing, water testing, water sealing and high pressure water jet.

Electrical performance testing. Temperature rise, current carrying capability, current cycling, derating curves, dielectric strength, insulation resistance, low level contact resistance and voltage drop.

Mechanical performance testing. Terminal to terminal insertion and withdrawal force, terminal to housing insertion force, retention force and push-back force, terminal normal force, connector mating and separation force, CPA and TPA insertion and withdrawal force, and mechanical strength of auxiliary structures.

Mechanical reliability testing. Mating cycles, audible mating confirmation, free drop, tumble drop, ferrule retention force for high voltage connectors, seal retention force, vibration, mechanical shock and combined three-axis testing, fretting corrosion and fretting wear.

Shielding effectiveness. Line injection, tube-in-tube and triaxial methods; transfer impedance and shielding attenuation.

Signal integrity of high speed cables and connectors. Insertion loss, return loss, voltage standing wave ratio, crosstalk, impedance, eye diagram and conductor crimp cross-section analysis.

4. Standards applied

Automotive connectors

SAE/USCAR 2, Performance Specification for Automotive Electrical Connector Systems.

SAE/USCAR 37, High Voltage Connector Performance Supplement to SAE/USCAR 2.

SAE/USCAR 17, Performance Specification for Automotive RF Connector Systems.

SAE/USCAR 49, Performance Specification for Miniature Automotive Coaxial Connectors.

GMW3191, Connector Test and Validation Specification.

VW 75174 (LV 214), Motor Vehicle Connectors Tests.

VW 80302 (LV 215-1), Motor Vehicle High Voltage Contacts Test Specification.

VW 80302 (LV 215-2), Electrical and Electronic Requirements for HV Contacts Performance Specification.

Q/JLY J7110195, Low-Voltage Connector of Automobile Wire Harness Technical Specification.

Q/JLY J7111175, FAKRA and HSD, Audio and Video Connector Technical Specification.

CTS-17.01.03.00, Automobile Connector Technical Specification.

SMTC 3 862 001, Electrical Connectors for Automobiles Test Method.

ISO 20860, Road vehicles - 50 ohms impedance radio frequency connection system interface.

Automotive terminals

SAE/USCAR 21, Performance Specification for Cable-to-Terminal Electrical Crimps.

SAE/USCAR 38, Performance Specification for Ultrasonically Welded Wire Terminations.

IEC 60512, Connectors for electronic equipment - Tests and measurements.

31832374, Battery and Ring Terminal Test Specification.

VW 60330, Crimp Connections Solderless Electrical Connections.

VW 75174-2, Vehicle Contacts Slow Motion Test.

Automotive cables

ISO 6722, Road vehicles - 60 V and 600 V single-core cables.

SAE J1742, Connections for High Voltage On-board Vehicle Electrical Wiring Harness - Test Methods and General Performance Requirements.

ISO 14572, Road vehicles - 60 V and 600 V screened and unscreened single or multi-core cables.

Automotive wire harness assemblies

SAE/USCAR 30, Performance Specification for Automotive Universal Serial Bus (USB) Connector Systems.

QC/T 1067.1, Automobile Wire Harness and Electrical Equipment Connector.

QC/T 29106, Automobile Wire Harness Technical Specification.

Q/JLY J7111252, High-Voltage Wire Harness Assembly for Passenger Vehicles Technical Requirements.

Q/JLY J7110446, Low-Voltage Wire Harness for Automobile Technical Specification.

SMTC 3 865 001, Battery Cable Assembly Test Method.