Testing & documentation
Tested before it is installed.
- electrical final testing
- 100 %
- certified
- ISO 9001
- documentation for series
- PPAP
Overview
Tested before it is installed.
Quality is created in two steps at Powertune: the machines monitor every processing step, and the electrical final testing confirms the finished wiring harness. We document both, on request with a test report for every delivery.
Powertune is certified to ISO 9001. Since 2011 an automated system has been testing pin assignment, resistance and cable faults and recording the results; high voltage and functional tests are added as required.
Scope of services
Testing & documentation at Powertune: what is included.
- Electrical final testing for continuity and short circuits
- Testing of pin assignment, resistance and cable faults
- Crimp force monitoring and crimp height measurement
- Seal position and stripping monitoring
- High voltage and functional testing as required
- Test records, measurement reports and documentation to PPAP
Every wiring harness we produce goes through 100 % electrical final testing.
Examples
From our production.
Process monitoring
Detecting faults while they occur.
The first test takes place inside the machine. The fully automatic cable processing machine records the force curve of every crimping operation and detects deviations, for example caused by missing strands or a badly seated contact. Monitoring systems additionally check the position of the single wire seal and the stripping result.
Conspicuous cables are sorted out immediately and never reach assembly. We check the crimp height with a crimp height measuring device.
- Crimp force monitoring with force curve
- Seal position and stripping monitoring
- Cut-in monitoring when stripping
- Crimp height measurement
Final testing
Every wiring harness is tested electrically.
The second test applies to the finished product. Since 2011 an automated system has been testing pin assignment, resistance and cable faults and recording the results. We test continuity and short circuits on every wiring harness: 100 % electrical final testing. Today we work with two test systems from Engberts (iCAT) for this: every connector is plugged onto a matching test module, and the test software shows the result directly at the workstation.
We carry out high voltage tests and functional tests as required. Together with you we define the scope of testing that makes sense for your project.
Documentation
Records for your incoming goods inspection.
On request you receive test records and measurement reports with every delivery. For series projects we prepare the documentation to PPAP. Batch and process traceability extends from the individual cable to the finished wiring harness.
Powertune is certified to ISO 9001; we will send you the certificate on request. You can read more about standards and test processes under quality management.
FAQ
Frequently asked questions.
Is every wiring harness tested?
Yes. Every wiring harness we produce goes through 100 % electrical final testing for continuity and short circuits. Our test system records pin assignment, resistance and cable faults and logs the results.
What is the difference between process monitoring and final testing?
Process monitoring assesses individual processing steps inside the machine, for example every crimp. Final testing assesses the finished product, that is whether every cable is connected correctly. Only the two together give a complete picture.
Which test system do you use?
With two modular test systems from Engberts (iCAT). For every connector there is a matching test module with the mating connector; the test software guides the operator through the sequence and shows the result at the workstation. Wiring harnesses with open cable ends are tested on test boards, where every cable end is contacted via a terminal. We define for each project which further tests a wiring harness receives.
What does crimp force monitoring measure?
It records the force curve during the crimping operation and compares it with a reference. If the curve deviates, for example because strands are missing or insulation has been crimped in, the cable is identified as faulty and sorted out.
Do you carry out high voltage tests?
Yes, as required. We agree the test voltage and the scope of testing with you for each project.
Do I receive a test report?
Yes, on request with every delivery. In addition we prepare measurement reports and, for series projects, the documentation to PPAP.
Is Powertune certified?
Powertune is certified to ISO 9001. You receive the certificate on request, see Documents.
Request a quote
Let us talk about your project.
Send us a drawing, a bill of materials or a sample, or sketch your wiring harness directly in the enquiry form. We will get back to you with a non-binding quote.
More services
Everything from a single source.
Cable assemblyReady to install cables, cable sets and wiring harnesses
Wiring harness manufacturingWiring harnesses to drawing, sample or 3D data
Development & designCAD design with EPLAN, documentation to PPAP
PrototypingSamples, single pieces and pre-series
Series productionFully automatic cable processing machines, MES controlled and traceableIndustry solutionsTo the overview