Electrical Connector/Cable Testing

Electrical connectors and cables are an integral part of all electronic products. They will have to withstand severe stresses in many applications such as automotive, aerospace, military, medical and telecom. Not only are broken solder joints or crimped leads an issue, but intermittent discontinuities during normal usage could cause a system fault.  Other failures such as cracking, wear, and fretting fatigue can occur.  It is essential that the mechanical and electrical properties of your cables and connectors are evaluated for use in vibration, shock and climatic environments. 

DES has the experience and equipment to perform accurate, repeatable testing of cables and connectors in our controlled, world class accredited lab.  Do you have a unique requirement?  No problem.  We are good at designing and making customized setups and fixtures. 

Some of the electrical connector and cable test methods that we can perform in-house include:

Environmental & Climatic Testing

  • Altitude (Pressure)
  • Salt Spray (Fog)
  • Temperature and Humidity
  • Thermal Aging and Temperature Life
  • Temperature Cycling and Thermal Shock
  • Sine and Random Vibration Testing
  • Mechanical Shock Testing

Mechanical Testing

  • Connector Mating/Un-mating Force
  • Contact Retention, Insertion/Removal Forces
  • Life Cycle Testing
  • Cable Pulling and Flexing
  • Crimp Tensile Strength
  • Terminal Pull Strength
  • Cable Flexing

Electrical Testing

  • Dielectric Withstand
  • Continuity
  • Low Level Contact Resistance (LLCR)
  • Insulation Resistance
  • Discontinuity/Event Detection

Typical Electrical Connector Test Standards

  • EIA-364 - Electrical Connector Performance Test Standards
  • GMW 3191 – Automotive Connector Test and Validation Specification
  • IEC 60512 - Connectors For Electrical And Electronic Equipment - Tests And Measurements
  • MIL-STD-1344A – Military Standard, Test Methods For Electrical Connectors
  • SAE USCAR2 - Performance Specification For Automotive Electrical Connector Systems
  • SAE USCAR21 - Performance Specification For Cable-To-Terminal Electrical Crimps 

Typical Cable Test Standards

  • IEC 60068-2 - Environmental Testing
  • MIL-STD-810 - Environmental Engineering Considerations and Laboratory Tests
  • RTCA/DO-160 - Environmental Conditions and Test Procedures for Airborne Equipment