INDUSTRIAL INFO-TAINMENT Wiring Harness News NOVEMBER / DECEMBER 2021 27
Automated Testing for Harnesses ( Part 2 )
Continued from page 25 ____________
better ). Typically , the DW test and IR tests are performed sequentially with the DW test performed first . In both cases the measurement is made between nets that are expected to be electrically isolated .
There can be variations in the process , but like low voltage isolation testing , each net must be tested against all others . A standard process for doing this is to connect a high voltage source to all points in one net while all other nets are held at ground ( Figure 4 page 25 ). At the same time the current flowing from source to ground is measured . The measured current is used to determine the pass / fail status of the DW test while Ohm ’ s law is used to calculate resistance for the IR test by dividing the voltage by the measured current ( R = V / I ). The calculated resistance is then compared to the IR threshold to determine the pass / fail condition . We ’ ll cover high voltage testing in greater detail in the future , but for now it ’ s enough to say that very little current is expected to flow between nets that are electrically isolated .
As with a low voltage isolation test , if a failure occurs , the tester only knows it occurred between the net at high potential and the group of nets held at ground . In the event of a DW failure , the tester will report the net that was at high potential , but it won ’ t usually execute a search to identify the specific net to which the failure occurred . Primarily , this is because arc events are not reliably reproducible , which often makes the search unproductive . However , IR failures are typically reproducible and testers with search capability can , therefore , identify the net to which the failure is occurring .
Hopefully , this brief summary will remove some of the mystery that can surround automated electrical testing and help build a foundation for better understanding of the testing process in general .
Cirris has been providing electrical test solutions for cables , harnesses and complex electrical assemblies since 1984 .
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