Application example of test probe cable harness test

Wire harness test
Reliable, efficient contact solutions

A wire harness is a ready-made bundle of individual cables that transmits signals or working currents. The cables are routed as a cable harness and sheathed, or held together by clamps, cable ties, binding twine, or hoses. 

In addition to requirements such as miniaturisation and cost efficiency as well as higher currents, signal rates and frequencies, the application area of wire harness testing is characterised by high diversity with low standardisation.

Despite advancing automation, wire harnesses in industry are mostly manufactured manually and assembled according to their geometric and electrical requirements.

Application-specific solutions are readily available.

Different types of test probes are used when testing wire harnesses: Screw-in test probes prevent the test probe from migrating out of the receptacle and are therefore preferable for wire harness testing, such as in the continuity test (connection test). Switching probes can be used to detect the presence of plugs and clips, for example, during the detection test. Step probes determine whether the contact terminals are correctly positioned in the connector housings during the position test. In addition, push-back probes are used in the push-back test to check whether the contact terminals remain in the correct position in the connector housing. Finally, non-rotating test probes ensure wear-free contacting of sockets or flat connector blades during connector testing.


Close up of  receptacle with stop-collar

Regardless of the wire harness test applications you need to test, INGUN has the right test solution for you.

Inquire now!

Go to the desired test solution:

Connection test    Detection test    Position test    Push-back test    Connector test   


Connection test using screw-in test probes

Many of the press-in test probes available from INGUN are also available as screw-in test probes. This ensures the test probe remains securely in the receptacle during the test. Screw-in test probes are especially recommended for applications where vibrations or unwanted side and axial forces may occur. INGUN offers screw-in test probes for the connection test in various sizes.

Spring-loaded test probe GKS-050 M
  • The screw-in test probe is securely installed in the KS using a torque screwdriver and bit tool. The required screw-in torque is applied via a square post on the receptacle.
  • Stainless steel versions for temperatures from -100 °C up to +200 °C available
Spring-loaded test probe GKS-075 M
  • Screw-in test probes for applications with possible vibrations or unwanted side and axial forces (migration of the test probe out of the receptacle is reliably prevented)
  • The screw-in test probe is securely installed in the KS using a torque screwdriver and bit tool. The required screw-in torque is applied via a square post on the receptacle.
  • Stainless steel versions for temperatures from -100 °C up to +200 °C available
Spring-loaded test probe GKS-112 M
  • Screw-in test probes for applications with possible vibrations or unwanted side and axial forces (migration of the test probe out of the receptacle is reliably prevented)
  • The screw-in test probe is securely installed in the KS using a torque screwdriver and bit tool. The required screw-in torque is applied via a square post on the receptacle.
  • Stainless steel versions for temperatures from -100 °C up to +200 °C available
Spring-loaded test probe GKS-899 M
  • Screw-in test probes for applications with possible vibrations or unwanted side and axial forces (migration of the test probe out of the receptacle is reliably prevented)
  • The screw-in test probe is securely installed in the KS using a torque screwdriver and bit tool. The required screw-in torque is applied via a square post on the receptacle.
Spring-loaded test probe GKS-113 M
  • Screw-in test probes for applications with possible vibrations or unwanted side and axial forces (migration of the test probe out of the receptacle is reliably prevented)
  • The screw-in test probe is securely installed in the KS using a torque screwdriver and bit tool. The required screw-in torque is applied via a square post on the receptacle.
  • Stainless steel versions for temperatures from -100 °C up to +200 °C available
Spring-loaded test probe GKS-854 M
  • Screw-in test probes for applications with possible vibrations or unwanted side and axial forces (migration of the test probe out of the receptacle is reliably prevented)
  • The screw-in test probe is securely installed in the KS using a torque screwdriver and bit tool. The required screw-in torque is applied via a square post on the receptacle.
  • Stainless steel versions for temperatures from -100 °C up to +200 °C available

Go to the desired test solution:

Connection test    Detection test    Position test    Push-back test    Connector test   


Detection test using switching probes

Switching probes are suitable for many various applications: not only can they be used for component detection tests and switches for closed/open checks, but also as a signal trigger for process control. Furthermore, in combination with other test probes (e.g., push-back probes), the position of contact terminals in plug housings is can be determined. INGUN offers a large variety of different switching test probes in different sizes and in versions as (switching circuit) Normally Open (NO) or Normally Closed (NC), so that a suitable test solution can be found for every application.

Switching probe SKS-215 MF
  • For a wide range of applications: performs components detection check, is a switch for detecting closed/open states, and a signal transmitter for process control
  • Various collar heights are available on the receptacles to adjust the installation height
  • The installation height can be varied, and the position of the switching point can be precisely adjusted via the probe’s thread. The SKS is secured in the correct position by crimp point in the KS.
  • The electrical connection is ensured by installation using a receptacle, optionally available with a quick-change system for easy exchange during maintenance
Switching probe SKS-463 MF
  • For a wide range of applications: performs components detection check, is a switch for detecting closed/open states, and a signal transmitter for process control
  • Various collar heights are available on the receptacles to adjust the installation height
  • The installation height can be varied, and the position of the switching point can be precisely adjusted via the probe’s thread. The SKS is secured in the correct position by crimp point in the KS.
  • The electrical connection is ensured by installation using a receptacle, optionally available with a quick-change system for easy exchange during maintenance
Switching probe SKS-465 MF
  • For a wide range of applications: performs components detection check, is a switch for detecting closed/open states, and a signal transmitter for process control
  • Various collar heights are available on the receptacles to adjust the installation height
  • The installation height can be varied, and the position of the switching point can be precisely adjusted via the probe’s thread. The SKS is secured in the correct position by crimp point in the KS.
  • The electrical connection is ensured by installation using a receptacle, optionally available with a quick-change system for easy exchange during maintenance
Switching probe SKS-465 SF
  • For a wide range of applications: performs components detection check, is a switch for detecting closed/open states, and a signal transmitter for process control
  • Various collar heights are available on the receptacles to adjust the installation height
  • The installation height can be varied, and the position of the switching point can be precisely adjusted via the probe’s thread. The SKS is secured in the correct position by crimp point in the KS.
  • The electrical connection is ensured by installation using a receptacle, optionally available with a quick-change system for easy exchange during maintenance
Switching probe SKS-115 M
  • For a wide range of applications: performs components detection check, is a switch for detecting closed/open states, and a signal transmitter for process control
  • Various collar heights are available on the receptacles to adjust the installation height
  • The installation height can be varied, and the position of the switching point can be precisely adjusted via the probe’s thread. The SKS is secured in the correct position by crimp point in the KS.
  • The electrical connection is ensured by installation using a receptacle
Switching probe SKS-435 M
  • For a wide range of applications: performs components detection check, is a switch for detecting closed/open states, and a signal transmitter for process control
  • Various collar heights are available on the receptacles to adjust the installation height
  • The installation height can be varied, and the position of the switching point can be precisely adjusted via the probe’s thread. The SKS is secured in the correct position by crimp point in the KS.
  • The electrical connection is ensured by installation using a receptacle
Switching probe SKS-339 M
  • Switching probe for detection test of plugs in test modules from the side
  • Especially suitable for applications with limited space
  • The switching test probe is activated by a ball and is resistant to side forces
  • The ball can transmit an electrical signal (not galvanically isolated from the connection pin)
Switching probe with ballhead SKS-499
  • The SKS-499 switching probes are designed for detection test of plugs in test modules from the side
  • SKS probes are activated by a ball and are resistant to side forces
  • Particularly suitable for limited working spaces in 256 Mil grids
  • In the SKS-499 405 500 U 1000 S05 G version, the ball is electrically isolated from the connection pin, meaning a potential-free contact to the DUT is made.
Switching probe with ballhead SKS-449 M
  • Switching probe for detection test of plugs in test modules from the side
  • SKS probe is activated by a ball and is resistant to side forces
  • Particularly suitable for limited working spaces in 295 Mil grids
Switching probe with ballhead SKS-559 M
  • Switching probe for detection test of plugs in test modules from the side
  • SKS probe is activated by a ball and is resistant to side forces
  • Particularly suitable for limited working spaces in 374 Mil grids

Go to the desired test solution:

Connection test    Detection test    Position test    Push-back test    Connector test   


Position test using step probes

Step probes are used to test the correct position of the contact terminals (contact lamellae) in the plug housings. Contact is only made when the terminals are in the correct position or when the wiring is correct. Step probes differ in terms of their overall length, resulting from the pin length, the pin diameter, and the diameter of the disc.

Step probe T-112 M
  • Step probes are used to test the correct position of the contact terminals (contact lamellae) in the plug housings. A connection test can be carried out at the same time. Contact will only occur when the tip of the step probe is correctly positioned
  • For optimum contacting, various tip styles are available in various tip ø, disc ø and pin lengths
Step probe T-912 M
  • Step probes are used to test the correct position of the contact terminals (contact lamellae) in the plug housings. A connection test can be carried out at the same time. Contact will only occur when the tip of the step probe is correctly positioned
  • For optimum contacting, various tip styles are available in various tip ø, disc ø and pin lengths
  • Version for test probes installed particularly close together: the screw-in torque is applied via the disc using a bit tool
Step probe T-899 M
  • Step probes are used to test the correct position of the contact terminals (contact lamellae) in the plug housings. A connection test can be carried out at the same time. Contact will only occur when the tip of the step probe is correctly positioned
  • For optimum contacting, various tip styles are available in various tip ø, disc ø and pin lengths
Step probe T-113 M
  • Step probes are used to test the correct position of the contact terminals (contact lamellae) in the plug housings. A connection test can be carried out at the same time. Contact will only occur when the tip of the step probe is correctly positioned
  • For optimum contacting, various tip styles are available in various tip ø, disc ø and pin lengths
Step probe T-888 M
  • Step probes are used to test the correct position of the contact terminals (contact lamellae) in the plug housings. A connection test can be carried out at the same time. Contact will only occur when the tip of the step probe is correctly positioned
  • For optimum contacting, various tip styles are available in various tip ø, disc ø and pin lengths
  • Version for test probes installed particularly close together: the screw-in torque is applied via the disc using a bit tool

Go to the desired test solution:

Connection test    Detection test    Position test    Push-back test    Connector test   


Push-back test using push-back probes

Push-back probes are used to test whether primary and / or secondary latching has occurred to ensure of the contact terminals are in the correct position in the connector housing. Only if the latching is correct, the contact lamellae remain in the correct position and the continuous plunger of the push-back probe presses on a test probe or switching probe installed below. INGUN offers a variety of push-back probes with different dimensions for various grid sizes and with either spade-shaped or round plunger tip.

Go to the desired test solution:

Connection test    Detection test    Position test    Push-back test    Connector test   


Connector test

Correctly aligned contacting is required for non-destructive testing of DUTs such as flat connectors or sockets. INGUN non-rotating probes ensure this. For tests on coaxial radio-frequency connectors, either radio-frequency probes (HFS) or dipole probes (DPS) are used for a simple continuity test. The latter is often referred to as four-wire or Kelvin measurement. INGUN offers suitable test solutions for all standardised automotive connectors.


Go to the desired test solution:

Connection test    Detection test    Position test    Push-back test    Connector test   



Test probes for wire harness applications at a glance

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