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Test high-current connectors reliably

powerful, precise, reproducible

In numerous industries, high currents must be transmitted safely and with low losses, in the energy supply network, industrial automation, or automotive engineering.

Reliable, robust connections are absolutely crucial in the charging infrastructure of hybrid and electric vehicles. Connectors form the central interface here: they establish the electrical connection between performance-related components and also serve as access points for function tests in the production process. This involves overcoming a variety of challenges: high currents and voltages, thermal loads, and contact elements with varying geometries - often round and flat. In addition, there are application-specific requirements, such as the intentional displacement of safety caps or alternative methods of contacting such as rolling or clamping.

The right contacting solution for every geometry

Whether for battery modules, power electronics or high-voltage connectors – in electric mobility in particular, a wide variety of high-current components must be tested in a reliable and reproducible manner. INGUN offers you a wide range of test probes for every geometry.

Our high-current test-probes have a split-plunger design: during the stroke movement, the two plunger components are radially deflected away from each other and pressed against the inner surface of the barrel. This reduces internal resistance and ensures efficient current transmission with minimum heat generation.

Test probes for various diameters and lengths are available for testing round posts. Thanks to their compact design, even closely installed contact elements can be tested without any problems.

For particularly gentle contacting, we recommend our patented, scratch-free test probes: during the stroke movement, contact lamellas are activated, which reliably prevent scratches and residues on contact surfaces.

Our four-wire versions are suitable for simultaneous measurement of current and voltage. In addition, test probes with integrated thermal sensors are available to monitor the temperature at the contact point. The presence of safety caps can also be tested.

Our test probes are compatible with all common high-voltage connectors, including those from Amphenol, Aptiv, Hirschmann Automotive, Rosenberger and TE Connectivity.

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Flat contact elements are particularly suitable for high-volume applications due to their low manufacturing cost. The terminals are integrated directly into the connector housing using injection moulding.

High-current solutions are available in various designs for reliable testing, even for connectors with closely installed contact elements.

For particularly gentle contacting, we recommend our patented, scratch-free clamps featuring contact lamellas that are activated during the stroke movement.

Alternatively, electrical contact can be established via a rolling motion. This method increases the contact surface area, boosts the current-carrying capacity, and at the same time prevents scratches from forming on the contact surface.

Our contacting solutions are compatible with all common high-voltage connectors, including those from Amphenol, Aptiv, KOSTAL and TE Connectivity.

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For freely accessible contact surfaces without housing restrictions – e.g. exposed flat contact elements – we recommend our robust high-current test probes, available with various tip styles.

They enable contact of flat surfaces via several contact points, minimise contact resistance, and ensure efficient heat dissipation even in application where current is applied continuously.

The freely accessible contact surface allows several test probes to be used in parallel to reliably transmit even higher currents. Versions with integrated sense contacts are also available for precise voltage monitoring during high-current testing.

Go to test probes

Background image right alt text

Test probes for various diameters and lengths are available for testing round posts. Thanks to their compact design, even closely installed contact elements can be tested without any problems.

For particularly gentle contacting, we recommend our patented, scratch-free test probes: during the stroke movement, contact lamellas are activated, which reliably prevent scratches and residues on contact surfaces.

Our four-wire versions are suitable for simultaneous measurement of current and voltage. In addition, test probes with integrated thermal sensors are available to monitor the temperature at the contact point. The presence of safety caps can also be tested.

Our test probes are compatible with all common high-voltage connectors, including those from Amphenol, Aptiv, Hirschmann Automotive, Rosenberger and TE Connectivity.

Go to test probes

Background image right alt text

Flat contact elements are particularly suitable for high-volume applications due to their low manufacturing cost. The terminals are integrated directly into the connector housing using injection moulding.

High-current solutions are available in various designs for reliable testing, even for connectors with closely installed contact elements.

For particularly gentle contacting, we recommend our patented, scratch-free clamps featuring contact lamellas that are activated during the stroke movement.

Alternatively, electrical contact can be established via a rolling motion. This method increases the contact surface area, boosts the current-carrying capacity, and at the same time prevents scratches from forming on the contact surface.

Our contacting solutions are compatible with all common high-voltage connectors, including those from Amphenol, Aptiv, KOSTAL and TE Connectivity.

Go to clamps

Background image right alt text

For freely accessible contact surfaces without housing restrictions – e.g. exposed flat contact elements – we recommend our robust high-current test probes, available with various tip styles.

They enable contact of flat surfaces via several contact points, minimise contact resistance, and ensure efficient heat dissipation even in application where current is applied continuously.

The freely accessible contact surface allows several test probes to be used in parallel to reliably transmit even higher currents. Versions with integrated sense contacts are also available for precise voltage monitoring during high-current testing.

Go to test probes

Background image right alt text

Four-wire measurements using dipole test probes

If the voltage also needs to be monitored during the high-current test, four-wire measurement is used.

Unlike classic four-wire measurement using four separate test probes, INGUN's dipole test probes combine the current and voltage paths via just two installation positions.

The specialised double-contact geometry enables voltage measurement directly at the contact point, while maintaining a stable current flow. This makes reproducible four-wire measurement possible, even with limited space.

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Electrified! High-current testing in practice

Learn more about possible contact methods, typical areas of application, and tips for practical implementation for your high-current tests in electromobility in our webinar.

Watch webinar

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