The detection test is a fundamental step in the verification of wire harnesses. It ensures that all designated connectors and contact terminals are fully and correctly assembled, i.e. that their presence can be detected.
These tests are conducted using test probes with integrated switches which emit an electrical signal when activated. Depending on the design, they are designed as normally open (NO) or normally closed (NC) contacts.
The continuity test – also known as the circuit test – checks for open connections, short circuits, and faulty wiring.
The focus is on reliable, repeatable contact with minimal contact resistance. This test is conducted using test probes with a threaded connection, which firmly secures the probe in the receptacle during the test.
This is particularly important in applications where snap effects, vibration influences, and transverse or longitudinal forces can occur.
The position test checks whether the contact terminals are correctly positioned in the connector housing. Electrical contact can only be reliably established if the positioning is exact and the wiring is error-free.
Step probes – also known as or collar probes – are recommended for this test. A wide range of tip styles as well varying proebe lengths, probes diameters, and disc diameters are available.
The push-back test ensures that the lamellae of a contact terminal are correctly installed in the connector housing – a basic requirement for a permanent, reliable electrical connection.
Specialised push-back probes are used to test this so-called primary latching. Only when the lamella is properly latched does the terminal remain in its intended position – and the continuous plunger of the push-back probe can reliably activate a test probe, switching probe, or switching receptacle installed below.
INGUN offers you a wide selection of push back probes in various grid sizes and designs – optionally with an angular or rounded design.
The detection test is a fundamental step in the verification of wire harnesses. It ensures that all designated connectors and contact terminals are fully and correctly assembled, i.e. that their presence can be detected.
These tests are conducted using test probes with integrated switches which emit an electrical signal when activated. Depending on the design, they are designed as normally open (NO) or normally closed (NC) contacts.
The continuity test – also known as the circuit test – checks for open connections, short circuits, and faulty wiring.
The focus is on reliable, repeatable contact with minimal contact resistance. This test is conducted using test probes with a threaded connection, which firmly secures the probe in the receptacle during the test.
This is particularly important in applications where snap effects, vibration influences, and transverse or longitudinal forces can occur.
The position test checks whether the contact terminals are correctly positioned in the connector housing. Electrical contact can only be reliably established if the positioning is exact and the wiring is error-free.
Step probes – also known as or collar probes – are recommended for this test. A wide range of tip styles as well varying proebe lengths, probes diameters, and disc diameters are available.
The push-back test ensures that the lamellae of a contact terminal are correctly installed in the connector housing – a basic requirement for a permanent, reliable electrical connection.
Specialised push-back probes are used to test this so-called primary latching. Only when the lamella is properly latched does the terminal remain in its intended position – and the continuous plunger of the push-back probe can reliably activate a test probe, switching probe, or switching receptacle installed below.
INGUN offers you a wide selection of push back probes in various grid sizes and designs – optionally with an angular or rounded design.
Testing connectors with geometrically aligned contact terminals – such as cable lugs – creates specific demands in terms of suitable contacting methods.
To prevent damage to the terminal, it is essential that it is correctly aligned. For example, it must be ensured that the cable lug is contacted on the outer circumferential edge, without the test probe penetrating the terminal.
INGUN's non-rotating test probes ensure this precise alignment and enables reliable, gentle contacting.
Coaxial connectors such as FAKRA consist of two concentrically arranged conductors: an inner signal conductor and a surrounding outer conductor, which also serves as shielding. The electrically conductivity of both the signal conductor and the outer conductor must be ensured during the continuity test – while preventing a conductive connection (short circuit) between the two.
During high-voltage testing – also known as dielectric strength testing or hi-pot testing – the electrical insulation between the conductors is also checked. The aim is to detect potential insulation faults or production defects at an early stage that could lead to voltage breakdowns or leakage currents.
These test methods are also used for data-transmitting connectors such as H-MTD with multiple differential signal pairs.
Dipole probes are used for continuity testing of coaxial connectors; specialised versions for high-voltage testing up to several kilovolts are also available.
Wire harnesses used in outdoor environments, for example, in the engine compartment – required reliable protection against water, dust and other environmental influences. This protection is achieved via various sealing measures, such as self-vulcanising tape material, cable grommets in the interior, or specially sealed connectors.
The leakage test checks whether these measures are fully effective. Test probes are inserted into airtight receptacles to create positive or negative pressure inside the test module.
Depending on the design, the receptacles are either closed (airtight) or have an axial bore that is completely sealed during the subsequent soldering process.
Testing connectors with geometrically aligned contact terminals – such as cable lugs – creates specific demands in terms of suitable contacting methods.
To prevent damage to the terminal, it is essential that it is correctly aligned. For example, it must be ensured that the cable lug is contacted on the outer circumferential edge, without the test probe penetrating the terminal.
INGUN's non-rotating test probes ensure this precise alignment and enables reliable, gentle contacting.
Coaxial connectors such as FAKRA consist of two concentrically arranged conductors: an inner signal conductor and a surrounding outer conductor, which also serves as shielding. The electrically conductivity of both the signal conductor and the outer conductor must be ensured during the continuity test – while preventing a conductive connection (short circuit) between the two.
During high-voltage testing – also known as dielectric strength testing or hi-pot testing – the electrical insulation between the conductors is also checked. The aim is to detect potential insulation faults or production defects at an early stage that could lead to voltage breakdowns or leakage currents.
These test methods are also used for data-transmitting connectors such as H-MTD with multiple differential signal pairs.
Dipole probes are used for continuity testing of coaxial connectors; specialised versions for high-voltage testing up to several kilovolts are also available.
Wire harnesses used in outdoor environments, for example, in the engine compartment – required reliable protection against water, dust and other environmental influences. This protection is achieved via various sealing measures, such as self-vulcanising tape material, cable grommets in the interior, or specially sealed connectors.
The leakage test checks whether these measures are fully effective. Test probes are inserted into airtight receptacles to create positive or negative pressure inside the test module.
Depending on the design, the receptacles are either closed (airtight) or have an axial bore that is completely sealed during the subsequent soldering process.
Poster: Test probes at a glance
For easy reference in your everyday work, we have summarised our test probes for wiring harness testing for you.
