Automotive Wire Connectors Voltage Drop Tester
The Automotive Wire Connectors Voltage Drop Tester measures voltage drop and contact resistance in automotive electrical connections under controlled current conditions. It uses a constant-current output and four-wire Kelvin measurement to evaluate electrical connection performance while minimizing the influence of test-lead resistance.
The system features a programmable current source, a 24-bit ADC, temperature-compensated measurement, and contact resistance mapping. Depending on the selected configuration, it supports current ranges from 0–100 A to optional high-current configurations up to 1,000 A. It can be configured for static voltage-drop tests, dynamic load profiles, and temperature-conditioned testing.
Application
(1) Automotive wire connectors, electrical terminals, and contact interfaces.
(2) Wiring harness connections and cable-to-terminal joints.
(3) Low-voltage automotive power distribution connections.
(4) Electric vehicle battery-pack connections, with the optional battery-pack adapter kit.
Standards
SAE J1128_202508 — Low Voltage Primary Cable
ISO 19642-2:2023 — Road vehicles — Automotive cables — Part 2: Test methods
USCAR2-9 — Performance Specification for Automotive Electrical Connector Systems
LV 214-2 — Vehicle Contacts, Slow Motion Tests
GMW3191, Issue 4 — Connector Test and Validation Specification
ISO 8092-2:2023 — Road vehicles — Connections for on-board electrical wiring harnesses — Part 2: Terminology, test methods and general performance requirements
Parameters
| Parameter | Specification |
|---|---|
| Input voltage | AC 220 V ±10%, 50 Hz |
| DC working current | Standard configuration: 0–100 A |
| Optional current configurations | 5 A, 10 A, 20 A, 50 A, 100 A, 200 A, 500 A, or 1,000 A, adjustable within the configured range |
| Current output mode | Constant current |
| Voltage-drop measurement range | 0–20 V |
| Selectable voltage ranges | 0–200 mV, 0–2 V, and 0–20 V |
| Display ranges | 0.01–199.99 mV; 0.1–1,999.9 mV; 1–19,999 mV |
| Rated power | 3,200 W |
| Maximum output voltage | 32 V |
| Example dynamic current sweep | 10–200 A, subject to the selected current configuration |
| Temperature-conditioned test range | −40°C to +125°C, with the configured environmental chamber |
Features
(1) Programmable constant-current output for controlled electrical testing.
(2) Four-wire Kelvin measurement for more reliable low-resistance measurements.
(3) 24-bit ADC and low-noise current source.
(4) Temperature-compensated results and real-time thermal derating.
(5) Contact resistance mapping for evaluating connection consistency.
(6) Built-in automotive test protocol library for configurable test profiles.
(7) Support for static voltage-drop testing and dynamic current sweeps. The supplied example profile uses a 100 A test current with a voltage-drop target of ≤50 mV.
(8) Temperature-conditioned measurements from −40°C to +125°C when used with the configured environmental chamber.
(9) Safety protection, including automatic overcurrent disconnection, reverse-polarity protection, isolated measurement inputs, and thermal overload shutdown.
Accessories
Standard Configuration
(1) Heavy-duty test leads rated for 500 A.
(2) Four-wire Kelvin clip probes.
(3) Basic environmental chamber.
(4) Test analysis software.
Optional Accessories and Functions
(1) EV battery-pack adapter kit.
(2) Vibration test module, with a stated frequency range of 5–200 Hz.
(3) CAN FD/LIN bus integration.
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