Automotive Wire AC/DC Current Carrying Capacity Temperature Rise & Voltage Drop Test System
The Automotive Wire AC/DC Current Carrying Capacity Temperature Rise & Voltage Drop Test System is designed to evaluate the thermal and electrical performance of automotive wires and connectors under AC and DC load conditions.
It accurately records conductor temperature, voltage drop, and current carrying capacity, providing reliable data for wire sizing, connector validation, and thermal management design.
Application
The system is used for comprehensive evaluation of automotive wire and connector performance, including:
Thermal performance verification of wire harnesses under AC or DC currents
Voltage drop measurements in connectors and terminals
Conductor temperature rise monitoring for various load conditions
Continuous cycling tests for durability and safety assessment
Suitable for primary wires, control cables, battery conductors, and automotive harness assemblies
Standards
(1) JASO D609:2001 — Electrical Performance of Automotive Wires
(2) QC/T 29106 — Automotive Wire Current Carrying Capacity
(3) QC/T 1067.1 — Low Voltage Automotive Cables
(4) QC/T 417.1 — Automotive Wire Voltage Drop Testing
(5) TICW 15 — Automotive Wire Thermal Evaluation
(6) ISO 6722 — Road Vehicles — Low Voltage Primary Cables
(7) SAE J1128 — Low Voltage Automotive Cables
Parameters
| Item | Specification |
|---|---|
| Input voltage | AC 380 V ±10%, 50 Hz |
| Load type | AC: constant current source; DC: switch-mode DC power supply |
| AC working current | 0–1000 A, open circuit voltage ≤10 V |
| DC working current | 10–1000 A, maximum output voltage 10 V |
| Current output control | Computer programmable |
| Current meter accuracy | ±1% + 3 digits |
| DC voltage drop range | 0.01 mV–199.99 mV / 0.1 mV–1999.9 mV (two channels) |
| Timer range | 0–9999.99 H/M/S, auto cutoff when time reached |
| Temperature measurement | 8-channel thermocouples (T1C, T2C, T3C, T1S, ambient); Type T, 30 AWG |
| Temperature control | Integrated thermostatic chamber with monitoring |
| Test modes | AC, DC, cycling tests |
Features
(1) Simultaneous measurement of conductor temperature, voltage drop, and current for precise thermal characterization.
(2) Programmable AC/DC current output with high accuracy and repeatability.
(3) Integrated multi-channel thermocouple system for real-time temperature monitoring.
(4) Automated timing control with safe automatic cutoff to protect samples.
(5) Supports continuous cycling tests for durability assessment.
(6) Compatible with a variety of connector and wire sizes, including primary, battery, and control wiring.
Accessories
(1) Main test system with AC/DC power supply
(2) Multi-channel temperature acquisition unit
(3) Thermocouple probes (Type T, 30 AWG)
(4) Connector and wire mounting fixtures
(5) Computer interface and control software
(6) Thermostatic chamber for low/high temperature conditions
Test Procedures
(1) Install the wire or connector specimen in the designated test fixtures.
(2) Configure the desired AC or DC current load via the computer interface.
(3) Set the measurement channels for voltage drop and thermocouples for temperature recording.
(4) Start the test; the system automatically records temperature rise, voltage drop, and current.
(5) If cycling mode is selected, the system performs repeated load/unload cycles according to programmed settings.
(6) After completion, analyze the data for thermal performance and electrical compliance.
Maintenance Information
Regularly check thermocouple connections and calibrate sensors for accuracy.
Inspect wiring, connectors, and clamps for wear or corrosion.
Maintain the AC/DC power supply, ensuring proper ventilation and clean contacts.
Verify timer and software functions before each test.
Clean and service the thermostatic chamber periodically to maintain uniform temperature control.
FAQ
What is this product?
It is a test system for evaluating automotive wires and connectors under AC/DC load, measuring temperature rise and voltage drop.
What is this tester used for?
It verifies the current carrying capacity, voltage drop, and thermal performance of wires and connectors under defined conditions.
Why is this tester important?
Accurate thermal and voltage drop data ensure wire sizing, connector reliability, and overall electrical system safety in vehicles.
Which industries is this tester suitable for?
Automotive manufacturers, wiring harness suppliers, connector manufacturers, and testing laboratories.
What types of products can be tested?
Low-voltage wires, battery cables, primary automotive wires, connectors, and wiring harness assemblies.
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