Cable, Harness and Wiring Testing Information
How and why should I test a cable?
You can find out all about connection, cable, harness and wiring testing, what to look for, which tests to do and how to test at www.cabletester.co.uk
Or you can download and view this information as a pdf (173k)
How much time and money could you save every year?
Reducing testing time by using Automatic Test Equipment (ATE) can save huge amounts of money.
There are other benefits too.
· Your parts will be tested the same way every time. Eliminate errors.
· Identify faults for fast rework
· The results can be stored for you and your customer.
. Printed results sheets and labels can be supplied to your customer making it easier to win key contracts.
· The employee is safe. What are the health and safety issues in your current testing methods. RSI? Shock Hazards?
Examples
of
Time
Saving. |
|
Example 1: Testing cables |
|
Equipment |
Tracy
Cable
tester |
Example
cable |
25
way
D
type
Male
to
female |
Test-time
including
load
and
unload |
8
Seconds |
Time
to
check
with
a
buzzer |
120
seconds |
Time
Saved
per
unit |
112
Seconds |
|
Example 2: Testing high integrity cable including 1000V AC test |
|
|---|---|
Equipment |
BA765
with
AC
option |
Example
cable |
80
wires.
Measure
resistance
in
Ohms
using
4
wire
tester,
check
DC
insulation
at
500V
D.C.
and
hi
pot
test
at
1000V
AC
(3
seconds
per
test) |
Test-time
including
load
and
unload |
350
seconds.
The
operator
can
perform
other
tasks
during
this
time
and
will
be
protected
from
shock
risk
during
this
time |
|
Time to check using stand alone instruments |
3440
Seconds or 57 Minutes Approx |
Time
Saved
per
unit |
3090
Seconds or 52 Minutes Approx |
Examples
of
Money
Saving. |
There are large cost savings when using semi automatic test equipment. The savings are often greater than initially expected for the following reasons.
The cost to a company of an employee is typically is a lot more than their hourly pay. The company is also paying for time spent training, holidays, sick time, breaks and other non productive hours. There are also overheads to consider such as at rates, rent, heat light. Most companies assume that the actual cost is between 2 and 3 times the hourly rate.
Testing is often performed by staff that are more qualified than would be necessary for semi automatic testing. A technician or an Engineer may sometimes be called in to do testing at rates many times normal production rates. These staff can be much more efficiently utilised when semi automatic test equipment is used.
Faults can be expensive to diagnose using manual equipment whilst a test system will allow the fault to be quickly identified and correctly enabling the order to be completed quickly and at minimum cost.
Here are the potential cost savings for the examples above.
|
|
Saving per cable |
112 Seconds |
Time saving for 100 cables a week. 100 * 112s |
11,200 Seconds or 3 Hours Approx |
Business labour cost for Test Technician |
15 GBP Per hour |
Yearly saving: £15 * 3 Hours/week * 52 Weeks |
£2,340 |
First year saving after subtracting tester investment |
£800 |
Saving over 3 Years |
£5,480 |
Example 2: Testing high integrity cable including 1000V AC test |
|
Saving per cable |
3,090 Seconds |
Time saving for 10 cables a week. 10 * 3,090s |
30,900 Seconds or 8.5 Hours Approx |
Business labour cost for Test Technician |
15 GBP Per hour |
Yearly saving: £15 * 8.5 Hours/week * 52 Weeks |
£6,630 |
First year saving after subtracting tester investment |
£600 |
Saving over 3 Years |
£13,860 |
You can make better estimates of your own savings using this table.
What to do next |
Find the system that meets you need and ask us for a quotation. You can then work out how your business will benefit from Banair Test equipment.
Here are the links for our most popular test systems.
Cable Testers
The
B801" Sharon: This
standalone cable
and harness tester
carries
out
a
full
continuity
check
and
displays
any
errors.
It
has
a
low
price
to
enable
you
to
test
during
build.
Wide
range
of
adaptors.
The
B857 "Tracy": This
is
a
very
cost
effective
modular
tester
for
cables,
harnesses,
wiring
looms and rotary switches.
Start
with
one
module
(128
connections)
and
add
more
when
you
need
them.
Interchangeable
with
all "Sharon" accessories.
The
BA765 "Henry": This
cable,
connection
and
harness
test
system
carries
out
a
full
continuity
check,
4
Wire
resistance
measurement
and
a
full
HiPot
test.
It
is
currently
being
used
for
aircraft
wiring,
computer
cables,
Networking
panels
and
in
many
other
high
application fields.
Membrane Switch tester
The B831 "Darren": PC based Membrane Switch Tester, easy to use, footswitch operation, fast, measure resistances, check LED. Screen display of your actual product. Incredibly fast to setup and use.
Universal Product tester
The BA310 "Samantha": PC based Universal tester. Control switch inputs, test LED Outputs, set up power supplies automatically, read voltages, currents, resistance and other values from a DVM to a PC, and print out the results.
The above prices are given as examples, the price and specification of these products may vary, please enquire for a current quotation
