Quality Control Tests for Cable Assemblies

Every Raineon cable assembly undergoes rigorous quality control testing before delivery. Our multi-stage inspection process ensures that each harness meets the highest standards of electrical performance, mechanical integrity, and workmanship.

Electrical Testing

• Continuity Testing: 100% continuity verification on every circuit using automated test equipment. Each wire is tested point-to-point to confirm correct routing and termination. Any open circuit or miswire is immediately flagged.
• Insulation Resistance (Megger) Testing: All circuits tested at 500VDC (or per specification) to verify insulation integrity between adjacent conductors and between conductors and shield/ground. Minimum acceptable value is typically 100 MΩ.
• Dielectric Withstand (Hi-Pot) Testing: High-voltage testing at 1000-1500VAC (or per specification) to verify the assembly can withstand transient voltage spikes without breakdown.
• Low-Level Circuit Resistance: Measurement of total circuit resistance including connector contacts, crimp terminations, and wire length. Verifies that contact resistance is within specification (typically less than 10mΩ per contact).

Mechanical Inspection

• Crimp Pull Testing: Sample crimp terminations are pull-tested to verify mechanical strength meets IPC/WHMA-A-620 requirements. Destructive testing performed on sacrificial samples from each production lot.
• Visual Inspection: 100% visual inspection per IPC/WHMA-A-620 Class 3 (high-reliability) standards. Inspectors verify wire preparation, crimp quality, solder joints, heat shrink, and overall workmanship.
• Dimensional Verification: Harness dimensions verified against form board drawings, including branch lengths, breakout points, and overall harness length.

Documentation

Each assembly ships with a Certificate of Conformance, test data sheets, material traceability records, and inspection reports. Full lot traceability from raw material to finished product.

Related Products:

• J30J Series Connectors
• MIL-DTL-38999 III Series Connectors
• Twist Pin Contacts