Air Leak & Continuity Test Bench for Automotive Wiring Harnesses

Short Description:

Automated test station performing integrated air leak and electrical continuity validation for automotive wiring harnesses. The system pressurizes connectors to detect seal and terminal leaks per IP specifications, while simultaneously checking for opens, shorts, miswires, and high-resistance connections. Features automatic pass/fail judgment with visual/audible alarms, barcode/RFID traceability, and comprehensive data logging for quality analysis. Ensures reliable, non-destructive testing with operator-safe low-voltage signals.

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Product Detail

Product Tags

1. **Air Leak Testing**

* Injects pressurized, clean air into the interior of wiring harness connectors and monitors pressure decay with high-precision sensors.
* Detects leaks caused by missing, damaged, or twisted seals (gaskets), or poorly crimped terminals, ensuring the IP (Ingress Protection) rating meets design specifications.

2. **Continuity (Electrical Performance) Testing**
* Applies a test signal to measure circuit resistance.
* Identifies electrical faults including open circuits, short circuits, miswires (crossed circuits), and high-resistance connections (intermittents).

3. **Integrated, High-Efficiency Testing**
* Combines both air leak and continuity testing into a single station, allowing for sequential completion of both checks in a single clamping operation, significantly improving production cycle time and test throughput.

4. **Automatic Pass/Fail Judgment and Alarm**
* The system automatically judges products as "Pass" or "Fail" based on preset parameters and provides immediate visual and audible feedback via a stack light and buzzer to quickly alert the operator.

5. **Test Data Logging and Traceability**
* Automatically archives detailed test data for each unit (e.g., measured values, results, timestamp, operator ID, harness serial number), creating comprehensive quality records for full product traceability and SPC (Statistical Process Control) analysis.

6. **Error-Proofing (Poka-Yoke) and Process Guidance**
* Utilizes barcode/RFID scanning to automatically call up the correct test program, preventing mis-testing. The HMI (Human-Machine Interface) provides graphical operator guidance and pinpoints the location of faults, reducing required skill level.

7. **Safe and Reliable Testing**
* Employs low-voltage, low-current signals for non-destructive testing, ensuring the process is completely safe for both the wiring harness product and the operator.