Wire Harness Testing & Quality Assurance

Wire harnesses serve as the backbone of countless electronic and electrical systems, providing the vital connectivity needed for seamless operation. Given their critical role, ensuring the quality and reliability of wire harnesses is paramount. 

When performing wire harness testing, our quality control department strictly follows the IPC/WHMA-A-620 Standard. 

In this blog post, we delve into the importance of testing and quality assurance in wire harness manufacturing.

Key testing procedures covered in this blog include:

  • Visual Inspection
  • Continuity Testing
  • Insulation Resistance Testing
  • High Voltage Testing
  • Environmental Testing

Call our team on 01978 437505, 07939 035 807, or use our contact form to discuss your wire harness requirements with one of our experts right away.

medical wire harnesses

The Significance of Wire Harness Testing & Quality Assurance

The significance of quality assurance plays a pivotal role in guaranteeing the performance, safety, and reliability of the final product. Pinnacle Harnesses adhere to strict and comprehensive guidance (in line with the IPC/WHMA-A-620 Standard) to ensure maximum testing procedures. As a result of adhering to rigorous quality standards without compromise, we can assure our clients that the product is 100% safe. It also helps us to identify potential issues before they impact the end-user.

Wire Harness Testing – Key Steps

  • Visual Inspection
  • Continuity Testing
  • Insulation Resistance Testing
  • High Voltage Testing
  • Environmental Testing

Visual Inspection

Upon completion of wire harness assembly, the first step to wire harness testing is visual inspection. In this stage, our trusted and accredited team will rigorously inspect any potential signs of damage, check secure connections, and ensure proper wire routing.

Continuity Testing

The next step of comprehensive wire harness testing is continuity testing. Here, continuity testing is used to verify the integrity of electrical connections within the wire harness. Pinnacle Harnesses promise to check individual wires and connectors to ensure all circuits are properly connected and functioning as intended.

Insulation Resistance Testing

Insulation resistance testing is conducted to assess the effectiveness of the insulation materials used in the wire harness. This test measures the resistance of the insulation to electrical current, helping to identify any potential weaknesses or defects that could compromise the integrity of the harness.

High Voltage Testing

High voltage testing is performed to assess the insulation strength of the wire harness under high electrical stress. By subjecting the harness to elevated voltages, Pinnacle Harnesses can ensure that it can withstand the rigours of real-world operation without risk of electrical breakdown or failure.

Environmental Testing

Environmental testing involves subjecting the wire harness to various environmental conditions, such as temperature extremes, humidity, vibration, and mechanical stress. This helps to simulate the conditions that the harness may encounter during normal use, allowing us to evaluate its performance and durability.

automotive wire harness manufacturer
automotive wire harness manufacturers

Benefits Of Comprehensive Wire Harness Testing

Comprehensive testing and quality assurance processes offer several key benefits:

Enhanced Reliability: Rigorous and comprehensive testing is paramount for enhanced reliability. Testing allows wire harness manufacturers, just like Pinnacle Harnesses, to address potential issues early in the manufacturing process.

Improved Safety: Rigorous testing helps to identify any potential safety hazards or defects that could pose a risk to users. By addressing these issues before the harnesses are deployed, manufacturers can help prevent accidents and ensure user safety.

Cost Savings: Investing in quality assurance and testing upfront can help avoid costly rework, repairs, and warranty claims down the line. By ensuring that wire harnesses meet quality standards from the outset, manufacturers can minimise the risk of product failures and associated expenses.

Contact Pinnacle Harnesses Today

Here at Pinnacle Harnesses, we place a great emphasis on rigorous and comprehensive wire harness testing. From visual inspection through to environmental testing, you’re in great hands with us. When performing wire harness testing, our quality control department strictly follows the IPC/WHMA-A-620 Standard, as you would expect.

Pinnacle Harnesses are proud to be your 5-star-rated wire harness manufacturers. We manufacture and test for a whole host of industries including automotive, medical, industrial, electronics, and more.

Get in touch with our trusted and highly-experienced team by calling us at 07939 035 807 or 01978 437505. You can also use our online contact form, if you prefer to email, and we’ll get back to you within 24 hours.