A large automotive electrical harness can contain hundreds of wires, dozens of connectors and several electronic components, such as relays and diodes. Despite crimp-force monitoring, pull-force testing and other checks, there’s no guarantee that every crimped connection will be tight, every inch of insulation will be undamaged and every wire will be inserted into its correct destination.
Whether it’s used in a vehicle that rolls, floats or flies, cable and wire harnesses must pass a battery of tests for continuity, functionality and safety. Testing ensures that things don’t go wrong, such as intermittent faults, misconnects, miswires, opens and shorts.