CAMI provides advanced systems for cable and wire harness test and cable management to discerning global customers who require accurate and dependable assembly and testing in order to deliver top quality product.

The CableEye ^® brand of automatic test equipment (ATE) represents flexible cable and harness test systems that are unlimited by connector type (or indeed whether connectors are present at all), and addresses test applications with long cables, short cables, or even no cables (e.g. backplane).

Our wiring analyzers and guided assembly systems are used for test applications of products destined for Automotive, Aerospace, Rail, Marine, Energy, Appliances, Medical Devices, Defense, Robotics, Telecom and many more sectors.

Here, we briefly look at cable test and assembly interface options for cables and harnesses with vehicular applications (encompassing automotive, commercial, industrial, and defense implementations).

Automation-ready cable and harness testers from CAMI’s low voltage (M2Z/M3Z/M4) and HiPot (HVX-series) CableEye product lines are valuable enablers of quality and productivity in the Consumer, Commercial, Industrial, & Military vehicle industries.

CableEye testers offer several set-up methods that consequently allow testing of any type of cable or harness with any type of connector. These methods include use of easily-interchangeable, auto detected, test interface fixtures known as Connector Boards, and/or of test interface harnesses, adapter cables, and panels.

Plug your own custom interface cables directly into any of the 64-pin headers on the tester, or you can use a test interface panel perhaps on a rack-mounted system. Map your mating harness or custom connector panel instantly with our optional PinMap™ software. We also offer custom test interface development.

The standard, out-of-the box operating software automatically displays a clear graphic of the connectors and wiring under test, and the tester can be readily programmed to do the same for custom boards and fixtures using the PinMap™ option.

The spectrum of connectors used in this industry is extensive, and and we offer a large library of stock, Connector Boards (see Connector Board Index). We can provide manufacturing dimensions to those customers who wish to make their own.

All CableEye boards quickly attach to the 64 pin headers on the control module, and to our QuickMount ^™ housings that attach to 64-pin headers on expansion modules via flat or Ampmodu cables. An array of different boards can be prepped for simultaneous use in this way (Fig. 1).

Most of our stock boards are pre-populated with connectors as shown in the Connector Board Index.

 

The CB29-series test interface board (Figs. 2 and 3) is our most popular stock board offering for an industry with such a wide pool of connector requirements - especially when those connectors change frequently, or when testing to 1500 V or even 2100 V.

EV Cables
Use Case

The CB8 (Figs. 4 through 7), CB30, and CB29 series of connector test boards allow a great deal of production and testing versatility in vehicular cable and harness manufacturing.

The CB8 and CB30 (double the pin capacity of the CB8) are advantageous for longer term custom solutions. These generic boards accept a wide range of circular or other connectors, and accommodate panel- and/or cable-mounted mating connectors as well as LIF test blocks. While a bulkhead connector mounted directly to the board produces a more compact interface, a cable-mounted solution would be preferred if the test cable consists of heavy-gauge wire or is bulky.

Users may use two identical boards together, or in combination with any other CB board to accept any cable type.

Motorsport
Use Case

In addition to being mounted directly to the CB8 board (e.g. Fig. 5), panel mounted connectors may be integrated on a fiberglass plate allowing a mix of wired and panel mounted connectors on the same board (Fig.1). The same fiberglass plate acts as an insulator for HV testing, while also protecting exposed wiring from physical damage.

These versatile universal boards may be wired to provide connections for batteries, spark plugs, and OBD (On Board Diagnostic) cables (Figs. 1, 6).

Click here for further examples from a variety of sectors.

Set-up for more complex UUTs or HiPot testing usually requires use of adapter cables, harnesses or panels (Figs. 3, 8) that connect to the tester via the 64-pin headers. Large UUTs require an expanded tester. Ribbon cables can be used when test voltages are ≤500 V, and Ampmodu cables for higher voltages.

Included with every tester, standard CableEye operating software offers out-of-the box automation capabilities with both Macros and Javascript scripting languages. By completely automating the test process after the operator attaches a cable, you will eliminate any chance that testing or documentation will differ from one cable to the next.

Use Macros to display work instructions with full color pictures and customized operator messages, and perform operations based on test results.

API integration with other equipment or software can be set up, and LabVIEW and .NET libraries are available.

The CB35 Relay Board (Fig. 9) allows you to manage external devices for full control and automation of your test station.

Guided Assembly

Use our AutoBuild™ software for guided assembly with speech for cable and wire harness manufacturing. During construction, the technician touches an unterminated wire using either a probe, or a finger with wriststrap, and the software reads the intended connection point using high-quality synthetic speech. The software also shows a connector graphic with the target pin highlighted. Once the connection is made, audible feedback confirms a proper connection or warns of an error.

Synthetic speech increases throughput, and helps the technician avoid repetitive motion injury to the neck and shoulders by eliminating the need to look constantly between the workpiece and the videoscreen. A simple half-open headset permits the speech to be easily heard in a noisy environment without interfering with other workers.

View build statistics and operator performance from the printable log. All insertion steps are logged, so that in the event of power failure or computer malfunction, the build can resume when normal operation is re-established.

Augment with CAMI's Light Director ™ optional guided-assembly accessory (Figs. 10, 11, 12) for even greater assembly speed and accuracy. With this, the target cavity is illuminated allowing for heads-down assembly.

Optional machined Delrin block fixtures allow for fast connection and disconnection during assembly and electrical tests.

Test While Building

Using AutoBuild ^™ guided assembly software, the operator follows spoken and visual instructions for first-sided then second-sided pinning. When performing second-sided pinning, they will place the wire in the target cavity and test for continuity. A warning will be triggered if the wire is inserted into the wrong cavity. To initiate the instruction they can touch the screen or, while second-sided pinning, they may choose to use a probe. The system can also be readily programmed to advance to the next instruction on the pressing of a foot pedal and could be scripted to advance automatically when an inserted wire is a PASS for continuity.

Watch Demo
(2:13 min)

Our versatile tester design offers you a variety of ways with which to connect to your article under test. Expandable and programmable, these future-ready testers provide PASS/FAIL and diagnostics with amazing graphics and documentation, for countless applications.

We have briefly looked at cable test and assembly interface options for cables and harnesses with vehicular applications. To learn more about the software that drives our testers, click the button below.

Software

CableEye Testers for Checking Connection Resistance

With the exception of M2-series testers, all models of CableEye testers can be used to check the quality of good connections and good non-connections (i.e. isolation).

CableEye Testers with HiPot Capability

Choose any of our HVX series models.

CableEye Testers with 4-Wire Measurement Capability

M4

4-Wire measurement capability with ±0.02 Ω resolution is a standard feature.

HVX Series

Advanced Measurements Option, Item 833, includes 4-wire measurement capability with ±0.02 Ω resolution. This option must be ordered at time of purchase of the control module.

4-Wire Kelvin Resistance Measurement Option, Item 832, provides 4-wire measurement capability with ±0.001 Ω resolution. This option can be retrofitted.

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