Cable Testing Service

Subcontract Cable & Harness Testing Services

As an established technical partner for UK electronics manufacturing, Cimbian UK Ltd provides specialised subcontract testing for cable assemblies and wire harnesses. We bridge the gap for organisations that require laboratory-grade validation but do not yet have the internal volume to justify a dedicated CableEye® installation.

High-Voltage (HiPot) & Insulation Validation

Safety-critical assemblies in the EV, Aerospace, and Medical sectors require more than a simple continuity check. We provide Dielectric Withstand Voltage (DWV) and Insulation Resistance (IR) testing to ensure the integrity of the dielectric material.

• DC Voltage Range: Precision testing up to 1500Vdc.

• AC Voltage Range: Standard-compliant testing up to 1000Vac.

• Leakage Detection: Programmable trip currents down to 0.1 mA to identify subtle insulation compromises or moisture ingress.

Precision Resistance & 4-Wire Kelvin Measurement

Standard 2-wire testing is insufficient for high-current power cables or precision signal lines, where test-lead resistance can mask the true value of the assembly.

• Resolution: Measurement of contact and wire resistance down to 1 mΩ.

• Methodology: Use of separate sense and source lines to eliminate “parasitic” resistance.

• Application: Ideal for verifying crimp quality, ultrasonic welds, and heavy-gauge battery cables.

Error-Free Traceability & Compliance (AS9100 / ISO 9001)

In a regulated environment, the test report is as critical as the test itself. Every assembly processed through our facility is logged within a secure database.

• Automated Reporting: We generate serialised, tamper-proof PDF certificates for every batch.

• Data Points: Reports include time/date stamps, operator IDs, and exact measured values (not just Pass/Fail).

• Audit Readiness: Our documentation is designed to meet the requirements of BSI and other external auditors for full lifecycle traceability.

Safety and Protection: Non-Destructive High-Voltage Validation

A common concern when specifying High-Voltage (HiPot) testing is the risk of damaging sensitive insulation or expensive custom connectors. At Cimbian, our testing protocols are designed to be entirely non-destructive, ensuring that we detect faults without creating them.

1. Advanced Current Limiting

Unlike rudimentary testers that can deliver a sustained “arc” upon failure, the CableEye® HVX system employs sophisticated current-limiting circuitry. Even at a full 1500Vdc or 1000Vac output, the total energy available is strictly controlled. This prevents the “carbon tracking” that can occur with high-energy discharges, protecting your harness from permanent dielectric damage.

2. Ultra-Fast Trip Sensing (0.1 mA)

Our systems monitor leakage current in real-time with micro-ampere precision. If the insulation begins to break down or a flashover is imminent, the system triggers a “trip” in milliseconds.

• Rapid Cut-off: The high voltage is disconnected almost instantaneously upon detection of a fault.

• Preservation of Evidence: By cutting the power before a full arc occurs, we can identify the exact location of a weak point (such as a nicked wire or a misplaced shield) without burning the evidence, allowing your team to perform a forensic analysis of the failure.

3. Ramp-Up and Dwell Controls

To avoid “voltage spikes” or inductive transients that could stress electronic components, we utilise controlled ramp-up profiles.

• Controlled Gradient: The voltage is increased steadily to the target level.

• Programmable Dwell: The system maintains the test voltage for the exact duration required by your specific standard (e.g., MIL-STD or IPC-620), ensuring a thorough soak-test without over-stressing the material.

4. Automatic Discharge

Following any high-voltage test, the CableEye® system automatically and safely discharges any residual capacitive energy in the cable before the operator can disconnect it. This protects both the equipment and the personnel from “stored charge” shocks.

The Cimbian “Interface Credit”

We operate a unique commercial model designed to support your growth. When you utilise our testing service, we design and build the necessary custom interfaces and test programmes.

• Ownership: These files and hardware remain your property.

• Zero-Cost Migration: If you subsequently invest in your own CableEye® tester, we will supply you with these existing programmes and interfaces free of charge, ensuring your internal production is operational from Day 1.

Cable testing service available from Cimbian UK includes:

• • Helping you with the test specification
  • Building the test interface, where necessary
  • Creating the test program
  • Barcoding
  • Test reports
  • Simple continuity testing
  • Measurement/verification of resistances and diodes (traceable to national standards)
  • Hi-Pot testing to 1500Vdc / 1000Vac

Not Just a Testing Service

Of course, we can also supply complete test solutions using a CableEye^® tester and custom interfacing, if needed. Take a look here: CableEye Cable Testing.