CableEye Barcodes

CableEye Barcodes


CableEye Application – Barcodes

A while ago an existing CableEye® customer asked us to add barcoding to their CableEye HVX tester, so we looked at what they were doing and how we could help.

When we assessed the existing process, we found that each cable was given a 7-character label that contained the year/month/sequence-in-batch when it was tested and was only fitted to cables that PASSED the cable test. This meant that all cables that were shipped could be identified by the month/year and where in the batch it was tested. Better than nothing, but not great.

We learned that all Works Order numbers (WO numbers) were unique to a customer order but that several Part numbers (cable types) could be contained within one Works Order.

After some discussion we came up with an alternative 14-digit code containing:

Part number / WO number / Assembly Serial Number.


A fixed-length field for each element was agreed upon with the customer and a single numerical string was designed. Each Part number became a numerical lookup (1-100,000) for a given cable name in a CSV file. The lookup is a cross-reference from the numerical value in the barcode field to an ASCII text, human-readable name of ‘unlimited’ length.

barcode lookup table

We then recommended that ALL cables received their unique ident label during assembly to improve the reporting from each assembly bench so that operator retraining needs could be identified, or their crimp tools recalibrated etc.

In operation:

As the cable is taken from one of our Protean Cable Stands and put on the test bench its barcode gets scanned by the test operator (identifiable by their unique log-in).

Our script then reads the WO-specific log file (on the customer’s network) to check if the assembly has been seen before. If it has been previously tested it asks the operator if this is a retest, or not. Retests could be due to the cable having previously FAILED on the tester and been reworked, or the operator having been distracted and trying to test the same cable twice.

The script then advises the test operator which connector adaptors are needed for this assembly and to which bank each must be connected. The correct test program is automatically loaded and ready for the ‘TEST’ button to be pressed.

Once ‘TEST’ has been pressed, the WO-specific log file is opened again, this time for writing, the test is run and the test results, along with the Date/Time and the tester operator’s ID stored in the log file. If the cable PASSES the test, a tamperproof sealing label is printed and placed over the end of the connector.


Using the CableEye Standalone Software option and built-in log tools, production management has an immediate view of the production throughput and statistics from their own desk.

This relatively simple change means that every assembly has a unique identity from the point at which it is assembled, identifying the workstation and the operator.

The configuration of the CableEye test station is semi-automated, speeding up the test process and reducing error time.

ALL cables that are delivered to ALL customers have full traceability, down to the individual conductor test results. Consequently, warranty claims are dealt with quicker with fewer ‘valid’ claims, and pre-emptive training or tool servicing is easier to manage.

All of the script work was done by Cimbian UK for the customer using standard, built-in tools included with EVERY CAMI Research CableEye, as standard!


Why use Barcodes?

Barcodes are reliable, fast and eliminate operator input errors. In this case, 14 characters are entered, without error in under a second!

How are Barcodes read?

A simple USB scanner is all that is needed to read a barcode in the CableEye software.

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New CableEye M2Z

New CableEye M2Z


Announcing the new CableEye M2Z

The all-new CableEye M2Z entry-level tester from CAMI Research provides essential continuity measurement in cables and small wire harnesses.

It is ideal for cables carrying digital signals or any electronic signalling where small amounts of resistance in the cable or connections will not affect the function of the equipment to which the cables are connected. The CableEye M2Z cable tester includes a 128-point fixture, a probe port, and electronics permitting it to test cables with up to 64 conductors.

Measurement for a typical cable completes in less than a second, with results displayed by LEDs on the tester as well as on the PC monitor.

We use industry-standard 64-pin dual-row latch headers as an interface to our plug-in connector boards and external test fixtures. Presently we have over 60 Connector Boards (CB) and most of them are directly compatible with the new CableEye M2Z

A standard Windows (7 and up) PC with one free USB port is all that is needed to use the powerful software supplied with the CableEye M2Z… exactly the same software used by the top-of-the-range CableEye testers.

cableeye m2z

The price includes a board set (CB15c), probe, operating software, power module, USB cable, Getting Started Guide, Software Introduction Booklet, User’s Manual (PDF), and Product Support Subscription.

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I need a cable harness tester, CableEye does both.

I need a cable harness tester, CableEye does both.

I need a cable harness tester,  not a cable tester!

During a recent discussion with a customer, he declared that he started out looking for a cable harness tester but was put-off by the price and complexity so he decided to opt for a cable tester to handle the ‘simple’ cables.

As the discussion moved ahead we went through some of the hundreds of applications currently running on CAMI Research CableEye systems around the world when the penny dropped for him… CableEye IS a cable harness tester!

CableEye also self-learns, tests, logs the test result data, and generates a test result record.

customer specific interface harness tester

He laid one of his cable harnesses on the table. the cable harness, which had seven connectors sections, was from a “mission-critical” project, where ‘near-enough’ was not ‘good enough’. Three connectors could clearly be seen as ‘one end’ of the harness whilst the other four were along the rest of the cable harness. This was, simply, no problem for CableEye.

As soon as the connectors had been selected/created in the PC’s library and added to a CableEye ‘fixture‘ it was a simple case of learning the cable harness, checking the learn against the design drawing, and saving. CableEye was now ready to test these harnesses. Development time around 10 minutes… test time, less than three seconds, including generating a PDF report!

cable harnes tester report

It is the power of the PC-based architecture that enables CableEye to be so versatile. Capturing continuity is one thing, using the captured results in a meaningful and useful way takes a PC and very special software.


What is cable harness tester?

A cable harness tester is a precision electronic instrument that will verify that a cable or wiring harness is connected correctly between the different connectors fitted. For example, CableEye is an automated tester that will also learn the correct connections from a known-good cable or wiring harness.

What is the difference between a cable and a harness?

A cable is typically made ‘end-to-end’. It may have multiple connectors on either end but don’t, generally split-out to additional connectors. a wire harness, on the other hand, may have one or multiple connectors at one end and may split out across several connectors along its length

How is testing a cable harness different from testing a cable?

The principle difference is in the software. Testing a harness requires advanced algorithms, such as in CableEye, to make sense of the interconnections between the terminal connectors. Most cheap cable testers struggle with this.

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