Under automotive-grade safety and reliability requirements, wiring harnesses not only need to complete basic tests such as continuity, withstand voltage, and insulation, but also need to undergo long-term aging tests to verify their long-term stability under high voltage, high current, temperature rise, vibration, and complex working conditions. Especially for terminals, connectors, and insulation materials, once contact resistance increases, abnormal heating occurs, or insulation performance declines during long-term operation, vehicle safety may be affected.

Therefore, the core of automotive wiring harness aging testing is not just “power-on operation,” but achieving multi-channel, long-duration, monitorable, traceable, safe, and reliable system-level verification.

2. ITECH Hardware Platform: Covering High-Current and Multi-Channel Aging Tests

To meet the requirements of high current, multi-channel, high density, and long-term operation in automotive wiring harness aging tests, ITECH provides a variety of hardware testing solutions.

For high-current aging tests, the IT-M3900 Series bidirectional programmable DC power supply provides powerful current output capability and is suitable for testing scenarios related to high-voltage wiring harnesses, high-current connectors, PDU/BDU, and power systems. Through master-slave parallel operation, the system can achieve output capability up to tens of thousands of amperes, meeting the requirements of extreme high-current aging and reliability verification.

For multi-channel parallel aging tests, ITECH mainly recommends the IT2700 Series Multi-channel Modular Power System. The IT2700 adopts a 1U eight-channel design, supports mixed configuration of four types of modules including DC power supplies, bidirectional power supplies, regenerative electronic loads, and SMUs, and supports master-slave parallel operation. The high power density design of up to 2kW in 1U can fully utilize valuable test space, making it especially suitable for aging cabinets, automated production lines, and multi-station parallel test systems.

3. IT2700 Software and Data Capabilities: Improving Production Line Efficiency and Test Traceability

The IT2700 is not only a hardware platform, but also a testing solution with system-level control capability.

The professional PV2700 PC software is completely free and can synchronously control up to hundreds of channels, helping users achieve unified multi-channel management, automated process control, and batch data recording, greatly improving production line throughput. For automotive wiring harness aging testing, this means more channels can operate simultaneously, more samples can be verified in parallel, and test efficiency is significantly improved.

At the same time, the IT2700 has a built-in 200kHz sampling rate and large memory capacity, supporting long-term multi-channel data recording at 50kHz, continuously capturing voltage and current fluctuations and abnormal transients during the aging process, and providing data support for subsequent quality traceability, failure analysis, and process optimization.

4. IT2700 Safety and Energy-Saving Advantages: Making Long-Term Aging More Reliable and Greener

Long-term aging tests place higher requirements on equipment safety. The IT2700 modules are equipped with built-in power relays and can work with emergency stop and interlock functions to achieve comprehensive monitoring and protection throughout the entire aging test process. When abnormal conditions occur during testing, the system can cut off the output in time to reduce risks to samples and equipment.

The device also provides CAN, LAN, USB, and other communication interfaces, and has a built-in VNC function, enabling real-time remote monitoring through tablets, allowing engineers to monitor the test status in real time without staying on-site for long periods.

In long-term and large-scale aging tests, energy consumption cost is also an important factor. The IT2700 regenerative electronic load module can feed energy back to the power grid during loading. Compared with traditional dissipative loads, it can effectively reduce electricity costs and heat dissipation pressure, helping production lines achieve more efficient and greener operation.

5. From Automotive Wiring Harnesses to More High-End Applications: IT2700 Is a General-Purpose Test Platform

The value of the IT2700 is not limited to automotive wiring harness aging tests. As a general-purpose high-end test platform, it has μs-level timing control capability and can meet synchronization and timing control requirements for complex systems and chip-level applications.

Its SMU modules, together with the built-in power consumption analysis software, are especially suitable for test objects focusing on dynamic and static power consumption, such as IoT wearable devices, medical electronics, and semiconductor devices. Through the flexible combination of power supply, bidirectional power supply, regenerative load, and SMU modules, the IT2700 can cover various test scenarios from production line aging and functional verification to precise power consumption analysis.

Overall, with its high power density, multi-module mixed configuration, free software platform, long-term data recording, safety protection, remote monitoring, and regenerative energy-saving capabilities, the IT2700 provides an efficient, reliable, and future-oriented system-level solution for automotive wiring harness aging tests, and also provides a flexible and universal test platform for more high-end users.