Establishing Control of the Cable Testing Process

Aug. 3, 2010 - PRLog -- One of the challenges in testing cables is maintaining control of the testing process.  Typically, the testing process is not fully automated.  Operators connect an untested cable to the test fixture, and remove a tested cable from the test fixture.  After a cable has been tested, it must be categorized as having passed or failed, and the operator must appropriately segregate the failed cables from the good ones.  At times, an operator may fail to properly segregate a failed cable, causing major problems downstream.  Another potential problem occurs when an operator fails to wait until the test is completed and removes a partially tested cable from the test fixture.

Cable manufacturers who use NX Cable Testers from Dynalab Test Systems have several options available to them to control the testing process to minimize the possibility of intermingling defective cables with good ones.  These methods include:
•   Activating a fixture clamp when the cable has passed all tests
•   Printing a label only when the cable has passed all tests
•   Sounding an alarm if the operator removes the cable before the test is completed

The following is a brief explanation of each approach.

Activating a fixture clamp:

Many high-volume manufacturers use fixture clamps to prevent the operator from removing the cable before the NX Cable Tester has verified that all tests have passed.  In this scenario, a defective cable can only be removed from the fixture through intervention of a supervisor or other authorized personnel.  This results in improved quality control.

A fixture clamp is a device that provides a means of locking a cable connector in place while the cable is being tested.  Most fixture clamp designs use a mechanical locking device that engages when a connector is inserted into a holder.  When all tests have passed, an electric solenoid is used to release the connector at the end of the test.  It is best to use fixture clamps that are closed and held by a mechanical latch and are opened by activation of an electrical solenoid.  This ensures that the clamp will remain closed even if the power is disconnected.

The NX Cable Tester may be equipped with the optional Control Port Module.  This enables the NX Tester to apply power to the fixture clamp solenoid when the cable has passed all tests.  Here is a description of the operational scenario involving the use of a fixture clamp with the NX Tester and NX Control Port Module:

•   When the operator inserts the cable connector into the fixture block, the connector becomes mechanically locked in place.  
•   When the cable passes all tests, the NX Cable Tester causes the Control Port Module to close – this applies power to the solenoid and releases the harness connector.  
•   After a short time delay, the NX Cable Tester causes the Control Port Module to open, turning off power to the solenoid.

If the cable is defective, and cannot be repaired, a supervisor or other authorized person can insert an NX Supervisor Key into the NX Tester’s key slot.  This releases the fixture clamp, allowing the defective cable to be removed from the fixture.

Printing a Label:

Dynalab NX Cable Testers can be programmed to print labels using the Dynalab Label Printer.  This prints a product label when a cable passes all tests.  This is a superior method to using pre-printed labels.  Using the NX Cable Tester to print a label when a cable passes all tests ensures that only good products receive labels.  This assurance does not exist when using pre-printed labels.  Using the NX Cable Tester to print labels also allows for dynamic data to be part of the label information, such as the current date and time, operator ID, and tester ID.  When only good cables get labels, it simplifies the process of segregating good product from bad.

Sounding an Alarm:

The NX Cable Tester may be programmed to enter into an Alarm Mode when a cable is removed from the test fixture before the Tester has completed testing  Upon entering the Alarm Mode, the NX Cable Tester does the following:

•   Stops testing
•   Sounds an audible alarm
•   Displays a message indicating early removal of the harness
•   Requires insertion of the Supervisor Key to de-activate the alarm

Once cable testing has begun, if the cable is removed before testing is completed,  the NX Cable Tester can be programmed to enter the alarm mode.  The alarm mode will abort the test, sound a continuous alarm, and display a message indicating early removal of the cable.  This behavior will continue until an authorized person with a Supervisor Key inserts the key into the NX Tester’s key slot.  The alarm condition can only be reset through insertion of the Supervisor Key.  Cycling the NX Tester’s power will not reset the alarm condition.

Using one or more of these approaches will enable cable manufacturers to improve control of the quality of their products.  NX Cable Testers from Dynalab Test Systems can provide these capabilities easily.  Complete application support is available from Dynalab Test Systems, including detailed application notes for each of these approaches.

NX Cable Testers have many more features and capabilities. To learn more, please visit the company’s website http://www.dynalabtesters.com or call 1-800-SOS-DYNA (USA/Canada Toll Free) or +614-729-6550.

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About Dynalab Test Systems, Inc.
Dynalab Test Systems, Inc. is a leading manufacturer of cable testers. Dynalab Test Systems supplies test equipment to many of the largest wire harness and cable assembly manufacturers in the world. With over 20 years of experience and over 20,000 testers sold, Dynalab Test Systems offers products that reflect an extensive level of industry knowledge and experience. The company’s systems, software, and services are designed to help wire harness manufacturers develop solutions for their testing needs quickly, reliably, and economically.

To learn more, please visit the company’s website http://www.dynalabtesters.com or call 1-800-SOS-DYNA (USA/Canada Toll Free) or +614-729-6550