Wire Harness Probes

Wire Harness Probes in a Test Module

For contacting connectors and sockets of a wire harness and for testing their functionality, various types of contact probes are required, which are also partly covered in other sections. Position tests of connector inlays are realized by step probes, switch probes and position sensor systems. Also, the twist-proof probes for connectors with slotted cavities are used. Ball probes and pneumatically actuated switch probes are often used for lateral presence detection. Radio-frequency probes are available for signal transmission, and specific high-current probes are required for connectors used in e-mobility applications.

Position Test with Step Probes

The test principle of a step probe is based on the fact that the plate of the probe is resting on the test object (e.g. connector housing) and thus a defined penetration depth into the connector housing can be realized. The pin of the step probe identifies by contacting the presence and/or the correct seating of the contact element. Feinmetall offers a very large variety of step probes with different diameters and pin lengths.

Contact Probe with LED for Guided Terminal Insertion of Connectors

The new LED contact probe system is a complete solution for guiding operators:

Guided insertion with LED indication of the correct cavity
Electrical continuity test of the wire harness in the same operation step

Previous solutions are either based on pure fibre indication in the cavity, without allowing electrical tests, or on LED indication next to the cavity, which is much less effective in terms of guiding the operator, leading to a higher risk of wrong assemblies.

Advantages of the LED contact probe solution
Both functions (LED indication and contacting) are included in one contact element. This leads to correct connector assembly and allows electrical test in one process step.