With the rapid growth of the new‑energy vehicle industry, wiring harnesses—key components for power transmission—have thermal‑rise performance that directly impacts the safety and reliability of the entire vehicle. Conventional thermal‑rise testing methods suffer from poor current stability, low measurement accuracy, and difficulties in data traceability, making it challenging to meet the stringent quality‑inspection requirements for new‑energy vehicle wiring harnesses.

Technical Challenges in Temperature Rise Testing of New Energy Vehicle Wiring Harnesses

Challenges in Current Stability Control During temperature‑rise testing of new‑energy vehicle wiring harnesses, fluctuations in supply voltage, variations in the resistance of connecting leads, and changes in the test specimen’s own resistance all compromise the stability of the test current, leading to inaccurate results. This effect is particularly pronounced in high‑current test scenarios, where conventional test equipment often fails to mitigate these sources of interference.

Complexity of High-Temperature Environmental Testing In practical applications, new‑energy vehicle wiring harnesses must withstand high‑temperature environments, particularly when operating in hot zones such as the motor compartment. Conventional testing methods lack effective control over high‑temperature conditions, making it difficult to replicate real‑world operating scenarios and to assess the harness’s thermal‑rise characteristics under elevated temperatures.

Data Traceability and Quality Control Requirements Modern manufacturing places increasingly stringent demands on product quality traceability. For new‑energy wiring harnesses, temperature‑rise test data must be linked to batch information, production dates, and other relevant details to establish a comprehensive quality‑control system. Conventional testing methods, however, exhibit significant shortcomings in data storage, retrieval, and traceability.

Technical Proposal for the Zhongjia Temperature Rise Testing System

ZJ-WS500A Temperature Rise Test System: Precise Constant Current Control Technology The ZJ-WS500A temperature rise test system developed by ZHONGJIA EQUIPMENT utilizes constant, adjustable current output technology, capable of stably delivering a test current ranging from DC 0 to 500.0 A. By employing advanced current control algorithms, the system effectively mitigates the impact of power supply voltage fluctuations, variations in the resistance of connecting leads, and changes in the specimen’s resistance on the test current, thereby ensuring the accuracy and consistency of test results.

The system supports 30 current‑time segments, enabling complex thermal cycling test profiles. With a cycle‑count setting ranging from 1 to 9,999 and an integrated power‑off memory function, it ensures continuity throughout long‑term testing. The voltage‑drop measurement feature (0–500 mV, resolution 0.1 mV, accuracy 1%) accurately characterizes the voltage drop of wire harnesses under high‑current loads.

High-Temperature Environmental Integration Testing Capability To meet the demanding high-temperature operating conditions of new‑energy vehicle wiring harnesses, Zhongjia Testing has launched the ZJ‑WS1500A temperature‑rise test system, which includes a high‑temperature chamber. This system integrates specialized high‑temperature control equipment, with a temperature‑control range spanning ambient conditions to 100°C, a temperature resolution of 0.1°C, and temperature deviation maintained within ±2°C.

The system delivers a high‑current output ranging from DC 10 to 1500.0 A, meeting the testing requirements of high‑power new‑energy vehicle wiring harnesses. The voltage‑drop measurement range has been extended to 0–1000 mV, while the resistance measurement range spans 0–200 mΩ with a resolution of 0.1 mΩ and an accuracy of 1%, enabling comprehensive evaluation of the electrical performance of wiring harnesses under high‑temperature, high‑current conditions.

Multi-point temperature monitoring and data analysis Both systems are equipped with 16 temperature measurement channels (including ambient temperature), with a temperature measurement range of 0 to 200°C and an accuracy of ±1% of reading plus 1°C. The thermocouple connector design allows for easy disconnection and reconnection, enhancing operational efficiency. The temperature data acquisition module can record temperature variations in real time, while the computer automatically generates temperature–time curves and supports automatic subtraction of the ambient temperature channel.

Intelligent Security Protection Mechanism The system features a built-in smoke‑detection alarm: when smoke is detected, the equipment immediately triggers an alarm and shuts off current output, effectively preventing safety incidents. The touchscreen provides real-time displays of current, time, temperature, and relevant trend curves, allowing operators to monitor test status and historical data at any time.

Application Value and Industry Fit

The quality control system is well-established. Zhongjia Testing’s temperature‑rise testing system provides a comprehensive quality‑control solution for new‑energy wiring harness manufacturers. The system is not only suitable for new‑energy wiring harnesses but can also be widely applied to the production, quality inspection, and research of products such as charging guns, connectors, grounding resistance testers, appliance switches, plugs and sockets, switchgear, busbars, and more.

Production Efficiency and Cost Control Through automated testing workflows and precise temperature control, the system significantly enhances testing efficiency, minimizes manual intervention, and reduces testing costs. The power‑off memory feature ensures stability during extended test runs, preventing test interruptions and data loss caused by unexpected power outages.

Adaptability to Technological Development Trends As new‑energy vehicles evolve toward higher voltages and greater power levels, the requirements for wire harness current‑carrying capacity and thermal‑rise performance will continue to increase. Zhongjia Testing’s thermal‑rise testing system, with its modular design and technological upgrades, is able to meet the demands of industry‑wide technological advancements, providing customers with long‑term, reliable testing solutions.

Conclusion

The technological advancements of the new-energy wiring harness temperature-rise testing system have not only enhanced testing accuracy and efficiency but have also provided crucial technical assurance for the safe development of the new-energy vehicle industry. Through continuous technological innovation and product optimization, ZHONGJIA EQUIPMENT has delivered professional, reliable temperature-rise testing solutions to new-energy wiring harness manufacturers, thereby elevating the overall industry’s testing standards. Looking ahead, as new-energy vehicle technologies continue to advance, temperature-rise testing systems will play an even more pivotal role in ensuring product quality and driving industry growth.