What are the applications of voltage testers in the automotive industry
The voltage tester is a core safety testing equipment in the automotive industry. Its core function is to test the insulation and voltage resistance performance of automotive electrical systems/components, avoid safety hazards such as leakage, short circuit, and breakdown, and adapt to the full process testing from components to the whole vehicle. It is classified and organized according to "compo
The voltage tester is a core safety testing equipment in the automotive industry. Its core function is to test the insulation and voltage resistance performance of automotive electrical systems/components, avoid safety hazards such as leakage, short circuit, and breakdown, and adapt to the full process testing from components to the whole vehicle. It is classified and organized according to "component testing", "whole vehicle testing", and "special scenario testing", with a clear structure that is in line with the actual industry situation:
1、 Core application logic (clarify the underlying role first)
Automobiles are a hybrid system of high voltage (new energy) and low voltage (traditional) electrical systems. The voltage tester applies a test voltage higher than the rated voltage for a specified period of time to determine whether the insulation layer is broken down and whether the leakage current exceeds the standard, ensuring:
1. Electrical components/lines have reliable insulation and no leakage;
2. No electrical faults occur under extreme working conditions (bumps, high temperatures, humidity);
3. Comply with mandatory safety standards in the automotive industry (such as GB/T 18384, ISO 6469).
2、 Core application scenario 1: Automotive parts inspection (mass production sampling/mandatory factory inspection)
This is the main application scenario of the voltage tester, covering all electrical components of the vehicle, and is a key testing item for the qualified delivery of components
1. High voltage components for new energy vehicles (core high-frequency applications)
Testing objects: power battery pack, motor, motor controller, OBC car charger, DC/DC converter, high-voltage wire harness, high-voltage connector, fuse
Detection function: The high voltage system voltage of new energy vehicles is mostly between 300V-800V. Insulation failure can cause electric shock and fire. Voltage withstand testing can investigate insulation layer damage, terminal creepage, and insulation aging problems, avoiding leakage and breakdown after installation.
Testing focus: The high-voltage insulation between the high-voltage terminal and the housing (grounding terminal) is used to prevent high-voltage electricity leakage to the vehicle body.
2. Traditional low-voltage electrical components for automobiles
Test objects: wiring harness assembly (engine wiring harness, body wiring harness), relay, fuse box, dashboard, headlights (headlights/taillights), air conditioning compressor, wiper motor, car audio and video equipment
Detection function: Although the voltage of the low-voltage system (12V/24V) is low, insulation damage can cause short circuits, erosion, and vehicle malfunctions (such as the lights not turning on or unable to start). Voltage withstand testing is used to check for broken wiring harnesses and poor internal insulation of components.
Key points of testing: voltage resistance between wires, between wires and shielding layer/grounding, to prevent cross current and leakage.
3. In car electronic components
Test objects: ECU electronic control unit, sensors (tire pressure/water temperature sensors), car charger, inverter
Detection function: To investigate the insulation of internal circuit boards and insufficient creepage distance between pins of electronic components, avoid breakdown and damage during operation, and ensure the stability of the electronic control system.
3、 Core application scenario 2: Vehicle assembly post inspection (offline final inspection)
After the completion of vehicle assembly, voltage withstand testing is a necessary inspection item for the electrical safety of the entire vehicle, to avoid electrical hazards caused by component assembly errors
1. Vehicle high-voltage system withstand voltage testing (exclusive for new energy)
Detection range: Vehicle high-voltage circuit (battery → motor → charger → high-voltage harness)
Detection function: To investigate issues such as compression damage of high-voltage wiring harnesses, incorrect connector insertion, and loose insulation fixation during the assembly process, ensuring that the high-voltage system of the entire vehicle has no leakage, which is the core safety check before the new energy vehicle leaves the factory.
2. Voltage withstand testing of the low-voltage electrical system of the entire vehicle
Testing scope: Low voltage wiring harness network of the entire vehicle, electrical equipment for the entire vehicle
Detection function: Check for broken wires, poor grounding, and incorrect wiring of components during assembly, to avoid short circuits and power outages during vehicle operation, and to prevent fires.
3. Linkage detection of vehicle grounding system
Detection logic: Combining withstand voltage testing with grounding resistance testing to determine whether the grounding of electrical components is reliable, avoiding poor grounding that leads to insulation withstand voltage not meeting standards, and preventing static electricity accumulation from causing faults.
4、 Core application scenario 3: Special scenario detection (R&D/aging/after-sales)
Covering non mass production stages to ensure electrical safety throughout the entire lifecycle of automobiles
1. Reliability testing during the R&D phase
Application scenarios: New vehicle development, new component selection
Detection function: After simulating extreme working conditions (high temperature, low temperature, vibration, humidity), perform voltage withstand tests on components/systems to verify the stability of insulation performance and provide data support for design optimization (such as the aging insulation performance of high-voltage wire harnesses).
2. Aging/durability testing matching
Application scenarios: Accelerated aging test of components, after vehicle durability road test
Detection function: To detect whether the insulation layer has aged or cracked after long-term use, determine the service life of components, and avoid insulation failure during vehicle service.
3. After sales maintenance and testing
Application scenarios: High voltage fault repair of new energy vehicles (such as battery pack detection after collision), low voltage circuit short circuit repair
Detection function: Check whether the insulation of the electrical system meets the standard after maintenance, to avoid secondary faults caused by improper maintenance (such as undetected insulation damage of the high-voltage wire harness after maintenance).
5、 Specialized testing requirements for the automotive industry (adapted to industry standards, highlighting professionalism)
1. Testing standards: Must comply with exclusive automotive industry standards, not General Electric standards
New Energy Vehicles: GB/T 18384.1-2025 (Safety Requirements for Electric Vehicles), GB/T 31467.3 (Safety of Power Batteries)
Traditional automobiles: GB 7258 (Technical Conditions for Motor Vehicle Operation Safety), QC/T 29106 (Technical Conditions for Automotive Wiring Harness)
2. Test parameters: Suitable for automotive electrical characteristics
Low voltage components: The test voltage is mostly 500V AC/1000V DC, and the test time is 1-3 minutes
High voltage components: Test voltage 2000V-5000V AC/DC, adapted according to the rated voltage, test time 1-5 minutes
3. Special requirements: It needs to be adapted to automotive working conditions, support "withstand voltage+insulation resistance" dual detection, and some scenarios require waterproofing and anti-interference (suitable for complex workshop environments)
WeChat number：
Home
Product
Wechat
Telephone