Automotive Wire Scratch Resistance Tester

Applicable Standards

The tester adheres to global standards for material abrasion testing, including:

• ISO 6722-1 (Road vehicles – Electrical cables – Test methods for abrasion resistance)
• SAE J2394 (Standard test for electrical resistance of automotive wire insulation under abrasion)
• LV 112 (Volkswagen standard for automotive cable durability)
• GB/T 5023 (China’s national standard for electric cables – Abrasion tests)
• UL 758 (Appliance Wiring Material standard for insulation integrity)

These standards ensure consistent evaluation of wire insulation durability, coating adhesion, and resistance to mechanical wear.

Main Parameters

Working Principle

The tester operates by controlled mechanical abrasion:

1. Sample Mounting: Automotive wires or cables are clamped between two moving jaws.
2. Abrasion Cycle: A weighted abrasive head (e.g., tungsten carbide) moves back and forth across the wire surface at a preset load (e.g., 20 N) and speed (e.g., 30 cycles/min).
3. Cycle Execution: The test runs until insulation breach or a predefined cycle count (e.g., 10,000 cycles) is reached.
4. Performance Assessment: Post-test, samples are evaluated for insulation damage, conductor exposure, or coating wear using microscopy or electrical continuity tests.

Test Principle & Applications

• Abrasion Resistance Testing (ISO 6722-1/SAE J2394):
  • Wires are subjected to 5,000–20,000 cycles to simulate years of vibration and friction.
  • Pass/fail criteria: No conductor exposure or insulation breach (e.g., <0.1 mm wear depth).
• Key Industries:
  • Automobil: Validating engine bay wiring, door harnesses, and battery cables.
  • Luft- und Raumfahrt: Testing in-flight entertainment system cables.
  • Consumer Electronics: Assessing USB-C and HDMI cable durability.

The Automotive Wire Scratch Resistance Testing Machine is essential for manufacturers developing robust wiring systems, ensuring compliance with safety standards and minimizing field failures. Its precision and adaptability make it a cornerstone of automotive component testing laboratories.