Whether testing for voltage withstand, inductance, capacitance, resistance, or triboelectric noise, we perform a variety of electrical tests on the custom cables we manufacture every day. Come take a virtual tour of our lab and see a sample of the tests we regularly offer.
In this tour of the New England Wire Technologies electrical testing lab, design engineer Tom Paquet showcases the advanced equipment and instrumentation used to ensure compliance, safety, and performance for custom cables. The lab works closely with customers to co-develop custom test methods for validation programs and first-article qualification.
Key testing capabilities include:
- High-Potential (Hi-Pot) Testing: Verifies dielectric insulation integrity and qualifies voltage ratings up to 50 kV AC, with leakage current testing up to 1 amp.
- LCR Meter Testing: Routine in-process and final testing of fundamental electrical properties: inductance ($L$), capacitance ($C$), and resistance ($R$).
- Vector Network Analyzer (VNA) Testing: Evaluates high-frequency RF transmission cables (coax, twinax) from 100 kHz up to 26.5 GHz, measuring differential impedance, intra-pair skew, return loss, insertion loss, and eye pattern analysis.
- 100% In-Line Spark Testing: Continuously verifies insulation integrity during primary wire extrusion to catch pinholes and dielectric defects immediately.
- Thermocouple Calibration & Testing: Validates temperature sensors based on the Seebeck thermoelectric effect against strict industry standards.
- Low-Noise Triboelectric Testing: Measures friction-induced electrical charges via ANSI/AAMI EC53 standards using a suspended weight-drop shock test monitored by an oscilloscope.
- Environmental Chambers & Accelerated Aging: Employs thermal ovens, humidity chambers, and cold chambers to accelerate thermoplastic aging and verify long-term physical and electrical retention.
Key Technical Takeaways
- Hi-Pot Voltage Limits: Capable of testing insulation breakdown up to 50 kV AC and leakage currents up to 1 A.
- High-Frequency RF Characterization: VNA testing up to 26.5 GHz measures impedance, insertion/return loss, skew, and eye diagrams.
- 100% Manufacturing Coverage: Continuous in-line spark testing monitors all primary insulation during active extrusion.
- Standardized Triboelectric Testing: Evaluates low-noise medical and sensor cables per ANSI/AAMI EC53 guidelines.
- Environmental Durability: Accelerated aging in thermal, cold, and humidity chambers validates long-term polymer performance.
Electrical Testing Lab Video Tour Transcript
Welcome to the Electrical Testing Lab
Hi, I’m Tom Paquet, a design engineer at New England Wire. Today we’d like to show you around our electrical testing lab. We utilize state-of-the-art equipment and instrumentation to ensure compliance and provide the highest quality products. We work closely with customers to co-develop test methods for validation programs and first article production. Let’s take a look.
High-Potential (Hi-Pot) & LCR Meter Testing
The high potential voltage tester, also known as hipot tester, confirms quality of insulation and qualifies a cable for the customer’s voltage rating. At NEWT, we can test products up to and including 50 kV AC, as well as perform leakage current measurements up to one amp.
An LCR meter is one of our more basic pieces of electrical test equipment. Whether it’s inductance, capacitance, or resistance, these measurements are routinely performed both in process and at final testing.
Vector Network Analyzer (VNA) for RF Transmission Lines
The VNA is used to qualify the performance of high-end transmission cables, such as twinaxes and coaxes, designed for RF applications. We commonly use this equipment to define raw cable performance characteristics of imaging and data transfer cables.
Examples of some tests are: differential impedance, intra-pair skew, return loss, insertion loss, and eye pattern analysis. This machine can test products over the range of 100 kHz to 26.5 GHz.
In-Line Spark Testing & Thermocouple Sensor Validation
Our in-line spark testing is performed on 100% of our primaries, testing continuous quality of insulation during the manufacturing process.
Thermocouples are used as sensors for temperature measurement. Two wires made of dissimilar materials fused on one end, sometimes known as the measuring point, produce a voltage on the other ends due to thermoelectric effect, specifically the Seebeck effect. This voltage changes if the temperature at the fused end changes. The voltage generated is converted into units of heat like Celsius or Fahrenheit. This test validates that the thermocouples you receive have been tested to industry standards.
Low-Noise Triboelectric Testing (ANSI/AAMI EC53)
The low noise tester tests for triboelectric noise. When cables are flexed or handled, internal components rub against each other, causing electrical charges to form, which causes electrical noise, also known as triboelectric noise. New England Wire tests low noise cables per ANSI/AAMI EC53 for ECG trunk cables and patient lead wires.
Basically, the cable is connected at both ends and to an oscilloscope. A weight is attached to the center of the cable and then dropped, generating noise that can be measured on the oscilloscope.
Environmental Chambers & Accelerated Material Aging
Ovens, humidity chambers, and cold chambers are primarily used at NEWT to qualify thermoplastics used for the extrusion process to see if they will meet one of many industry standards.
These thermoplastics are initially tested for physical and electrical properties. Then they are placed in an oven or chamber for a predetermined time period, with set conditions that accelerate the aging process. After the required time has passed, the aged samples are again tested for the same physical and electrical properties, and comparisons are made to the pre-aged samples.
We hope you enjoyed touring our electrical testing lab. If you have additional questions or require custom testing, please contact us at newenglandwire.com.