Standards
- 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)
Main Parameters
| Parameter | Specification |
|---|---|
| Load Range | 1–50 N (adjustable for light to heavy abrasion) |
| Abrasion Head | Tungsten carbide tip (1 mm diameter) or steel wool (customizable) |
| Stroke Length | 10–100 mm (programmable) |
| Test Speed | 10–60 cycles/min (adjustable) |
| Sample Dimensions | Up to 5 meters (cable length); 1–10 mm diameter |
| Control System | PLC-based with 7-inch touchscreen (multilingual interface) |
| Power Supply | 220V/50Hz, 200W |
| Dimensions | 600 × 450 × 1200 mm (L × W × H) |
Working Principle
The tester operates by controlled mechanical abrasion:
- Sample Mounting: Automotive wires or cables are clamped between two moving jaws.
- 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).
- Cycle Execution: The test runs until insulation breach or a predefined cycle count (e.g., 10,000 cycles) is reached.
- 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:
- Automotive: Validating engine bay wiring, door harnesses, and battery cables.
- Aerospace: Testing in-flight entertainment system cables.
- Consumer Electronics: Assessing USB-C and HDMI cable durability.
