Nuline’s USP is our expertise in designing and manufacturing testing systems for the Automotive industry. These include custom developed test systems like racks, EMI/EMC boxes, breakout boxes, test jigs, cable harnesses and other such customised offerings.
The automotive industry relies heavily on test systems to ensure the safety, reliability, and performance of vehicles and their components. These systems range from simple mechanical setups to complex, computer-controlled simulations. They are used throughout the entire vehicle development process, from initial design and prototyping to final production and quality control.
Test systems in the automotive industry serve various purposes:
- Validating design and performance: Test systems are used to verify that components and systems meet design specifications and performance requirements. This includes testing things like engine power, fuel efficiency, braking performance, and handling.
- Ensuring safety: Safety is paramount in the automotive industry, and test systems play a crucial role in ensuring that vehicles meet safety standards. This involves crash testing, as well as testing of safety-critical systems like airbags and anti-lock brakes.
- Improving reliability and durability: Test systems are used to assess the long-term reliability and durability of components and systems. This includes subjecting them to extreme conditions, such as temperature variations, vibration, and corrosion.
- Meeting regulatory requirements: Governments around the world have strict regulations for vehicle safety and emissions. Test systems are used to ensure that vehicles comply with these regulations.
The automotive industry is constantly evolving, with new technologies like electric vehicles and autonomous driving systems being developed. Test systems are also evolving to meet the challenges of these new technologies.
Breakout Boxes:
A breakout box is a specialised piece of testing equipment used for troubleshooting and analysing electrical signals in a circuit. It acts as an intermediary between two connectors, providing access points to test individual circuits without disrupting the main connection. Modern vehicles have incredibly intricate electrical systems. Breakout boxes make it easier to pinpoint problems by providing clear access to each wire and connection.
Common Uses in Automotive Industry
- CAN Bus Diagnostics: The Controller Area Network (CAN bus) is the backbone of communication in modern vehicles. Breakout boxes are essential for diagnosing issues within this complex network.
- Sensor and Actuator Testing: Verify proper signals to and from various sensors (oxygen, temperature, etc.) and actuators (motors, relays, etc.).
- Wiring Harness Troubleshooting: Quickly identify shorts, open circuits, or miswired connections within a vehicle’s wiring harness.
- OBD-II Diagnostics: Some breakout boxes are designed specifically for the OBD-II (On-Board Diagnostics) port, providing access to its various pins for advanced diagnostics.
Advantages of Using Breakout Boxes
- Non-destructive testing: Avoids damaging wires or connectors by providing safe access points.
- Faster diagnostics: Speeds up the troubleshooting process by providing clear access to test points.
- Improved accuracy: Enables precise measurements and analysis of electrical signals.
- Versatility: Can be used with a variety of diagnostic tools.
With an unparalleled in-house R&D capability to understand end-to-end concept-to-product development needs, we assure you that your specifications will be converted to a functional product within no time with no compromise on quality.
All stages of product development are addressed by our qualified in-house team.
Over the years, we have developed numerous test systems.
Some of the projects we have undertaken include
- 196 pin break out boxes
- 154 pin break out boxes
- 130 pin break out boxes
- 112 pin break out boxes
- 94 pin break out boxes
- Reconfiguration of break out boxes
Automotive Test Jigs:
In the fast-paced world of automotive manufacturing, precision and efficiency are paramount. This is where automotive test jigs come into play. These specialised tools are essential for ensuring the quality, safety, and reliability of vehicles and their components.
Automotive test jigs are custom-designed fixtures that hold and support components or assemblies during testing procedures. They provide a stable and repeatable platform for various tests, ensuring accuracy and consistency in results.
Benefits of Using Automotive Test Jigs
- Enhanced Accuracy: Jigs provide a stable and repeatable testing environment, minimising variations and ensuring accurate results.
- Improved Efficiency: Jigs streamline testing procedures, reducing setup time and increasing throughput.
- Reduced Errors: By providing a consistent testing setup, jigs minimise the risk of human error and ensure reliable results.
- Increased Safety: Jigs help create a safe testing environment for operators, reducing the risk of accidents and injuries.
- Cost Savings: By improving efficiency and reducing errors, jigs contribute to cost savings in the long run.
Cable Harnesses: The Nervous System of Modern Vehicles
In the intricate world of automotive engineering, cable harnesses play a vital, yet often unseen role. They act as the central nervous system of a vehicle, connecting every electrical and electronic component, enabling communication and power distribution throughout the system.
A cable harness, also known as a wire harness, wiring harness, or wiring loom, is an organized assembly of wires, cables, terminals, and connectors designed to transmit electrical signals and power within a vehicle. These components are bound together by protective materials like:
- Tapes: Provide insulation and bundling.
- Ties and Straps: Secure the harness and prevent movement.
- Conduits and Sleeves: Offer additional protection against abrasion and environmental factors.
Why are Cable Harnesses Important?
- Organisation: They replace the chaos of loose wires with a structured, manageable system.
- Protection: They shield wires from damage caused by vibration, abrasion, moisture, and extreme temperatures.
- Space Optimisation: They bundle wires efficiently, saving valuable space within the vehicle.
- Ease of Installation and Maintenance: They simplify the assembly process and make it easier to locate and repair circuits.
- Reliability: They ensure consistent and reliable electrical connections, reducing the risk of failures.
Cable harnesses are essential for the operation of modern vehicles. They ensure reliable electrical connections, protect vital circuits, and contribute to the overall safety and performance of the vehicle. As technology advances, cable harnesses will continue to evolve, meeting the ever-increasing demands of the automotive industry.
Range of systems developed by us include
- Automotive engine simulators
- Body simulators
- Relay load boxes
- Load boxes – inductive and resistive
- Breakout boxes
- Endurance test load systems
- Cable/Wiring harnesses
- Test PCBs
To know more about the various kind of test systems that we develop, please visit our Concept-to-Product page.