What’s inside must endure and function reliably over time – ensuring safety at every interface
They may seem inconspicuous—yet they are critical to the system: connectors, crimp connections and electronic interfaces are among the key components of modern devices and vehicles. A single faulty connection can lead to signal loss or total failure—especially when exposed to vibration, heat, dust, water, high humidity or tensile stress over the course of years.
That is why we test every connection to its limits in AUCOTEAM’s accredited testing laboratory. Our services include all standard environmental simulation tests, and futhermore thermography, derating, dry-circuit testing, contact interruption (< 1 µs), current cycling, high-voltage testing, high-current testing, slow-motion bending tests, contact opening measurement and many more.
Services and Areas of Expertise
Whether it’s a plug, single pin, crimp connection, spring contact, sensor connector, module contact or multi-connector—we test interfaces of every kind. In doing so, we record all relevant thermal and electrical parameters under defined conditions—individually or in combination, for short periods or over weeks.
What we test:
Standards and Quality Assurance
Our testing procedures are based on the following standards and guidelines:
- IEC 60512 – Test methods for connectors
- GS 95006-7-1 – Wiring harnesses in motor vehicles – Connector testing
- GS 95006-7-2 – Slow-motion testing
- VW 75174 – Automotive connectors
- VW 75174-2 – Slow-motion testing
- VW 80332 – Automotive high-voltage contacts
- VW 80302 – Automotive High-Voltage Contacting
- MBN 10384 – Automotive Connectors
- MBN 10384-2 – Slow-motion testing
- LV 124 – Automotive Connectors
- LV 214 – Automotive Connectors (LV)
- LV 215 – Automotive Connectors (HV)
- FCA CS 00056 – Electrical and Electronic Components in Motor Vehicles
- DIN EN 62368-1 – Equipment for Audio/Video, Information and Communication Technology
- MIL-STD-810 – Environmental Engineering Considerations and Laboratory Tests
- RTCA DO-160G – Environmental Conditions and Test Procedures for Airborne Equipment
- SAE/USCAR – Performance Specifications for Automotive Electrical Connector Systems
All tests are performed using:
- Documentation of the test specimens, the test setup and the measuring and testing equipment
- Full collection of all measured values
- Evaluation according to standards or individually defined limit values
As an accredited testing laboratory (DIN EN ISO/IEC 17025), we provide you with globally recognized test reports:
- in digital form
- with presentation of measured values
- with comprehenisve photographic documentation
- recognized by official authorities
Testing Methods and Technologies
Our test benches and measurement systems are designed to reliably meet specific testing objectives—from individual connections to complex component assemblies. Tests are conducted statically, dynamically or cyclically—under documented conditions.
Mechanical tests
- Vibration and shock tests, including temperature or climatic stress
- Compression/tensile tests on crimped or welded connections as well as on plug contacts and pins
- Snap-fit tests: Opening/closing cycles of latches
- Pin Push/Pull: Compression/tensile tests on individual contacts
- Force-displacement analysis, including breaking force and deformation behavior
Electrical tests
- Contact Resistance Measurement
- Dry-circuit test
- Insulation resistance and dielectric strength
- High-voltage and high-current tests
- Derating and thermography
- Current cycling test
Thermal and climatic testing
- Rapid and slow temperature cycling from -75 °C to +250 °C
- Humidity exposure, condensation, long-term climate tests
- UV weathering for outdoor applications
Cyclic loads with constant monitoring
- Control of insertion cycles, force control, contact status
- Monitoring of contact temperatures and integration into current control
- Automated test sequences according to customer specifications (test automation)
- Recording and visualization of all relevant data and test steps
- Processing and editing of video data from thermography and live image recordings
Who We Test For– An Overview of Industries
Automotive & Electric Mobility
- LV and HV connectors
- Battery contacts and battery management systems (BMS)
- Charging infrastructure
Railway Technology
- Car and System Connections
- Track contacts
- Signaling and communication systems
Device Development / Industrial Electronics
- Connectors for Sensors, Power Components and Communication
- PCB connector systems
- Board-to-board connections (ribbon cables)
Smart Buildings & Building Automation
- Connectors for alarm, smoke and fire detection systems
- Window and door contacts
- Contacts for control units, actuators and connections for smart building applications
Customer benefits when working with AUCOTEAM
- Connector testing, slow-motion testing, thermography, derating – all from a single source
- Standard-based methods (VW, MBN, GS SAE/USCAR and many more) and customer-specific test procedures
- Realistic test procedures
- Can be combined with climate tests, endurance tests or IP tests
- Customizable test sequences and test rigs
- Perfect for research & development and series approval
- Fully documented results for audits, certification or internal quality assurance
- Consulting by experienced engineers with industry expertise
Have your connectors tested now!
Would you like to know the design limits of your connectors or contacts, or whether your connectors can withstand environmental influences in the long run?
Then talk to us. We simulate real-world conditions and provide reliable, comparable results—in compliance with standards and based on practical experience.