A leading automotive wiring harness manufacturer faced recurring challenges during cable validation. Their cables undergo continuous bending and twisting in real-world environments—inside vehicle doors, dashboards, tailgates, steering systems, and various other moving mechanisms.
However, their existing testing methods were manual, inconsistent, and time-consuming, resulting in:
Delayed product approvals
Higher testing costs
Frequent cable failures due to unpredictable stresses
The Challenge
The client required a durable, accurate, and operator-friendly test solution capable of replicating real-world mechanical stresses. Their key pain points included:
1. Frequent Cable Failures
Caused by improper and inconsistent stress analysis
2. Lack of Repeatable Testing Parameters
Manual testing with no standardized method
Variation in test angles, cycles, and speeds
3. Limited Test Visibility
No accurate tracking of:
Rotation counts
Bending angles
Cycle progression
4. High Maintenance Downtime
Time-consuming setup adjustments
Difficulty in servicing existing equipment
5. Operator Safety Concerns
Exposure to rotating parts
No protective enclosure or automated safety controls
6. Absence of Standardized Durability Validation
No reliable method to predict long-term cable performance before mass production
The client needed a reliable Bending & Torsion Test Setup to streamline quality checks and accurately predict cable life.
The Solution: enProducts® Bending & Torsion Test Setup
enProducts® provided a specialized, precision-engineered Bending and Torsion Test Setup designed to evaluate cable endurance through repetitive bending and twisting cycles.
The system accurately simulates real-world mechanical movements with high precision, long-term repeatability, and operator safety.
Key Features & Enhancements
1. Customizable Cycle Parameters
Operators can configure:
Bending angle
Torsion angle
Rotational direction (CW/CCW)
Speed
Dwell time
Based on specific testing standards and requirements
2. High-Capacity Cycle Testing — Up to 1 Million Cycles
Supports long-term endurance validation
Suitable for automotive-grade wiring harness reliability testing
3. Adjustable Tensile Load Testing
Allows cables to be tested under controlled tensile load
Mimics real installation and operating stress conditions
4. Automatic Test Resume After Power Interruption
Smart memory system resumes from the last recorded cycle
Prevents test repetition
Reduces testing time and improves efficiency
5. Digital Display for Real-Time Monitoring
Shows:
Cycle counts
Test parameters
Operational status
Offers complete test visibility and easier documentation
6. Robust, Low-Maintenance Mechanical Design
Built for continuous operation
Ideal for production floors and R&D laboratories
7. Advanced Safety Features
Protective guards
Safety sensors
Controlled motion mechanisms
Ensures safe operation with minimal risk to operators
Results & Impact
The upgraded test setup enabled the manufacturer to:
Standardize their cable validation process
Improve cable durability and mechanical performance
Reduce early-stage failures
Accelerate product approvals
Enhance overall reliability of automotive wiring harnesses
This solution ensured safer, more reliable, and higher-performing cables for the automotive sector.