Wire Harness Testing Methods: Continuity, Hipot, and Insulation Resistance Explained
A single wiring defect in a cable harness can cause anything from an intermittent fault to overheating, system failure, or fire. Visual inspection alone cannot detect damaged insulation, voltage-dependent shorts, or insulation resistance that has degraded below an acceptable threshold. Therefore, electrical testing of wire harnesses is critical across a wide range of applications. This applies to automotive body harnesses, aerospace interconnects, multi-conductor medical cables, EV high-voltage systems, industrial power distribution assemblies, and other cable assemblies used in reliability-critical environments. Each conductor must be verified for correct connectivity, insulation integrity under voltage stress, and compliance with insulation resistance requirements [...]
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