AEROSPACE CASE STUDY
Applications Consulting / 2-Day
January 2025
Designing & Implementing Hipot Testing Best Practices
Overview
A global aerospace company that produces and tests wire harnesses for use in commercial and defense aircraft engaged Ikonix Consulting to develop electrical testing best practice guidelines, train its operators, and improve its overall safety processes.
Wire harnesses are a network of electrical components, wires, and connectors that join different systems and components within an aircraft such as those transmitting power, signals, and data between electrical devices, instruments, and control systems. Since these harnesses are critical aircraft engine components, stringent point-to-point continuity and isolation testing must be completed to ensure their safety and reliability.
The client, which had been using an automated third-party testing system, contacted Ikonix Consulting to discuss enhancing operator protection and improving testing efficiency following multiple safety incidents.
Day 1: Test Setup, Hands-on Best Practices Workshop
The consulting engagement was completed over two successive days.
The first day consisted of evaluating the client’s hipot testing setup and making several adjustments. Next came a hands-on electrical testing best practices workshop for both the production and implementation teams.
A 14-pin harness was the first product tested. The 24-step test sequence included processes for continuity, DC dielectric withstand (DCW), and insulation resistance (IR). The initial tests revealed an incorrect pin configuration which was quickly resolved by reprogramming the test sequence.
HypotULTRA® 7800 and SmartGFI®
Since the client’s concern centered around operator safety, the Ikonix consultant demonstrated the SmartGFI functionality which is standard on all Associated Research HypotULTRA 7800 series hipot testers.
SmartGFI provides maximum operator protection by detecting excessive current leakage in the event a device under test (DUT) is isolated from ground, instantly saving test operators from electrical shock if they come into contact with high voltage.
The SmartGFI functionality was verified using an oscilloscope. This instrument indicates whether a ground-fault-generated fast circuit shutdown took place during hipot testing.
Next, a cable harness of up to 90-pins was tested. Due to the short cycle time required by the DUT, a third-party switching system was needed to complete the test in the allotted time. After making parameter, timing, and scripting adjustments, the combined Ikonix and third-party system successfully completed test sequence testing.
Day 2: Additional Sample Testing
Programming test routines and completing sample tests of additional harness types kicked off the second day of the consulting engagement. This included assisting the third-party system builder develop a proper test sequence for multiple products.
Results
The implementation of the Associated Research HypotULTRA 7850 system, with its embedded Smart GFI operator protection capability, significantly enhanced the safety and reliability of the client’s testing processes. Key to this was the new system’s capacity to accurately identify faults that the client’s previous system had overlooked (despite slower test cycle times).
In addition, integration of a third-party multiplexer made handling complex wire harnesses more efficient, eliminating the need for custom test leads by simplifying the setup and reducing potential errors.
Summary
This case highlights the importance of adaptability and collaboration in resolving complex technical challenges. By addressing the client’s safety and efficiency concerns, Ikonix provided a robust solution that not only met their immediate needs, but also offered long-term competitive benefits that included installation of a best practices-based testing environment, more knowledgeable production teams, process streamlining, and higher product testing throughputs.
Consulting Scope of Work
- Development, implementation, and operator training of an industry best practices electrical testing framework.
- 90-pin cable harness testing – including continuity, DCW, and IR.
- Setup and programming of Associated Research HypotULTRA series hipot testers and SC6540 multiplex scanners.
- Integration of standard HypotULTRA 7800 series SmartGFI capability to prevent shock incidents during high-voltage testing.
- Third-party software test script programming.
- Collaboration with third-party system builder.