When designing electronic systems, device manufacturers will often outsource cables, such as USB, HDMI, or DisplayPort, from external vendors rather than building them in-house. For example, smartphone makers, laptop manufacturers, and gaming console producers frequently rely on third-party cables to simplify their supply chains and reduce costs.
While outsourcing can streamline production, it is crucial that third-party cables are thoroughly tested as variations in quality can vary widely between vendors and could ultimately compromise the performance and reliability of the final product. Comprehensive cable testing ensures safety and data transmission integrity, and verifies that the cable meets regulatory requirements as well as the manufacturer’s quality standards.
Photo by Using the Advanced Cable Tester v2 To Test Outsourced Cables
The Total Phase Advanced Cable Tester v2 is the quickest and most convenient solution for electronic device manufacturers to comprehensively test outsourced USB, HDMI, and DisplayPort cables used in their designs.
Combining blazing fast performance with a low cost-per-test, this cable tester enables rapid spot-checking of cables with easy-to-understand reports for 100% test coverage in lab and production environments at a fraction of the price, time, and labor versus other solutions. This tool has local storage of up to 1,000,000 test results and an option to create custom cable profiles. With high precision, accuracy, and thorough test coverage, the Advanced Cable Tester v2 provides real-time results for the following tests:
- Pin Continuity: this test analyzes the cable for any shorts or opens of various pins by applying voltage at one end of the cable and measuring the incoming signal at the opposite end of the cable. The following tests are conducted to ensure proper configuration: VBUS to Ground short, CC/VCONN to Ground short, VBUS to CC/VCONN short, shorts between all other pins, and continuity and mis-wires of defined and present pins.
- Direct Current Resistance (DCR): this test measures the DCR for all wires except high-speed data lines, and measures the DCR for all power and ground pins, as well as the total DCR of an entire USB-C cable. This test is performed by applying current at one end of the cable and then measuring various points along the cable to determine the resistance.
- E-Marker Verification: An E-marker is an integrated chip within a USB Type-C cable that stores the cable’s characteristics and specifications. Verifying E-marker content ensures the cable accurately reports its capabilities, including power capacity, data rates, and manufacturer details.
- Signal Integrity Test: this test measures the performance and signal quality of the cable by evaluating the differentially paired wires. Configurable from 1,030 MHz to 12.8 GHz, it can test up to five differential pairs. The test assesses signal quality through a speed test and provides easy-to-read eye diagrams that visually represent signal integrity. A well-made cable will display a wider eye, while a lower-quality cable will show a smaller eye opening. These diagrams include a mask to reference the Horizontal Eye Opening (HEO) and Vertical Eye Opening (VEO) values.
Performing Incoming Quality Control Testing to Ensure Cable Reliability
To help ensure device manufacturers are sourcing quality cables for their designs, it’s important to include thorough testing as part of the incoming quality control (IQC) process. This not only ensures compliance to established cable standards, but also a precise level of quality and safety required for reliable performance.
These quality and safety benchmarks are defined by industry standards organizations, which establish the compliance requirements and testing procedures for specific cable types, including USB (USB Implementors Forum (USB-IF)), HDMI (HDMI.org), DisplayPort (Video Electronics Standards Association (VESA)) and Apple (MFi program). Cables that pass compliance tests are able to use and display the respective certified logo.
While certified cables provide a baseline for selecting generally reliable cable designs, certification alone isn’t enough to ensure individual quality, especially in mass production. Even sourcing from vendors supplying “certified” cables, quality can vary, as many cable manufacturers don’t perform 100% quality control on every unit. That means device makers may still receive cables that technically meet compliance requirements, but fail to deliver consistent performance in real-world use.
The Advanced Cable Tester v2 makes it possible to perform individual quality control on each cable, ensuring they meet both cable and internal quality standards by performing a number of comprehensive tests. Each cable is evaluated using a defined test profile, and measured values are compared against the cable specification including checks for pin continuity, DCR (DC resistance), E-Marker accuracy, and signal integrity. Each test provides a clear pass or fail result, with the option to review detailed reports for further analysis.
By adding this extra layer of inspection, reliability is enhanced and system failures are minimized. Discover a real-world example where an infrastructure team at a Fortune 500 company used this tool to test third-party USB cables and improve the reliability of their mobile test farm.
Photo by Streamlined Cable Testing and Cost Savings
Comprehensive, individual quality testing on cables doesn’t have to be a burden to a manufacturer’s time-to-market. The Advanced Cable Tester v2 provides quick and efficient testing of multiple cable types within seconds at a low cost per test. Its intuitive interface and easy-to-understand reports make it accessible for engineers at any skill level. Additionally, it can be integrated into a test system through a network interface for remote operation. This greatly streamlines operations by identifying faulty cables early, helping to prevent downstream issues such as system instability and increased support efforts.
Furthermore, verifying cable quality with this tool helps manufacturers avoid costly warranty claims, product returns, and expensive recalls and repairs by catching cable defects before integration. In recent years, major companies like Amazon and Nintendo have faced serious issues such as electronics catching fire and power failures caused by faulty cables. These incidents can lead to lawsuits, costly recalls, and lasting damage to brand reputation. Preventing these outcomes with individual quality control testing with the Advanced Cable Tester v2 can save a company hundreds of thousands of dollars.
Conclusion
Ensuring safety and reliability of third-party cables is a critical responsibility for device manufacturers outsourcing cables for their designs. By implementing a comprehensive cable testing solution using the Advanced Cable Tester v2, manufacturers can not only verify compliance with cable standards, but also further improve product integrity and reduce long-term costs. This will efficiently ensure overall cable performance and reliability, protect a brand’s reputation, and deliver consistent value to consumers.
The Advanced Cable Tester v2 supports testing a large variety of cables via a system of easily interchangeable modules, including:
- USB Type-C to USB Type-C
- USB Type-C to USB Standard-A
- USB Type-C to USB Micro-B
- USB Type-C to USB Standard-B
- USB Standard-A to USB Micro-B
- USB Standard-A to USB Standard-B
- HDMI Type-A to HDMI Type-A
- DisplayPort to DisplayPort
Total Phase also offers a USB Type-C Connector Module Bundle and a Video Connector Module Bundle.
For more information on how our tools can help test third-party cables or develop and debug I2C, SPI, USB, or CAN systems, please email us at sales@totalphase.com or request a demo.
Total Phase Advanced Cable Tester v2