Introduction
Cable Matters is a leading provider of connectivity solutions for homes, offices, and data centers. Their products are thoughtfully designed, carefully engineered, and extensively tested in-house to deliver an ideal customer experience. They offer a variety of AV/data cables, adapters, docking stations, and networking devices, supporting connectivity standards such as HDMI, DisplayPort, USB, Ethernet, and Thunderbolt. Being committed to ensuring the highest quality standards for their products, Cable Matters is continually improving their testing methods and production standards. A robust and reliable tool like the Advanced Cable Tester v2 is an integral part of their ability to deliver high-quality cables.
Background/Problem
Cable Matters offers innovative, reliable, and affordable technology accessories that empower everyday users to stay connected and productive. Their core products include USB, USB-C, HDMI, DisplayPort, Thunderbolt, Ethernet, and other AV/data cables, adapters, docking stations, and networking devices.
As the company expanded its product portfolio into more complex cables, like USB-C, HDMI 2.1, and DisplayPort 1.4, it remained focused on consistently delivering extensively-tested, high-quality cables. To support this goal, the Quality Assurance (QA) and Product Development teams, who perform product testing, supplier audits, compliance verification, and new product qualifications, evaluated the effectiveness of their existing testing methods.
They found that traditional testing methods, like basic continuity checks and wire mapping, were insufficient and costly. This led them to seek a comprehensive solution to accurately and efficiently verify signal integrity, pin mapping, wiring continuity, and shielding for high-speed cables.
Technical Approach
After being introduced to the Advanced Cable Tester v2, Cable Matters found it be a solution that met their requirements and seamlessly integrated into their lab and production environments. Unlike other solutions that lacked speed, thoroughness, or were exorbitantly expensive, the Advanced Cable Tester v2 provided a cost-effective and convenient way to comprehensively test complex cables. Since then, it has become a critical part of Cable Matters’ testing regimen, used daily in their R&D labs and incoming QA inspection lines.
Advanced Cable Tester v2 Test Parameters
The Advanced Cable Tester v2 performs a variety of quality and safety checks on USB, HDMI, and DisplayPort cables, reducing the need for multiple separate testing equipment. The numerous in-depth tests have also improved testing accuracy and efficiency, allowing for faster identification of defective cables, especially with complex, high-speed interfaces. Tests performed by the cable tester include:
Pin Continuity Test
The Pin Continuity 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. The real-time pin map visualization proved to be especially helpful in Cable Matters’ diagnosis of cross-wiring.
An example of a passing Pin Continuity test on a USB-C cable is shown here:
DCR Test
The Direct Current Resistance (DCR) 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 the 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.
An example of a failing DCR test on a USB-A to USB-C cable is shown here:
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.
An example of a passing E-Marker test on a USB-C cable is shown here:
Signal Integrity Test
The Signal Integrity 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. These tests proved to be especially helpful in Cable Matters’ diagnosis of shielding issues and impedance mismatches.
An example of a Signal Integrity test on an HDMI cable with passing and failing results is shown here:
Exceeding Cable Quality Expectations
By using the Advanced Cable Tester v2, Cable Matters was able to quickly diagnose shielding issues, cross-wiring, and impedance mismatches that would be otherwise be very difficult to detect. Its smooth integration into their current processes, combined with its intuitive user interface and detailed reporting, enabled lab technicians to adopt the tool quickly. As a result, the tool has become an integral part of their standard operating procedures including incoming random production audits, and new product qualification testing.
Since adopting the tester, Cable Matters has achieved a 50% reduction in inspection time for complex cables. It has also helped accelerate their time-to-market for new cable products by streamlining the R&D validation phase. Because of this, they’ve also seen a 25% reduction in RMAs (return merchandise authorization) related to cable failures. As their product portfolio and operations continue to expand, they plan on integrating additional units of the Advanced Cable Tester v2 into their supplier audit processes overseas.
Conclusion
As Cable Matters expanded their product portfolio with more complex cables, they required a cable testing solution that could efficiently and reliably verify cable quality. The Advanced Cable Tester v2 enabled their QA Product Development teams to successfully and accurately diagnose cable issues that would be difficult or impossible to detect using with alternative methods. Additionally, this tool has greatly streamlined their operations, reduced costs, and significantly lowered return rates related to cable failures.
Quote
“The Advanced Cable Tester v2 has become an essential tool for Cable Matters. Its precision, speed, and versatility have dramatically improved our cable testing processes, ensuring that we consistently deliver high-quality connectivity products to our customers.” – Product Quality Manager
Product Brief
The Total Phase Advanced Cable Tester v2 is the quickest and most convenient way to comprehensively test USB, HDMI, and DisplayPort cables. 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. With high precision, accuracy, and thorough test coverage, the Advanced Cable Tester v2 provides real-time results for pin continuity, DC resistance, signal integrity, E-marker, and other tests to ensure cables meet the required standards.