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Test plugs are assemblies made from different high-performance materials. They are used as standard for reliable 100% testing of vehicle electronics by leading manufacturers in the automotive industry. They are supplied directly ex works as a plug-and-play module. Also ideal for combined function/swash circumference tests thanks to the optional infeed ramp.
 

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The material combination of high-performance ceramics, engineering plastics and metal provide a perfect balance of all required properties:

Our ceramic test plugs perform multiple tasks simultaneously. First of all, of course, they perform functional tests and the programming if necessary. The swash circumference test then checks the pluggability of the assembly. The swash circumference describes how far the contact pins are permitted to deviate from the target position in the X and Y direction. Its size is specified as a diameter. If the pins deviate from it, they are pressed against the very hard but fracture-resistant ceramic test plug during the test process and the drive system stops. This approach ensures that rejects are easily detected.

Beneficial characteristics of the ceramic test plugs:

  • Extremely wear-resistant ceramic for substantially longer service lives
  • Non-magnetic
  • Can also be used to realise the smallest geometries: 0.3 mm wall thickness
  • High technical purity: no abrasion in the component, no incorrect measurements, no premature failure of the pogo pins

Different test plug variants

DOCERAM - Test plugs

DOCERAM - Test plugs

DOCERAM - Test plugs

DOCERAM - Test plugs

Swash circumference plug-in test

Process reliability, product quality – we know what matters

DOCERAM - Test plugs
Contact pin outside the swash circumference = NOK
DOCERAM - Test plugs
NOK contact pin is bent, which means contacting is not possible

Ceramic

Swash circumference plug-in test

DOCERAM test adapters made from high-performance ceramics for reliable 100% testing of vehicle electronics are already in successful use as standard by leading automotive suppliers.

DOCERAM - Test plugs
NOK contact pins = abrasion / dirt
DOCERAM - Test plugs
Abrasion / dirt = massively reduced pogo pin service life = shape / tolerance of plug NOK

Plastic

Abrasion / signs of wear

Compatible Materials

Material - Cerazur

Cerazur®

When used in technical applications, Cerazur offers enormous potential for designing procedures and processes that are more stable, durable and ultimately more reliable.

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Zirconium oxide

Zirconium oxide is an inorganic non-metal material that belongs to the group of oxide ceramics.

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Properties Unit Cerazur Aluminium oxide
Composition - ZrO2 Y-PSZ AI2O3
>99.7%
Colour - blue ivory
Density (g/cm3) 6 3.9
Flexural strength (MPa) 1300 390
Compressive strength (MPa) 3000 3900
E-modulus (GPa) 205 390
Impact resistance (MPa m1/2) 12 5.2
Weibull modulus - 25 12
Vickers hardness (HV 0.5) 1150 2000
Thermal expansion (10-6K-1) 10 5.5-8.4
Thermal conductivity (W/mK) <2d>28
Thermal-shock resistance (ΔT°C) 280 120
Maximum operating temperature (°C) 1000 1700
Specific resistance at 20°C (Ω cm) > 1010 > 1017
Dielectric strength (kV/mm) - 22