New at SOMA: Bespoke test adapters and contact solutions with SOMA Connect

A test adapter connects the device under test electrically to the test system. That may sound like a minor detail. In practice, however, it determines whether measurement results are reproducible and whether the test sequence remains stable. If the contact drifts, the test result may also drift.

A test adapter must therefore do more than simply hold the component mechanically. It must be compatible with the geometry of the device under test, its electrical specifications, the cycle time, the environment and the existing test system. The design must take into account current, voltage, signal quality and EMC requirements. Added to this is the question of whether the mating and contact behaviour remains reproducible over the planned service life, and how servicing and spare parts will be organised in the future.

This is where SOMA Connect comes in, guided by the principle of ‘test adapters with test DNA’. SOMA has been manufacturing test technology for industry for over 50 years and, through its own systems, has in-depth knowledge of the test processes in which the adapters will subsequently operate. SOMA Connect combines this understanding of the processes with the contact and connector expertise of the KOSTAL Group.
 

From the individual test connector to the complete test adapter

A test connector is the individual electrical contact point to the test specimen. The test adapter is the complete assembly comprising the mechanical components, the mounting bracket and the integrated test connectors. SOMA Connect develops both components as a coordinated unit.

The portfolio encompasses a wide variety of contact types, such as:

• DC contacting
• AC contacting
• Water contacting
• Seal contacting
• Manual contacting
• Contactor contacting
• Communication contacting

SOMA’s test engineers work with the customer to determine which solution is most suitable during the requirements analysis.
 

Test adapters for laboratory, series production and high-voltage applications

In-line test adapters for series production

On the production line, a high number of mating cycles, short cycle times and consistent contact performance across every test specimen are essential. SOMA Connect’s in-line test adapters are designed for end-of-line testing, functional, communication, high-voltage and leak tests. Acceptance procedures and the service concept are documented.

Manual test adapters for laboratories and development

For prototype testing, validation and small-batch production, SOMA relies on modular design and flexible manufacturing, for example via 3D printing. This allows custom test adapters to be produced cost-effectively even in the early stages of development, from as little as one unit.

Test adapters for printed circuit boards and electronics

Assembled printed circuit boards are connected at defined test points: for in-circuit testing (ICT), functional tests and end-of-line (EoL) testing. Depending on the application, spring-contact-pin bed-of-nails fixtures or customised connector layouts are used, tailored to the existing test system.

High-voltage test adapters for e-mobility and the automotive sector

Drive controllers, inverters, on-board chargers and DC/DC converters place special demands on the contact design. SOMA Connect supplies high-voltage-rated and 4-pole contact assemblies for these applications, with active temperature control and integrated media connections on request.

For automotive control units, battery management systems and charging electronics, the design is based on the automotive industry’s series production standards. This is underpinned by the expertise of KOSTAL Kontakt Systeme as a connector manufacturer.

The test adapters are also used in the switchgear industry, in PV inverters and wall boxes. In these applications, they must withstand vibration, temperature fluctuations and contamination.
 

From the field:
High-voltage contacting for e-mobility

A project from the e-mobility sector demonstrates what SOMA is capable of in the high-voltage field (view case study). For a fully automated test system, SOMA has developed high-voltage and high-current contact systems for 800 V-class drive controllers. This contact system is rated for 1 kV and 1 kA, with an EMC-compliant design, 4-pole measurement concepts, active temperature control and integrated media connections. 

However, this is not the upper limit: SOMA has already implemented contact assemblies for voltages exceeding 1 kV.

Another example comes from Zollner Elektronik AG. There, SOMA has refurbished existing test set-ups and adapted them to new test variants. The interfaces to the existing test system were retained. Reusable components and a documented design shortened the time-to-production.
 

Five steps to the finished test adapter

The process begins with a technical consultation, during which SOMA’s test engineers analyse the test requirements, test specimen geometry, electrical specifications and interfaces to the test system. This is followed by the conceptual design, incorporating standard components, customer-specific elements or 3D-printed parts. Once approved, a binding delivery date is set.

The test adapter is then manufactured and tested against the agreed requirements. Tests may include, for example, electrical continuity, contact resistance and mechanical function. If required, SOMA also assesses the current-carrying capacity under the specified temperature conditions and presents this in derating curves. The scope of testing and documentation are agreed on a project-by-project basis. SOMA typically delivers prototypes within a few weeks.

SOMA also provides support with integration into existing test systems or incorporation into new installations. Even after delivery, SOMA remains available for maintenance, spare parts and modifications. On request, maintenance and service information can be accessed via a QR code on the test adapter.

For businesses, this means:

• reproducible measurement results from the very first test specimen
• less engineering effort required from their own team
• faster time-to-production thanks to tried-and-tested concepts
• a single point of contact from initial enquiry right through to the complete test system
• long-term supply of spare parts within the group
   

Support from the KOSTAL Group

SOMA Connect is a business division of SOMA GmbH and thus part of the KOSTAL Group. Together with KOSTAL Kontakt Systeme, a connector manufacturer with over 80 years’ experience in the automotive sector, SOMA Connect combines test technology, contact technology and industrial manufacturing. SOMA is ISO 9001 certified. Manufacturing takes place in Germany and, where required, at SOMA’s site in the Czech Republic.

Would you like to discuss your test requirements?

You can find full details on contact types, applications and references on the SOMA Connect test adapters page. Alternatively, describe your requirements to us directly. Our test engineers will get in touch with you.

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