Cable Tester

The Cable Tester streamlines cable validation with interchangeable cartridges—combining electrical testing and serviceability in one modular platform.

OVERVIEW + BACKGROUND

Reducing Repair Costs

Pason Systems | Internship Project
Role: Lead Mechanical Design & Electronics Integration
Concept to Deployment: Five Months
Team Members: Three (Two Electricals & Myself)

Background & Problem

Pason provides rental equipment used to collect data, monitor personnel, and track hazards in demanding environments.

Its devices rely on custom cables designed for explosive and exposed conditions, where a single failure can take critical equipment out of service.

With over 2,000 custom cables in Pason’s inventory, reliable testing is essential to reduce downtime, replacement costs, and the risk of field failures.

Existing solutions resort to using custom connector panels such that the cables can be mated on both sides. From here, a 'Hipot' (high voltage) test and continuity test ensure no current leaks through and that all individual pins work.

So what is the problem?

Every Cable Counts

With the average cable costing around $160 CAD, being able to repair even a small percent makes a huge difference.

Why existing options didn't work

Maintenance and testing cycles
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Even a single failed connector could take the entire panel offline, halting cable testing for days while repairs were completed.

Quantity of connectors used
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A single pannel would need constant updating to refelct the dozens of connectors introduced every year.

Shipping and installation
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Large, fixed test panels were difficult and costly to ship, install, and replace across global facilities.

Erganomics and cable variety
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With cables ranging anywhere from 1 to 52 pins, as well as some weighing up to 100 lbs, single pannel solutions often fail to accomodate this range of form factors.

Region specific approved cables
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Different regions require specific cable and connector configurations, making a universal fixed panel inefficient.

Process optimization and autonomy
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Exisiting setups relied heavily on manual test speed, with considerable time loss is finding specific connectors on large panels.

Eliminating The Unknowns

Development began by defining the extremes the tester needed to support, including the largest connector footprint, heaviest cable assemblies, and maximum pin count. These requirements established the mechanical envelope and PCB trace count and width required for safe high-voltage testing.

Prototyping Different Iterations

The tester progressed through 16 design iterations, with each prototype 3D printed for hands-on testing and feedback from the technicians who would ultimately use it. Each revision improved ergonomics and serviceability while ensuring the final design remained inexpensive and straightforward to machine.

A modular cable testing platform combines interchangeable connector cartridges, positive-locking handles, and precision locating features to accommodate a wide range of cable types.

July 18, 2025

Assembly of Final Rev.

Through making the cable tester a cartridge-based system, future cables of any kind can have their corresponding connectors made into cartridges and added to the existing inventory for all corporate manufacturers to seamlessly adopt & integrate.

Through making the cable tester a cartridge-based system, future cables of any kind can have their corresponding connectors made into cartridges and added to the existing inventory for all corporate manufacturers to seamlessly adopt & integrate.

Through making the cable tester a cartridge-based system, future cables of any kind can have their corresponding connectors made into cartridges and added to the existing inventory for all corporate manufacturers to seamlessly adopt & integrate.

61%

Reduction in wasted cables. Faulty pins can be identified and fixed before deployment.

61%

Reduction in wasted cables. Faulty pins can be identified and fixed before deployment.

61%

Reduction in wasted cables. Faulty pins can be identified and fixed before deployment.

50000 Cycles

Robust design capable of withstanding thousands of testing cycles.

Deployed in over 20 facilities

50000 Cycles

Robust design capable of withstanding thousands of testing cycles.

Deployed in over 20 facilities

50000 Cycles

Robust design capable of withstanding thousands of testing cycles.

Deployed in over 20 facilities

Future Proofing | Cartridges

What separates this design from existing cable testers on the market is the ability to change out connectors based on what cables are being tested at any given moment. Each cartridge is constructed from four key components, optimized for both cost and durability.

Robust aluminum shell for machined precision and contact grounding.

Matching male and female connectors allow for individual pin testing.

Main module board delivers 1000 volts to test for arcing between up to 52 pins.

Flex PCBs implemented for all form factors with resistor identification.

  1. Cartridges have built in keying features to ensure they can only be inserted in one orientation to prevent assembly or test failure.

  2. As the locking handle is pushed back to keep the cartridge in place, the alignment pins prevent individual pin damage, increasing their lifespan.

  3. With thousands being produced, optimizing machining cost was critical. DFM reduced the cost to $20 CAD per cartridge. Negligible compared to the average military connector at over $50 CAD.

  4. Alignment rib features allow for seamless insertion and removal.

  5. The back face features a recessed cavity where the assembly facing connectors are positioned to prevent pin damage if dropped.

  6. Threaded holes in the front face allow laser engraved plastic, sheet metal, or custom adapter lids to be attached based on needs.

  1. Cartridges have built in keying features to ensure they can only be inserted in one orientation to prevent assembly or test failure.

  2. As the locking handle is pushed back to keep the cartridge in place, the alignment pins prevent individual pin damage, increasing their lifespan.

  3. With thousands being produced, optimizing machining cost was critical. DFM reduced the cost to $20 CAD per cartridge. Negligible compared to the average military connector at over $50 CAD.

  4. Alignment rib features allow for seamless insertion and removal.

  5. The back face features a recessed cavity where the assembly facing connectors are positioned to prevent pin damage if dropped.

  6. Threaded holes in the front face allow laser engraved plastic, sheet metal, or custom adapter lids to be attached based on needs.

User Experience

“The new cable tester has made testing significantly simpler with us being able to use any cartridge on demand... The bins of damaged cables that used to pile up are practically empty since this deployed.”

— Anonymous Field Repair Technician | Emailed Feedback

How to Use The Cable Tester

01
Enter Cable ID

Entering the cable number identifies which two cartridges to use.

02
Insert The Cartridge

Cartridges are placed in each module and locked in placewith the handle.

03
Cable Connected

Cables to be tested are connected to both modules of the tester.

04
Test Commences

A Hipot and continuity test is run on all individual pins.

Save Repair Costs

Resolving issues in individual conductors.

Quick Deployment

Two modules deployed simply.

Future Proof

Constantly updated library of cartridges.