AEM TestPro Automotive

Descriptions of AEM  TestPro Automotive

TestPro Automotive is the industry’s most versatile and user-friendly handheld solution for testing automotive wire harnesses—directly in the vehicle. Designed to eliminate the need for disassembly or bulky lab equipment, TestPro streamlines diagnostics across production lines, service centers, and quality assurance teams.

With support for high-frequency testing up to 6GHz, TestPro is fully compatible with modern automotive communication protocols, including infotainment systems, ADAS, and EV platforms. It delivers fast, accurate, and real-world diagnostics that help you catch issues early and keep vehicles on the road.

Benefits for Automotive Manufacturers

• Improved Quality Control: The tester enables you to detect defects in the installed wire harness on the production floor prior to vehicle shipping.
• Increased Efficiency: Rapid testing and diagnosis save time and resources at both the manufacturing site and service centers.
• Enhanced Reliability: Ensure the wire harness systems of the vehicles meet the highest standards, building trust with your customers
• Reduced Warranty Claims: Identify and fix issues before they become major problems, minimizing warranty claims and associated costs.

Key Features

• Distance to Fault Identification: The tester utilizes cutting-edge technology to detect even the smallest kinks, faults and defects and reports distance to the fault.
• Intuitive User Interface: Visualization of wire harness connectors and where fault has been identified allows service technicians to quickly understand the location in the vehicle the fault is location and work to remediate the fault. Analytics views show faults in plot form providing different types of views of a fault that work best for each user.
• Customizable Testing Limits: Use Smart Trace to define tailored thresholds for each wire harness configuration.
• Data Analysis and Reporting: Generate test reports that can be uploaded to the TestDataPro results management database and viewed by distributed team members.
• Ruggedized For Field Use: Rubberized protective shell protects against drops.

TestPro Automotive empowers engineers and technicians with a faster, smarter, and more precise approach to wire harness validation—right where it matters most: in the vehicle.

Capabilities

TDR Test

The TDR (Time Domain Reflectometer) is a powerful tool to diagnose defects in the data cable. Traditional TDR testers cannot differentiate the inline connectors from unwanted features such as kinks. TestPro provides intelligent configuration and limit setting which can help accurately pinpoint faults. Its Smart-trace plot clearly highlights faults while suppressing the connector peaks.

The results are also presented as event map, showing the cable with identified connectors that match pre-defined configuration, and unexpected features representing faults.

Setting TDR Limits and Cable Configuration

The configuration of cable can be specified using spread-sheet, and the csv file can be loaded to the TestPro using accompanying TestDataPro PC software. Alternatively, configuration can also be created on-the-fly on the tester itself.

Tolerances in cable length and impedance can be specified to allow for part-to-part variation.

Impedance limits can be applied on the TDR plot to identify a variation as a fault.

The limits are organized in a folder-like structure, allowing the users to save limits for all harnesses in a vehicle and invoke appropriate limit while testing.

Return Loss Test

The TestPro also performs frequency measurements on the cable under test. A separate limit can be specified for return loss (reflection) across the frequency range.

The TestPro reports PASS/FAIL for TDR and Return Loss independently. Most customer determine the cable as FAIL when both TDR and frequency results fail.

The frequency range of the return loss test depends on the adapter used. If the 6GHz AD-1P-6G adapter is attached, the frequency measurements are performed up to 6 GHz. For other automotive test adapters, frequency measurements are performed up to 3 GHz.

Reference Setting

As an alternative to specifying detailed cable features, a reference cable can be first tested, and the TestPro will subsequently compare the cable under test with the features of the reference cable, and detect faults when variation between the reference cable and the cable under test exceeds limit value.

Test Results Management

The test results can be saved on the tester itself for later viewing. The results can also be uploaded to the TestDataPro software for recording, tracing, and documenting the results, including storing as pdf or csv test reports.

Live Test Mode

In addition to performing validation tests, TestPro also allows performing “Live” test for active troubleshooting. In this mode, the device performs repeated tests, helping identify intermittent cable faults.

Technical specifications of AEM TestPro Automotive

Accessories for

Photo	Model	Description
	AD-6G-1P	Single 6GHz 1-port SMA test adapter
	TESTPRO-WH-02E	Dual ended Wire Harness test system with SMA coax adapter set.
	AD-1P-APTIV-AMEC	Aptiv AMEC 1P Adapter Pair
	AD-SMA-1P	SMA 1 PORT ADAPTER PAIR
	AD-4P-Auto-E6S204	Rosenberger Automotive 4P Adapter Pair
	AD-2P-Auto-E6S20B	Rosenberger Automotive 2P Adapter Pair
	AD-1P-TE-MATEnet	TE MATEnet 1P Adapter Pair
	AD-1P-Auto-E6S201	Rosenberger Automotive 1P Adapter Pair
	AD-4P-BAREWIRE-TB	Adapter provides terminal block connection points for testing a non-terminated cable.
	AD-SPE-BAREWIRE-TB	Adapter provides terminal block connection points for testing a non-terminated cable.