A risk-based receiving checklist for high-voltage cables, connectors and contactors covering identity, traceability, packaging, visual condition, dimensions, assembly, documents, sampling and nonconformance control.
Incoming inspection should confirm that delivered EV high-voltage parts match the approved purchase specification before entering production or service stock. It should not create new engineering limits or replace supplier qualification. The plan must be based on the approved drawing, manufacturer documentation, control plan and application risk.
1. Confirm identity
- Purchase order and line item.
- Manufacturer, full part number, suffix and revision.
- Quantity and unit.
- Lot, batch or date code.
- Origin when required.
- Packing list and certificate references.
Quarantine material when the label or suffix does not match. Do not relabel an uncertain part to fit the order.
2. Inspect packaging
Check crushed cartons, water exposure, broken seals, contamination, loose terminals, bent contacts and protection of sealing surfaces. Photograph transport damage before repacking.
3. Check visual condition
Use the drawing or visual standard for housings, terminals, cables, seals, threads, busbars and markings. Observations can include cracks, deformation, corrosion, plating damage, cut insulation, exposed braid, missing seals, backed-out terminals and incorrect keying. Link decisions to documented requirements.
4. Verify dimensions and interfaces
Measure only characteristics in the inspection plan with calibrated equipment. Connector checks may include keying, terminal position and seals. Cable assemblies may require length, branch length, diameter and stripped dimensions. Contactors may require mounting pattern, terminal orientation and envelope.
5. Check assembly and retention
Confirm locks, CPA, terminal position assurance, HVIL contacts, seals and backshells are seated. Manufacturer specifications may define insertion and pull-check steps. TE's HVA 1200 application specification describes inspection of inserted HVIL contacts; use the exact family and revision.
6. Control electrical testing
Continuity, insulation, contact resistance, coil or hipot tests are appropriate only under an approved procedure with equipment, limits and safety controls. High-voltage or high-energy tests require qualified personnel and suitable facilities.
7. Match documents to the shipment
- Datasheet and drawing revision.
- Certificate of conformity if required.
- Inspection or test report.
- Approval certificate/report number.
- Material declaration when applicable.
- Lot traceability.
A family certificate may not cover every suffix or assembly. Check scope and part-number linkage.
8. Use an approved sampling plan
The buyer's quality function should select sampling and criteria based on risk, history and contract. This guide does not prescribe an AQL because it belongs to the approved quality plan.
9. Control nonconformance
Segregate the lot, preserve traceability, record evidence and notify responsible parties. Do not mix suspect material with accepted stock. Deviations require authorization.
FAQ
Can receiving inspection prove application suitability?
No. It checks conformance within its scope. Application validation and supplier qualification are separate.
Should every lot receive a high-voltage test?
Only when the approved plan requires it and qualified facilities and controls exist.
Primary references
- TE Connectivity HVA 1200 application specification
- UL Solutions EV charging cable testing and certification
Next step: include inspection and documentation requirements in the RFQ before shipment.