High Voltage Automated Cable Tester Project

Introduction

This project is a fully self-designed and built high-voltage cable testing system developed to automate continuity and insulation verification for multi-core subsea and industrial cables. The system generates a controlled ~1 kV DC test voltage and performs precise, repeatable measurements across multiple channels, replacing slow and error-prone manual testing methods.

Designed from the ground up, the tester integrates modular hardware, isolated measurement architecture, and embedded control to ensure safe and reliable operation in demanding environments. The platform includes automated channel switching, precision current sensing, real-time diagnostics, and onboard logging, enabling clear pass/fail identification and traceable test data.

A key focus of the project was engineering robustness and scalability. The system uses a distributed microcontroller architecture, high-voltage-aware PCB design, and modular expansion capability, allowing it to scale to high channel counts while maintaining measurement integrity and electrical isolation.

This project demonstrates advanced skills in high-voltage electronics, mixed-signal measurement, embedded systems, and practical engineering design — from concept and schematic capture through to PCB layout, system integration, and real-world deployment.