Breakout boxes – often referred to as connection boxes for structured signal routing – are used in the NVH (Noise, Vibration, Harshness) field to reliably connect multiple sensor signals to measurement equipment. Especially in multi-channel measurement setups, such as in vehicle development or on test benches, cabling often poses a challenge: individual coaxial cables must be bundled, routed, and clearly assigned.
Conventional solutions often rely on individually assembled cables that are connected within a junction box and then bundled together using screw connections and braided sleeving. In practice, this approach can lead to limitations, particularly regarding mechanical stability, defined bending characteristics, and complex routing.
An alternative approach is the use of integrated multicore cables. Here, multiple signal lines are combined into an industrially manufactured cable structure that is tailored to the requirements of measurement technology, both mechanically and electrically.
Compared to traditional bundle solutions, this offers several advantages:
defined mechanical properties during movement and installation
High EMC safety through coordinated shielding concepts
Reduced installation effort due to bundled signal routing
Reproducible measurement results even under real-world operating conditions
Especially for mobile measurements in vehicles or complex test bench setups, this approach helps to significantly simplify handling and reduce sources of error.
The selection of the appropriate breakout box depends largely on the sensor technology used and the specific measurement task.
Coaxial breakout boxes are typically used for applications with microphones and uniaxial sensors. Low-noise signal transmission is crucial here, especially for dynamic measurements. Low-noise coaxial cables ensure stable and reproducible measurement results even under demanding conditions.
Triaxial breakout boxes are designed for multi-channel acceleration measurements with triaxial sensors. The multicore structure enables the bundled connection of multiple sensors via a central cable, thereby reducing cabling effort and significantly improving the clarity of the measurement setup.
Breakout boxes or connection boxes for measurement technology with multicore cables are used in various environments:
Vehicle measurements under real operating conditions
Test benches in development and validation
Laboratory environments with reproducible test setups
Integration into control cabinets and measurement systems
Especially in applications with many sensors and limited installation space, multicore-based connection solutions offer advantages in terms of clarity, handling, and mechanical stability.
Selecting the right solution
The choice of the appropriate breakout box depends primarily on the sensor technology used and the measurement task. While coaxial systems are primarily suitable for classic NVH measurements with microphones and simple sensors, triaxial solutions offer advantages for multi-channel acceleration measurements with high channel density.