Testing solder connections

You can vibrate the alternator while monitoring the resistance of the circuit. If this is an automotive alternator, just run the car off the battery while monitoring the circuit, the engine vibration should be enough.

I need to be able to test this before it is installed in the alternator..

thanks for all your help.

The standard way to test a solder connection is with a pull test. You need a force gauge or spring and you just pull on the wire - enough force to see if it's soldered but not so much that you break it.

You can also Megger test it. I know meggering is usually for insulation, but for this instant, by applying a voltage to it, any loose or broken connection will show up.

MidniteFighter

A bonding meter should be used this passes a very low voltage high current for a short period. Any doubtful joint will fizzle. The electricity people use a fritter this pressents a dead short for a couple of milli seconds and records the current.

Are you worried about the solder or a broken wire?

I agree with above, do the pull test to see if the solder will hold, then Megger test the system to be sure you don't have a loose wire somewhere.

I am worried about the wire coming unsoldered when rpms are put to it.

Sometimes, solder connections can be tested by sending a low voltage pulse through a short coaxial cable or twisted wire pair through the solder connection to a resistive termination on the other side of the solder connection. Observe the reflections with an oscilloscope in parallel with the pulse generator. A small capacitor or inductor across the resistor will show up clearly as a spike on the oscilloscope timebase. A clean, solid solder joint will not reflect any energy. If you have access to a time domain reflectometer, you can do the same test.