Intelligent wire harness detection system

Abstract

The invention discloses an intelligent wire harness detection system, and relates to the technical field of wire harness detection, and the system comprises a data collection module which completes the collection and uploading of to-be-detected data according to the planning condition of a to-be-detected wire harness planning module; the wire harness test module at least comprises a conduction test unit, an insulation test unit and a withstand voltage test unit, and the units are respectively used for completing corresponding test items according to the to-be-tested data; the power supply management module is used for power supply control and test signal generation control; and the test management module is used for memorizing the mapping relation between the system test channel and the tested wire harness and controlling the wire harness test module to complete related test functions. The system has a self-learning capability, can complete the detection of the connection relation of unknown cable harnesses, and achieves the automatic detection of the to-be-detected harnesses.

Description

Technical Field

[0001] The present application relates to the technical field of wire harness detection, and in particular to an intelligent wire harness detection system. Background Art

[0002] Aircraft wiring harnesses are the core components of aircraft electrical systems and are responsible for transmitting electrical signals. Their quality and reliability directly affect the safety and operating efficiency of the aircraft.

[0003] In related technologies, traditional electrical testing equipment has complex operating steps, slow detection speed and is easily affected by human factors, resulting in missed detection or false detection, making it difficult to adapt to the diverse needs of complex wiring harnesses. In order to meet the automatic testing tasks of the continuity test of the entire aircraft and wiring harness, and to automatically record the test results of each contact pair of the wiring harness, while ensuring product quality and improving production efficiency, a wiring harness intelligent detection system with self-learning function is needed. Summary of the Invention

[0004] The main purpose of this application is to provide an intelligent wire harness detection system, aiming to solve the technical problem of low wire harness detection efficiency in related technologies.

[0005] To achieve the above objectives, the present application provides a wiring harness intelligent detection system, the system comprising: A wire harness intelligent detection system, characterized in that the system includes: The data acquisition module completes the collection and upload of the test data according to the planning of the test harness planning module; The wiring harness test module includes at least a continuity test unit, an insulation test unit, and a withstand voltage test unit, each of which is used to complete corresponding test items according to the test data; Power management module, used for power control and test signal generation; The test management module is used to detect and learn the mapping relationship between the system test channel and the tested wiring harness, and control the wiring harness test module to complete related test functions.

[0006] In one embodiment, the test management module further includes: an engineering maintenance unit, a test control unit, and a report generation unit; The test control unit is used to switch between manual test mode and automatic test mode according to display control instructions.

[0007] In one embodiment, when the system is in automatic test mode, the testing steps include: Obtain the conduction file to be identified; Through self-learning, the system learns the mapping relationship between unknown wiring harnesses and test interfaces in the connectivity file to be identified, and updates the connection status between the test channel and the cable under test. Conduct the conductivity performance test of the tested cable through the harness test module to detect the conductivity status of the tested cable; If the tested wiring harness passes the conductivity test, the tested cable is subjected to insulation test and voltage withstand test in turn to obtain the test results.

[0008] In one embodiment, when the continuity test unit performs a continuity test, the test steps include: Determine the on-resistance of the harness under test based on the cable type of the harness under test; A test method that determines the conductivity performance of the tested wiring harness based on the on-resistance. The test method includes either a two-wire system or a four-wire system.

[0009] In one embodiment, when the insulation testing unit performs an insulation test, the testing steps include: According to the mapping relationship between the test interface and the wiring harness under test, the voltage signal generated by the power control module is applied to both ends of the insulation resistance to be measured, and the insulation resistance value of the wiring harness under test is obtained by the current-voltage method; Determine the insulation performance of the tested wiring harness by comparing the insulation resistance value with the preset standard.

[0010] In one embodiment, when the withstand voltage test unit performs the withstand voltage test, the test steps include: According to the mapping relationship between the test interface and the wiring harness under test, the AC voltage signal generated by the power control module is applied to the wiring harness end of the wiring harness under test and maintained for a preset time; Obtain the leakage current of the wiring harness to be tested by the current-voltage method; By comparing the leakage current with the preset standard, the withstand voltage performance of the tested wiring harness is determined.

[0011] In one embodiment, if the tested wiring harness fails the continuity test, a test breakpoint location determination is performed, and the step of determining the test breakpoint location includes: Determine the capacitance value at the breakpoint between the conductors of the harness under test; The relative distance X between the breakpoint and one end of the cable is calculated according to the test formula. The test formula is: Among them, C1 is one end of the cable, and C2 is the other end of the cable.

[0012] In one embodiment, the system confirms whether voltage exists in the circuit under test before performing a continuity test; If it exists, stop the continuity test.

[0013] In one embodiment, the engineering maintenance unit is used to perform a self-check on the system hardware and output the check result when the system starts running.

[0014] In one embodiment, the system includes a plurality of test units, each of which is used for testing a tested wiring harness.

[0015] The one or more technical solutions proposed in this application have at least the following technical effects: 1. The system of this application has the ability of self-learning, which can complete the detection of the connection relationship of unknown cable harnesses. By automatically detecting and learning the connection relationship of unknown cables, it automatically forms a functional detection program to realize the automated detection of the harness to be tested.

[0016] 2. The system of this application can meet the automatic testing tasks of the continuity test of the aircraft and wiring harness, and can automatically record the test results of the conduction, insulation, voltage resistance and other functions of each contact pair of the wiring harness, relay and switch board, thereby improving production efficiency while ensuring product quality.

[0017] 3. This application adopts a distributed wire harness detection system with high scalability. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments consistent with the present application and, together with the description, serve to explain the principles of the present application.

[0019] In order to more clearly illustrate the technical solutions in the embodiments of the present application or related technologies, the following is a brief introduction to the drawings required for use in the embodiments or related technical descriptions. Obviously, for ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0020] Figure 1 This is a schematic diagram of the module connection of the wiring harness intelligent detection system in Example 1 of the present application.

[0021] Figure 2 This is a software framework diagram of the wire harness intelligent detection system in Example 1 of this application.

[0022] Figure 3 This is the software logic flow of the first control unit in Example 1 of the present application.

[0023] Figure 4 This is a hardware structure diagram of the test device in Example 1 of this application.

[0024] Figure 5 This is a two-wire connection circuit diagram.

[0025] Figure 6 This is a four-wire connection circuit diagram.

[0026] Figure 7 This is the insulation test schematic.

[0027] Figure 8 This is the schematic diagram of the voltage withstand test.

[0028] Figure 9 Schematic diagram for breakpoint testing.

[0029] The purpose, features and advantages of this application will be further explained in conjunction with embodiments and with reference to the accompanying drawings. DETAILED DESCRIPTION

[0030] It should be understood that the specific embodiments described herein are only used to explain the present application and are not intended to limit the present application.

[0031] It should be understood that the specific embodiments described herein are merely used to explain the technical solutions of the present application and are not intended to limit the present application.

[0032] In order to better understand the technical solution of the present application, a detailed description will be given below in conjunction with the accompanying drawings and specific implementation methods.

[0033] Aircraft wiring harnesses are the core components of aircraft electrical systems and are responsible for transmitting electrical signals. Their quality and reliability directly affect the safety and operating efficiency of the aircraft.

[0034] In related technologies, traditional electrical testing equipment has complex operating steps, slow detection speed and is easily affected by human factors, resulting in missed detection or false detection, making it difficult to adapt to the diverse needs of complex wiring harnesses. In order to meet the automatic testing tasks of the continuity test of the entire aircraft and wiring harness, and to automatically record the test results of each contact pair of the wiring harness, while ensuring product quality and improving production efficiency, a wiring harness intelligent detection system with self-learning function is needed.

[0035] Based on this, refer to Figure 1 , Figure 1 This is a schematic diagram of the module connection of the first embodiment of the wiring harness intelligent detection system. The specific embodiments and implementation methods are as follows: The present invention provides a wiring harness intelligent detection system, which includes: The data acquisition module completes the collection and upload of the test data according to the planning of the test harness planning module; The wiring harness test module includes at least a continuity test unit, an insulation test unit, and a withstand voltage test unit, each of which is used to complete corresponding test items according to the test data; Power management module, used for power control and test signal generation; The test management module is used to detect and learn the mapping relationship between the system test channel and the tested harness, and control the harness test module according to the mapping relationship to complete related test functions.

[0036] It should be noted that the system is divided into hardware and software parts.

[0037] Specifically, if Figure 1 As shown, the test management module is primarily used to manage the mapping relationship between system test channels and cables under test, establish test projects, and control the harness test module based on this mapping relationship to complete related test functions for various types, models, and packages of harness cables. Specifically, after establishing a mapping relationship once, the test management module can memorize the correct cable mapping relationship, allowing it to quickly detect cable faults such as short circuits, opens, and misconnections when testing the same cable again.

[0038] Furthermore, based on the established mapping relationship, the test management module selectively connects the test channel of the control system to the tested harness according to the specific test project. Figure 2 As shown, the measuring device applies the test signal to the corresponding test point via the measurement bus and the matrix switch. The test management module can control the working state of each switch in the switch matrix according to the specific test items, thus achieving interconnection between the measuring device and the corresponding test point.

[0039] The data acquisition module collects signal data for transmission to the harness testing module for relevant testing and analysis. In this embodiment, cable inspection items may include continuity testing, insulation testing, and voltage withstand testing. The test management module controls the harness testing module via the control bus based on user needs to complete relevant testing functions.

[0040] The power management module is used for power control and test signal generation.

[0041] In one possible implementation, Figure 3 As shown, the test management module includes an engineering maintenance unit, a test control unit and a report generation unit.

[0042] Among them, the engineering maintenance unit is mainly used to maintain basic engineering information, such as the mapping relationship adaptation between the system test channel and the tested wiring harness, test parameter configuration, test item authorization, etc.

[0043] The test control unit is used to switch between manual test mode and automatic test mode according to the display control instructions, mainly including test item selection, test mode determination, test log analysis, etc.

[0044] The report generation unit is mainly used for custom report generation and analysis.

[0045] Specifically, the test device can be operated in both automatic and manual modes. In automatic mode, the continuity test is performed first. After all the continuity tests are passed, the insulation and withstand voltage tests are performed.

[0046] For example, Figure 4As shown, the intelligent harness testing system consists of hardware (data acquisition module, harness testing module, etc.) and software (test management module). The hardware component primarily comprises an industrial control card, a multi-channel switch control board, a high-voltage insulation test module card, a continuity resistance test module, a bus backplane, and a test cable interface. The software, based on the hardware structure of the harness tester, primarily controls, inspects, and manages the basic harness testing resources, providing a convenient, practical, and user-friendly human-machine interface for developers and operators. By controlling hardware infrastructure such as multi-channel matrix switches and high-voltage monitoring, the software generates multi-functional test modes, automatically completing harness continuity, insulation, and withstand voltage tests, meeting the diverse needs of various user testing projects.

[0047] Specifically, the hardware part of the wire harness intelligent detection system is mainly composed of a test host and other test function boards. The test host is connected to the cable under test through a tooling cable or a test fixture, and automatically completes the test of the cable under test's conductivity, insulation, withstand voltage, relay and switch board function tests and other parameters.

[0048] The test host includes various test boards, communication boards, programmable high-voltage power supplies, and control boards, among other key components for implementing test functions. It executes test commands to control programmable power supplies, generate test signals, control high-voltage switches, and perform various test functions.

[0049] The test host has a built-in high-performance industrial control computer board and runs the Windows 7 operating system. The main function of its software part is to control the test display through the human-computer interaction interface, and control the various functional boards in the host through the control bus to complete the programming, testing, recording, display, printing and other functions of related test functions.

[0050] During the test process, the system automatically performs functional tests on each set test point according to the test program selected by the user, records and displays the test results, and is highly intelligent.

[0051] In single-shot automatic measurement mode, the host computer sends the measurement point address information to the switch card via the bus, which switches the corresponding high-voltage relays and simultaneously controls the various measurement units to read data from the cable under test. Upon completion, the host computer automatically discharges the cable under test and resets the relevant high-voltage relays. The test results are then saved to the database and a test report is generated.

[0052] In a feasible implementation manner, in the automatic test mode, the test steps include: Obtain the conduction file to be identified; Through self-learning, the system learns the mapping relationship between unknown wiring harnesses and test interfaces in the connectivity file to be identified, and updates the connection status between the test channel and the cable under test. Conduct the conductivity performance test of the tested cable through the harness test module to detect the conductivity status of the tested cable; If the tested wiring harness passes the conductivity test, the tested cable is subjected to insulation test and voltage withstand test in turn to obtain the test results.

[0053] Specifically, the to-be-identified continuity file can be a directly identifiable continuity file table in a preset format, such as EXCEL or TXT. In automatic testing mode, the system confirms the connection relationship between the cable under test and the system test interface based on the imported to-be-identified continuity file. For newly added unknown cables under test, the system has a self-learning test function that can automatically detect the connection relationship and precise resistance value of the unknown cable harness and automatically generate test procedures such as continuity testing and insulation testing based on the connection relationship. For example, before automatic testing, a basic test signal is first generated by the power management module, and each matrix switch is turned on in sequence to confirm the connection relationship between all cables under test and the system test channels and update the connection status between the test channels and the cables under test.

[0054] After confirming the connection between all cables under test and the test channels, the harness test module performs a continuity test on the cables under test. This test primarily detects any connectivity issues caused by wire path problems, short circuits, open circuits, misaligned pins, or poor connections. In one example, the conductive performance of ordinary wires can be monitored by analyzing their on-resistance.

[0055] Specifically, when the continuity test unit performs a continuity test, the test steps include: determining a conduction resistance of the wiring harness under test based on a cable type of the wiring harness under test; Based on the on-resistance, a test mode for the conduction performance of the tested wiring harness is determined; the test mode includes one of a two-wire system and a four-wire system.

[0056] Specifically, the cable continuity test verifies the correct continuity of the cable, which can be determined by measuring the cable's continuity resistance. As you can understand, the continuity resistance range varies depending on the cable type and structure. Therefore, to more accurately test cable continuity resistance, the device uses two-wire and four-wire methods to test cables with different resistance ranges. Furthermore, when performing a cable continuity test, the continuity resistance threshold should be set to accurately determine the cable's continuity.

[0057] The two-wire system uses only two wires to connect the resistance to be measured. The working principle diagram is as follows: Figure 5 The two-wire system connects a wire at each end of the resistor to be measured. This connection method is simple and low-cost, and is widely used in real life.

[0058] The multimeter used for testing contains a precision current source and a voltmeter with a high internal resistance. The multimeter measures the resistance's ability to block current by measuring the voltage. However, the voltage measured in a two-wire system is not actually the voltage across the resistor being measured. It also includes the conduction resistance of the wires and the contact resistance of the test leads. The mathematical expression for the measured resistance is: Rmeasured = R + 2r + 2Rs, where R is the resistor being measured, r is the wire resistance, and Rs is the contact resistance.

[0059] The typical conduction resistance of a wire ranges from 1mΩ to 100mΩ, and the contact resistance between the test leads and the test point is also in the milliΩ range. If the resistance to be measured, R, is sufficiently large, the conduction and contact resistances can be almost ignored. Therefore, the two-wire resistance measurement method is suitable for situations where the on-resistance is relatively large (>1Ω).

[0060] Test voltage source range: 0.1VDC-48VDC, adjustable step 0.1 V Test current source range: 1mA-2A, adjustable step 1mA Resistance test range: 1Ω~910KΩ, maximum range (0.1Ω-1MΩ) Resistance test accuracy: ±1%±0.5Ω.

[0061] Compared with the two-wire measurement method, the four-wire measurement method can automatically compensate for the internal resistance of the tester, lead resistance and contact resistance, thereby accurately measuring the resistance value of the component under test. Figure 6 As shown in the figure, VMETER is the voltage measured by the tester, VDUT is the actual voltage value across the device under test, Rsystem is the system internal resistance, RLoad is the detection lead resistance, and RContact is the contact resistance.

[0062] Since the voltmeter can be regarded as a resistor with a large resistance value, the induced current flowing through the ammeter in the circuit is very small, so it can be concluded that: VMETER=VDUT Thus: Rmeasure = VMETER / ITEST = VDUT / ITEST = Ractual Test voltage source range: 0.1VDC-48VDC, adjustable step 0.1 V Test current source range: 1mA~2A, adjustable step 1mA Resistance test range: 0.01Ω~999Ω Resistance test accuracy: ±1%±0.003Ω.

[0063] Furthermore, before conducting a continuity test, confirm whether there is voltage in the circuit under test; If present, the continuity test is stopped.

[0064] Specifically, the device loop measurement has an automatic protection function and prompts. For example, during the continuity test and loop resistance check, if there is voltage in the measured circuit, the power supply will be automatically stopped and the measuring equipment will not be damaged.

[0065] Furthermore, if the tested wiring harness passes the continuity test, the unknown wiring harness is subjected to insulation testing and voltage withstand testing to obtain test results.

[0066] In a feasible implementation manner, when the insulation testing unit performs the insulation test, the testing steps include: According to the mapping relationship between the test interface and the wiring harness under test, the voltage signal generated by the power control module is applied to both ends of the insulation resistance to be measured, and the insulation resistance value of the wiring harness under test is obtained by the current-voltage method; Determine the insulation performance of the tested wiring harness by comparing the insulation resistance value with the preset standard.

[0067] When the withstand voltage test unit performs a withstand voltage test, the test steps include: According to the mapping relationship between the test interface and the wiring harness under test, the AC voltage signal generated by the power control module is applied to the wiring harness end of the wiring harness under test and maintained for a preset time; Obtain the leakage current of the wiring harness to be tested by the current-voltage method; By comparing the leakage current with the preset standard, the withstand voltage performance of the tested wiring harness is determined.

[0068] Specifically, during the insulation test, the programmable high-voltage power supply module inside the device generates a set voltage, and the signal is input to each cable core through the switch matrix of the channel card. Then the insulation resistance test is performed and the corresponding test value is obtained. The software automatically determines whether the insulation value is within the set range; if it is within the range, the tested cable is judged to be a qualified cable; if it exceeds the set range, the cable insulation parameters are considered unqualified.

[0069] The accuracy and precision of insulation testing have always been of paramount concern. When testing cable insulation performance, a high-voltage excitation source must be applied directly to both ends of the cable under test via connectors. To ensure that the test signal output by the measurement circuit does not exceed the sampling voltage range, a voltage divider circuit must be constructed using a precision resistor network and other relevant components. Common insulation resistance measurement methods include the current-voltage method, the capacitor charging method, and the Wheatstone bridge method. Due to its simple principle and ease of implementation, and the fact that this system utilizes appropriate correction parameters, the current-voltage method is used for insulation resistance testing. Figure 7 This is the principle diagram of the current-voltage method. In the figure, Ui is the power supply potential, R1 and R2 are the high-voltage sampling internal resistances, Rf is the sampling resistor, and Rx represents the insulation resistance of the cable harness.

[0070] The voltage drop generated by the current through the entire measurement circuit on the sampling resistor Rf is Uf, and the value of the insulation resistance Rx can be calculated by Ohm's law.

[0071] Rx= (Vi-Uf) / (Uf / Rf) The voltage-current method determines the insulation resistance of the cable harness under test, thereby determining its insulation performance. Two test modes are available: traditional one-to-other and two-way rapid testing. For harnesses with large numbers of points, the two-way method significantly reduces insulation withstand voltage testing time, improves efficiency, and complies with international testing practices.

[0072] Insulation voltage range: 100VDC-1500VDC, accuracy ±5%; Insulation resistance range: 100V-500V: 10KΩ - 100MΩ, accuracy ±3%; 500V-1500V: 100MΩ - 1GΩ, accuracy ±3%; Rise time 0.1s-60s; Hold time 0.1s-499s.

[0073] Custom insulation test, for testing the insulation resistance of cable assemblies or passive DUTs, with test voltage increasing by 1V DC, quickly performing point-to-point or grouped insulation resistance tests between wires and between wires and housings.

[0074] The schematic diagram of the withstand voltage test is as follows: Figure 8 As shown in the figure, an AC high-voltage excitation source consisting of an AC amplifier and voltage regulator circuit and a transformer is connected to the cable harness under test through a measurement channel switching unit. The measurement channel switching unit, composed of a relay array, switches the cable harness under test to form a measurement path. The AC withstand voltage test is designed to verify the insulation performance between two disconnected cables, meaning they have no continuity.

[0075] After the AC high-voltage excitation source is applied to the cable harness under test according to the correct selection path, it must remain on the cable harness for a certain period of time as required. The current-limiting resistor and sampling resistor are not shown in the figure, but the principles of the AC withstand voltage test are similar to those of the insulation resistance test. The only difference is that the insulation resistance test uses a DC high-voltage excitation source, which reflects the insulation performance as a resistance value, while the AC withstand voltage test uses an AC high-voltage excitation source, which reflects the insulation performance as a leakage current. After the AC high-voltage excitation source is maintained on the cable harness under test for a certain period of time, the current value obtained is the leakage current value of the cable harness under test. If this value meets the requirements of the detection system, the cable harness under test is considered safe for operation in the system.

[0076] Withstand voltage range: 100VDC / AC-1500VDC / 1000VAC, ±5% Leakage current range: 0.1mA-5mA, ±5%±0.1mA.

[0077] Customized Hi-Pot Test: Tests the voltage withstand performance of cables or passive components with DC / AC test voltage in 1V increments. Rapidly conducts point-to-point or grouped tests of leakage current between wires and between wires and housings, displaying AC voltage and leakage waveforms in real time.

[0078] Furthermore, if the tested wiring harness fails the conductivity test, a test breakpoint position determination is performed, and the step of determining the test breakpoint position includes: determining a capacitance value at a breakpoint between conductors of the wiring harness under test; The relative distance X between the breakpoint and one end of the cable is calculated according to the test formula: Among them, C1 is one end of the cable, and C2 is the other end of the cable.

[0079] Specifically, the principle of using distributed capacitance to determine the breakpoint position is as follows: Figure 9 As shown: Select two uniform conductors of equal length and equal spacing in the cable: conductor ab and conductor cd. Set the two endpoints of conductor ab to a and b, and the two endpoints of conductor cd to c and d, with endpoints a and c on the same side. Connect the two test leads of the capacitance test instrument or device to the end point a and the end point c of the wire ab and the wire cd respectively, and measure the distributed capacitance C1 between the wire ab and the wire cd; Connect the two test leads of the capacitance test instrument or device to the end point b and the end point d of the wire ab and the wire cd respectively, and measure the distributed capacitance C2 between the wire ab and the wire cd; The relative distance X between the breakpoint position and the endpoint c is calculated according to the formula.

[0080] Furthermore, the system includes a plurality of test units, each of which is used for testing the tested wiring harness.

[0081] Specifically, the test unit supports continuity, insulation, and withstand voltage tests, with 40,960 test channels for two-wire and 20,480 for four-wire. The system automatically outputs a qualified label barcode and saves test records, allowing for printing and other data analysis as needed. It is widely used for production line testing. The test unit chassis, a standard 19U rack-mountable chassis, consists of a chassis backplane, a multi-channel switch control board, a continuity test module, an insulation test high-voltage module, an AC withstand voltage test module, a test power-off detection function, an automatic protection function, and an EasyMate connector.

[0082] Specifically, the system features both independent and combined testing capabilities. Each test unit functions as a single system, with 10,240 test points, and a four-wire system with 5,120 test points. Any unit can be selected as the master to control the others. Each unit is equipped with a high-voltage insulation and withstand voltage source, a high-end industrial computer, and a master control system. It features 80 128-point test matrix channels, allowing each unit to independently establish a test product database and conduct independent testing.

[0083] When the four-wire system has more than 5120 test points, two units can be connected via a high-speed bus. Similarly, one unit can be configured as the master control computer, while the other unit shuts down its main control computer and main control board, shielding its internal high-voltage source and utilizing only its test channels, thereby expanding the test channels. The current system has 40,960 test points. Later, additional units or test channels can be added based on user needs. Units can be added in multiples of the two-wire system's 2048 points.

[0084] The 40,960 test points consist of 10 relay modules with approximately 500 points each, 34 relay modules with approximately 1,000 points each, and three relay modules with at least 200 points each and automatic onboard relay excitation for testing. Each relay module must also be equipped with at least 10 dedicated relay test points. A daisy-chain bus structure is used to connect the host computer to the relay modules, and between the relay modules. The total bus cable length must meet the requirements for complete aircraft testing. The bus provides power to the relay modules, 28 VDC, and 115 VAC / 400 Hz onboard relay excitation power.

[0085] Furthermore, the engineering maintenance unit is used to perform a self-check on the system hardware when the system starts running and output the check result.

[0086] Specifically, when the tester is powered on, it automatically performs a self-test of the high-voltage module, channel board, and other related hardware. If any self-test error occurs, a prompt will be displayed. The system also features a self-test function that can detect switches, measurement modules, and high-voltage output modules. The switch self-test function can detect internal switch closures and disconnections, locating switch faults. The tooling self-test function can detect tooling short circuits and open circuits. During testing, various alarms, including audio, visual, and electrical, alert testers to testing risks.

[0087] Furthermore, the wiring harness intelligent detection system is equipped with a set of portable movable trailers, which is convenient for carrying the host, display, keyboard, mouse, and probes to the assembly site and various test benches for testing, and is suitable for indoor movement; it can automatically and quickly complete the precise conduction, insulation, voltage resistance, relay and switch board function tests of the cable network, determine the test results according to the set standards, quickly locate the fault, and find out quality risks such as poor contact, poor welding, broken wire cores, insufficient connection, wrong connection, and excessive connection of parallel wires.

[0088] The design and manufacture of the equipment feature advanced mechanical structures: it uses high-strength materials, has modular installation, is easy to disassemble, install, and maintain, and can adapt to mobility needs.

[0089] Advanced manufacturing process: Using the most advanced sheet metal and PCB manufacturing processes on the market, the technology is mature, and the structural parts and circuit boards are safe, stable and highly reliable.

[0090] Advanced control system: adopts high-performance industrial control host, I7CPU, and fast response.

[0091] Safety of use: The protection circuit can protect equipment and products from damage and has a high voltage warning function.

[0092] User-friendly design of the equipment: concise software interface, simple operation process, and reasonable cabinet design.

[0093] It should also be noted that the embodiments described above are merely illustrative, in which the units described as separate components may or may not be physically separated, and the components displayed as units may or may not be physical units, that is, they may be located in one place, or they may be distributed across multiple network units. Some or all of the modules may be selected according to actual needs to achieve the purpose of the present embodiment. In addition, in the drawings of the device embodiments provided in this application, the connection relationship between the modules indicates that there is a communication connection between them, which can be specifically implemented as one or more communication buses or signal lines. A person of ordinary skill in the art can understand and implement the present invention without inventive work.

[0094] The above are only preferred embodiments of the present application and do not limit the patent scope of the present application. Any equivalent structure or equivalent process transformation made using the contents of the present application specification and drawings, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present application.

Claims

1. A wire harness intelligent detection system, characterized in that: The system comprises: Data acquisition module, used to collect test data and upload; The wiring harness test module includes at least a continuity test unit, an insulation test unit, and a withstand voltage test unit, each unit being used to complete corresponding test items according to the test data; Power management module, used for power control and test signal generation; The test management module is used to detect and learn the mapping relationship between the system test channel and the tested wiring harness, and control the wiring harness test module according to the mapping relationship to complete the relevant test functions.

2. The wire harness intelligent detection system according to claim 1, characterized in that: The test management module also includes: an engineering maintenance unit, a test control unit and a report generation unit; The test control unit is used to switch between a manual test mode and an automatic test mode according to a display control instruction.

3. The wire harness intelligent detection system according to claim 2, characterized in that: When the system is in automatic test mode, the test steps include: Obtain the conduction file to be identified; Learning the mapping relationship between the unknown wiring harness and the test interface in the to-be-identified connectivity file through self-learning, and updating the connection status between the test channel and the tested cable; Performing a conductivity performance test on the tested cable by using the harness test module to detect the conductivity status of the tested cable; If the tested wiring harness passes the conductivity test, insulation testing and voltage withstand testing are performed on the tested cable in sequence to obtain test results.

4. The intelligent wire harness detection system according to claim 3, characterized in that: When the continuity test unit performs the continuity test, the test steps include: determining a conduction resistance of the wiring harness under test based on a cable type of the wiring harness under test; Based on the on-resistance, a test mode for the conduction performance of the tested wiring harness is determined; the test mode includes one of a two-wire system and a four-wire system.

5. The wire harness intelligent detection system according to claim 3, characterized in that: When the insulation testing unit performs an insulation test, the test steps include: According to the mapping relationship between the test interface and the wiring harness to be tested, the voltage signal generated by the power control module is applied to both ends of the insulation resistance to be tested, and the insulation resistance value of the wiring harness to be tested is obtained by the current-voltage method; By comparing the insulation resistance value with a preset standard, the insulation performance of the tested wiring harness is determined.

6. The wire harness intelligent detection system according to claim 3, characterized in that: When the withstand voltage test unit performs the withstand voltage test, the test steps include: According to the mapping relationship between the test interface and the wiring harness to be tested, the AC voltage signal generated by the power control module is applied to the wiring harness end to be tested and maintained for a preset time; Obtaining the leakage current of the wiring harness to be tested by a current-voltage method; By comparing the leakage current with a preset standard, the withstand voltage performance of the tested wiring harness is determined.

7. The intelligent wire harness detection system according to claim 3, characterized in that: If the tested wiring harness fails the conductivity test, a test breakpoint position determination is performed, wherein the step of determining the test breakpoint position includes: determining a capacitance value at a breakpoint between conductors of the wiring harness under test; The relative distance X between the breakpoint and one end of the cable is calculated according to the test formula: Among them, C1 is one end of the cable, and C2 is the other end of the cable.

8. The intelligent wire harness detection system according to claim 7, characterized in that: The system confirms whether there is voltage in the circuit under test before conducting a continuity test; If it exists, stop the continuity test.

9. The wire harness intelligent detection system according to claim 8, characterized in that: The engineering maintenance unit is used to perform a self-check on the system hardware and output the check result when the system starts running.

10. The wire harness intelligent detection system according to any one of claims 1 to 9, characterized in that: The system includes a plurality of test units, each of which is used for testing the tested wiring harness.

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