Wire harness electrical performance test system and device

Abstract

The invention discloses a wire harness electrical performance test system and device, two ends of a wire harness are connected with two identical test modules, and the test modules are provided with sockets in butt joint with the wire harness, so that the conduction condition between multi-channel wire harnesses can be directly tested, the test is more efficient, and the insulation condition of the wire harness can be tested through a single test module; meanwhile, a network transceiving unit is arranged in the data processing unit, the network transceiving unit can receive an instruction of an upper computer, the multiple test modules can be remotely controlled to test the wire harness at the same time, test data can be uploaded to the upper computer to be stored, and a test result can be followed.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of wire harness testing, and particularly relates to a wire harness electrical performance testing system and device. BACKGROUND

[0002] Various electronic components are arranged on electrical equipment, and the electronic components are usually connected through wire harnesses. The electrical performance of the wire harnesses mainly includes conductivity and insulation, and the conductivity and insulation of the wire harnesses play a crucial role in the safe operation of the electrical equipment. Therefore, when the electrical equipment is assembled or overhauled, the conductivity and insulation of various wire harnesses on the electrical equipment need to be checked and tested to ensure that the wire harnesses have good conductivity and insulation performance, otherwise the wire harnesses need to be replaced in time to avoid accidents. The existing wire harness performance testing device has a complex structure and single function, poor testing precision, and cannot effectively upload and record testing data, so that the testing record cannot be traced and saved, and the testing result is difficult to verify.

[0003] Therefore, in view of the above defects in the prior art wire harness testing process, the application discloses a wire harness electrical performance testing system and device. SUMMARY

[0004] The application discloses a wire harness electrical performance testing system and device, which can directly test the conductivity between multi-channel wire harnesses and test the insulation of the wire harnesses through a single testing module.

[0005] The application is implemented through the following technical solutions:

[0006] A wire harness electrical performance testing system comprises at least one testing module, the testing module comprises a data processing unit, a wire harness testing unit, a power supply unit and a relay unit, the power supply unit is connected with the data processing unit, the wire harness testing unit and the relay unit respectively, the data processing unit is connected with the wire harness testing unit and the relay unit respectively, the wire harness testing unit is connected with the relay unit, the wire harness is connected with the relay unit, and the relay unit is used for the conductivity of the wire harness testing unit; and the data processing unit is used for receiving an instruction and sending a control instruction to the relay unit.

[0007] In order to better implement the application, further, the wire harness testing unit comprises a conductivity testing unit and an insulation testing unit, the insulation testing unit is connected with the relay unit, the data processing unit and the power supply unit respectively, and the conductivity testing unit is connected with the relay unit, the processor unit and the power supply unit.

[0008] In order to better realize the present application, further, the relay unit is provided with a mode selection unit between the wire harness test unit, the mode selection unit is connected with the power supply unit; the mode selection unit is used for controlling the power supply of the conduction test unit or the insulation test unit.

[0009] In order to better realize the present application, further, the data processing unit includes a processor unit, a network transceiver unit, the network transceiver unit is used for connecting the relay unit, the processor unit and the upper computer, the processor unit is connected with the insulation test unit and the conduction test unit respectively.

[0010] In order to better realize the present application, further, the conduction test unit includes resistance R1, resistance Rf and resistance R2 connected in series, the interface of the connecting wire harness is arranged between the resistance R1 and the resistance Rf; the voltage sampling circuit is arranged at both ends of the resistance Rf.

[0011] In order to better realize the present application, further, the insulation test unit includes resistance R5 and resistance R6 arranged in parallel, the resistance R5 and the resistance R6 are short-circuited with relay K5 and relay K6 respectively.

[0012] A wire harness electrical performance test device, including a shell, the inside of the shell is internally provided with a group of wire harness electrical performance test systems, the first end of the shell is provided with an external conduction socket, the external conduction socket is used for connecting two wire harness electrical performance test systems through the measured wire harness, the second end of the shell is provided with a plurality of internal conduction sockets, the internal conduction socket is connected with the relay unit.

[0013] In order to better realize the present application, further, the shell is provided with a display screen.

[0014] Compared with the prior art, the present application has the following advantages and beneficial effects:

[0015] The wire harness is connected with two same test modules at both ends, the socket of the test module is provided with the butt joint wire harness, the conduction condition between the multiple channel wire harnesses can be directly tested, the test is more efficient, and the insulation condition of the wire harness can be tested through a single test module; meanwhile, the network transceiver unit is arranged in the data processing unit, the network transceiver unit can receive the instruction of the upper computer, a plurality of test modules can be controlled remotely to test the wire harness at the same time, and the test data can be uploaded to the upper computer storage, and the test result can be traced. BRIEF DESCRIPTION OF DRAWINGS

[0016] Figure 1 It is the logic diagram of the wire harness electrical performance test system of the present application;

[0017] Figure 2 It is the front structure schematic diagram of the wire harness electrical performance test device in the present application;

[0018] Figure 3 It is the back structure schematic view of the wire harness electrical performance testing device in the application;

[0019] Figure 4 It is the internal structure schematic view of the wire harness electrical performance testing device in the application;

[0020] Figure 5 It is the circuit structure schematic view of the wire harness electrical performance testing device in the application;

[0021] Figure 6 It is the wire harness electrical performance testing device in the application to the wire harness on-off test principle diagram;

[0022] Figure 7 It is the wire harness electrical performance testing device in the application to the wire harness insulation performance test circuit principle diagram.

[0023] Among them: 1-housing, 2-outer on-off socket, 3-inner on-off socket, 4-display screen, 5-connector, 6-lattice plate. DETAILED DESCRIPTION

[0024] Example 1:

[0025] A wire harness electrical performance testing system of the embodiment, including at least one test module, the test module includes data processing unit, wire harness test unit, power supply unit and relay unit, the power supply unit is connected with data processing unit, wire harness test unit and relay unit respectively, the data processing unit is connected with wire harness test unit and relay unit respectively, wire harness test unit is connected with relay unit, wire harness is connected with the relay unit, the relay unit is used for wire harness test unit on-off; The data processing unit is used for receiving instruction and sending control instruction to relay unit.

[0026] Further, the wire harness test unit includes on-off test unit and insulation test unit, the insulation test unit is connected with relay unit, data processing unit and power supply unit respectively; The on-off test unit is connected with relay unit, processor unit and power supply unit.

[0027] Further, the mode selection unit is arranged between the relay unit and the wire harness test unit, the mode selection unit is connected with the power supply unit; The mode selection unit is used for controlling the power supply of on-off test unit or insulation test unit.

[0028] Further, the data processing unit includes processor unit, network transceiver unit, the network transceiver unit is used for connecting relay unit, processor unit with host computer, the processor unit is connected with insulation test unit and on-off test unit respectively.

[0029] Further, the conduction test unit comprises a resistor R1, a resistor Rf and a resistor R2 connected in series, and a voltage sampling circuit is arranged at two ends of the resistor Rf.

[0030] Further, the insulation test unit comprises a resistor R5 and a resistor R6 connected in parallel, and the resistor R5 and the resistor R6 are short-circuited with a relay K5 and a relay K6 respectively.

[0031] The test module comprises a data processing unit, a wire harness test unit, a power supply unit and a relay unit, the power supply unit is electrically connected with the data processing unit, the wire harness test unit and the relay unit respectively, the data processing unit is electrically connected with the wire harness test unit and the relay unit respectively, the wire harness test unit is electrically connected with the relay unit, the wire harness to be tested is connected with the relay unit, the relay unit is used for the conduction of the wire harness test unit, the wire harness is connected with the wire harness test unit through the relay unit, the wire harness test unit can test the conduction and insulation of the wire harness and display the test results through the data processing unit; the data processing unit can receive the instruction of an external host computer and send a control instruction to the relay unit to control the relay unit to conduct the wire harness test unit; the wire harness test unit comprises a conduction test unit and an insulation test unit, the insulation test unit is connected with the relay unit, the data processing unit and the power supply unit respectively, the insulation test unit can test the insulation performance of the wire harness and display the test results in the data processing unit and the host computer; the conduction test unit is connected with the relay unit, the data processing unit and the power supply unit, the conduction test unit can test the conduction of the wire harness and display the test results in the data processing unit and the host computer; a mode selection unit is arranged between the relay unit and the wire harness test unit, and the mode selection unit is connected with the power supply unit; the mode selection unit is used for controlling the power supply of the conduction test unit or the insulation test unit, the test mode of the wire harness can be selected through the mode selection unit, and the conduction test or the insulation test can be switched between the two modes; the relay unit is connected with a plurality of sockets respectively, the sockets comprise a 128-core external conduction socket and a plurality of single-core internal conduction sockets, the wire harness to be tested is connected with the external conduction socket to connect two test modules, the conduction performance of the thicker wire harness to be tested is tested through the cooperation of the two test modules, so that the test efficiency is improved; the single-core wire harness can also be tested for conduction or insulation through the single-core internal conduction socket on one test module, when the insulation test is performed, the other end of the wire harness is empty, and the insulation between the test wire harness and the wire harness or the single-core wire harness itself is tested.

[0032] The network transceiver unit is connected with the relay unit and the processor module respectively, the network transceiver unit can transmit 5G network signal, receive the instruction of the upper computer or send the test result data of the wire harness test unit to the upper computer for storage and comparative analysis; the data processing unit further comprises a display unit, the display unit can display the test data of the wire harness on the test module; the network transceiver unit is arranged between the relay unit and the data processing unit and is electrically connected with the relay unit, and the upper computer can directly control the test module to test the performance of the wire harness through the network transceiver unit.

[0033] Embodiment 2

[0034] The wire harness electrical performance test device of the embodiment mainly tests the conduction and insulation of the wire harness, such as Figure 2 、 Figure 3 and Figure 4As shown, when the wire harness is tested, multiple sets of wire harness electrical performance testing devices can work simultaneously to test different wire harnesses; the wire harness electrical performance testing device comprises a shell 1, the shell 1 is a cuboid structure, a relay unit, a power supply unit, a conduction test unit, an insulation test unit and a control assembly are arranged in the shell 1; the power supply unit is electrically connected with the relay unit, the conduction test unit, the insulation test unit and the control assembly respectively; the conduction test unit is electrically connected with the relay unit and the control assembly respectively; the insulation test unit is electrically connected with the relay unit and the control assembly respectively; four inner conduction sockets 3 are arranged at the front end of the shell 1, the inner conduction sockets 3 are electrically connected with the relay unit, and the inner conduction sockets 3 are used for testing the conduction or insulation performance of single-core or thinner wire harness by the wire harness electrical performance testing device, and the test can be completed through the relay 2, the conduction test unit and the insulation test unit inside the shell 1; in addition, an outer conduction socket 2 is arranged at the rear end of the shell 1, the outer conduction socket 2 is a 128-core socket, and the outer conduction socket 2 is used for connecting two wire harness electrical performance testing devices through the wire harness to be tested to test only the conduction performance of the wire harness, and thicker multi-core wire harnesses can be plugged into the 128-core sockets on the two wire harness electrical performance testing devices to test the conduction performance of the multi-core wire harnesses; a mode selection switch is arranged between the relay unit and the conduction test unit and the insulation test unit, the mode selection switch can switch the test mode of the wire harness to make the conduction test unit or the insulation test unit powered on; the control assembly comprises a processor unit, a network transceiver unit and a display screen 4; the network transceiver unit is connected with the relay unit and the processor unit respectively, the processor unit is connected with the insulation test unit and the conduction test unit respectively, the display screen 4 is connected with the processor unit and arranged on the surface of the shell 1, an external host computer can send control instructions to the network signal transceiver, at the same time, the network transceiver unit can transmit the test signal data to the external host computer, the host computer collects and analyzes the test data of all wire harness electrical performance testing devices to judge whether each tested wire harness has conduction or insulation failure; the display screen 4 is arranged on the surface of the shell 1 and can display the test results of the wire harness electrical performance testing device, if two non-polar wire harness testing mechanisms are connected through the 128-core socket, the results displayed on the two wire harness electrical performance testing devices remain consistent; the insulation test unit and the control assembly are arranged on one side of the relay unit, and the power supply unit is arranged below the insulation test unit and fixed in the shell 1; grating plates 6 are arranged at the left and right ends of the shell 1 and fixed through connecting pieces 5, there are eight connecting pieces 5 arranged on the left and right sides of the shell 1, the connecting pieces 5 are L-shaped structures, one side of the connecting pieces 5 is connected with the shell 1, and the other side is used for limiting the grating plates 6, and the grating plates 6 are used for heat dissipation of the internal components of the shell 1.

[0035] As Figure 5 and Figure 6As shown, two harness electrical performance testing device between the same can test single-core harness, that is, through the two harness electrical performance testing device on the inner through the socket 3 between the connection of single-core harness conduction performance test, also can be through the 128 core socket connection multi-core harness conduction performance test; test insulation performance only needs a single harness electrical performance testing device can complete the test. Resistance R1 is a current-limiting resistor, resistance Rx is equivalent to the harness, resistance Rf is a reference resistance. Considering that the insulation resistance value is usually large, the voltage across the resistance Rx cannot be directly sampled by ADC, only the voltage of Uf can be sampled. After derivation, the resistance Rx can be calculated by the formula Rx=(Vstim×Rf) / Vf-(R1+Rf). In actual insulation test, the resistance Rf can usually be ignored.

[0036] By controlling the corresponding mode selection switch on the harness electrical performance testing device, the voltage / current on the harness electrical performance testing device is transmitted to the tested harness, the on-off of the tested harness is judged by judging the signal at both ends of the tested harness, and the conduction of the tested harness is displayed by the test system software. Vstim is the conduction test excitation source, resistance R1 is a known current-limiting resistor, resistance Rx is a hypothetical equivalent resistance of the measured harness connected to the test network, and resistance Rf is a known reference resistance. By selecting a high-precision, low-drift instrument operational amplifier, the voltage signal Uf across the resistance Rf is appropriately conditioned and sent to ADC sampling for processing by the internal DSP master chip. After calibration algorithm, the voltage Uf can be accurately measured. Similarly, after similar processing, the voltage Ux across the resistance Rx can be accurately measured. According to the simple Ohm's law:

[0037] If=Uf / Rf Ix=Ux / Rx

[0038] From If=Ix, it can be deduced that Rx=(Ux / Vf)×Rf

[0039] Since Ux is sampled as the true voltage across the resistance Rx, the calculated If is the true current flowing through the resistance Rx, so the test accuracy of this method is high.

[0040] As Figure 7 shown, the insulation test unit is used for insulation test of the harness: insulation test is a two-by-two insulation test of a harness by a single harness electrical performance testing device.

[0041] The holding time after DC voltage stabilization of the insulation test can be set by the upper computer software. After the holding time, the continuous sampling conversion starts, and the average of 30 times of sampling conversion is calculated in this design.

[0042] When the high-voltage test mode is performed, there is a booster power module inside, which can boost the voltage of 24V to 500V±10%, the voltage precision: then the program sends the excitation instruction, the excitation source Vstim voltage is activated under the instruction, and then the test is performed. Through the design, the test range of 5KΩ-1GΩ, the maximum insulation current value of 2mA, and the precision of ±10% can be met.

[0043] In the test circuit, the current limiting resistor R5 and the resistor R6 are connected in parallel with the relay K5 in short, thereby reducing the system test error. In the actual wire harness test process, the control computer issues the corresponding starting and ending pin numbers according to the wire harness insulation table, the main control module receives the pin information, converts the corresponding voltage value, relay control, address and data information according to the protocol, and issues them to the corresponding module board, and then the corresponding module circuit performs the corresponding action, the sampling circuit completes the voltage and current value in the test principle, calculates the actual resistance value and uploads it to the upper computer, compares it with the threshold value set in advance, judges whether there is a short circuit, and finally completes the entire insulation test process.

[0044] The remaining part of the embodiment is the same as that of embodiment 1, and thus is not described here.

[0045] The above is the preferred embodiment of the present application, which does not limit the present application in any form, and any simple modification or equivalent change made according to the technical essence of the present application to the above embodiment falls within the protection scope of the present application.

Claims

1. A wiring harness electrical performance test system comprising at least one test module, characterized by, The test module comprises a data processing unit, a wire harness test unit, a power supply unit and a relay unit, the power supply unit is connected with the data processing unit, the wire harness test unit and the relay unit respectively, the data processing unit is connected with the wire harness test unit and the relay unit respectively, the wire harness test unit is connected with the relay unit, the wire harness is connected with the relay unit, and the relay unit is used for turning on the wire harness test unit; the data processing unit is used for receiving instructions and sending control instructions to the relay unit.

2. The wire harness electrical performance test system of claim 1, wherein, The wire harness test unit comprises a conduction test unit and an insulation test unit, the insulation test unit is connected with the relay unit, the data processing unit and the power supply unit respectively, and the conduction test unit is connected with the relay unit, the processor unit and the power supply unit.

3. The wire harness electrical performance test system of claim 2, wherein, A mode selection unit is arranged between the relay unit and the wire harness test unit, the mode selection unit is connected with the power supply unit, and the mode selection unit is used for controlling power supply of the conduction test unit or the insulation test unit.

4. The wire harness electrical performance test system of claim 3, wherein, The data processing unit comprises a processor unit and a network transceiver unit, the network transceiver unit is used for connecting the relay unit and the processor unit with a host computer, and the processor unit is connected with the insulation test unit and the conduction test unit respectively.

5. The wire harness electrical performance test system of claim 4, wherein, The conduction test unit comprises resistors R1, Rf and R2 connected in series, an interface for connecting a wire harness is arranged between the resistors R1 and Rf, and voltage sampling circuits are arranged at both ends of the resistor Rf.

6. The wire harness electrical performance test system of claim 4, wherein, The insulation test unit comprises resistors R5 and R6 connected in parallel, and the resistors R5 and R6 are short-circuited with relays K5 and K6 respectively.

7. A wiring harness electrical performance testing device comprising a housing (1), characterized in that, The shell (1) is internally provided with a wire harness electrical performance test system, a first end of the shell (1) is provided with an external conduction socket (2), the external conduction socket (2) is used for connecting two wire harness electrical performance test systems through a wire harness to be tested, and a second end of the shell (1) is provided with a plurality of internal conduction sockets (3) connected with the relay unit.

8. The wiring harness electrical performance testing device of claim 7, wherein, A display screen (4) is arranged on the shell (1).

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