Wire harness detection device

Abstract

The invention discloses a wire harness detection device, which comprises a power supply and a detection circuit, the detection circuit comprises detection branches of which the number is the same as that of wire cores of a to-be-detected wire harness, every two adjacent detection branches are connected in series, and the power supply is arranged in a series loop formed by the detection branches; each detection branch is further provided with a light-emitting diode, one end of the light-emitting diode is connected with the detection branch, and the other end of the light-emitting diode is connected with the positive electrode or the negative electrode of the power supply; the detection circuit is configured to be used for detecting faults of the wire harness to be detected, wherein the faults comprise at least one of wire breakage, crossing and staggering of two adjacent wire cores, crossing and staggering of two wire cores every other wire core, crossing and staggering of two wire cores every other two wire cores and crossing and staggering of three wire cores; the light emitting diodes are used for emitting light corresponding to the fault occurrence position when a fault occurs.

Description

Technical Field

[0001] This invention relates to the field of detection technology, and in particular to a wire harness detection device. Background Technology

[0002] Currently, the common testing approach involves connecting the plugs at both ends of the tested wiring harness to sockets on the device. The device's panel is equipped with several double-throw switches and indicator lights. Internally, a power module is used. By operating each double-throw switch, the presence of an indicator light indicates whether that circuit is open. If the wiring harness connectors are correctly wired, the circuit is continuous, and the indicator light illuminates. If the indicator light does not illuminate, the wire is either open or incorrectly connected. During testing, observing whether all indicator lights are lit is used to determine if the tested wiring harness has open circuits or incorrect wiring.

[0003] Current technology requires manual operation of switches to perform continuity tests on each wire of a multi-core wire harness. This method is time-consuming and has a low degree of automation. More importantly, when miswiring occurs (miswiring refers to incorrect insertion of connectors at both ends of the wire harness, such as two or more wires crossing each other), it cannot be clearly identified and requires time difference to determine. Summary of the Invention

[0004] The present invention provides a wire harness detection device to solve at least one defect existing in the prior art.

[0005] This invention provides a wire harness detection device, comprising:

[0006] Power supply and detection circuit;

[0007] The detection circuit includes a detection branch with the same number of wire cores as the wire harness to be tested, and two adjacent detection branches are connected in series. The power supply is located in the series loop formed by the detection branches.

[0008] Each of the detection branches is also equipped with a light-emitting diode, one end of which is connected to the detection branch and the other end is connected to the positive or negative terminal of the power supply.

[0009] The detection circuit is configured to detect faults in the wire harness, including at least one of the following: broken wire, cross-connection of two adjacent wires, cross-connection of two wires separated by one wire, cross-connection of two wires separated by two wires, and cross-connection of three wires.

[0010] The light-emitting diode is used to emit light at the location of the fault when one of the aforementioned faults occurs.

[0011] Optionally, one of the detection circuits includes a first pin, a second pin, and a first diode;

[0012] In the odd-numbered detection branches, the first diode and the second pin are connected in series; in the even-numbered detection branches, the first diode and the first pin are connected in series.

[0013] The first pin and the second pin are configured to be connected to the first end and the second end of one of the wire cores, respectively.

[0014] Optionally, one of the detection circuits further includes a second diode;

[0015] In the odd-numbered detection branches, the second diode is connected in series with the first pin; in the even-numbered detection branches, the second diode is connected in series with the second pin.

[0016] Optionally, the detection circuit configuration for faults in the wire harness to be detected also includes: four wire cores being crossed or misaligned.

[0017] Optionally, the power supply includes an AC-DC conversion unit;

[0018] The AC-DC conversion unit is used to provide DC power to the detection circuit.

[0019] Optionally, it also includes a detection switch, which is disposed in the series circuit formed by the detection branch;

[0020] The detection switch is configured to connect or disconnect the power supply from the detection circuit.

[0021] Optionally, the detection switch is a self-locking button.

[0022] Optionally, the input of the ACDC conversion unit is AC power, and the output is 5-24V DC power.

[0023] Optionally, the number of wire cores in the wire harness to be tested is 12 to 64.

[0024] Optionally, the first pin and the second pin are disposed in a socket that is adapted to the connector plug of the wire harness to be tested.

[0025] Compared with existing technologies, the advantages of this invention are as follows: This invention proposes a wire harness testing device, which includes several detection branches arranged in series. These branches allow the wire cores of the wire harness to be tested to be connected in series to form a circuit, thereby enabling the detection of various wire breaks and misalignments in a single test. This testing device can accurately detect various common faults in wire harnesses, such as wire breaks, misalignments between adjacent wire cores, misalignments between every other wire core (one or two cores), and misalignments between three cores. It covers the main problems that easily occur during the production, installation, and use of wire harnesses, meeting diverse fault detection needs. The illumination state of the LED directly corresponds to the location of the fault, allowing operators to quickly identify the fault point and type without specialized knowledge. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the wire harness detection device in the embodiment;

[0027] Figure 2 This is a schematic diagram of the wire harness detection device in the embodiment;

[0028] Figure 3 This is a schematic diagram of a wiring harness failure in one of the embodiments;

[0029] Figure 4 This is a schematic diagram of another wiring harness failure in the embodiment;

[0030] Figure 5 This is a schematic diagram of another type of wire harness failure in the embodiment;

[0031] Figure 6 This is a schematic diagram of another type of wire harness failure in the embodiment;

[0032] Figure 7 This is a schematic diagram of another type of wire harness failure in the embodiment;

[0033] Figure 8 This is a schematic diagram of another wire harness detection device in the embodiment;

[0034] Figure 9 This is a schematic diagram of another type of wire harness failure in the embodiment;

[0035] Figure 10 This is a schematic diagram of another type of wire harness failure in the embodiment;

[0036] Figure 11 This is a schematic diagram of another type of wire harness failure in the embodiment;

[0037] Figure 12 This is a schematic diagram of another type of wire harness failure in the embodiment;

[0038] Figure 13 This is a schematic diagram of another type of wire harness failure in the embodiment;

[0039] Figure 14 This is a schematic diagram of another type of wire harness failure in the embodiment;

[0040] Figure 15 This is a schematic diagram of another type of wire harness failure in the embodiment;

[0041] Figure 16 This is a schematic diagram of another type of wire harness failure in the embodiment;

[0042] Figure 17 This is a schematic diagram of another type of wire harness failure in the embodiment. Detailed Implementation

[0043] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, the accompanying drawings show only the parts relevant to the present invention, and not all of the structures.

[0044] Figure 1 This is a schematic diagram of the wire harness detection device in the embodiment, for reference. Figure 1 This embodiment proposes a wire harness detection device, including: a power supply 100 and a detection circuit 200.

[0045] In this scheme, the detection circuit includes detection branches with the same number of wire cores as the wire harness to be tested. Two adjacent detection branches are connected in series, and the power supply is located in the series loop formed by the detection branches.

[0046] Each detection branch is also equipped with a light-emitting diode (LED). One end of the LED is connected to the detection branch, and the other end is connected to the positive or negative terminal of the power supply.

[0047] In this scheme, the detection circuit is configured to detect at least one of the following faults in the wire harness to be tested: broken wire, cross-connection of two adjacent wire cores, cross-connection of two wire cores separated by one wire core, cross-connection of two wire cores separated by two wire cores, and cross-connection of three wire cores.

[0048] In this scheme, the light-emitting diode is used to illuminate the light-emitting diode corresponding to the location of the fault when a fault occurs.

[0049] For example, in this solution, the power supply is configured to output DC power.

[0050] In this solution, the number of wire cores in the wire harness to be tested is not limited. Taking a number of wire cores of 4 as an example, the wire harness testing device can include 4 testing branches, denoted as branch 1, branch 2, branch 3, and branch 4, which correspond to wire cores A, B, C, and D respectively.

[0051] Adjacent detection branches are connected in series, that is, the output of branch 1 is connected to the input of branch 2, the output of branch 2 is connected to the input of branch 3, and the output of branch 3 is connected to the input of branch 4, forming a series loop. The positive terminal of the power supply is connected to the input of branch 1, and the negative terminal of the power supply is connected to the output of branch 4.

[0052] Each detection branch is equipped with one light-emitting diode. One end of LED1 is connected to the node between the output terminal of detection branch 1 and the negative terminal of the power supply; one end of LED2 is connected to the output terminal of branch 2 and the other end is connected to the negative terminal of the power supply; one end of LED3 is connected to the output terminal of detection branch 3 and the other end is connected to the negative terminal of the power supply; one end of LED4 is connected to the output terminal of detection branch 4 and the other end is connected to the negative terminal of the power supply (the conduction direction of the LED is from the positive terminal to the negative terminal).

[0053] For example, in this solution, the specific circuit structure of the detection branch is not limited. For instance, the detection branch can be designed to satisfy:

[0054] If wire A breaks, branch 1 will be disconnected, interrupting the original series circuit (detection branch 1-detection branch 2-detection branch 3-detection branch 4). LEDs 1 through 4 will not light up. If wire B breaks, LED 1 will light up, while LEDs 2 through 4 will not light up.

[0055] If A and B are crossed and the output terminal of detection branch 1 is mistakenly connected to the output terminal of branch 2, and the input terminal of detection branch 2 is mistakenly connected to the input terminal of detection branch 1, an abnormal loop is formed. At this time, both the output terminals of detection branch 1 and detection branch 2 will have a positive voltage due to being connected to the loop.

[0056] LED1 and LED2 are both turned on and emit light because there is a positive voltage at both ends; although detection branches 3 and 4 are partially connected to the circuit, the output potential does not reach the threshold for LED3 and LED4 to turn on, so they do not emit light, thus indicating that A and B are crossed and misaligned.

[0057] If A and C are crossed and the output terminal of detection branch 1 is mistakenly connected to the input terminal of detection branch 3, and the output terminal of detection branch 3 is mistakenly connected to the input terminal of detection branch 1, both the output terminals of detection branch 1 and detection branch 3 will have a positive voltage because they are in a closed circuit.

[0058] LED1 and LED3 are conducting and emitting light because there is a positive voltage at both ends; the output potential of detection branches 2 and 4 is insufficient to drive LED2 and LED4, so they do not emit light, indicating that A and C are crossed and misaligned.

[0059] If A and D are crossed and the output terminal of branch 1 is mistakenly connected to the input terminal of branch 4, and the output terminal of branch 4 is mistakenly connected to the input terminal of branch 1, forming a complete loop, then current flows through both the output terminals of branch 1 and branch 4, and they carry a positive voltage.

[0060] LED1 and LED4 are lit due to positive voltage conduction; detection branches 2 and 3 are not connected to a valid path, there is no voltage at the output terminal, LED2 and LED3 do not light up, indicating that A and D are crossed and misconnected.

[0061] If A, B, and C are crossed and misconnected, their input and output terminals will be connected in a disordered manner, forming multiple paths. These paths will cause the output terminals of branches 1, 2, and 3 to all have positive voltage.

[0062] LED1, LED2, and LED3 are connected to the output terminals of branches 1, 2, and 3 respectively and the negative terminal of the power supply. Because there is a positive voltage at both ends, they are turned on and light up. The detection branch 4 is not involved in the miswiring, and there is not enough voltage at the output terminal. Therefore, LED4 does not light up, indicating that A, B, and C are crossed and miswired.

[0063] This embodiment proposes a wire harness testing device, which includes several detection branches arranged in series. These branches connect the wire cores of the wire harness to be tested, forming a circuit, allowing for the detection of various wire breaks and misalignments in a single test. This testing device can accurately detect a variety of common faults in wire harnesses, such as wire breaks, misalignments between adjacent wire cores, misalignments between every other wire core (one or two cores), and misalignments between three cores. It covers the main problems that easily occur during the production, installation, and use of wire harnesses, meeting diverse fault detection needs. The location of the fault is directly correlated to the illumination state of the LEDs, allowing operators to quickly identify the fault point and type without specialized knowledge.

[0064] Figure 2 This is a schematic diagram of the wire harness detection device in the embodiment, for reference. Figure 2 Based on any of the aforementioned schemes, in one possible implementation, a detection circuit includes a first pin, a second pin, and a first diode.

[0065] In the odd-numbered detection branch, the first diode and the second pin are connected in series; in the even-numbered detection branch, the first diode and the first pin are connected in series. The first pin and the second pin are configured to be connected to the first end and the second end of a wire core, respectively.

[0066] In this scheme, 12 detection branches are set up. The positive terminal of the power supply 100 is connected to the input terminal of the first detection branch, and the output terminal of the 12th detection branch is connected to the negative terminal of the power supply 100.

[0067] In this scheme, H1 to H12 are LEDs configured for each detection branch (as indicator lights), and V1 to V12 are first diodes (diodes have unidirectional conductivity; in this circuit, when the connector points at both ends of the wire harness are misconnected, the diodes are cut off and the circuit is broken, and the corresponding indicator lights do not light up, thereby determining the misconnection point of the tested connector wire harness).

[0068] In this scheme, 1XS (points from 1 to 12) are the first pins of each detection branch, and 2XS (points from 1 to 12) are the second pins of each detection branch; 1XP (points from 1 to 12) and 2XP (points from 1 to 12) are the connector plugs of the 12-core wire harness of the test subject.

[0069] In this scheme, when testing the wire harness, 1XP and 2XP are connected to the corresponding 1XS and 2XS. At this time, the 12 cores of the entire wire harness under test are connected in series with each test branch. If the power supply is 100, all 12 light-emitting diodes will light up, which can be used to determine that there is no wiring fault in the wire harness.

[0070] When there is a broken wire in the test wire harness, the wire cores connected in series will be broken, and the light-emitting diodes from the point of breakage to the end will not light up. For example, if the wire at point 3 of the test wire harness is broken, when power is supplied by power supply 100, the first detection branch and the second detection branch will be conductive; because 1XP3-2XP3 is broken, 2XP3, 2XS3, and V3 are not connected to the power supply, and H3 will not light up; and all subsequent circuits will not be powered due to this break point, and the indicator lights H3 to H12 will not light up.

[0071] Based on the illumination status of each indicator light, it is possible to determine if there is a break in the tested wiring harness. Furthermore, the location of the break in the tested wiring harness can be determined by the first point where the light is not lit, which makes fault finding very convenient.

[0072] When there is a crossover between two adjacent points in the subject's wire harness, the connected wire cores will be connected by a bridging circuit. At this time, only the first indicator light of the crossover and the indicator lights before it will light up, while the subsequent indicator lights will not light up.

[0073] Figure 3 This is a schematic diagram of a wiring harness fault in one of the embodiments, for reference. Figure 3 The wiring harness fault was a cross-wiring error at points 3 and 4 of the tested wiring harness. When power supply U was applied, the first and second detection branches were conducting. After passing through 1XS3-1XP3, due to the cross-wiring error, 1XP3 directly connected to 2XP4 and 2XS4, and indicator light H3 lit up. However, because diode V3 was not conducting in reverse, the circuit was interrupted, and indicator lights H4 and subsequent H5-H12 did not light up.

[0074] When two non-adjacent points in the test subject's wire harness have crossed wires, the wire cores connected in series also show cross-wire continuity. If the cross-wire is connected by one wire, only the first two wires of the cross-wire connection are not connected, and the corresponding two indicator lights are not lit, while the other indicator lights are still lit.

[0075] Figure 4 This is a schematic diagram of another wiring harness failure in the embodiment, see reference. Figure 4The wiring harness fault is a cross-wiring error at points 3 and 5. When power is supplied by power source U, the first and second detection branches are conductive. After passing through 1XS3-1XP3, due to the cross-wiring error, 1XP3 is directly connected to 2XP5 and 2XS5, V5 is conductive, and the indicator lights H3 and H4 that are crossed are not lit. However, indicator lights H5 and subsequent H6 to H12 are powered on and lit normally.

[0076] If two wires are connected incorrectly, the first three wires of the bridging will be disconnected, the first indicator light will not light up, while the third indicator light will still light up, and all subsequent indicator lights will also turn off.

[0077] Figure 5 This is a schematic diagram of another wiring harness failure in the embodiment, see reference. Figure 5 The wiring harness fault was a cross-wiring error at points 3 and 6 of the tested wiring harness. When power was supplied by power source U, the first and second detection branches were conductive; however, due to the cross-wiring error, 1XP3 was directly connected to 2XP6 and 2XS6, causing the indicator lights H3 and H4 to remain off. H5, however, lit up due to the incorrect connection, while the subsequent indicator lights H6 through H12 remained off due to a circuit failure.

[0078] When there are three points where the wires in the test subject's wire harness cross or are misaligned, the wire cores connected in series also exhibit cross-wire conduction. As a result, the indicator lights do not light up after the crossing, or the first two lights do not light up after the crossing, but then all the lights light up.

[0079] Figure 6 This is a schematic diagram of another wiring harness failure in the embodiment, see reference. Figure 6 The wiring harness fault was a miswiring at points 3, 4, and 5 of the tested wiring harness. When power supply U was applied, the first and second detection branches were connected, passing through 1XS3-1XP3. Due to the miswiring, 1XP3 was directly connected to 2XP4 and 2XS4, and indicator light H3 lit up. However, because V3 was reversed and not conducting, subsequent indicator lights H4 to H12 did not light up.

[0080] Figure 7 This is a schematic diagram of another wiring harness failure in the embodiment, see reference. Figure 7 The wiring harness fault was a three-wire crossover at points 2, 3, and 4 of the tested wiring harness. When power supply U was applied, the first detection branch was conductive; after passing 2XS2-2XP2, due to the crossover, 2XP2 directly connected to 1XP4 and 1XS4, bypassing paths 2 and 3. The H2 and H3 indicator lights were off, and H4 and all subsequent indicator lights were directly connected, causing all indicator lights from H4 to H12 to illuminate.

[0081] In this solution, during the testing of the wiring harness, if one or more lights fail to illuminate, the status of the indicator lights can be used to determine if there are any broken or misaligned wires. The locations of these broken or misaligned wires will be at the points where the lights initially failed to illuminate. With these test results, the wiring harness under test can be re-inspected to locate and repair any broken or misaligned wires.

[0082] Figure 8 This is a schematic diagram of another wire harness detection device in the embodiment, for reference. Figure 8 ,exist Figure 2 Based on the scheme shown, in one possible implementation, a detection circuit further includes a second diode.

[0083] In the odd-numbered detection branch, the second diode is connected in series with the first pin; in the even-numbered detection branch, the second diode is connected in series with the second pin.

[0084] In this design, D1 to D12 are the second diodes.

[0085] Figure 9 This is a schematic diagram of another wiring harness failure in the embodiment, see reference. Figure 9 The fault in the tested wiring harness was a broken wire at point 3. When power supply U was applied, the first and second detection branches were connected. After passing through V3-2XS3-2XP3, the subsequent circuit was not connected due to the open circuit of 1XP3-2XP3, and the indicator lights H3 to H12 did not light up.

[0086] By conducting this test and observing the illumination of each indicator light, it is possible to determine if there is a break in the tested wiring harness. Furthermore, the break point in the tested wiring harness can be determined by the first point where the light does not illuminate, making fault finding very convenient.

[0087] In this scheme, when there are intersecting or misaligned lines between two adjacent points in the subject's wiring harness, two phenomena will occur. The first is that the indicator lights at the first misaligned line position will not light up from beginning to end, similar to the phenomenon of a broken wire. The second is that only the first indicator light of the misaligned line will not light up, while the others will remain lit.

[0088] Figure 10 This is a schematic diagram of another wiring harness failure in the embodiment, see reference. Figure 10 The fault in the tested wiring harness is a cross-wiring at points 3 and 4. When power supply U is applied, the first and second detection branches are connected. After passing through V3-2XS3-2XP3-1XP4-1XS4-D4, this path is interrupted due to reverse cutoff at D4, and the indicator lights H3, H4, and subsequent lines do not light up.

[0089] Figure 11 This is a schematic diagram of another wiring harness failure in the embodiment, see reference. Figure 11The fault in the tested wiring harness is a cross-wiring at points 5 and 6. When power is supplied by power source U, the first, second, third, and fourth detection branches are conductive.

[0090] After passing through V5-2XS5-2XP5-1XP6-1XS6-D6, this path is completed, and the H6 indicator light is on. The H5 indicator light, which is crossed by this path, is off. After this, the circuit is completed normally, and the other H7-H12 indicator lights are all on normally.

[0091] In this scheme, when two non-adjacent points in the subject's wiring harness have crossed or misconnected wires (with one wire missing), two phenomena will occur. The first is that the indicator lights at the first misconnected wire position will not light up from the beginning to the end, similar to the phenomenon of a broken wire. The second is that only the first misconnected wire light will not light up, while the others will remain lit.

[0092] Figure 12 This is a schematic diagram of another wiring harness failure in the embodiment, see reference. Figure 12 The fault in the tested wiring harness was a cross-wiring at points 2 and 4. When power supply U was applied, the first detection branch was activated. When passing through V2-2XS2-2XP2-1XP4-1XS4-D4, the circuit was interrupted due to the reverse cutoff of diode D4. As a result, indicator lights H2, H3, and subsequent H4-H12 did not illuminate.

[0093] Figure 13 This is a schematic diagram of another wiring harness failure in the embodiment, see reference. Figure 13 The fault in the tested wiring harness was a cross-wiring at points 3 and 5. When power supply U was applied, the first and second detection branches were conductive. This circuit was conductive when passing through V3-2XS3-2XP3-1XP5-1XS5-D5, at which point indicator H5 lit up. After passing through indicators H3 and H4, the circuit conducted normally thereafter, and the other indicator lights H6-H12 all lit up normally.

[0094] In this scheme, when two non-adjacent points in the subject's wiring harness have crossed or misconnected wires (two wires apart), only the first, second, and third indicator lights of the misconnected wires will not light up, while the others will light up normally.

[0095] Figure 14 This is a schematic diagram of another wiring harness failure in the embodiment, see reference. Figure 14 The fault in the tested wiring harness was a cross-wiring error at points 4 and 7. When power supply U was applied, the first, second, and third detection branches were conductive; this path was conductive after passing through D4-1XS4-1XP4-2XP7-2XS7-D7, and indicator light H7 illuminated. Indicator lights H8-H12 subsequently illuminated normally. Indicator lights H4, H5, and H6 were bypassed.

[0096] In this design, when there are three points where the wires in the test harness cross or are misaligned, two phenomena may occur. The first is that the indicator light at the first misaligned point will not illuminate from the beginning to the end. The second is that only the first two indicator lights at the misaligned point will not illuminate, while the other indicator lights will illuminate.

[0097] Figure 15 This is a schematic diagram of another wiring harness failure in the embodiment, see reference. Figure 15 The fault in the tested wiring harness is a cross-connection at points 2, 3, and 4. When power supply U is applied, the first detection branch is activated. When passing through V2-2XS2-2XP2-1XP4-1XS4-D4, the circuit is interrupted because diode D4 is reverse-biased. Therefore, indicator lights H2, H3, and subsequent H4-H12 do not light up.

[0098] Figure 16 This is a schematic diagram of another wiring harness failure in the embodiment, see reference. Figure 16 The fault in the tested wiring harness was a cross-connection at points 3, 4, and 5. When power supply U was applied, the first and second detection branches were conductive. This conductive path, passing through V3-2XS3-2XP3-1XP5-1XS5-D5, illuminated indicator H5. After passing H3 and H4, the circuit continued normally, and the other indicator lights H6 through H12 illuminated normally.

[0099] exist Figure 8 Based on the scheme shown, in one possible implementation, the detection circuit configuration for the fault of the wire harness to be tested also includes: four wire cores crossing and misaligning.

[0100] In this solution, the situation of four-wire intersection is quite complex. There may be a break in the circuit at any point among the four wires. The pattern of the indicator lights turning on and off is related to the location of the misalignment, but there will always be some indicator lights that are not lit. This phenomenon can be used to determine if there is a problem with the circuit.

[0101] Figure 17 This is a schematic diagram of another wiring harness failure in the embodiment, see reference. Figure 17 The fault in the tested wiring harness was that the four wires at points 3, 4, 5, and 6 were crossed and miswired. When power supply U was applied, the first and second detection branches were conductive; this path was also conductive when passing through V3-2XS3-2XP3-1XP5-1XS5-D5, and the H5 indicator light illuminated; however, when passing through V6-2XS6-2XP6-1XP4-1XS4-D4, the circuit was interrupted due to the reverse polarity of diode D4, and the H4, H3, and subsequent H6-H12 indicator lights did not illuminate.

[0102] Based on any of the aforementioned schemes, in one possible implementation, the power supply includes an AC-DC conversion unit; the AC-DC conversion unit is used to provide DC operating power to the detection circuit.

[0103] In this solution, the AC-DC conversion unit is used to convert the external AC power (such as 220VAC mains power) into the DC operating power required by the detection circuit, providing stable DC power support for each detection branch and light-emitting diode in the detection circuit 200, ensuring that the detection circuit can work normally to identify various faults (broken wires, multiple cross-wiring, etc.) of the wire harness under test.

[0104] In this solution, by using an AC-DC converter, the detection device can be directly connected to a common AC power source without relying on a specific DC power source.

[0105] For example, in this solution, the ACDC conversion unit can be a finished product, and its parameters can be set according to actual needs. For example, the output voltage can be selected as 12VDC, the output current as 1A, and its input terminal can be directly connected to 220VAC mains power.

[0106] The ACDC converter unit may include rectification, filtering, and voltage regulation circuits to ensure low DC power output ripple and high stability, preventing power fluctuations from affecting the accuracy of the detection circuit. The ACDC converter unit may also have overcurrent and short-circuit protection functions to prevent damage to the converter unit or external power supply in case of detection circuit failure.

[0107] Based on any of the aforementioned solutions, in one possible implementation, a detection switch is further included, which is disposed in the series circuit formed by the detection branch; the detection switch is configured to connect or disconnect the power supply and the detection circuit.

[0108] In this design, a detection switch has been added to the wire harness detection device. The detection switch is connected in series in the series circuit formed by the detection branch, serving as a control component for the on / off switching between the power supply and the detection circuit.

[0109] When the detection switch is closed, the power supply and the detection circuit form a closed loop, and the detection circuit is powered on to perform fault detection on the wiring harness; when the detection switch is open, the connection between the power supply and the detection circuit is interrupted, the detection circuit is powered off, and the detection work stops.

[0110] In this solution, the addition of a detection switch makes the device more convenient to operate, allowing the start and stop of the detection process to be controlled without plugging or unplugging the power supply. At the same time, it avoids component damage that may be caused by the long-term power supply to the detection circuit, thus improving the safety and service life of the device.

[0111] For example, in this solution, the detection switch can be a single-pole single-throw push-button switch or a rocker switch. The rated voltage and current of the detection switch are matched with the detection circuit to ensure that the switch can withstand the operating current of the detection circuit.

[0112] refer to Figure 3 or Figure 8Based on any of the aforementioned solutions, in one possible implementation, the detection switch is a self-locking button SA.

[0113] In this scheme, a self-locking button SA with rated parameters matching the detection circuit is selected, such as a rated voltage of 12VDC and a rated current of 2A (which must be greater than the working current of the detection circuit, which is usually within 500mA).

[0114] In this scheme, the self-locking button SA is connected in series between the positive DC output of the power supply U and the input terminal of the first detection branch, while the connections of other parts of the detection circuit remain unchanged.

[0115] In this design, the self-locking button SA can be installed on the panel of the wiring harness detection device. When the button SA is pressed, the contacts are closed, and it remains closed even when released. Only by pressing the button again will the contacts be opened. The self-locking button SA is used to allow the circuit to be kept closed for a longer period of time during testing if a problem of a non-lit light is found, making it easier to carefully observe the non-lit point.

[0116] Based on any of the aforementioned schemes, in one possible implementation scheme, the input of the AC-CDC conversion unit is AC mains power, and the output is 5-24V DC power.

[0117] In this solution, the output of the AC-DC conversion unit is one of 5 to 24V, and its specific output is set according to the actual needs of the detection circuit to meet the wire harness detection scenarios with different wire core specifications and different detection accuracy requirements. For example, the output can be 12VDC.

[0118] In this solution, the AC-DC conversion unit converts high-voltage mains power into safe low-voltage DC power, providing flexible power supply options for the detection circuit. This ensures that the LEDs can stably illuminate to indicate faults under different detection requirements, and that the detection branches can conduct normally to achieve fault identification. Ultimately, this guarantees the reliability and applicability of the device in diverse scenarios.

[0119] Based on any of the aforementioned schemes, in one possible implementation scheme, the number of wire cores in the wire harness to be tested is 12 to 64.

[0120] In this solution, for wire harnesses with 12 to 64 cores to be tested, each core corresponds to one testing branch, and adjacent testing branches are connected in series. An AC-DC conversion unit (input AC mains power, output 5 to 24V DC power) provides DC power with appropriate power for the circuit. A self-locking detection switch controls the circuit on and off, and each branch is equipped with one LED for fault location indication.

[0121] In this solution, for wire harnesses with different numbers of wire cores, the usage and fault determination methods of the wire harness detection device are the same as those described in the aforementioned corresponding solutions, and the specific details will not be elaborated further.

[0122] Based on any of the aforementioned solutions, in one possible implementation, the first pin and the second pin are disposed in a socket that is adapted to the connector plug of the wire harness to be tested.

[0123] In this solution, for multi-core wire harnesses under test, the first and second pins of the testing branch are directly integrated into a dedicated socket that is compatible with the wire harness connector plug. The corresponding positions of each wire core within the socket also integrate the first and second pins. Through precise matching of the connector plug and socket, a one-to-one correspondence between the wire cores and the testing branch is achieved, avoiding wiring errors and significantly improving batch testing efficiency.

[0124] In this solution, the socket is selected according to the plug model of the wire harness connector to be tested, so as to ensure that the plug can be directly inserted without conversion.

[0125] In this scheme, each wire core corresponds to 1 set of pins (2 pins), that is, a 12-core socket contains 24 pins and a 64-core socket contains 128 pins. The pins are arranged linearly in the order of wire core number 1 to n (e.g., wire core 1 corresponds to the first pin 1-1 and the second pin 1-2; wire core 2 corresponds to the first pin 2-1 and the second pin 2-2).

[0126] In this scheme, one end of the first pin is connected in series in the corresponding detection branch, and the other end is a contact terminal inside the socket, which contacts the wire core terminal of the wire harness plug; one end of the second pin is connected in series in the corresponding detection branch, and the other end is also a contact terminal inside the socket, which contacts the wire core terminal of the wire harness plug.

[0127] In this scheme, the wire cores are connected in series in the corresponding detection branch through the first pin and the second pin. The series connection method can be: input terminal of detection branch n - first pin of detection branch n - first end of wire core n - second end of wire core n - second pin of detection branch n - output terminal of detection branch n - input terminal of detection branch n+1 ... - output terminal of detection branch n+1.

[0128] refer to Figure 8 and Figure 9 Based on any of the aforementioned solutions, in one possible implementation, the wire harness testing device includes (plug-in connector) sockets (such as...) that correspond to the connector plugs at both ends of the wire harness under test. Figure 3 The 1XS and 2XS sockets are used as interfaces for inserting the connector plug of the tested wire harness.

[0129] In this design, power supply 100 uses an AC220V / DC12V1A switching power supply to provide power to the detection circuit. A self-locking button SA is installed on the panel of the testing device. The detection circuit is equipped with indicator lights H1 to H12, and 24 diodes are installed inside the device (12 of which are designated V1 to V12, and 12 are designated D1 to V12).

[0130] In this design, the negative terminal of power supply 100 is connected to the negative terminals of the 12 indicator lights, the positive terminal of power supply 100 is connected to the self-locking button SA, the other end of the self-locking button SA is connected to the positive terminal of diode D1, the negative terminal of diode D1 is connected to point 1 of socket 1XS, point 1 of socket 2XS is connected to the positive terminal of diode V1, the negative terminal of diode V1 is connected to two wires, one to indicator light H1 on the panel, and the other to the positive terminal of diode V2, and the negative terminal of diode V2 is connected to point 2 of connector socket 2XS.

[0131] Connect point 2 of socket 1XS to the positive terminal of diode V2. Connect the negative terminal of diode V2 to two wires: one to indicator light H2 on the panel and the other to the positive terminal of diode V3. Connect the negative terminal of V3 to point 3 of connector socket 2XS.

[0132] And so on, according to Figure 8 Connect the wires until they reach the 12 o'clock positions of connector sockets 1XS and 2XS. This completes the wiring for the 12-pin wire harness connector plug test device. To test various connector wire harnesses such as 32-pin, 46-pin, and 64-pin harnesses, simply follow this design approach and add more connector pins, indicator lights, diodes, and wiring.

[0133] In this procedure, when using the wire harness testing device, connect the connector plugs at both ends of the wire harness under test to the socket of the testing device, turn on the power, and press the self-locking button SA to start the test. If the wire core of the wire harness under test is fault-free and its connector plug is correctly wired, the circuit will conduct normally, and all indicator lights will be on. If none of the indicator lights are on from a certain point to the end, or if one or more lights are off while the later lights are on, that is, if any lights are off, it indicates that there is a broken or incorrect wire connection in the connector of the wire harness under test, and the point of breakage or incorrect wiring is at the point where the lights first went off. In this case, the test should be stopped, the connector plug of the wire harness under test should be unplugged, the problem should be fixed, and the above operation should be repeated until all indicator lights are on during the test.

[0134] Note that the above description is merely a preferred embodiment of the present invention and the technical principles employed. Those skilled in the art will understand that the present invention is not limited to the specific embodiments described herein, and various obvious changes, readjustments, and substitutions can be made without departing from the scope of protection of the present invention. Therefore, although the present invention has been described in detail through the above embodiments, the present invention is not limited to the above embodiments, and may include many other equivalent embodiments without departing from the concept of the present invention, the scope of which is determined by the scope of the appended claims.

Claims

1. A wiring harness detection device characterized by comprising: The application relates to a line bundle detection device. The device comprises a power supply and a detection circuit. The detection circuit comprises detection branches equal in number to the cores of the line bundle to be detected, and adjacent two detection branches are connected in series. Each detection branch is provided with a light-emitting diode, one end of which is connected to the detection branch, and the other end is connected to the positive or negative pole of the power supply. The detection circuit is configured to detect at least one of the following faults of the line bundle to be detected: wire breakage, adjacent two core cross-wiring, one-core-separated two-core cross-wiring, two-core-separated two-core cross-wiring, and three-core cross-wiring. When one of the faults occurs, the light-emitting diode corresponding to the fault position emits light.

2. The wiring harness detection apparatus according to claim 1, characterized by One detection circuit comprises a first pin, a second pin and a first diode. In the single detection branch, the first diode is connected in series with the second pin, and in the double detection branch, the first diode is connected in series with the first pin. The first pin and the second pin are configured to be connected to the first end and the second end of one core, respectively.

3. The wiring harness detection apparatus according to claim 2, characterized by One detection circuit further comprises a second diode. In the single detection branch, the second diode is connected in series with the first pin, and in the double detection branch, the second diode is connected in series with the second pin.

4. The wiring harness detection apparatus according to claim 3, wherein The detection circuit is configured to detect four-core cross-wiring of the line bundle to be detected.

5. The wiring harness detection apparatus of claim 1, wherein The power supply comprises an AC-DC conversion unit. The AC-DC conversion unit is configured to provide a direct-current working power supply for the detection circuit.

6. The wiring harness detection apparatus of claim 1, wherein The device further comprises a detection switch. The detection switch is arranged in the series loop formed by the detection branches.

7. The wiring harness detection apparatus of claim 6 wherein, The detection switch is configured to connect or disconnect the power supply and the detection circuit.

8. The wiring harness detection apparatus of claim 5 wherein, The detection switch adopts a self-locking button.

9. The wiring harness detection apparatus of claim 1, wherein The input of the AC-DC conversion unit is commercial power, and the output is 5-24V direct current.

10. The wiring harness detection device of claim 2, wherein, The number of cores of the line bundle to be detected is 12-64. The first pin and the second pin are arranged in a socket adapted to the connector plug of the line bundle to be detected.

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