Test system and method for detecting fault of non-standard cable
The test system, with its custom wiring templates and optocoupler isolation design, solves the problem that existing equipment cannot detect non-standard cables, achieving efficient and accurate cable fault detection and multi-interface adaptation, while reducing equipment costs.
Patent Information
- Application Number
- CN202511716252.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-11-21
- Publication Date
- 2026-02-06
AI Technical Summary
Existing equipment cannot efficiently and cost-effectively detect the correctness of the wiring sequence and connectivity of non-standard cables, and it cannot meet the needs of non-standard customized cables.
A testing system was designed, including a main control module, a signal transmitting module, a signal receiving module, a human-machine interaction module, and a storage module. It supports custom wiring sequence template input, prevents equipment damage through optocoupler isolation design, and detects cable reliability through a motor drive module.
It enables efficient and accurate detection of wiring sequence, continuity, and short circuit faults in non-standard cables, supports multiple interface expansions, reduces equipment costs, and improves detection efficiency and accuracy.
Smart Images
Figure CN121477047A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of cable testing technology. Background Technology
[0002] With the increasing complexity of electronic devices and communication systems, self-made cables are widely used in data centers, industrial control, and consumer electronics. The correctness of the cable wiring sequence, connectivity, and insulation performance directly affect signal transmission quality and equipment safety. Therefore, it is necessary to use specialized equipment to quickly detect faults (such as open circuits, short circuits, and incorrect wiring sequences).
[0003] Currently, most manual testing equipment uses discrete LED indicators or buzzers. The technical principle involves connecting both ends of the cable under test to the master and slave ends of the testing equipment, respectively, and triggering each pin individually for continuity testing. This process is cumbersome and time-consuming. While some existing automated testing equipment uses a microprocessor-controlled scanning matrix, determining continuity by sequentially activating individual pins of the cable under test and detecting signal feedback from other pins, such equipment typically requires pre-loading standard wiring templates (such as RJ45 and RJ11), making it unsuitable for testing non-standard custom cables, and also incurring higher costs. Summary of the Invention
[0004] To address the testing needs of non-standard cables, this invention provides a testing system and method for testing non-standard cables, overcoming the shortcomings of existing equipment such as high cost and poor compatibility.
[0005] A testing system for detecting non-standard cables includes: The main control module is used for overall control logic and data processing. It is electrically connected to a signal transmitting module and a signal receiving module. The signal transmitting module connects to the head end of the cable under test and transmits signals. The signal receiving module connects to the tail end of the cable under test, receives signals through the cable, and transmits them to the main control module. The main control module is also electrically connected to a human-machine interface module and a storage module. The human-machine interface module supports the input and editing of custom wiring sequence templates and stores these templates in the storage module for easy retrieval. The main control module, signal transmitting module, and signal receiving module are integrated on a circuit board.
[0006] On the other hand, the test method for detecting non-standard cables includes the following steps: Step 1, Cable Connection: Connect both ends of the cable under test to the A-end interface of the signal transmitting module and the B-end interface of the signal receiving module, respectively. Step 2: Configure the wiring sequence through the human-computer interaction module; Step two specifically involves: Select a preset wiring sequence template or create a new cable type using the touch matrix keypad. The creation process involves defining the function of each pin in sequence and entering the number of cable channels. The data is then saved to the storage module. Select the cable type from the template library in the storage module, and the main control module will automatically load the corresponding wiring sequence.
[0007] Step 3: Fault detection of the cable under test: Signal transmission: The main control module sequentially activates individual channels of the signal transmission module and outputs pulse signals; Signal reception: The signal receiving module detects all channels of the B-end interface input to determine the cable sequence, continuity, and short circuit status, and displays the test results on the display screen.
[0008] Technical effects: This invention can efficiently and accurately detect the status of cables, especially for non-standard cables that cannot be detected by existing technologies. By inputting and editing a custom wiring sequence template, different channels at the signal output end are activated sequentially, and the signal feedback at the signal input end is detected to determine whether the cable has short circuits, open circuits, or incorrect wiring sequence faults. Simultaneously, optocoupler isolation and anti-interference design are incorporated: the signal transmitting / receiving modules use independent optocoupler isolation to effectively prevent short-circuit current backflow from damaging the internal chips of the main control module. Furthermore, the motor drive module can drive a DC motor to generate a vibration effect, detecting the reliability of the cable and identifying cables with poor contact. At the same time, the main control interface supports expanding the types of cables that can be detected by changing the adapter (e.g., converting to DB9 or XLR interfaces), increasing the overall system's modular expansion capabilities. Attached Figure Description
[0009] Figure 1 This is a block diagram showing the overall module connection relationship of an embodiment of the test system of the present invention.
[0010] Figure 2 This is the circuit diagram for the 24V to 5V power management module.
[0011] Figure 3 This is the circuit diagram for the 24V to 3.3V power management module.
[0012] Figure 4 This is a circuit diagram of the optocoupler isolation circuit for the signal transmitting / receiving module. Detailed Implementation
[0013] To make the technical solution of the present invention clearer, the technical solution of the present invention will be described in detail below with reference to the accompanying drawings and specific embodiments.
[0014] This embodiment provides a testing system for detecting non-standard cables, including: The main control module is used for overall control logic and data processing. It is electrically connected to a signal transmitting module and a signal receiving module. The signal transmitting module connects to the head end of the cable under test and transmits signals. The signal receiving module connects to the tail end of the cable under test, receives signals through the cable, and transmits them to the main control module. The main control module is also electrically connected to a human-machine interface module and a storage module. The human-machine interface module supports the input and editing of custom wiring sequence templates and stores these templates in the storage module for easy retrieval. The main control module, signal transmitting module, and signal receiving module are integrated on a circuit board.
[0015] It also includes a power management module for powering each module. It supports 220V AC input, which is converted to 24V DC via a power adapter to supply power to the circuit board. It can also convert 24V DC to 5V and 3.3V DC. The 5V DC is used to power the internal circuitry of the signal transmission module, and the 3.3V DC is used to power the MCU of the main control module.
[0016] Furthermore, such as Figure 2 As shown, the 24V input is protected against reverse voltage through diode VD2, and there is also overcurrent protection from fuse F1 in the subsequent stage. D2 is a TVS diode that protects other sensitive components connected in the same circuit from damage by high voltage. The power module U1, Zener diode VD4, inductor L1, and capacitors C8 and C9 together form a 24V to 5V power conversion circuit for powering the internal circuitry of the signal transmission module. Capacitor C8 is used for filtering, inductor L1 and capacitor C9 form the power module feedback circuit to ensure the accuracy of the output voltage, and VD4 is used to stabilize the voltage range. Specifically, the power module U1 uses, but is not limited to, an LM2596.
[0017] Furthermore, such as Figure 3 As shown, the 5V power supply is converted to 3.3V via the LDO chip D3, which powers the MCU of the main control module. Capacitors C13, C10, C11, and C12, and resistor C18 are used for filtering, while LED V1 indicates the voltage output. Specifically, the LDO chip D3 is, but is not limited to, SPX29300T-3.3.
[0018] The human-computer interaction module also includes a display screen and a touch matrix keyboard, allowing users to select a preset line sequence or create a new line sequence type via touch operation.
[0019] Both the signal transmitting module and the signal receiving module are equipped with optically isolated circuits, such as Figure 4As shown, optocoupler isolation effectively isolates signals, ensuring the device is not damaged when a short circuit occurs in the cable being tested. The signal transmitting module has a maximum drive current of 50mA per channel and supports 5V pulse signal output; the signal receiving module is equipped with an RC filter network per channel to suppress high-frequency noise interference.
[0020] The storage module integrates a Flash chip and is connected to the main control module via an SPI interface. It is used to store user-defined line sequence templates and also supports TF card memory expansion.
[0021] In one possible implementation, a motor drive module is added and connected to the main control module, which then controls its operation. Specifically, the L6506+L298P drive scheme can drive a DC motor to generate vibration, thereby detecting cable reliability and improving the ability to identify latent faults such as poorly connected cables.
[0022] Another aspect of this embodiment provides a testing method for detecting non-standard cables based on the above-described testing system, comprising the following steps: Step 1, Cable Connection: Connect both ends of the cable under test to the A-end interface (CN1, 32-pin terminal) of the signal transmitting module and the B-end interface (CN2) of the signal receiving module, respectively. Step 2: Configure the wiring sequence through the human-computer interaction module; Step two specifically involves: Select a preset wiring sequence template or create a new cable type using the touch matrix keypad. The creation process involves defining the function of each pin in sequence (e.g., A_Pin1→B_Pin3, A_Pin2→B_Pin5), while simultaneously inputting the number of channels in the cable. The data is then saved to the storage module. Select the cable type from the template library in the storage module, and the main control module will automatically load the corresponding wiring sequence.
[0023] Step 3: Fault detection of the cable under test: Signal transmission: The main control module activates a single channel (such as Pin1) of the signal transmission module sequentially through a shift register and outputs a pulse signal. Signal reception: The signal receiving module detects all channels of the B-end interface input to determine the cable sequence, continuity, and short circuit status, and displays the test results on the display screen.
[0024] Furthermore, the specific steps for determining the fault in the tested cable and outputting the result in step three are as follows: Open circuit: If no response signal is detected at the B-end interface, it is determined to be an open circuit. The screen will display "open circuit", the status light will turn red, and the buzzer will sound an alarm.
[0025] Short circuit: If multiple channels of the B-end interface detect response signals, it is determined to be a short circuit. The screen will display a short circuit, the status light will turn red, and the buzzer will sound an alarm.
[0026] Wiring sequence error: If the actual response channel detected by the B end does not match the preset wiring sequence template, the screen will display a wiring sequence error, the status light will turn red, and the buzzer will sound an alarm.
[0027] Cable pass test: If all signals emitted by all channels at end A can be detected by end B with a response signal, and the detected response channel matches the preset wiring sequence, then the cable is deemed to have passed the test and is qualified.
[0028] The beneficial effects of the present invention are further illustrated below through two specific embodiments.
[0029] Specific Implementation Example 1: Basic Function Verification of Standard Cables: Verifying the ability to detect open circuits, short circuits, and wiring errors in standard RJ45 cables. Test Conditions: The cable under test is a Category 5e unshielded twisted pair cable (3 meters), with a preset artificial fault (short circuit in cores 3 and 6, open circuit in core 7).
[0030] Experimental steps: Cable connection: Insert both ends of the standard RJ45 cable into the device's A end (CN1) and B end (CN2) interfaces respectively.
[0031] Wiring configuration: Select the "RJ45 T568B" preset template via the display screen.
[0032] Fault detection: The main control module activates the A-end interfaces Pin1-Pin8 sequentially through the shift register to transmit a 5V / 100kHz pulse signal. The signal receiving module samples each channel of the B-end and records the amplitude and rise time of the response signal.
[0033] Results analysis: Open circuit detection: No response signal (amplitude < 0.2V) at pin 7 of terminal B indicates an open circuit.
[0034] Short circuit detection: When high amplitude signals (>4.8V) are detected simultaneously at Pin3 and Pin6 at the B end, it is determined to be a short circuit.
[0035] Line sequence verification: The actual response channel is fully matched with the T568B standard, with no mismatch alarms.
[0036] Test conclusion: The equipment completes full-channel detection within 3.2 seconds, with a fault identification accuracy of 100%.
[0037] Specific Implementation Example 2: Modular Adaptation Test of Non-standard Cables: Verifying the ability to detect custom wiring sequences and interface expandability of 32-core non-standard cables. Test conditions: The cable under test is a 32-core industrial cable (mixed wire diameters of 0.2mm² to 1.5mm²), with a custom wiring sequence (A_Pin1→B_Pin24, A_Pin2→B_Pin18…).
[0038] Experimental steps: Cable connection: Connect via the corresponding terminals of the extension cable. For example, this embodiment is equipped with a port connection board, which has 2.0mm, 2.54mm, 3.96mm, and 4.2mm pitch socket soldering interfaces, DB9, network ports, and other commonly used socket soldering interfaces, as well as sockets that users can solder according to their own needs for cable connection.
[0039] Line sequence configuration: Create a new line sequence template, define the mapping relationship between Pin1-Pin32 on end A and the corresponding channel on end B (e.g., A1→B24), save the line sequence template to Flash and name it.
[0040] Fault detection: The signal transmitting module sequentially activates each channel on end A, and the signal receiving module detects the response on end B. When the A_Pin15 transmitting signal is detected, Pin30 on end B responds (which does not match the preset template), triggering a wiring sequence error alarm.
[0041] Test conclusion: The device is perfectly compatible with the DB9 interface through the adapter, which verifies the flexibility and efficiency of the modular design.
[0042] Therefore, as illustrated by the two specific embodiments above, this embodiment demonstrates significant advantages in terms of detection efficiency, fault location accuracy, compatibility with non-standard cables, and identification of latent faults. Furthermore, all content not described in detail in this specification is prior art known to those skilled in the art. For those skilled in the art, based on the principles of this invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of this invention.
Claims
1. A testing system for detecting non-standard cables, characterized in that, The system includes a main control module for overall control logic and data processing. The main control module is electrically connected to a signal transmitting module and a signal receiving module. The signal transmitting module connects to the head end of the cable under test and transmits signals. The signal receiving module connects to the tail end of the cable under test, receives signals through the cable under test, and transmits them to the main control module. The main control module is also electrically connected to a human-machine interface module and a storage module. The human-machine interface module supports the input and editing of custom wiring sequence templates and stores these templates in the storage module for easy retrieval. The main control module, signal transmitting module, and signal receiving module are integrated on a circuit board.
2. The testing system for detecting non-standard cables according to claim 1, characterized in that, It also includes a power management module for powering each module. It supports 220V AC input, which is converted to 24V DC via a power adapter to supply power to the circuit board. It can also convert 24V DC to 5V and 3.3V DC. The 5V DC is used to power the internal circuitry of the signal transmission module, and the 3.3V DC is used to power the MCU of the main control module.
3. The testing system for detecting non-standard cables according to claim 1, characterized in that, The human-computer interaction module also includes a display screen and a touch matrix keyboard, allowing users to select a preset line sequence or create a new line sequence type via touch operation.
4. The testing system for detecting non-standard cables according to claim 1, characterized in that, Both the signal transmitting module and the signal receiving module are equipped with optocoupler isolation circuits. The maximum drive current of each channel of the signal transmitting module is 50mA, and it supports 5V pulse signal output. Each channel of the signal receiving module is equipped with an RC filter network, which can suppress high-frequency noise interference.
5. The testing system for detecting non-standard cables according to any one of claims 1 to 4, and the testing method for detecting non-standard cables, characterized in that, Includes the following steps: Step 1, Cable Connection: Connect both ends of the cable under test to the A-end interface of the signal transmitting module and the B-end interface of the signal receiving module, respectively. Step 2: Configure the wiring sequence through the human-computer interaction module; Step 3: Fault detection of the cable under test: Signal transmission: The main control module sequentially activates individual channels of the signal transmission module and outputs pulse signals. Signal reception: The signal receiving module detects all channels of the B-end interface input to determine the cable sequence, continuity, and short circuit status, and displays the test results on the display screen.
6. The test method for detecting non-standard cables according to claim 5, characterized in that, Step two specifically involves selecting a preset wire sequence template or creating a new cable type via a touch matrix keyboard. The creation process involves defining the function of each pin in sequence, inputting the number of channels in the cable, and saving the data to the storage module. Select the cable type from the template library of the storage module, and the main control module will automatically load the corresponding cable sequence.
7. The test method for detecting non-standard cables according to claim 5, characterized in that, The output of step three is as follows: Open circuit: If no response signal is detected by the B-end interface, it is determined to be an open circuit. The screen will display an open circuit, the status light will turn red, and the buzzer will sound an alarm. Short circuit: If multiple channels of the B-end interface detect response signals, it is determined to be a short circuit. The screen will display a short circuit, the status light will turn red, and the buzzer will sound an alarm. Wiring sequence error: If the actual response channel detected by the B-end interface does not match the preset wiring sequence template, the screen will display a wiring sequence error, the status light will turn red, and the buzzer will sound an alarm. Cable pass test: If the B-end interface can detect the response signal of all channels emitted by the A-end interface, and the detected response channel matches the preset wiring sequence, then the cable is judged to have passed the test and is qualified.