Wire harness internal resistance detection device and detection system thereof

Abstract

The application relates to a wire harness internal resistance detection device and a detection system thereof, relates to the wire harness processing and detection technical field, and aims to provide a device capable of quickly and accurately detecting the internal resistance of a wire harness. A constant current module and a voltage detection module of the wire harness internal resistance detection device are connected into a detection loop through two first wire harnesses. A wire harness first terminal is arranged in series between the constant current module and the voltage detection module, and two poles of a first power supply module are connected with a power supply first terminal in sequence. A preset wire harness is detachably connected between one wire harness first terminal and one power supply first terminal, so that the first power supply module and the voltage detection module are arranged in parallel, and the preset wire harness at least comprises a wire harness to be detected. A first power supply switch is arranged in series between at least one wire harness first terminal and the constant current module, and a first detection switch is arranged in series between at least one wire harness first terminal and the voltage detection module.

Description

Technical Field

[0001] This application relates to the field of wire harness processing and testing technology, and in particular to a wire harness internal resistance testing device and its testing system. Background Technology

[0002] Battery packs are an important component of new energy vehicles and energy storage. A battery pack consists of multiple cells connected in series or parallel. The status of each cell can be monitored in real time through a data acquisition harness.

[0003] As a crucial component of the battery pack, the data acquisition harness plays a vital role in collecting cell voltage and temperature data. Accurate voltage and temperature parameters are essential for ensuring the safe operation of the battery pack. However, the internal resistance of the data acquisition harness can affect the accuracy of voltage and temperature data collection. Therefore, a device capable of quickly and accurately detecting the internal resistance of the data acquisition harness is needed. Summary of the Invention

[0004] This application provides a wire harness internal resistance detection device and system, aiming to provide a device that can quickly and accurately detect the internal resistance of a wire harness.

[0005] On one hand, this application provides a wire harness internal resistance detection device, including a constant current module, a first power supply module, a voltage detection module, two first wire harnesses, two wire harness first terminals, two power supply first terminals, a first power supply switch, and a first detection switch. The constant current module and the voltage detection module are connected in a detection circuit via the two first wire harnesses. Between the constant current module and the voltage detection module, each first wire harness has a wire harness first terminal connected in series, and the two poles of the first power supply module are sequentially connected to a power supply first terminal. A preset wire harness is detachably connected between a wire harness first terminal and a power supply first terminal, so that the first power supply module and the voltage detection module are connected in parallel, and the preset wire harness includes at least the wire harness to be detected. At least one wire harness first terminal and the constant current module have a first power supply switch connected in series, and at least one wire harness first terminal and the voltage detection module have a first detection switch connected in series.

[0006] In some embodiments, there are two first power supply switches, with the first power supply switch connected in series between the first terminal of each wire harness and the constant current module. There are also two first detection switches, with the first detection switch connected in series between the first terminal of each wire harness and the detection module.

[0007] In some embodiments, the wire harness internal resistance detection device includes a first detection branch, which comprises a second power module, two second wire harnesses, two wire harness second terminals, two power supply second terminals, two second power supply switches, and two second detection switches. Each second wire harness has a wire harness second terminal connected in series, and the two poles of the second power module are sequentially connected to a power supply second terminal. A preset wire harness is detachably connected between a wire harness second terminal and a power supply second terminal. One end of each of the two second wire harnesses is connected to the two poles of a constant current module, and the other end of each of the two second wire harnesses is connected to the two poles of a voltage detection module. A second power supply switch is connected in series between each wire harness second terminal and the constant current module, and a second detection switch is connected in series between each wire harness second terminal and the voltage detection module.

[0008] The number of first detection branches is at least two, and at least two first detection branches are set in parallel.

[0009] In some embodiments, the wire harness internal resistance detection device includes a second detection branch, which comprises two second wire harnesses, two second wire harness terminals, two second power supply terminals, two second power supply switches, and two second detection switches. One end of each of the two second wire harnesses is connected to the two poles of a constant current module, and the other end of each of the two second wire harnesses is connected to the two poles of a voltage detection module. Each second wire harness is connected in series with one second wire harness terminal, and the two poles of the first power supply module are sequentially connected to one second power supply terminal. A preset wire harness is detachably connected between one second wire harness terminal and one second power supply terminal. A second power supply switch is connected in series between each second wire harness terminal and the constant current module, and a second detection switch is connected in series between each second wire harness terminal and the voltage detection module.

[0010] The number of second detection branches is at least two, and at least two first detection branches are set in parallel.

[0011] In some embodiments, the first power supply switch, the first detection switch, the second power supply switch, and the second detection switch are electronic switches. The wire harness internal resistance detection device also includes a control module, which is electrically connected to the first power supply switch, the first detection switch, the second power supply switch, the second detection switch, and the voltage detection module. The controller is used to control the on and off states of the electronic switches and to acquire voltage detection parameters.

[0012] In some embodiments, the control module includes a controller, a first decoder, and a second decoder. The controller is electrically connected to the voltage detection module and is used to acquire voltage detection parameters. The input terminal of the first decoder is electrically connected to the controller, and the first decoder has at least four output terminals. A first detection switch and a second detection switch are connected to the output terminals of the first decoder in a one-to-one correspondence. The input terminal of the second decoder is electrically connected to the controller, and the second decoder has at least four output terminals. A first power supply switch and a second power supply switch are connected to the output terminals of the first decoder in a one-to-one correspondence.

[0013] The first decoder is configured in pairs to synchronously control either the first or second detection switch in the same detection circuit. The second decoder is configured in pairs to synchronously control the first and second power supply switches in the same detection circuit.

[0014] In some implementations, the wire harness internal resistance detection device further includes an interaction module electrically connected to the control module for inputting and outputting parameters.

[0015] In some implementations, the interaction module includes a touchscreen.

[0016] On the other hand, embodiments of this application provide a wire harness internal resistance detection system, including the wire harness internal resistance detection device described in the previous aspect. The wire harness to be tested is detachably connected between a first terminal of the wire harness and a first terminal of the power supply.

[0017] In another aspect, embodiments of this application provide a wire harness internal resistance detection system, including the wire harness internal resistance detection device described in the first aspect. The preset wire harness includes a wire harness to be tested and a calibration wire harness. The wire harness to be tested is detachably connected between a first terminal of one wire harness and a first power supply terminal, and the calibration wire harness is detachably connected between a first terminal of another wire harness and another first power supply terminal.

[0018] The technical solutions provided in this application have the following advantages compared with the prior art: By connecting the first power supply module and the voltage detection module into a detection circuit, and utilizing a constant current module to provide a stable current, the voltage acquisition range is stabilized. Based on this, by setting detachable wire harness first terminals and power supply first terminals, it is easy to install and remove a preset wire harness (such as the wire harness to be tested) between the wire harness first terminals and the power supply first terminals. The voltage detection module outputs the corresponding initial voltage U0 and detection voltage U1 through the first detection switch and the first power supply switch, achieving precise control of the detection circuit. Simultaneously, the precise internal resistance value of the wire harness to be tested is calculated by combining the initial voltage U0, the detection voltage U1, and the internal parameters of the detection equipment. This improves the flexibility and ease of operation of the internal resistance detection of the wire harness to be tested, and helps to improve the efficiency and accuracy of wire harness quality inspection in new energy products. Attached Figure Description

[0019] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.

[0020] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] One or more embodiments are illustrated by way of example with reference numerals in the accompanying drawings. These illustrations do not constitute a limitation on the embodiments. Elements with the same reference numerals in the drawings are denoted as similar elements. Unless otherwise stated, the figures in the drawings are not to be limited by scale.

[0022] Figure 1 A circuit connection diagram of the first type of wire harness internal resistance detection system provided in the embodiments of this application; Figure 2 This is a circuit connection diagram of the second type of wire harness internal resistance detection system provided in the embodiments of this application; Figure 3 A circuit connection diagram of the third type of wire harness internal resistance detection system provided in the embodiments of this application; Figure 4 for Figure 3 The diagram shows a control timing sequence between the control module and the switching device.

[0023] Explanation of reference numerals in the attached figures: 100. Constant current module; 200. Voltage detection module; 310. First power module; 320. First wiring harness; 330. First terminal of wiring harness; 340. First power terminal; 350. First power supply switch; 360. First detection switch; 400. Pre-set wiring harness; 510, First detection branch; 520, Second detection branch; 501, Second power supply module; 502, Second wiring harness; 503, Second terminal of wiring harness; 504, Second power supply terminal; 505, Second power supply switch; 506, Second detection switch; 610. Control module; 611. Controller; 612. First decoder; 613. Second decoder; 620. Interaction module. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0025] The following disclosure provides numerous different embodiments or examples for implementing various structures of this application. To simplify the disclosure, specific examples of components and arrangements are described below. These are merely examples and are not intended to limit the scope of this application. Furthermore, reference numerals and / or letters may be repeated in different examples. Such repetition is for simplification and clarity and does not in itself indicate a relationship between the various embodiments and / or arrangements discussed.

[0026] For ease of description, spatial relative terms may be used in the text to describe the relative position or movement of one element or feature relative to another element or feature, as shown in the figure. These relative terms include, for example, "inside," "outside," "middle," "outer," "below," "below," "above," "front," "back," etc. Such spatial relative terms are intended to include different orientations of the device in use or operation, other than those depicted in the figure. For example, if the device in the figure undergoes a positional flip, orientation change, or change of motion, these directional indications will change accordingly. For instance, an element described as "below other elements or features" or "below other elements or features" will subsequently be oriented "above other elements or features" or "above other elements or features." Therefore, the example term "below" can include both upper and lower orientations. The device may be otherwise oriented (rotated 90 degrees or in other directions), and the spatial relative descriptors used in the text will be interpreted accordingly.

[0027] Please see Figures 1 to 4 This application provides a wire harness internal resistance detection device and system, aiming to provide a device that can quickly and accurately detect the internal resistance of a wire harness.

[0028] like Figure 1 and Figure 2As shown, this application embodiment provides a wire harness internal resistance detection device, including a constant current module 100, a first power supply module 310, a voltage detection module 200, two first wire harnesses 320, two wire harness first terminals 330, two power supply first terminals 340, a first power supply switch 350, and a first detection switch 360. The constant current module 100 and the voltage detection module 200 are connected in a detection circuit through the two first wire harnesses 320. Between the constant current module 100 and the voltage detection module 200, each first wire harness 320 is connected in series with a wire harness first terminal 330, and the two poles of the first power supply module 310 are sequentially connected to a power supply first terminal 340. A preset wire harness 400 is detachably connected between a wire harness first terminal 330 and a power supply first terminal 340, so that the first power supply module 310 and the voltage detection module 200 are connected in parallel. The preset wire harness 400 includes at least the wire harness to be tested. A first power supply switch 350 is connected in series between at least one wire harness first terminal 330 and constant current module 100, and a first detection switch 360 is connected in series between at least one wire harness first terminal 330 and voltage detection module 200.

[0029] The constant current module 100 provides a stable current output to ensure that the current flowing through the wire harness under test remains constant during the detection process, thus providing an accurate current reference for internal resistance calculation. The first power supply module 310 provides electrical energy, and its output voltage and current can be adjusted according to the detection requirements to provide operating power to the wire harness under test. The voltage detection module 200 is used to accurately measure the voltage value at a specific location.

[0030] The first wiring harness 320 is used to connect different modules, ensuring the effective transmission of current and voltage signals. A first terminal 330 is located at the first wiring harness 320, and a first power terminal 340 is located at both ends of the first power module 310, used to install a preset wiring harness 400 to be tested between the first terminal 330 and the first power terminal 340. The detachable structure facilitates the replacement of the preset wiring harness 400.

[0031] The first power supply switch 350 is located between the constant current module 100 and the first power supply module 310, and is used to control the circuit connection between the constant current module 100 and the first power supply module 310, thereby controlling whether current flows to the wire harness under test. The first detection switch 360 is located between the voltage detection module 200 and the first power supply module 310, and is used to control whether the voltage detection module 200 is connected to the circuit for voltage acquisition.

[0032] At both ends of the first power module 310, two sets of detachable wire harness first terminals 330 and power supply first terminals 340 are provided, allowing a preset wire harness 400 to be detachably installed between one wire harness first terminal 330 and the first power supply first terminal 340 for detecting the internal resistance of the preset wire harness 400. Exemplarily, the wire harness first terminals 330 and the power supply first terminals 340 can employ various types of connectors, such as bolt-fixed terminals or spring-clamp terminals, to facilitate the connection of the preset wire harness 400. The preset wire harness 400 includes at least the wire harness to be tested, which can be any wire or cable requiring internal resistance testing. For example, the wire harness to be tested can be manually inserted or mechanically fixed between the terminals.

[0033] In a wire harness internal resistance detection device, a preset wire harness 400 is installed between two corresponding first terminals to detect the internal resistance of the preset wire harness 400 through a wire harness internal resistance detection system. Taking an example where both the first power supply switch 350 and the first detection switch 360 are in an open-circuit state: First, the first detection switch 360 is closed to connect the voltage detection module 200 and the first power supply module 310, used to detect the initial voltage U0 of the first power supply module 310. Then, the first power supply switch 350 is closed to connect the constant current module 100 to the detection circuit and supply power to the first power supply module 310. At this time, the voltage detection module 200 outputs a detection voltage U1.

[0034] During the detection of the initial voltage U0, the detection current between the first power supply module 310 and the voltage detection module 200 is very small and can be ignored. At this time, the initial voltage U0 can be regarded as the current voltage value of the first power supply module 310.

[0035] The first terminal 330 of the wiring harness, the preset wiring harness 400, the first power supply terminal 340, the first power supply module 310, the first power supply terminal 340, the preset wiring harness 400, and the first terminal 330 of the wiring harness are used as module branches. During the acquisition of the detection voltage U1, the constant current module 100 inputs a known constant current I0 to the module branch, while the loop current between the first power supply module 310 and the module branch can be ignored. At this time, the detection voltage U1 output by the voltage detection module 200 is the current voltage of the module branch.

[0036] Wherein, the total resistance of the module branch is defined as R = R0 + R1 + R2 + R3, where R0 is the internal resistance of the first power module 310, R1 and R2 are the internal resistances of the two preset wire harnesses, and R3 is the sum of the internal resistances of the first terminals 330 of the two wire harnesses, the first terminals 340 of the two power supplies, and any existing connecting wire harnesses (i.e., the internal resistance of the device). U1 = I0 × R, and U0 = I0 × R0.

[0037] According to the above formula, since the initial voltage U0 and the detection voltage U1 are known parameters output by the voltage detection module 200, and the internal resistance value R3 of the device is a fixed value and can be obtained through test, the internal resistance of the preset wire harness 400 is R1+R2=((U1-U0) / I0)-R3.

[0038] For two preset wire harnesses 400, there are multiple ways to install the preset wire harnesses 400 in the detection system using the wire harness internal resistance detection device.

[0039] Taking the preset wire harness 400 as the wire harness to be tested as an example, since the wire harnesses to be tested are mostly paired products, one wire harness to be tested can be installed sequentially between the two sets of first terminals at both ends of the first power module 310, so that the total internal resistance (i.e., R1+R2) of the two wire harnesses to be tested can be detected by the wire harness internal resistance detection device. Since the paired wire harnesses to be tested have the same wire diameter, the internal resistance values ​​of the two wire harnesses to be tested can be calculated separately according to the length ratio of the two wire harnesses. If the inner diameter and length of the two wire harnesses to be tested are the same (i.e., R1=R2), the internal resistance values ​​of the two wire harnesses to be tested can be directly calculated by averaging.

[0040] Alternatively, when the harness to be tested is a single harness structure, or when the internal resistance of the harness needs to be tested separately, the preset harness 400 includes the harness to be tested and a calibration harness, wherein the calibration harness is a preset harness 400 with known internal resistance. At both ends of the first power module 310, the calibration harness can be installed between one set of first terminals, and the harness to be tested can be installed between the other set of first terminals. Then, the total internal resistance (i.e., R1 + R2) of the harness to be tested and the calibration harness is detected by the harness internal resistance detection device. The internal resistance value of the harness to be tested is then obtained by subtracting the known internal resistance of the calibration harness from the total internal resistance.

[0041] By connecting the first power supply module 310 and the voltage detection module 200 into a detection circuit, and utilizing the constant current module 100 to provide a stable current, the voltage acquisition range is stabilized. Based on this, by setting detachable wire harness first terminals 330 and power supply first terminals 340, it is convenient to install and remove a preset wire harness 400 (such as the wire harness to be tested) between the wire harness first terminals 330 and power supply first terminals 340. The first detection switch 360 and the first power supply switch 350 control the voltage detection module 200 to output the corresponding initial voltage U0 and detection voltage U1, achieving precise control of the detection circuit. Simultaneously, the precise internal resistance value of the wire harness to be tested is calculated by combining the initial voltage U0, detection voltage U1, and the internal parameters of the detection equipment. This improves the flexibility and ease of operation of the internal resistance detection of the wire harness to be tested, and helps to improve the efficiency and accuracy of quality inspection of wire harnesses in new energy products.

[0042] The number of the first power supply switch 350 and the first detection switch 360 is one, which can simplify the number of components in the wire harness internal resistance detection equipment.

[0043] Or, such as Figure 1 As shown, there are two first power supply switches 350, with each first power supply switch 350 connected in series between the first terminal 330 of each wire harness and the constant current module 100. There are also two first detection switches 360, with each first detection switch 360 connected in series between the first terminal 330 of each wire harness and the detection module.

[0044] By setting two of each of the first power supply switch 350 and the first detection switch 360, and by setting the first power supply switch 350 and the first detection switch 360 on both the current input side and the output side, fine control can be achieved over the current input path and the voltage detection path, ensuring the accuracy and authenticity of the detection results and the internal resistance calculation results.

[0045] In some embodiments, such as Figure 2 As shown, the wire harness internal resistance detection device includes a first detection branch 510, which includes a second power module 501, two second wire harnesses 502, two wire harness second terminals 503, two power supply second terminals 504, two second power supply switches 505, and two second detection switches 506. Each second wire harness 502 is connected in series with a wire harness second terminal 503, and the two poles of the second power module 501 are sequentially connected to a power supply second terminal 504. A preset wire harness 400 is detachably connected between a wire harness second terminal 503 and a power supply second terminal 504. One end of each of the two second wire harnesses 502 is connected to the two poles of the constant current module 100, and the other end of each of the two second wire harnesses 502 is connected to the two poles of the voltage detection module 200. A second power supply switch 505 is connected in series between each wire harness second terminal 503 and the constant current module 100, and a second detection switch 506 is connected in series between each wire harness second terminal 503 and the voltage detection module 200. The number of first detection branches 510 is at least two, and at least two first detection branches 510 are set in parallel.

[0046] The first detection branch 510 refers to a set of circuit units used to expand detection capabilities, in addition to the main detection circuit. Its function is to provide additional detection channels, enabling the detection equipment to simultaneously or alternately connect and detect multiple preset wire harnesses 400, thereby improving detection efficiency and flexibility.

[0047] The second power module 501, similar to the first power module 310, provides power to the preset wiring harness 400 connected to the detection branch. The second power module 501 and the first power module 310 can be the same type of power supply, such as both being ternary lithium batteries or lithium iron phosphate batteries. This provides a stable current or voltage to the preset wiring harness 400 during the detection process, cooperating with the constant current module 100 and the voltage detection module 200 to complete the internal resistance measurement. The difference is that the power supply in the first detection branch 510 is the second power module 501, while the power supply in the main detection circuit is the first power module 310.

[0048] Two second wiring harnesses 502 are used to connect the second power module 501, the second wiring harness terminal 503, the second power supply terminal 504, the constant current module 100, and the voltage detection module 200. The second wiring harness terminal 503, the first wiring harness terminal 330, the first power supply terminal 340, and the second power supply terminal 504 can be of the same terminal structure type, and can enable detachable connection and installation of the preset wiring harness 400, only with different names depending on the installation location.

[0049] Among them, the second power supply switch 505, the first power supply switch 350, the first detection switch 360 and the second detection switch 506 can be manual switches, so that users can manually turn the corresponding switches on or off as needed to realize the internal resistance detection of the wire harness to be tested.

[0050] Alternatively, the second power supply switch 505, the first power supply switch 350, the first detection switch 360, and the second detection switch 506 can be configured as magnetically or electrically controlled electronic switches. For example, the detection switches and power supply switches can be configured as relays, MOSFET (Metal-Oxide-Semiconductor Field-Effect Transistor) switches, IGBT (Insulated Gate Bipolar Transistor) switches, silicon carbide switches, gallium nitride switches, or transistor switches, etc. The switches can be driven to either be in an on or off state by a signal voltage or signal current, thereby achieving automated switching and control of the detection circuit.

[0051] Based on this, by connecting at least two first detection branches 510 in parallel on the main detection circuit, the installation and removal processes of multiple wire harnesses to be tested can be centralized into the installation and removal steps. During the detection of the internal resistance of the wire harnesses to be tested, the operating states of the corresponding power supply switch and detection switch can be directly switched to allow different detection circuits to sequentially output initial voltage U0 and detection voltage U1. Based on the initial voltage U0, detection voltage U1, and preset parameters, the internal resistance value of the wire harnesses to be tested in the corresponding detection circuit can be calculated sequentially. This centralized installation and removal process for the wire harnesses to be tested reduces operation time and improves detection efficiency.

[0052] Thus, the wire harness internal resistance testing device of this application significantly improves the flexibility and efficiency of testing by introducing at least two parallel first detection branches 510. In a basic single detection path configuration, testing multiple wire harnesses or performing comparative tests often requires frequent manual plugging and unplugging of the wire harnesses or reconfiguration of the circuit, which is not only time-consuming but also increases the risk of operational errors. However, by setting up multiple parallel first detection branches 510, each branch is equipped with an independent second power module 501, a wire harness second terminal 503, a power supply second terminal 504, a second power supply switch 505, and a second detection switch 506, allowing the device to connect multiple wire harnesses to be tested simultaneously. For example, during installation, multiple wire harnesses to be tested can be sequentially installed between the corresponding wire harness terminals and detection terminals. During testing, by controlling the on / off state of the corresponding power supply switch and detection switch, the testing object can be quickly switched and the testing parameters output. Finally, the wire harness to be tested can be replaced by disassembly, eliminating the need for frequent physical plugging and unplugging, thereby greatly simplifying the operation process and shortening the testing time. Furthermore, this multi-branch parallel design provides a foundation for automated and batch testing, improving the overall testing efficiency and reliability of the testing system.

[0053] It should be noted that in the above scheme, each detection circuit is equipped with a power supply module, such as the first power supply module 310 or the second power supply module 501. The connection state between the power supply modules can be series connection, parallel connection, or no connection between them, all of which are applicable to the wire harness internal resistance detection device in the embodiments of this application.

[0054] Based on this, only one set of constant current module 100 and voltage detection module 200 is needed. With the adaptation of power supply switch and detection switch, each detection circuit can be switched in sequence to provide stable current and output the corresponding initial voltage U0 and detection voltage U1 to calculate the internal resistance value of the corresponding wire harness to be tested. It has a wide range of applicable applications.

[0055] In some other embodiments, such as Figure 3As shown, the wire harness internal resistance detection device includes a second detection branch 520, which includes two second wire harnesses 502, two wire harness second terminals 503, two power supply second terminals 504, two second power supply switches 505, and two second detection switches 506. One end of each of the two second wire harnesses 502 is connected to the two poles of the constant current module 100, and the other end of each of the two second wire harnesses 502 is connected to the two poles of the voltage detection module 200. Each second wire harness 502 is connected in series with one wire harness second terminal 503, and the two poles of the first power supply module 310 are sequentially connected to one power supply second terminal 504. A preset wire harness 400 is detachably connected between one wire harness second terminal 503 and one power supply second terminal 504. A second power supply switch 505 is connected in series between each wire harness second terminal 503 and the constant current module 100, and a second detection switch 506 is connected in series between each wire harness second terminal 503 and the voltage detection module 200. The number of second detection branches 520 is at least two, and at least two first detection branches 510 are set in parallel.

[0056] The difference between the second detection branch 520 and the first detection branch 510 is that each second detection branch 520 does not have an independent power supply module, but instead shares a first power supply module 310. In this case, multiple sets of second power supply terminals 504 need to be connected in parallel across the two ends of the first power supply module 310.

[0057] Specifically, at one electrode of the first power module 310, at least two second power supply terminals 504 and one first power supply terminal 340 are connected in parallel to the positive terminal of the first power module 310. At the other electrode of the first power module 310, at least two second power supply terminals 504 and one first power supply terminal 340 are connected in parallel to the negative terminal of the first power module 310. The second wiring harness terminals 503 in at least two second detection branches 520 are correspondingly arranged with the second power supply terminals 504 and are detachable, used to install the wiring harness to be tested or the calibration wiring harness between them.

[0058] Thus, by switching the power supply switch and the detection switch, the voltage detection module 200 and the constant current module 100 are sequentially connected to each detection circuit, and the voltage detection module 200 outputs the corresponding initial voltage U0 and detection voltage U1, thereby sequentially calculating and obtaining the internal resistance value of the wire harness to be tested in the corresponding detection circuit.

[0059] In this way, multiple wire harnesses to be tested can be sequentially installed between the corresponding wire harness terminals and detection terminals during the installation process. During testing, the testing object can be quickly switched and testing parameters can be output by controlling the on / off state of the corresponding power supply switch and detection switch. Finally, the wire harness to be tested can be replaced by disassembly, without the need for frequent physical plugging and unplugging, thus greatly simplifying the operation process and shortening the testing time. In addition, this multi-branch parallel design also provides a foundation for automated testing and batch testing, improving the overall testing efficiency and reliability of the testing system.

[0060] Meanwhile, in a wire harness internal resistance detection device equipped with at least two second detection branches 520, only one set of constant current module 100, voltage detection module 200 and first power supply module 310 is needed. Under the adaptation of the power supply switch and detection switch, each detection circuit can be switched sequentially to provide a stable current and output the corresponding initial voltage U0 and detection voltage U1 to calculate and obtain the internal resistance value of the corresponding wire harness to be tested. It has a wide range of applicable applications and simplifies the number of equipment parts to reduce costs.

[0061] In some embodiments, such as Figure 3 As shown, the wire harness internal resistance detection device also includes a control module 610. The control module 610 is electrically connected to the first power supply switch 350, the first detection switch 360, the second power supply switch 505, the second detection switch 506, and the voltage detection module 200. The control module 610 is used to control the on and off states of the electronic switches and to acquire voltage detection parameters.

[0062] The control module 610 is the core control unit of the entire detection equipment. Its main responsibilities are to receive instructions, execute logic processing, and output corresponding control signals to achieve precise control of the aforementioned electronic switches. In addition, the control module 610 can also receive and acquire voltage detection parameters (such as the initial voltage U0 and detection voltage U1 of each detection circuit) output by the voltage detection module 200.

[0063] Taking an electronic switch, specifically a relay, as an example, when the control module 610 needs to close a relay, it sends a drive signal to the relay, energizing the relay coil and causing the contacts to close, thus completing the corresponding circuit. Conversely, when it needs to disconnect, it removes the drive signal, de-energizing the relay coil and resetting the contacts, thereby disconnecting the circuit. The presence of the control module 610 enables the entire wiring harness internal resistance detection device to achieve automation and intelligence in the detection process. It can precisely control the on / off sequence and combination of various power supply switches and detection switches according to a preset detection program or user input, thereby achieving sequential switching of different detection circuits.

[0064] Thus, by introducing the timing control and data receiving functions of the control module 610, this application effectively solves the problems of low efficiency and error-proneness in manual switch operation. The control module 610 can accurately and quickly control the on and off states of each electronic switch according to a preset detection process or external commands, thereby achieving automated switching of the detection circuit and acquiring the corresponding voltage parameters. This not only significantly improves the automation level and detection efficiency of wire harness internal resistance detection, reduces manual intervention, and lowers the risk of operational errors, but also ensures the consistency and repeatability of the detection process, making the detection results more reliable.

[0065] For example, such as Figure 3 As shown, the control module 610 includes a controller 611, a first decoder 612, and a second decoder 613. The controller 611 is electrically connected to the voltage detection module 200 and is used to acquire voltage detection parameters. The input terminal of the first decoder 612 is electrically connected to the controller 611, and the first decoder 612 has at least four output terminals. The first detection switch 360 and the second detection switch 506 are connected one-to-one with the output terminals of the first decoder 612. The input terminal of the second decoder 613 is electrically connected to the controller 611, and the second decoder 613 has at least four output terminals. The first power supply switch 350 and the second power supply switch 505 are connected one-to-one with the output terminals of the first decoder 612.

[0066] The first decoder 612 is configured in pairs to synchronously control either the first detection switch 360 or the second detection switch 506 in the same detection circuit. The second decoder 613 is configured in pairs to synchronously control either the first power supply switch 350 or the second power supply switch 505 in the same detection circuit.

[0067] The first decoder 612 is a digital logic circuit capable of converting an N-bit binary input signal into a 2-bit binary input signal. 2 One or more valid signals from the output signals. For example, the first decoder 612 can be a 2-to-4 line decoder, a 3-to-8 line decoder, or a 4-to-16 line decoder. The input of the first decoder 612 is electrically connected to the controller 611 to receive encoded signals from the controller 611 (such as an MCU, Micro Controller Unit). Each first decoder 612 has at least four outputs, which are connected one-to-one with the first detection switch 360 and the second detection switch 506. That is, one first detection switch 360 transmits a control signal through one output of the first decoder 612, and the other second detection switch 506 transmits control signals through the other outputs of the first decoder 612.

[0068] Based on this, two first decoders 612 are set as a group to synchronously control the first detection switch 360 or the second detection switch 506 in the same detection circuit. For example, the two first detection switches 360 in the main detection circuit are synchronously controlled by the two first decoders 612 in the same group to synchronously switch between the on and off states. Correspondingly, the two second detection switches 506 in the same first detection branch 510 or the same second detection branch 520 are synchronously controlled by the two first decoders 612 in the same group to synchronously switch between the on and off states.

[0069] The second decoder 613 is structurally the same as the first decoder 612, except that the second decoder 613 is used to connect to different output sides of the controller 611, and the output terminal of the second decoder 613 is connected to the corresponding first power supply switch 350 and second power supply switch 505.

[0070] For example, the second decoder 613 can be a 2-to-4 line decoder, a 3-to-8 line decoder, or a 4-to-16 line decoder. The input of the second decoder 613 is electrically connected to the controller 611 to receive encoded signals from the controller 611 (e.g., a Micro Controller Unit). Each second decoder 613 has at least four outputs, which are connected one-to-one with the first detection switch 360 and the second detection switch 506. That is, a first power supply switch 350 transmits control signals through one output of the second decoder 613, and the other second power supply switches 505 transmit control signals through the other outputs of the second decoder 613.

[0071] Based on this, two second decoders 613 are set as a group to synchronously control the first power supply switch 350 or the second power supply switch 505 in the same detection circuit. For example, the two first power supply switches 350 in the main detection circuit are synchronously controlled by the two second decoders 613 in the same group to synchronously switch between the on and off states. Correspondingly, the two second power supply switches 505 in the same first detection branch 510 or the same second detection branch 520 are synchronously controlled by the two second decoders 613 in the same group to synchronously switch between the on and off states.

[0072] Taking the first decoder 612 and the second decoder 613 as 3-8 line decoders as an example, the wire harness internal resistance detection device can additionally connect seven sets of first detection branches 510 or seven sets of second detection branches 520 in parallel to improve detection efficiency.

[0073] The control module 610 incorporates a controller 611, a first decoder 612, and a second decoder 613. The controller 611 sends coded signals to the decoders, which convert these signals into multiple independent control signals, thereby controlling the on / off states of the first detection switch 360, the second detection switch 506, the first power supply switch 350, and the second power supply switch 505. This design eliminates the need for a separate control pin for each electronic switch, significantly reducing the number of output pins required by the controller 611, simplifying the wiring of the control circuit, and lowering hardware costs and design complexity. Simultaneously, centralized control via the decoders improves the efficiency and flexibility of the system in managing multiple switch states, enhancing the reliability and maintainability of the entire wiring harness internal resistance detection device.

[0074] For example, such as Figure 3 and Figure 4 As shown, the controller 611 can control the first decoder 612 and the second decoder 613 through a 3.3V voltage signal, so that the corresponding pins of the first decoder 612 and the second decoder 613 output status signals, which control the relay switch to the corresponding on or off state through the optocoupler isolation device and the transistor driver, so as to control the detection on state of the main detection circuit and the first detection branch 510 (or the second detection branch 520).

[0075] In some embodiments, such as Figure 3 As shown, the wire harness internal resistance detection device also includes an interaction module 620, which is electrically connected to the control module 610 and is used for inputting and outputting parameters. The interaction module 620 can be a host computer, or the interaction module can be configured to include a touch screen.

[0076] The interaction module 620 is a hardware and / or software interface used to realize human-machine information exchange. It may include, but is not limited to, a display screen, buttons, indicator lights, a touchscreen, and voice input / output devices. The main function of this module is to receive user operation commands and parameter inputs, and to provide feedback to the user on the device's operating status, detection data, and error messages.

[0077] The electrical connection between the interaction module 620 and the control module 610 refers to the establishment of a data and control signal transmission channel between the two. This connection can be implemented in various ways, such as using a serial communication interface (e.g., UART, SPI, I2C), a parallel data bus, or a network interface. Through this electrical connection, the interaction module 620 can send user-input operation commands and parameters to the control module 610, while simultaneously receiving processed detection data and system status information from the control module 610 and displaying them to the user.

[0078] The interaction module 620 is used for input parameters, meaning that users can provide necessary information to the wire harness internal resistance detection device through the interaction module 620, such as test mode selection, the number of the wire harness to be tested, the test current value, and the test duration. For example, users can set the type of the preset wire harness 400 through the interaction module 620. If the preset wire harness includes a calibration wire harness or a wire harness to be tested, the wire harness type at the corresponding position is input. Taking the preset wire harness 400 as a calibration wire harness as an example, the known internal resistance value of the calibration wire harness can be input. If two preset wire harnesses in the same detection circuit are both wire harnesses to be tested, the length ratio of the two wire harnesses to be tested is input, etc. In addition, users can also input preset parameters such as the internal resistance value R3, the output current I0 of the constant current module, and the start-up time and pneumatic sequence of the decoder according to the interaction module 620.

[0079] In addition, users can also use the interaction module 620 or the initial test data, as well as the calculated output parameters such as the internal resistance value of the wire harness under test. That is, the interaction module 620 can present the internal operating status of the wire harness internal resistance detection device, the real-time detected voltage and current, the calculated internal resistance value, the test results (such as pass / fail), and fault alarm information to the user in a visual manner (such as numbers, charts, and text prompts).

[0080] The interactive module 620 facilitates the input and output of relevant parameters. This not only greatly improves the ease of operation and user experience of the device and reduces the complexity of manual intervention, but also helps operators quickly judge the test results and promptly identify and handle abnormalities through intuitive data display, thereby significantly improving the efficiency and accuracy of wire harness internal resistance detection.

[0081] For example, the interaction module 620 can be configured as a touch screen, allowing users to operate through an intuitive graphical interface, directly inputting parameters, selecting test modes, starting detection, and viewing detection data and results in real time on the screen. This interaction method significantly simplifies the operation process, reduces the user's learning cost, and improves the execution efficiency of the detection task. The touch screen can display information in a richer and clearer visual form. For example, it can display the connection diagram of the wire harness to be tested, current and voltage curves, internal resistance calculation results, etc., enabling users to understand the device status and detection data more quickly and accurately, thereby effectively solving the problems of complex operation and unintuitive information display in traditional interaction methods, and improving the user experience and practicality of the wire harness internal resistance detection device. Taking a wire harness internal resistance detection device including seven first detection branches 510 applied to a wire harness internal resistance detection system as an example, firstly, preset parameters are loaded through the interaction device. Then, the corresponding eight sets of preset wire harnesses 400 are installed sequentially (each set of preset wire harnesses may include at least one wire harness to be tested). The control module 610 starts the wire harness internal resistance detection device, so that the controller 611 controls the two first decoders 612 and the two second decoders 613 to sequentially start the main detection circuit (the circuit where the first detection switch 360 and the first power supply switch 350 are located) and the seven first detection branches 510. In each main detection circuit and the first detection branch 510, two detection switches form a group, and two power supply switches form a group. After being started sequentially, they are simultaneously turned off and the next detection circuit is started. During the sequential start-up of the main detection circuit and the seven first detection branches 510, the controller 611 sequentially records eight sets of initial voltage U0 and detection voltage U1, and outputs the detection results through the touch screen.

[0082] The detection results can be the raw data of the corresponding eight sets of initial voltages U0 and detection voltages U1.

[0083] Alternatively, the detection result may also include the internal resistance value of the corresponding wire harness to be tested, calculated and output by the controller 611. That is, the controller 611 can calculate the total internal resistance value R1+R2 of the two preset wire harnesses 400 in the same detection circuit according to the formula R1+R2=((U1-U0) / I0)-R3. Among them, the output current I0 of the constant current module 100 and the internal resistance value R3 of each detection circuit are known input parameters.

[0084] When all two wire harnesses in the same preset group 400 are wire harnesses to be tested, their internal resistance values ​​are calculated based on the length ratio (a known input parameter). For example, if the length ratio of the two wire harnesses is 1:2 and their internal resistance R1 + R2 = 12mΩ, then their internal resistance values ​​are 4mΩ and 8mΩ, respectively. If the lengths of the two wire harnesses are the same, then their internal resistance values ​​are both 6mΩ.

[0085] If the same set of preset wire harnesses 400 includes both the wire harness to be tested and the calibration wire harness, the internal resistance R1 of the calibration wire harness is 2mΩ (a known parameter). Given that the internal resistance R1 + R2 = 5mΩ of the two preset wire harnesses 400, the internal resistance R2 of the wire harness to be tested can be directly calculated to be 3mΩ. Similarly, after each automatic test, eight sets of internal resistance values ​​for the wire harnesses to be tested can be output.

[0086] It should be understood that the terminology used herein is for the purpose of describing particular exemplary embodiments only and is not intended to be limiting. Unless the context clearly indicates otherwise, the singular forms “a,” “an,” and “described” as used herein may also include the plural forms. The terms “comprising,” “including,” “containing,” and “having” are inclusive and therefore indicate the presence of the stated features, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, steps, operations, elements, components, and / or combinations thereof. The method steps, processes, and operations described herein are not construed as requiring them to be performed in a particular order described or illustrated unless the order of performance is explicitly indicated. It should also be understood that additional or alternative steps may be used.

[0087] Although terms such as first, second, third, etc., may be used in this document to describe multiple elements, components, regions, layers, and / or segments, these elements, components, regions, layers, and / or segments should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or segment from another. Unless the context clearly indicates otherwise, terms such as "first," "second," and other numerical terms used herein do not imply order or sequence. Therefore, the first element, component, region, layer, or segment discussed below may be referred to as the second element, component, region, layer, or segment without departing from the teachings of the exemplary embodiments.

[0088] The above description is merely a specific embodiment of this application, enabling those skilled in the art to understand or implement this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features claimed herein.

Claims

1. A wire harness internal resistance detection device, characterized in that, It includes a constant current module, a first power supply module, a voltage detection module, two first wire harnesses, two first terminals of the two wire harnesses, two first terminals of the power supply, a first power supply switch, and a first detection switch; The constant current module and the voltage detection module are connected to form a detection circuit through two first wire harnesses; between the constant current module and the voltage detection module, each first wire harness is connected in series with a first terminal of the wire harness, and the two poles of the first power module are connected to a first power terminal in sequence. A preset wire harness is detachably connected between a first terminal of the wire harness and a first terminal of the power supply, so that the first power supply module and the voltage detection module are connected in parallel. The preset wire harness includes at least the wire harness to be detected. The first power supply switch is connected in series between at least one of the first terminals of the wire harness and the constant current module, and the first detection switch is connected in series between at least one of the first terminals of the wire harness and the voltage detection module.

2. The wire harness internal resistance detection device according to claim 1, characterized in that, There are two first power supply switches, and the first power supply switch is connected in series between the first terminal of each wire harness and the constant current module; The number of the first detection switches is two, and the first detection switches are connected in series between the first terminal of each wire harness and the detection module.

3. The wire harness internal resistance detection device according to claim 2, characterized in that, The wire harness internal resistance detection device includes a first detection branch, which includes a second power module, two second wire harnesses, two wire harness second terminals, two power supply second terminals, two second power supply switches, and two second detection switches. Each of the second wire harnesses is connected in series with a second terminal of the wire harness, and the two poles of the second power module are connected to a second power terminal of the power supply in sequence. A preset wire harness is detachably connected between a second terminal of the wire harness and a second terminal of the power supply. One end of each of the two second wire harnesses is connected to the two poles of the constant current module, and the other end of each of the two second wire harnesses is connected to the two poles of the voltage detection module; a second power supply switch is connected in series between the second terminal of each wire harness and the constant current module, and a second detection switch is connected in series between the second terminal of each wire harness and the voltage detection module; The number of the first detection branches is at least two, and at least two of the first detection branches are connected in parallel.

4. The wire harness internal resistance detection device according to claim 2, characterized in that, The wire harness internal resistance detection device includes a second detection branch, which includes two second wire harnesses, two wire harness second terminals, two power supply second terminals, two second power supply switches, and two second detection switches. One end of each of the two second wire harnesses is connected to the two poles of the constant current module, and the other end of each of the two second wire harnesses is connected to the two poles of the voltage detection module; Each of the second wire harnesses is connected in series to one of the second terminals of the wire harness, and the two poles of the first power module are sequentially connected to one of the second power terminals; The preset wire harness is detachably connected between a second terminal of the wire harness and a second terminal of the power supply. A second power supply switch is connected in series between each of the second terminals of the wire harness and the constant current module, and a second detection switch is connected in series between each of the second terminals of the wire harness and the voltage detection module; The number of the second detection branches is at least two, and at least two of the first detection branches are connected in parallel.

5. The wire harness internal resistance detection device according to claim 3 or 4, characterized in that, The first power supply switch, the first detection switch, the second power supply switch, and the second detection switch are electronic switches; The wire harness internal resistance detection device also includes a control module, which is electrically connected to the first power supply switch, the first detection switch, the second power supply switch, the second detection switch, and the voltage detection module. The controller is used to control the on and off states of the electronic switch and to acquire the voltage detection parameters.

6. The wire harness internal resistance detection device according to claim 5, characterized in that, The control module includes: A controller, electrically connected to the voltage detection module, is used to acquire voltage detection parameters; A first decoder, the input of the first decoder is electrically connected to the controller, the first decoder has at least four outputs, and the first detection switch and the second detection switch are connected to the outputs of the first decoder one by one; And a second decoder, the input of the second decoder being electrically connected to the controller, the second decoder having at least four outputs, and the first power switch and the second power switch being connected one-to-one with the outputs of the first decoder; The first decoder is configured in pairs to synchronously control either the first detection switch or the second detection switch in the same detection circuit; the second decoder is configured in pairs to synchronously control both the first power supply switch and the second power supply switch in the same detection circuit.

7. The wire harness internal resistance detection device according to claim 5, characterized in that, The wire harness internal resistance detection device also includes an interaction module, which is electrically connected to the control module and is used to input and output parameters.

8. The wire harness internal resistance detection device according to claim 7, characterized in that, The interactive module includes a touch screen.

9. A wire harness internal resistance detection system, characterized in that, Includes the wire harness internal resistance detection device as described in any one of claims 1-8; The wire harness to be tested is detachably connected between the first terminal of the wire harness and the first terminal of the power supply.

10. A wire harness internal resistance detection system, characterized in that, Includes the wire harness internal resistance detection device as described in any one of claims 1-8; The preset wire harness includes a wire harness to be tested and a calibration wire harness; the wire harness to be tested is detachably connected between a first terminal of one wire harness and a first terminal of the power supply, and the calibration wire harness is detachably connected between a first terminal of another wire harness and a first terminal of another power supply.

Images