An engine test bench universal integrated process wire harness and a control method thereof

Abstract

This invention discloses a universal integrated process wiring harness for an engine test bench and its control method. The wiring harness includes a bench-side interface unit, a channel switching unit, an engine-side interface unit, and an alarm unit. The bench-side interface unit includes a first terminal, and the engine-side interface unit includes a second terminal. In use, the method acquires the identifier of the functional module to be tested from the test engine; based on the identifier, it retrieves the corresponding target transmission channel position and controls the channel switching unit to switch, thereby connecting the corresponding first and second terminals to form the target transmission channel; then, it determines whether the target transmission channel has a fault; if a fault exists, it controls the disconnection of the target transmission channel and triggers an alarm. Therefore, this invention is adaptable to multiple platforms and models, has good versatility, reduces the number of wiring harnesses by more than 70%, enables model switching in seconds, significantly improves test efficiency, reduces the number of plug-in / plug-out operations, and reduces the risk of poor contact and misconnection through fault diagnosis.

Description

Technical Field

[0001] This invention relates to the field of process wiring harness technology, and in particular to a universal integrated process wiring harness for an engine test bench. Background Technology

[0002] With the rapid development of natural gas engines, they have been widely used in vehicle assembly and operation. To prevent a large number of engines from failing in the market, engines must undergo hot testing before leaving the factory.

[0003] Currently, in the field of engine hot testing, the existing technical solution closest to this traceability project mainly uses traditional process wiring harnesses as the connection carrier, in conjunction with an external independent control system, and its specific implementation is as follows:

[0004] Sensor signals, power supply lines and communication signals at the equipment site are laid through independent wires. Various signal lines, power lines and control lines are not integrated, but simply bundled together with ordinary cable ties or sleeves to form multi-core wire harnesses.

[0005] The two ends of the wiring harness are connected to the engine and the measurement and control system respectively using ordinary plug-in connectors or terminal blocks. The connection to the engine end requires the use of multiple connectors, and the numbers must be cleared. Compared with traditional wiring harnesses, the difficulty of use is not reduced. The wiring harness body is only used as a physical connection carrier and does not have any signal processing, data acquisition or logic control functions.

[0006] After use, it was found that the existing technology has the following main drawbacks:

[0007] Because the wiring harness is only a passive connection structure and does not integrate acquisition and control units, all signals must be led to an external controller. The large number of wiring harnesses and the lengthy wiring result in messy internal wiring and low installation and disassembly efficiency.

[0008] Because multiple circuit signals are transmitted along the same line over long distances, and the wiring harness lacks integrated shielding and partition isolation structures, the signals are susceptible to power supply, drive, and external electromagnetic interference during transmission, resulting in signal distortion, control malfunctions, and poor system stability.

[0009] Because the signals, drives, and power supplies are wired separately and there is no unified integrated interface, the compatibility between different devices is poor, the workload of changeover and debugging is large, and it is difficult to meet the needs of rapid changeover and intelligent monitoring of automated production lines.

[0010] Because the harness itself does not integrate status acquisition and fault detection functions, when a short circuit, open circuit, poor contact, or overcurrent or overvoltage abnormality occurs in the line, it is impossible to achieve local real-time monitoring and rapid location. It can only rely on manual segment-by-segment troubleshooting, which makes fault maintenance time long. Summary of the Invention

[0011] To address the aforementioned shortcomings, the technical problem to be solved by this invention is to provide a universal integrated process wiring harness and its control method for engine test benches, which can be adapted to multiple platforms and models, has good versatility, reduces the number of wiring harnesses by more than 70%, has a fast model switching time of seconds, significantly improves test efficiency, reduces the number of plugging and unplugging, and reduces the risk of poor contact and misconnection through fault diagnosis.

[0012] To solve the above-mentioned technical problems, the technical solution of the present invention is as follows:

[0013] A control method for a universal integrated process wiring harness for an engine test bench, the universal integrated process wiring harness for the engine test bench including a test bench-side interface unit, a channel switching unit, an engine-side interface unit, and an alarm unit, wherein the test bench-side interface unit and the engine-side interface unit are electrically connected to the channel switching unit, the test bench-side interface unit includes multiple first terminals, and the engine-side interface unit includes multiple second terminals; the control method includes the following steps:

[0014] S10. Obtain the identifier of the functional module to be tested for the test engine;

[0015] S20. Based on the identifier of the functional module to be tested, retrieve the corresponding target transmission channel location;

[0016] S30. Generate a corresponding switching signal based on the location of the target transmission channel;

[0017] S40. According to the switching signal, control the channel switching unit to turn on and off, so as to connect the corresponding first terminal in the bench-side interface unit and the corresponding second terminal in the engine-side interface unit to form a target transmission channel.

[0018] S50. Determine if there is a fault in the target transmission channel;

[0019] S60. If the target transmission channel is faulty, the control channel switching unit will activate, disconnect the target transmission channel, and trigger an alarm.

[0020] In a preferred embodiment, the universal integrated process wiring harness for the engine test bench further includes a display unit; the control method further includes the following steps:

[0021] Generate a corresponding display signal based on the location of the target transmission channel;

[0022] Based on the display signal, the control display unit displays the position of the target transmission channel.

[0023] In a preferred embodiment, S50 includes:

[0024] Monitor the status of the target transmission channel;

[0025] Determine if a fault exists based on the status of the target transmission channel;

[0026] If an anomaly is detected, the target transmission channel is faulty;

[0027] If no abnormalities are found, the target transmission channel is normal.

[0028] In a preferred embodiment, the universal integrated process wiring harness of the engine test bench further includes a communication unit, which is communicatively connected to the test bench's measurement and control terminal.

[0029] The S60 includes:

[0030] If the target transmission channel is faulty, the control channel switching unit disconnects and generates an alarm information packet containing the location of the target transmission channel, the fault type, and a timestamp.

[0031] The alarm information packet is transmitted to the test bench control terminal through the communication unit and the alarm unit is triggered.

[0032] In a preferred embodiment, the universal integrated process wiring harness for the engine test bench further includes an extended test bench side interface unit, an extended channel switching unit, and an extended engine side interface unit, wherein the extended test bench side interface unit, the extended channel switching unit, and the extended engine side interface unit are used to form an extended transmission channel;

[0033] When the extended channel switching unit is set up, the extended configuration command is transmitted to the bench-side interface unit through the bench measurement and control terminal.

[0034] The control method further includes the following steps:

[0035] Receive extended configuration instructions from the test bench control terminal, the extended configuration instructions including configuration information for the extended transmission channel;

[0036] Based on the configuration information of the extended transmission channel, identify and store the corresponding extended transmission channel location.

[0037] A universal integrated process wiring harness for an engine test bench includes a control unit and a bench-side interface unit, an engine-side interface unit, a channel switching unit, and an alarm unit, all electrically connected to the control unit. The bench-side interface unit includes multiple first terminals, each electrically connected to the channel switching unit. The bench-side interface unit also includes a universal interface for electrical connection to a test bench control terminal. The engine-side interface unit includes multiple second terminals, each electrically connected to the channel switching unit. The engine-side interface unit also includes a compatible interface for electrical connection to an engine ECU. The channel switching unit includes multiple relays, each relay connected to one of the first terminals. The control unit is electrically connected to the second terminal to form a transmission channel. The control unit acquires the identifier of the functional module to be tested of the test engine, retrieves the corresponding target transmission channel position according to the identifier, generates a corresponding switching signal according to the target transmission channel position, and controls the relay at the corresponding position in the channel switching unit to conduct according to the switching signal, so as to connect the corresponding first terminal in the bench-side interface unit and the corresponding second terminal in the engine-side interface unit to form a target transmission channel. The control unit also determines whether there is a fault in the target transmission channel. If there is a fault in the target transmission channel, it controls the channel switching unit to disconnect the target transmission channel and triggers the alarm unit.

[0038] In a preferred embodiment, the control unit further includes a display unit electrically connected to the control unit. The control unit generates a corresponding display signal based on the target transmission channel position and then transmits the display signal to the display unit, which displays the position of the target transmission channel.

[0039] In a preferred embodiment, the alarm unit includes a local alarm unit and a remote alarm unit. The local alarm unit includes an alarm light, and the remote alarm unit includes a communication unit. The communication unit is communicatively connected to the test bench control terminal. When the control unit determines that there is a fault in the target transmission channel, it triggers the alarm light to flash and transmits a remote alarm signal to the communication unit. The communication unit then transmits the remote alarm signal to the test bench control terminal.

[0040] A preferred embodiment further includes an extended test bench-side interface unit, an extended channel switching unit, and an extended engine-side interface unit, all electrically connected to the control unit. The extended test bench-side interface unit includes an extended first terminal; the extended engine-side interface unit includes an extended second terminal; the extended channel switching unit includes an extended relay; the extended relay is electrically connected to both the extended first terminal and the extended second terminal to form an extended transmission channel; the control unit receives an extended configuration command from the test bench control terminal, the extended configuration command containing configuration information for the extended transmission channel, and identifies and stores the corresponding extended transmission channel position based on the configuration information.

[0041] In a preferred embodiment, the transmission channel includes a signal channel, a communication channel, and a power supply channel; the signal channel includes a digital signal channel and an analog signal channel, the digital signal channel is used to transmit digital signals between the engine ECU and the test bench terminal, and the analog signal channel is used to transmit analog signals between the engine ECU and the test bench terminal; the communication channel is used to transmit CAN communication signals or LIN communication signals to ensure that the bus protocols of different models do not interfere with each other; the power supply channel is used to supply power to the engine ECU main power supply, ignition power supply, and actuator power supply.

[0042] After adopting the above technical solution, the beneficial effects of the present invention are:

[0043] The present invention relates to a universal integrated process wiring harness for an engine test bench and its control method. The universal integrated process wiring harness for the engine test bench includes a test bench-side interface unit, a channel switching unit, an engine-side interface unit, and an alarm unit. The test bench-side interface unit and the engine-side interface unit are electrically connected to the channel switching unit. The test bench-side interface unit includes multiple first terminals, and the engine-side interface unit includes multiple second terminals. The control method includes the following steps: obtaining the identifier of the functional module to be tested in the test engine; retrieving the corresponding target transmission channel position based on the identifier of the functional module to be tested; generating a corresponding switching signal based on the target transmission channel position; controlling the channel switching unit to switch based on the switching signal to connect the corresponding first terminal in the test bench-side interface unit and the corresponding second terminal in the engine-side interface unit to form a target transmission channel; determining whether the target transmission channel is faulty; if the target transmission channel is faulty, controlling the channel switching unit to disconnect the target transmission channel and trigger an alarm. As can be seen, this invention achieves a single integrated wiring harness that is compatible with multiple OEM protocols and multiple electrical control systems through integrated configuration, interface standardization, signal multiplexing and path optimization. It significantly reduces the types of wiring harnesses and material costs, simplifies on-site switching operations, improves commissioning efficiency and connection reliability, reduces operation and maintenance and management costs, and meets the application requirements of mixed-line commissioning of multiple models, platforms and systems. Attached Figure Description

[0044] Figure 1 This is a flowchart illustrating the universal integrated process wiring harness for the engine test bench in this invention.

[0045] Figure 2 This is a schematic diagram of the general integrated process wiring harness for the engine test bench in this invention;

[0046] In the diagram: 1 - Motherboard. Detailed Implementation

[0047] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below 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 are not intended to limit the invention.

[0048] It should be noted that in the description of this invention, the terms "upper", "lower", "left", "right", "inner", "outer", etc., which indicate directions or positional relationships, are based on the directions or positional relationships shown in the accompanying drawings. This is only for the convenience of description and is not intended to indicate or imply that the device or element must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation of this invention.

[0049] Furthermore, it should be noted that, in the description of this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0050] The process harness mentioned here is used to connect the test bench control terminal and the engine ECU. The main wiring includes the CAN communication line, power supply line, accelerator pedal power supply, etc.

[0051] Example 1:

[0052] like Figure 1 As shown, a control method for a universal integrated process wiring harness for an engine test bench is disclosed. The control method of the present invention is applied to the universal integrated process wiring harness for an engine test bench described in Embodiment 2. The harness includes a test bench-side interface unit, a channel switching unit, an engine-side interface unit, and an alarm unit. The test bench-side interface unit and the engine-side interface unit are electrically connected to the channel switching unit. The test bench-side interface unit includes multiple first terminals, and the engine-side interface unit includes multiple second terminals. The channel switching unit may include multiple switching elements.

[0053] The control method of the present invention includes the following steps:

[0054] Step S10: Obtain the identifier of the functional module to be tested for the test engine;

[0055] The identifier for the functional module to be tested can be the engine model, engine fuel system, engine ignition system, configuration information of sensors and actuators, or the test functional module number, etc. (Information such as engine model, electronic control system, ignition system, sensor power supply module, and accelerator pedal signal can be read by scanning the engine barcode).

[0056] Step S20: Based on the identifier of the functional module to be tested, retrieve the corresponding target transmission channel location;

[0057] The target transmission channel location can be retrieved from the preset channel configuration table, which is stored in the Flash memory inside the storage unit or control unit. The mapping relationship in the preset channel configuration table can be: the correspondence between the test function module identifier and the target transmission channel location.

[0058] Step S30: Generate a corresponding switching signal based on the target transmission channel location;

[0059] Step S40: According to the switching signal, control the channel switching unit to turn on and off, so as to connect the corresponding first terminal in the test bench side interface unit and the corresponding second terminal in the engine side interface unit to form a target transmission channel.

[0060] It should be noted that when the channel switching unit includes multiple switching elements, controlling the channel switching unit to turn on or off actually means controlling the switching element at the corresponding position to close and the switching elements at other positions to open. After the switching element at that position closes, the corresponding first terminal and second terminal are connected, so that the corresponding target transmission channel is open, so as to realize digital or analog signal transmission, communication signal transmission and power supply, etc.

[0061] For example: Assume all the first terminals of the bench-side interface unit are divided into groups A, B, C, D, etc., according to the actual test requirements. Similarly, all the second terminals of the engine-side interface unit are divided into groups a, b, c, d, etc., according to the actual test requirements. The positions of all switching elements in the channel switching unit are defined as 01, 02, 03, 04, etc. Assume that one end of the switching element at position 01 is connected to group A and the other end is connected to group a. When the switching element at position 01 is closed, group A is connected to group a, forming a transmission channel, which can be defined as position 01. When the target transmission channel position is determined to be 01 according to the test function module identifier, the generated switching signal is used to close the switching element at position 01. Group A can be reused. Groups a, b, and c of the engine-side interface unit can all be connected to group A through switching elements at different positions, configured according to actual requirements.

[0062] Step S50: Determine if there is a fault in the target transmission channel;

[0063] Step S60: If the target transmission channel is faulty, the control channel switching unit disconnects the target transmission channel and triggers an alarm to avoid transmission channel switching errors that could affect engine testing and to prevent wiring errors from occurring.

[0064] like Figure 1 As shown, the control method of the universal integrated process wiring harness for engine test bench of the present invention mainly determines the position of the target transmission channel by parsing the identifier of the functional module to be tested collected or input, then generates the corresponding switching signal, and finally controls the channel switching unit to switch the target transmission channel to the conducting state, so that the universal integrated process wiring harness for engine test bench connects the test bench side and the engine side.

[0065] During engine testing, this invention can diagnose whether the target transmission channel is faulty in real time. Once a fault occurs, the target transmission channel is disconnected in time to avoid affecting the engine test and an alarm is triggered for timely handling.

[0066] After the engine test is completed, the connection between the bench-side interface unit and the bench control terminal can be easily and quickly disconnected, and the connection between the engine-side interface unit and the engine ECU can be easily and quickly re-established for the next test.

[0067] As can be seen, the control method of this invention achieves high versatility and flexibility. By automatically switching the transmission channel through the control channel switching unit, the traditional fixed and dedicated test harness is transformed into a configurable universal platform that can adapt to the testing needs of different engine models, fundamentally solving the technical problems of high cost and long production cycle.

[0068] In some embodiments, when the universal integrated process wiring harness of the engine test bench also includes a display unit, the control method of the present invention further includes the following steps:

[0069] Generate a corresponding display signal based on the location of the target transmission channel;

[0070] Based on the display signal, the control display unit displays the position of the target transmission channel.

[0071] The display unit may include, but is not limited to, a digital display screen. This screen shows the current location of the target transmission channel, allowing staff to visually observe the working status of the universal integrated process wiring harness on the engine test bench. Referring to the example above: when the determined target transmission channel location is 01, the display unit shows "01".

[0072] In some embodiments of the present invention, the step of determining whether a fault exists in the target transmission channel specifically includes:

[0073] Monitor the status of the target transmission channel;

[0074] Determine if a fault exists based on the status of the target transmission channel;

[0075] If an anomaly is detected, the target transmission channel is faulty;

[0076] If no abnormalities are found, the target transmission channel is normal.

[0077] It should be noted that monitoring the status of the target transmission channel can specifically include: monitoring the data stream of the target transmission channel, or monitoring whether a response signal is received from the test bench or engine ECU, or monitoring whether the status of the target transmission channel is input via the human-machine interface unit, etc.

[0078] This invention can determine whether there is a hardware malfunction by monitoring the status of the target transmission channel. Once a malfunction occurs, it can be disconnected in time to avoid affecting the engine test results and avoid wiring errors.

[0079] In some embodiments, the universal integrated process wiring harness for the engine test bench further includes a communication unit. This communication unit is communicatively connected to the test bench's measurement and control terminal. The communication unit can be, but is not limited to, a wired communication unit such as CAN communication, or a wireless communication unit such as GPS or WIFI. In these embodiments, step S60 of the present invention specifically includes:

[0080] If the target transmission channel is faulty, the control channel switching unit disconnects the target transmission channel and generates an alarm information packet containing the location of the target transmission channel, the fault type, and a timestamp.

[0081] The alarm information packet is transmitted to the test bench control terminal through the communication unit, and the alarm unit is triggered.

[0082] As can be seen from the above steps, in the event of a malfunction, the present invention can simultaneously provide local and remote alarms to reliably alert the user. Additionally, the alarm unit may include an alarm light; upon triggering a local alarm, the alarm light can flash at a high frequency to alert the user.

[0083] In some embodiments, the universal integrated process harness for the engine test bench further includes an extended test bench-side interface unit, an extended channel switching unit, and an extended engine-side interface unit. These units are used to form an extended transmission channel. Once the extended channel switching unit is configured, extended configuration commands can be transmitted to the test bench-side interface unit via the test bench control terminal. In these embodiments, the control method of the present invention further includes the following steps:

[0084] Receive extended configuration instructions from the test bench control terminal. The extended configuration instructions contain configuration information for the extended transmission channel.

[0085] Based on the configuration information of the extended transmission channel, identify and store the corresponding extended transmission channel location.

[0086] This invention expands the functionality and transmission channels to meet the testing needs of more engine models, thus broadening its application range and improving its versatility.

[0087] In addition, the control method of the present invention also includes a data traceability and management step, specifically, automatically recording all switching operations, status data, and test data, generating a traceable test report, and supporting data export and analysis.

[0088] In summary, the control method for the universal integrated process wiring harness of the engine test bench of the present invention has the following advantages:

[0089] It improves the intelligence and automation of the testing process, and can automatically retrieve and switch the corresponding transmission channel according to the identifier of the functional module to be tested. It realizes one-click configuration of test connection, reduces the workload and error rate of manual plugging and unplugging and checking of cables, and improves the efficiency and accuracy of test preparation.

[0090] It enhances security and reliability by integrating real-time fault detection, such as monitoring transmission channel status, data flow, and alarm mechanisms. Once a target transmission channel fails, it can automatically disconnect the transmission channel and trigger local and remote alarms, promptly notifying operators or the bench control terminal (or other remote terminals), effectively preventing test data errors, equipment damage, or even safety accidents caused by wiring harness failures.

[0091] Status visualization: The display unit shows the current location of the transmission channel in real time, which makes it easy for on-site personnel to quickly understand the system status and troubleshoot problems.

[0092] Modular expansion: By expanding the bench-side interface unit, the channel switching unit, and the engine-side interface unit, the number of transmission channels can be flexibly increased to meet more complex or future testing needs, protecting the initial investment and extending the system life cycle.

[0093] Centralized management: Alarm information includes location number, fault type and timestamp, and is reported through communication unit, which facilitates systematic fault statistics, analysis and predictive maintenance.

[0094] Signal integrity is ensured and interference is prevented: Different types of signals (digital, analog, bus) are physically isolated and switched by independent switching elements, ensuring the transmission quality of high-precision analog signals and high-speed bus signals, and preventing mutual interference between bus protocols of different models or modules.

[0095] Example 2:

[0096] like Figure 2 As shown, a universal integrated process wiring harness for engine test benches can be applied to the control method of the universal integrated process wiring harness for engine test benches described in Embodiment 1. The integrated process wiring harness includes a main board 1, on which a control unit and a test bench-side interface unit, an engine-side interface unit, a channel switching unit, an alarm unit, a display unit, and a communication unit are respectively electrically connected to the control unit. The control unit can be, but is not limited to, a 32-bit industrial-grade microcontroller. The control unit has built-in Flash memory, which can store signal channel configuration tables for multiple models and can support one-key recall (this one-key recall can be achieved through the operation buttons on the test bench control terminal; when the present invention includes a control keyboard, this one-key recall can be achieved through the control keyboard).

[0097] The bench-side interface unit includes multiple first terminals, each of which is electrically connected to a channel switching unit. The bench-side interface unit also includes a universal interface for electrical connection to the bench's measurement and control terminal; specifically, the universal interface is used to connect to the bench power supply, measurement and control system, sensor / actuator interface, etc. In this invention, the bench-side interface unit includes a detachably connected first row of pins and a first row of connectors. The first row of pins or the first row of connectors is connected to an external wiring harness, wherein the first row of connectors or the first row of pins corresponds to a first terminal.

[0098] The engine-side interface unit includes multiple second terminals, each electrically connected to a channel switching unit. The engine-side interface unit also includes a compatible interface for electrical connection to the engine ECU. Specifically, the compatible interface connects to the engine ECU-side compatible interface, adapting to different engine models, platform ECUs, etc. In this invention, the engine-side interface unit includes a detachably connected second row of pins and a second row of connectors. The second row of pins or connectors connects to an external wiring harness, wherein the second row of pins or connectors corresponds to a second terminal.

[0099] The channel switching unit includes multiple switching elements. In this embodiment, the switching elements are relays. Each relay is electrically connected to the corresponding first terminal and the corresponding second terminal, which can form multiple transmission channels. In this embodiment, the channel switching unit includes multiple sets of small white relays or optocoupler relays. All relays are arranged in a matrix, and each set of relays corresponds to one transmission channel.

[0100] It should be noted that the transmission channels include signal channels, communication channels, and power supply channels. The signal channels include digital signal channels and analog signal channels. The digital signal channels are used to transmit digital signals between the engine ECU and the test bench control terminal, while the analog signal channels are used to transmit analog signals between the engine ECU and the test bench control terminal. The communication channels are used to transmit CAN communication signals or LIN communication signals to ensure that the bus protocols of different models do not interfere with each other. The power supply channels are used to supply power to the engine ECU main power supply (12V / 24V), ignition power supply, and high-power actuator power supply, supporting a maximum current of 30A or more.

[0101] In a preferred embodiment, each relay is a high-power relay with a transparent housing, which illuminates when triggered, allowing the user to directly observe whether the activated relay is functioning correctly.

[0102] The alarm unit of this invention includes a local alarm unit and a remote alarm unit. The local alarm unit includes an alarm light, and the remote alarm unit includes a communication unit (the communication unit can also be a wireless communication unit such as GPS). When the communication unit is a wired communication unit, it includes a separately configured communication interface, which is connected to the test bench control terminal via a communication line. When the control unit determines that there is a fault in the target transmission channel, it triggers the alarm light to flash and transmits a remote alarm signal to the communication unit. The communication unit then transmits the remote alarm signal to the test bench control terminal, thereby realizing remote alarm.

[0103] like Figure 2 As shown, when this invention is put into use, the control unit obtains the identifier of the functional module to be tested of the test engine, retrieves the corresponding target transmission channel position according to the identifier of the functional module to be tested, generates a corresponding switching signal according to the target transmission channel position, and controls the channel switching unit to switch on and off according to the switching signal, so as to connect the corresponding first terminal in the test bench side interface unit and the corresponding second terminal in the engine side interface unit to form a target transmission channel. During the engine test, the control unit also determines whether there is a fault in the target transmission channel. If there is a fault in the target transmission channel, the control channel switching unit disconnects the target transmission channel and triggers the alarm unit.

[0104] Simultaneously, the control unit generates a corresponding display signal based on the target transmission channel location, and then transmits the display signal to the display unit. The display unit displays the location of the target transmission channel. Specifically, the location of the target transmission channel can be, but is not limited to, the target transmission channel location number. In this embodiment, the display unit can be, but is not limited to, a digital display screen. When the display unit includes a display screen, it can display other information, such as whether a fault exists.

[0105] In some embodiments, the present invention further includes an extended bench-side interface unit, an extended channel switching unit, and an extended engine-side interface unit, all electrically connected to the control unit. The extended bench-side interface unit includes an extended first terminal, which may have the same structure as the first terminal, for connection to a bench measurement and control terminal. The extended engine-side interface unit includes an extended second terminal, which may have the same structure as the second terminal, for connection to an engine ECU.

[0106] The extended channel switching unit includes an extended relay, which is electrically connected to an extended first terminal and an extended second terminal to form an extended transmission channel. This extended transmission channel increases the adaptability and versatility of the invention and reduces user costs.

[0107] In actual transmission channel expansion, after the expansion test bench side interface unit, expansion channel switching unit, and expansion engine side interface unit are configured, the user can input expansion configuration commands through the test bench control terminal, or through a separately set human-machine interface unit (HMI). The HMI can be an operation keyboard detachably connected to the control unit. Upon receiving the expansion configuration command, which includes the configuration information of the expansion transmission channel, the control unit identifies and stores the corresponding expansion transmission channel location based on this configuration information.

[0108] Once the extended transmission channel is stored, the control unit can control the extended channel switching unit to switch according to the received identifier of the functional module to be tested, so as to perform the corresponding functional test of the engine.

[0109] In summary, the universal integrated process wiring harness for engine test benches of this invention integrates the control unit directly within the wiring harness, enabling the harness to independently complete signal acquisition, logic operations, timing control, and fault diagnosis without relying on an external controller, thus achieving intelligent and autonomous operation of the wiring harness. The integrated communication unit supports real-time data upload and remote command control with a host computer, providing the wiring harness with network monitoring and remote debugging capabilities, meeting the needs of automated production lines and intelligent equipment. Automatic switching of transmission channels ensures strong versatility, rapid model changeover, and convenient maintenance of the wiring harness, significantly reducing costs.

[0110] It should be noted that the motherboard 1 of this invention uses a double-layer FR-4 PCB as the process wire harness carrier, integrating all the connection relationships of traditional multi-group discrete wire harnesses onto a single PCB. By replacing traditional wires with PCB traces, 100% integration of the wire harness is achieved. See [link to relevant documentation]. Figure 2 ;

[0111] High-density pin layout: The high-density terminal block array is integrated on the side of the PCB, corresponding to the pin definitions of different test modules. By optimizing the routing topology, 62 pins (corresponding to the first or second terminal) are integrated within a limited PCB area, which reduces the volume by more than 70% compared to traditional discrete wire harnesses.

[0112] Process reliability design: The PCB traces adopt impedance matching design, critical circuits are redundantly traced, and the terminal area adopts reinforced pad design to improve reliability under vibration and high temperature environments and meet the requirements of industrial field use.

[0113] The PCB integrates a multi-channel relay array, with each relay corresponding to a set of pins (first terminal and second terminal) for on / off control. By opening / closing the relay contacts, the fast switching between different test modules and pins can be achieved.

[0114] Modular grouping design: Relays are grouped according to test modules, with each group corresponding to the pin group of a test module. The main control unit controls the on / off state of the relays in the corresponding group, realizing one-click switching between different modules without the need for manual wiring.

[0115] Integrated driver circuit: It adopts a Darlington transistor array driver chip, which integrates multiple relay drivers on a single chip to achieve synchronous control of the relay array, improving the integration level by 80% compared with discrete transistor solutions;

[0116] Full-link protection design: Relay coil end: Parallel freewheeling diode + TVS diode to absorb the back electromotive force when the coil is de-energized, preventing damage to the driver chip; Contact end: Series self-resetting fuse + varistor to achieve overcurrent and surge protection, adapting to different load types; Driver end: Integrated optocoupler isolation circuit to achieve electrical isolation between control signals and drive circuit, blocking interference from entering the main control system.

[0117] It can include industrial communication interfaces such as CAN, RS485, and Ethernet, and support industrial protocols such as Modbus and Profinet to achieve seamless connection with host computers and measurement and control terminals, receive switching commands and upload status data;

[0118] The PCB has pre-reserved standardized slots / terminals to support quick plugging and unplugging of different test modules without the need for rewiring;

[0119] Configurable pin definitions: By configuring the pin correspondence, the same PCB process harness can be adapted to different product models and different test conditions without modifying the hardware.

[0120] Extended design: Reserved relay and terminal pad positions, allowing for expansion of the number of pins and modules through cascading, supporting switching of up to hundreds of pins and dozens of modules to adapt to product iteration needs.

[0121] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications made within the spirit and principles of the present invention, improvements to the equivalent universal integrated process wiring harness and control method for engine test benches, etc., should be included within the protection scope of the present invention.

Claims

1. A control method of a general-purpose integrated process line harness of an engine test bench, characterized by, The universal integrated process wiring harness for the engine test bench includes a bench-side interface unit, a channel switching unit, an engine-side interface unit, and an alarm unit. The bench-side interface unit and the engine-side interface unit are electrically connected to the channel switching unit. The bench-side interface unit includes multiple first terminals, and the engine-side interface unit includes multiple second terminals. The control method includes the following steps: S10. Obtain the identifier of the functional module to be tested for the test engine; S20. Based on the identifier of the functional module to be tested, retrieve the corresponding target transmission channel location; S30. Generate a corresponding switching signal based on the location of the target transmission channel; S40. According to the switching signal, control the channel switching unit to turn on and off, so as to connect the corresponding first terminal in the bench-side interface unit and the corresponding second terminal in the engine-side interface unit to form a target transmission channel. S50. Determine if there is a fault in the target transmission channel; S60. If the target transmission channel is faulty, the control channel switching unit will activate, disconnect the target transmission channel, and trigger an alarm.

2. The control method for the universal integrated process wiring harness of the engine test bench according to claim 1, characterized in that, The universal integrated process wiring harness for the engine test bench also includes a display unit; The control method further includes the following steps: Generate a corresponding display signal based on the location of the target transmission channel; Based on the display signal, the control display unit displays the position of the target transmission channel.

3. The method of claim 1, wherein the method further comprises: The S50 includes: Monitor the status of the target transmission channel; Determine if a fault exists based on the status of the target transmission channel; If an anomaly is detected, the target transmission channel is faulty; If no abnormalities are found, the target transmission channel is normal.

4. The method of claim 1, wherein the method further comprises: The general integrated process wiring harness of the engine test bench also includes a communication unit, which is connected to the test bench measurement and control terminal. The S60 includes: If the target transmission channel is faulty, the control channel switching unit disconnects and generates an alarm information packet containing the location of the target transmission channel, the fault type, and a timestamp. The alarm information packet is transmitted to the test bench control terminal through the communication unit and the alarm unit is triggered.

5. The method of claim 4, wherein the method further comprises: The universal integrated process wiring harness for the engine test bench also includes an extended test bench side interface unit, an extended channel switching unit, and an extended engine side interface unit. The extended test bench side interface unit, the extended channel switching unit, and the extended engine side interface unit are used to form an extended transmission channel. When the extended channel switching unit is set up, the extended configuration command is transmitted to the bench-side interface unit through the bench measurement and control terminal. The control method further includes the following steps: Receive extended configuration instructions from the test bench control terminal, the extended configuration instructions including configuration information for the extended transmission channel; Based on the configuration information of the extended transmission channel, identify and store the corresponding extended transmission channel location.

6. A generic integrated process line harness for an engine test bench, characterized in that, It includes a control unit and a bench-side interface unit, an engine-side interface unit, a channel switching unit, and an alarm unit, which are electrically connected to the control unit respectively; The bench-side interface unit includes multiple first terminals, each of which is electrically connected to the channel switching unit. The bench-side interface unit includes a general interface for electrical connection to the bench measurement and control terminal. The engine-side interface unit includes a plurality of second terminals, each of which is electrically connected to the channel switching unit. The engine-side interface unit includes a compatible interface for electrical connection to the engine ECU. The channel switching unit includes multiple relays, each of which is electrically connected to the first terminal and the second terminal to form a transmission channel. The control unit acquires the identifier of the functional module to be tested of the test engine, retrieves the corresponding target transmission channel position according to the identifier of the functional module to be tested, generates a corresponding switching signal according to the target transmission channel position, and controls the relay at the corresponding position in the channel switching unit to be turned on according to the switching signal, so as to connect the corresponding first terminal in the bench-side interface unit and the corresponding second terminal in the engine-side interface unit to form a target transmission channel. The control unit also determines whether there is a fault in the target transmission channel. If there is a fault in the target transmission channel, it controls the channel switching unit to disconnect the target transmission channel and triggers the alarm unit.

7. The engine test stand universal integrated process line harness of claim 6, wherein, It also includes a display unit electrically connected to the control unit. The control unit generates a corresponding display signal according to the position of the target transmission channel and then transmits the display signal to the display unit. The display unit displays the position of the target transmission channel.

8. The engine test stand universal integrated process line harness of claim 7, wherein, The alarm unit includes a local alarm unit and a remote alarm unit. The local alarm unit includes an alarm light, and the remote alarm unit includes a communication unit. The communication unit is communicatively connected to the test bench control terminal. When the control unit determines that there is a fault in the target transmission channel, it triggers the alarm light to flash and transmits a remote alarm signal to the communication unit, which then transmits the remote alarm signal to the test bench control terminal.

9. The engine test stand universal integrated process line harness of claim 7, wherein, It also includes an extended bench-side interface unit, an extended channel switching unit, and an extended engine-side interface unit, which are electrically connected to the control unit, respectively. The expansion bench-side interface unit includes an expansion first terminal; The extended engine-side interface unit includes an extended second terminal; The extended channel switching unit includes an extended relay; The extended relay is electrically connected to the extended first terminal and the extended second terminal respectively to form an extended transmission channel; The control unit receives an extended configuration instruction from the test bench terminal. The extended configuration instruction includes configuration information for the extended transmission channel. Based on the configuration information for the extended transmission channel, the control unit identifies and stores the corresponding extended transmission channel location.

10. The engine test stand universal integrated process line harness of claim 6, wherein, The transmission channel includes a signal channel, a communication channel, and a power supply channel; The signal channel includes a digital signal channel and an analog signal channel. The digital signal channel is used to transmit digital signals between the engine ECU and the test bench control terminal, and the analog signal channel is used to transmit analog signals between the engine ECU and the test bench control terminal. The communication channel is used to transmit CAN communication signals or LIN communication signals to ensure that the bus protocols of different models do not interfere with each other. The power supply channel is used to supply power to the engine ECU main power supply, ignition power supply and actuator power supply.

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