Device for checking insulation resistance and conduction of multi-core connector assembly

Abstract

A device for checking insulation resistance and conduction of a multi-core connector assembly relates to the field of space flight and aviation and electronic and electrical, and comprises a shell, and a first test hole, a second test hole, test switches and a test tool socket which are arranged on the shell, and each test switch is provided with an upper connection point, a lower connection point and a switch midpoint. The upper connection point is connected with the first test hole, the lower connection point is connected with the second test hole, and the plurality of test switches are K1, K2... Ki respectively; each test tool socket is provided with i point positions, the first point position of each test tool socket is connected to the switch midpoint of the K1, the second point position of each test tool socket is connected to the switch midpoint of the K2, and the ith point position of each test tool socket is connected to the switch midpoint of the Ki; the first test hole is used for connecting a red meter pen, the second test hole is used for connecting a black meter pen, and an insulation meter is connected between the red meter pen and the black meter pen. Insulation resistance inspection and conduction inspection of cables, wire harness finished products and connector assemblies are completed with high efficiency, high quality and low cost.

Description

Technical Field

[0001] In the aerospace, aviation, and electrical and electronic industries, conduct continuity and insulation resistance tests on electronic products and cables according to design requirements to determine the basic compliance of the products. Background Art

[0002] Insulation resistance is a high-voltage test used to check the resistance of insulating materials. Insulation resistance testing is a basic requirement for cable assembly production in the aerospace electronics and electrical industries. In particular, cable assemblies used in military electronic equipment have specific requirements for insulation resistance testing. Cable assemblies are required to use a 500V insulation tester to test the insulation resistance between the core wire and the shield, the core wire, and the metal shell of the connector, with a minimum of 20MΩ. The relevant standards are as follows:

[0003] GJBZ 162 Multi-core Cable Welding Guide

[0004] General technical requirements for the production of QJ603A cable assemblies

[0005] HB 7262.3 Production of electrical wiring harnesses and cables for aviation products.

[0006] For current aerospace cables, wire harnesses and most military cables, insulation resistance inspections are carried out on finished cables and wire harnesses in strict accordance with standard requirements.

[0007] There are currently two ways to perform insulation resistance testing: one is to use a traditional handheld insulation meter to check point by point, and the other is to use a large programmable insulation resistance tester.

[0008] Most companies use the traditional handheld insulation meter to check point by point. The advantages of this method are low cost and high flexibility, but the disadvantages are low efficiency and high rate of electric shock.

[0009] Use a large programmable insulation resistance tester for testing. Currently, some companies use insulation resistance testers to intelligently check the insulation resistance of cables with a large number of cores in batch production. The advantages of this method are high efficiency and high accuracy, but the disadvantage is high cost. It is suitable for batch production products. Utility Model Content

[0010] The technical problem solved by the present application is: to overcome the deficiencies of the prior art and provide a device for insulation resistance and continuity inspection of multi-core connector assemblies, so as to achieve high efficiency, high quality and low cost completion of insulation resistance inspection and continuity inspection of cables, wire harness products and connector assemblies.

[0011] The technical solutions provided in this application are as follows:

[0012] A device for checking the insulation resistance and continuity of a multi-core connector assembly comprises a housing, and a first test hole, a second test hole, a plurality of test switches and a plurality of test tool sockets arranged on the housing. The test switch is a three-point three-gear switch, each test switch has an upper connection point, a lower connection point and a switch midpoint, the upper connection point is connected to the first test hole, and the lower connection point is connected to the second test hole. The plurality of test switches are K1, K2, K3, K4... Ki, i is the maximum point position of the cable assembly that can be tested by the device; each test tool socket is a three-point three-gear switch. The socket has ≤i points. The first point of each test tool socket is connected to the switch midpoint of K1, the second point of each test tool socket is connected to the switch midpoint of K2, and the i-th point of each test tool socket is connected to the switch midpoint of Ki; the first test hole is used to connect the red test lead, the second test hole is used to connect the black test lead, and an insulation meter or multimeter is connected between the red test lead and the black test lead; the test tool socket is used to connect to the connector at one end of the cable assembly to be tested, and the points of the connector correspond to the points of the test tool socket.

[0013] The first points of all the test tool sockets are connected in series to the switch midpoint of K1, the second points of all the test tool sockets are connected in series to the switch midpoint of K2, and the i-th points of all the test tool sockets are connected in series to the switch midpoint of Ki.

[0014] The plurality of test switches are all mounted on the upper surface of the shell, the first test hole and the second test hole are arranged on the upper surface of the shell, and the plurality of test tool sockets are all mounted on the side surface of the shell.

[0015] The shell is also provided with a handle to facilitate moving the shell.

[0016] The test switch, the test fixture socket and the test switch are connected by a wire, and the cross-sectional area of ​​the wire is not less than 0.35mm 2 .

[0017] Among the multiple test switches, the midpoint of the switch Kx1 is connected to the upper connection point, and the midpoint of the switch Kx2 is connected to the lower connection point, x1∈(1-i), x2∈(1-i). At this time, the measurement result is the insulation resistance and conduction result between the point of the cable assembly connected to Kx1 and the point of the cable assembly connected to Kx2.

[0018] Among the multiple test switches, the midpoint of Kx1 is connected to the upper connection point, and the midpoints of all other test switches are connected to the lower connection point, x1∈(1-i). At this time, the measurement result is the insulation resistance and conduction result between the point of the cable assembly connected to Kx1 and other points of the cable assembly.

[0019] The test switch is a single-pole double-throw switch.

[0020] In summary, this application has at least the following beneficial technical effects:

[0021] This device can control the connection and disconnection between any one point and other points or multiple points. A single control point can be reused multiple times through switching. It offers advantages such as high efficiency, low cost, reduced risk of electric shock, good portability, ease of use, simple operation, and high accuracy. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 is a schematic diagram of the device in the embodiment, specifically a schematic diagram of the insulation resistance between point 2 and points 3-10;

[0023] Figure 2 Schematic diagram for testing the insulation resistance between point 1 and points 3-10;

[0024] Figure 3 A front view of a side surface of the housing;

[0025] Figure 4 is a front view of the other side of the housing;

[0026] Figure 5 for Figure 4 A top view of

[0027] Figure 6 A schematic diagram of the three-dimensional structure of the device.

[0028] Explanation of the accompanying figures: 1. Test switch; 2. Housing; 3. Test tool socket; 4. Handle; 5. First test hole; 6. Second test hole. DETAILED DESCRIPTION

[0029] In order to make the purpose, technical solutions and advantages of the present invention more clear, the embodiments disclosed in the present invention will be further described in detail below with reference to the accompanying drawings.

[0030] The embodiment of the present application discloses a device for checking the insulation resistance and continuity of a multi-core connector assembly. In order to further improve product production efficiency, ensure product quality, and meet the cable insulation resistance test requirements, the insulation resistance inspection device of this patent is designed according to the test requirements. Before the insulation resistance inspection, the cable assembly should first be inspected for continuity, and the cable assembly should be disconnected from all devices during the inspection. Figure 1 and 2As shown, the device includes a housing 2, a first test hole 5, a second test hole 2, a plurality of test switches 1, and a plurality of test tool sockets 3 provided on the housing 2. The plurality of test switches 1 are mounted on the upper surface of the housing 2, the first test hole 5 and the second test hole 2 are provided on the upper surface of the housing 2, and the plurality of test tool sockets 3 are mounted on the side of the housing 2. The housing 2 is also provided with a handle 4 to facilitate moving the housing.

[0031] The design principle is as attached Figure 1 and attached Figure 2 As shown, the test switch 1 is a three-point, three-position switch. Each test switch 1 has an upper connection point, a lower connection point, and a midpoint. The three positions of the test switch 1 are: the upper connection point is connected to the midpoint of the switch, the lower connection point is connected to the midpoint of the switch, and none of the upper, lower, and midpoints are connected. The multiple test switches 1 are K1, K2, K3, K4, ... Ki, where i is the maximum position of the cable assembly that can be tested by the device. The upper connection point is connected to the first test hole 5 via a wire, and the lower connection point is connected to the second test hole 6 via a wire. Each test fixture socket 3 has ≤ i positions. The first position of each test fixture socket 3 is connected in series to the midpoint of K1, the second position of each test fixture socket 3 is connected in series to the midpoint of K2, and the i-th position of each test fixture socket 3 is connected in series to the midpoint of Ki. The first test hole 5 is used to connect the red test lead, and the second test hole 2 is used to connect the black test lead. An insulation meter or a multimeter is connected between the red test lead and the black test lead. In this embodiment, an insulation meter is used.

[0032] The multiple test fixture sockets 3 are respectively TX1, TX2, ..., TXy, where y is the maximum number of cable assemblies that can be connected to the device.

[0033] By controlling the gear position of the test switch 1, the insulation resistance test between the point and the shield, between the point and the metal shell of the connector, and between points can be achieved.

[0034] The following uses cable assemblies W1 to W10 as an example for explanation. As shown in Table 1, the wiring of cable assemblies W1 to W10 is as shown in Table 1. Specifically, for example, the connectors at both ends of cable assembly W1 are X1 and XS1 respectively. During testing, X1 is used to connect to the test tool socket 3, and XS1 is not connected. The cable assembly is a shielded layer with a metal connector.

[0035] Table 1 Cable connection table

[0036]

[0037] Internal wiring of tooling:

[0038] a) Press the required number of test switches 1 Figure 1The short circuit shown is that the upper row is short-circuited and connected to the test hole 1 - the red test lead of the insulation tester (serial number 5), and the lower row is short-circuited and connected to the test hole 2 - the black test lead of the insulation tester (serial number 6).

[0039] b) Connect the connector to be tested in Table 1 to the midpoint of the test switch through the corresponding test fixture socket 3. To facilitate operation and reduce the number of switches, the tested connectors are connected in sequence according to the test points, and finally connected to the switch through a test connector, ensuring that one switch controls one wire in one connector.

[0040] c) Determine the switch number used for each connector to facilitate testing.

[0041] d) When a fault occurs, turn all involved switches to the midpoint (i.e., the upper connection point, the lower connection point and the midpoint of the switch are not connected), disconnect the insulation meter and any test points, and test the fault points one by one.

[0042] Structural design

[0043] The sockets of the connectors that need to be tested in the cable assembly are centrally installed on the test box, and the test control switch is centrally installed on the test box for easy operation. Figure 1 shown.

[0044] Material selection requirements:

[0045] For the design of this device, the selection requirements of components and parts are as follows:

[0046] a) The connector or connector should be able to be accurately plugged into the connector of the cable assembly to be tested;

[0047] b) Test switch 1 is a single-pole double-throw switch (three pins, three gears);

[0048] c) The first test hole and the second test hole should be well insulated from the shell to facilitate measurement;

[0049] d) The cross-sectional area of ​​the internal connecting wire is not less than 0.35mm 2 .

[0050] Directions:

[0051] a) Connect one end of the cable assembly to be tested to the test fixture socket 3 and place the test switch 1 in the test state, that is, the middle position.

[0052] b) Use an insulation meter to measure the insulation resistance between points 1 to 10 and the shielding layer (touch the insulation resistance once with the test lead). If there is a fault, disconnect the switches one by one (set the switches to the center) to troubleshoot.

[0053] c) Press Figure 2Connect the insulation meter, connect the red test lead of the insulation meter to the first test hole 5, and the black test lead of the insulation meter to the second test hole 6. Turn the switches to the test end in sequence to complete the insulation resistance test between any two points in sequence (turn 10 switches in sequence). If there is a fault, disconnect the test switches one by one (that is, set the test switch to the center) to troubleshoot.

[0054] First Figure 2 Test the insulation resistance between point 1 and points 3-10. At this time, connect the midpoint of the switch K1 to the upper connection point, and the midpoint of the switch K2-K10 to the lower connection point. If the test result is continuity, then perform troubleshooting. Troubleshooting includes disconnecting K2-K10 one by one. If the test result shows good insulation, then continue as follows Figure 1 The insulation resistance between point 2 and points 3-10 is tested. If the insulation resistance between point 1 and points 3-10 is good, the switch midpoint of K1 can be left connected to the upper connection point, and the switch midpoint of K2 can be connected to the upper connection point, and the switch midpoints of K3-K10 can be connected to the lower connection point. Alternatively, K1 can be disconnected, and the switch midpoint of K2 can be connected to the upper connection point, and the switch midpoints of K3-K10 can be connected to the lower connection point.

[0055] The following is a comparison between the insulation resistance test of this device and the traditional handheld insulation meter test.

[0056] For cables with n connectors at one end, when performing insulation inspection:

[0057] Traditional handheld insulation meter inspection requires n*(n-1) / 2 times to check the insulation resistance between any wire cores, n times to check the insulation resistance between the wire core and the connector metal, and n times to check the insulation resistance between the wire core and the shielding layer, for a total of n*(n-1) / 2+2n times. When n=30, the total number of operations is 495.

[0058] Use this device to check the insulation resistance. The insulation resistance test between any wire cores needs to be performed n-1 times, the insulation resistance test between the wire core and the connector metal needs to be performed once, and the insulation resistance test between the wire core and the shielding layer needs to be performed once, for a total of n+1 times. When n=30, the total operation is 31 times.

[0059] Ignoring the time spent on finding points and fixing connectors during the handheld insulation meter test, and only considering the number of measurements, the efficiency of the device is improved by (495-31) / 495*100%=93%.

[0060] From the above, it can be seen that the device greatly improves the efficiency of the operation, and operating the switch is safer, simpler and more accurate than manually moving the insulation meter probe.

[0061] The contents not described in detail in this application specification are common knowledge to those skilled in the art.

[0062] The present application has been described in detail above with reference to specific embodiments and exemplary examples. However, these descriptions should not be construed as limiting the present application. Those skilled in the art will appreciate that, without departing from the spirit and scope of the present application, various equivalent substitutions, modifications, or improvements may be made to the technical solutions and implementations of the present application, all of which fall within the scope of the present application. The scope of protection of the present application shall be determined by the appended claims.

Claims

1. A device for checking insulation resistance and continuity of a multi-core connector assembly, characterized by: The invention comprises a housing (2), a first test hole (5), a second test hole (6), a plurality of test switches (1) and a plurality of test tool sockets (3) arranged on the housing (2); the test switch (1) is a three-point three-gear switch; each test switch (1) has an upper connection point, a lower connection point and a switch midpoint; the upper connection point is connected to the first test hole (5), and the lower connection point is connected to the second test hole (6); the plurality of test switches (1) are respectively K1, K2, K3, K4...Ki, where i is the maximum point position of the cable assembly that can be tested by the device; each test tool socket (3) has There are ≤i points, the first point of each test tool socket (3) is connected to the switch midpoint of K1, the second point of each test tool socket (3) is connected to the switch midpoint of K2, and the i-th point of each test tool socket (3) is connected to the switch midpoint of Ki; the first test hole (5) is used to connect a red test lead, the second test hole (6) is used to connect a black test lead, and an insulation meter or a multimeter is connected between the red test lead and the black test lead; the test tool socket (3) is used to connect to a connector at one end of a cable assembly to be tested, and the points of the connector correspond to the points of the test tool socket (3).

2. The device for checking insulation resistance and continuity of a multi-core connector assembly according to claim 1, characterized in that: The first points of all the test tool sockets (3) are connected in series with each other and then connected to the switch midpoint of K1, the second points of all the test tool sockets (3) are connected in series with each other and then connected to the switch midpoint of K2, and the i-th points of all the test tool sockets (3) are connected in series with each other and then connected to the switch midpoint of Ki.

3. The device for checking insulation resistance and continuity of a multi-core connector assembly according to claim 1, wherein: The plurality of test switches (1) are all mounted on the upper surface of the housing (2), the first test hole (5) and the second test hole (6) are arranged on the upper surface of the housing (2), and the plurality of test tool sockets (3) are all mounted on the side of the housing (2).

4. The device for checking insulation resistance and continuity of a multi-core connector assembly according to claim 1, wherein: The housing (2) is also provided with a handle (4) to facilitate moving the housing (2).

5. The device for checking insulation resistance and continuity of a multi-core connector assembly according to claim 1, wherein: The test switch (1), the test tool socket (3) and the test switch (1) are connected by a wire, and the cross-sectional area of ​​the wire is not less than 0.35mm 2 .

6. The device for checking insulation resistance and continuity of a multi-core connector assembly according to claim 1, characterized in that: Among the multiple test switches (1), the switch midpoint of Kx1 is connected to the upper connection point, the switch midpoint of Kx2 is connected to the lower connection point, x1∈(1-i), x2∈(1-i), and the measurement result at this time is the insulation resistance and conduction result between the point of the cable assembly connected to Kx1 and the point of the cable assembly connected to Kx2.

7. The device for checking insulation resistance and continuity of a multi-core connector assembly according to claim 1, characterized in that: Among the multiple test switches (1), the switch midpoint of Kx1 is connected to the upper connection point, and the switch midpoints of all other test switches (1) are connected to the lower connection point, x1∈(1-i), and the measurement result at this time is the insulation resistance and conduction result between the point of the cable assembly connected to Kx1 and other points of the cable assembly.

8. The device for checking insulation resistance and continuity of a multi-core connector assembly according to claim 1, wherein: The test switch (1) is a single-pole double-throw switch.

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