A wire harness failure detection device

Abstract

This utility model discloses a ribbon cable fault detection device, including a battery, a power switch, a start-end socket, a tail-end socket, and multiple indicator lights. The start-end plug and tail-end plug of the ribbon cable under test are respectively inserted into the start-end socket and tail-end socket. The wire cores of the ribbon cable under test are evenly divided into two groups. One end of each of the multiple indicator lights is connected to one end of the power switch through different wire cores of the first group, and the other end is connected to the negative terminal of the battery through different wire cores of the second group. All wire cores of the ribbon cable are connected in series in the power supply circuit of the indicator lights. The other end of the power switch is connected to the positive terminal of the battery. This utility model connects all wire cores of the ribbon cable in series in the power supply circuit of the indicator lights, and simultaneously detects multiple wire cores by observing the illumination of the indicator lights, which greatly improves the testing efficiency. Moreover, by twisting or other operations on the ribbon cable, it can quickly and accurately determine the fault of broken wires or poor contact, preventing the reuse of problematic ribbon cables and ensuring the safe operation of electrical equipment.

Description

Technical Field

[0001] This utility model relates to a cable fault detection device, which can quickly and accurately detect cable breakage or poor contact faults, and belongs to the field of testing technology. Background Technology

[0002] A ribbon cable consists of multiple thin wires arranged in parallel on a plastic or rubber substrate. It connects to electronic equipment through terminals soldered or crimped at both ends to transmit signals and power. A ribbon cable typically contains an even number of thin wires.

[0003] After a period of use, cable trays may experience breakage or poor contact, causing equipment malfunctions. During equipment maintenance, the common method for determining whether cable trays have broken wires or poor contact is for two technicians to test each tray individually with a multimeter. This method is not only labor-intensive and inefficient, but also highly susceptible to human error, resulting in low accuracy. In particular, some poor contact faults are difficult to detect. For example, in repairing certain ABB ACS800 inverter models, the most common fault encountered is a broken or poorly connected IGBT drive cable. This type of inverter has three drive cables, each composed of 20 thin wires, connected to the IGBT drive board at both ends via 2mm*10 double-row terminals. Often, a significant amount of time is spent trying to locate the faulty wire, and some problematic cables are frequently reused, leading to inverter failures, IGBT damage, and losses of tens of thousands of yuan. Therefore, designing a device that can quickly and accurately detect broken or poorly connected cable trays is essential. Utility Model Content

[0004] The purpose of this invention is to address the shortcomings of existing technologies by providing a cable fault detection device that can quickly and accurately detect cable breaks or poor contact, thereby ensuring the safe operation of electrical equipment.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A ribbon cable fault detection device includes a battery, a power switch, a start-end socket, a tail-end socket, and multiple indicator lights. The start-end plug and tail-end plug of the ribbon cable under test are respectively inserted into the start-end socket and tail-end socket. The wire cores of the ribbon cable under test are divided into two groups. One end of each of the multiple indicator lights is connected to one end of the power switch through different wire cores of the first group. The other end of each of the multiple indicator lights is connected to the negative terminal of the battery through different wire cores of the second group. All the wire cores of the ribbon cable under test are connected in series in the power supply circuit of the indicator lights. The other end of the power switch is connected to the positive terminal of the battery.

[0007] The aforementioned cable fault detection device also includes an operation box and a display box. The power switch and the first-end socket are both installed on the outer wall of the operation box, the battery is installed inside the operation box, and multiple indicator lights and the last-end socket are all installed on the outer wall of the display box.

[0008] The aforementioned cable fault detection device includes an indicator light comprising a current-limiting resistor and a light-emitting diode, wherein the current-limiting resistor and the light-emitting diode are connected in series.

[0009] The aforementioned cable fault detection device uses a rechargeable battery and is equipped with a charging circuit.

[0010] In the aforementioned cable fault detection device, the current-limiting resistor, the light-emitting diode, and the tail socket are soldered onto the same PCB board.

[0011] In the aforementioned cable fault detection device, the first-end socket is soldered to the power switch, battery, and charging circuit on the same PCB board.

[0012] This invention connects the ribbon cable to be tested between two matching sockets and connects all its wire cores in series in the power supply circuit of the indicator light. By observing the illumination of the indicator light, multiple wire cores can be tested simultaneously, which greatly improves the testing efficiency. Moreover, by twisting or shaking the ribbon cable, a broken or poorly connected fault can be quickly and accurately determined, preventing the reuse of faulty ribbon cables and ensuring the safe operation of electrical equipment. Attached Figure Description

[0013] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0014] Figure 1 This is a schematic diagram of the external shape of this utility model, wherein... Figure 1 (a) is an outline drawing of the control box. Figure 1 (b) is an outline drawing of the display box;

[0015] Figure 2 This is the electrical schematic diagram of this utility model.

[0016] The labels in the diagram are as follows: 1. Operation box, 2. Display box, 3. First end socket, 4. Last end socket, 5. Cable under test, 6. Charging port, K. Power switch, B. Battery, R. Current limiting resistor, D. Light-emitting diode. Detailed Implementation

[0017] See Figure 1 and Figure 2 This utility model mainly includes an operation box 1 and a display box 2.

[0018] The outer wall of the operation box 1 is equipped with a power switch K and a head socket 3 that matches the head plug of the ribbon cable 5 being tested. A battery B is installed inside the operation box 1. The outer wall of the display box 2 is equipped with multiple indicator lights and a tail socket 4 that matches the tail plug of the ribbon cable 5 being tested. The indicator lights are used to indicate the continuity of the ribbon cable.

[0019] When testing the ribbon cable, the first end plug of the ribbon cable 5 under test is connected to the first end socket 3, and the second end plug of the ribbon cable 5 under test is connected to the second end socket 4. The wire cores of the ribbon cable 5 under test are divided into two groups. One end of each of the multiple indicator lights is connected to one end of the power switch K through different wire cores of the first group. The other end of each of the multiple indicator lights is connected to the negative terminal of the battery B through different wire cores of the second group. All the wire cores of the ribbon cable 5 under test are connected in series in the power supply circuit of the indicator lights. The other end of the power switch K is connected to the positive terminal of the battery B.

[0020] After connecting the ribbon cable 5 to be tested, turn on the power switch K; all indicator lights will illuminate. Perform a series of manual operations on the ribbon cable 5, including twisting, shaking, swaying, and vibrating. If none of the indicator lights go out or flash during the operation, it indicates that the ribbon cable is normal, without any broken wires, loose connections, or poor contact, and can be used normally. If an indicator light goes out or flashes, it indicates that the corresponding wire core has a broken wire, loose connection, or poor contact, and should be repaired or replaced.

[0021] This invention connects a wire core to each end of the indicator light, which can reduce the number of indicator lights. The number of indicator lights is equal to half the number of wire cores of the tested cable 5, thus reducing the testing cost while ensuring the testing effect.

[0022] Each indicator light includes a current-limiting resistor R and an LED D, with the current-limiting resistor R connected in series with the LED D.

[0023] Battery B is a rechargeable battery and is equipped with a charging circuit (not shown in the figure).

[0024] Since different ribbon cables have different numbers of wire cores, the number of indicator lights needs to be determined according to the number of wire cores in the ribbon cable. Figure 1 and Figure 2The cable fault detection device shown is designed for R8 IGBT drive cables. Each cable has 20 wires, therefore 10 indicator lights are required. When the cable under test (5) is inserted into the socket, every two wires form a circuit with one indicator light, illuminating one indicator light. A total of 10 indicator lights are needed to test the entire cable. If any indicator light fails to remain lit during the test, the cable fails the test and cannot be used. When repairing certain ABB ACS800 inverter models, if fault codes such as 2340 are encountered, after ruling out the manufacturer's listed causes, this device can quickly screen faulty cables in just a few minutes, saving time and reducing the cost of replacing new cables.

[0025] Since this invention uses the same socket as the original, the two plugs of the original ribbon cable can be directly inserted into the two sockets of this testing device, allowing multiple wire cores to be tested simultaneously, which greatly improves testing efficiency.

[0026] In addition, battery B is a lithium battery that can be charged with a mobile phone charger (charging port 6 is located on the side wall of operation box 1), and can be used continuously for more than 30 hours on a single charge.

[0027] In display box 2, multiple current-limiting resistors R, multiple light-emitting diodes D, and tail socket 4 are soldered onto the same PCB board.

[0028] In the control box 1, the first socket 3 can be soldered onto the same PCB board as the power switch K, battery B, and charging circuit.

[0029] In this testing device, the voltage of battery B is stabilized at around DC 5V, and the current through each light-emitting diode D is controlled at around 3mA through the current-limiting resistor R.

[0030] The operation box 1 and display box 2 of this utility model adopt a split structure, which makes it easy to twist, shake, swing and other operations on the tested cable 5.

[0031] This invention requires only one person to operate for a few minutes to complete the test of a set of cables, which greatly improves the maintenance efficiency of equipment such as frequency converters and saves spare parts procurement costs.

Claims

1. A wire disconnection detection device, characterized by, Includes a battery (B), a power switch (K), a first-end socket (3), a second-end socket (4), and multiple indicator lights. The first-end plug and the second-end plug of the tested cable (5) are respectively plugged into the first-end socket (3) and the second-end socket (4). The cores of the tested cable (5) are divided into two groups. One end of each of the multiple indicator lights is connected to one end of the power switch (K) through different cores of the first group. The other end of each of the multiple indicator lights is connected to the negative terminal of the battery (B) through different cores of the second group. All cores of the tested cable (5) are connected in series in the power supply circuit of the indicator lights. The other end of the power switch (K) is connected to the positive terminal of the battery (B).

2. The cable fault detection device according to claim 1, characterized in that, It also includes an operation box (1) and a display box (2). The power switch (K) and the first end socket (3) are both installed on the outer wall of the operation box (1). The battery (B) is installed inside the operation box (1). Multiple indicator lights and the tail end socket (4) are both installed on the outer wall of the display box (2).

3. A cable fault detection device according to claim 1 or 2, characterized in that, The indicator light includes a current-limiting resistor (R) and a light-emitting diode (D), with the current-limiting resistor (R) and the light-emitting diode (D) connected in series.

4. The cable fault detection device according to claim 3, characterized in that, The battery (B) is a rechargeable battery and is equipped with a charging circuit.

5. A cable fault detection device according to claim 4, characterized in that, The current-limiting resistor (R), the light-emitting diode (D), and the tail socket (4) are soldered onto the same PCB board.

6. A cable fault detection device according to claim 5, characterized in that, The first socket (3) is soldered to the same PCB board as the power switch (K), battery (B) and charging circuit.

Images