System and method for wireless test module of wireless harness automated measurement system

Abstract

To provide a system and method for a wireless test module of a wireless harness automated measurement system.SOLUTION: A system comprises a wireless transceiver, an electrical wiring harness, and a wireless test module (WTM) which can be physically coupled to the electrical wiring harness. The WTM comprises a chassis and a variable front end connected to the chassis using hot-swap connectors. The WTM is configured to wirelessly receive, using the wireless transceiver, a plurality of test instructions according to an automated test plan from a computer system. The WTM is configured to perform, using the variable front end, one or more tests on the electrical wiring harness according to the plurality of test instructions. The WTM is configured to wirelessly communicate, using the wireless transceiver, test results to the computer system.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates generally to wireless testing modules (WTM) for wireless harness automatic measurement systems (WHAMS), and more particularly to large and small WTM modules. [Background technology]

[0002] Electrical wiring harnesses are used in many different industries and vehicles. For example, large, complex electrical wiring harnesses with numerous wires and connectors are used in the aerospace industry to produce aircraft. As another example, electrical wiring harnesses are used in the automotive industry to produce automobiles. Summary of the Invention [Problem to be solved by the invention]

[0003] Electrical wiring harnesses for vehicles such as aircraft and automobiles typically require rigorous and thorough inspection to ensure that there are no defects in the connectors or wires of the electrical wiring harness. For example, electrical wiring harnesses are inspected to ensure that there are no shorted wires, swapped connector pins, damaged wires, etc. [Means for solving the problem]

[0004] According to some embodiments, the system includes a computer system and a plurality of wireless inspection modules. Each wireless inspection module includes a wireless transceiver and is physically coupled to the electrical wiring harness. The computer system is operable to send inspection commands to the plurality of wireless inspection modules according to an automated inspection plan. Each wireless inspection module is operable to wirelessly receive one or more of the plurality of inspection commands from the computer system using the wireless transceiver and to perform one or more inspections on the electrical wiring harness according to the one or more inspection commands received from the computer system. Each wireless inspection module is further operable to wirelessly communicate inspection results to the computer system using the wireless transceiver.

[0005] According to some embodiments, the system includes a computer system and a wireless inspection module. The wireless inspection module is physically coupled to the electrical wiring harness. The wireless inspection module includes a wireless transceiver. The computer system is operable to send a plurality of inspection commands to the wireless inspection module according to an automated inspection plan. The wireless inspection module is operable to wirelessly receive one or more of the plurality of inspection commands from the computer system using the wireless transceiver and to perform one or more tests on the electrical wiring harness according to the one or more inspection commands received from the computer system. The wireless inspection module is further operable to wirelessly communicate inspection results to the computer system using the wireless transceiver.

[0006] According to some embodiments, the system includes a hot swap connector for connecting the chassis of the wireless inspection module to the variable front end of the wireless inspection module. The variable front end of the wireless inspection module is matable with an aircraft connector. The hot swap connector includes a WTM side hot swap connector and a front end side hot swap connector located between the chassis of the wireless inspection module and the variable front end of the wireless inspection module. The WTM side hot swap connector is matable with the front end side hot swap connector for connecting the chassis of the wireless inspection module to the variable front end of the wireless inspection module. The WTM side hot swap connector includes a female connector, alignment pegs configured to couple to the variable front end of the wireless inspection module, a slip ring configured to secure the wireless inspection module in place, and electrically erasable programmable read-only memory (EEPROM) read / write lines integrated on a circuit board operable to read / write data from / to the aircraft connector. The front-end hot swap connector includes a male connector, an alignment peg configured to couple to a chassis of the wireless inspection module, threads configured to couple to a slip ring of the WTM hot swap connector, and an EEPROM integrated on the circuit board operable to store data of the aircraft connector.

[0007] According to some embodiments, the WTM-side hot swap connector is further operable to attach the adjustable front end of the wireless test module to the chassis of the wireless test module. The WTM-side hot swap connector is further operable to detach the adjustable front end of the wireless test module from the chassis of the wireless test module. The WTM-side hot swap connector is further operable to transfer data to the wireless test module when the chassis and the adjustable front end of the wireless test module are mated. The WTM-side hot swap connector is a universal connector located at the end of the chassis of the wireless test module, and the universal connector is attached to the front-end hot swap connector located at the end of the adjustable front end of the wireless test module. The wireless test module is further operable to wirelessly communicate with a central computer system using a wireless transceiver to transfer data stored in the EEPROM associated with the EEPROM read / write lines. The female connector includes a plurality of contacts ranging from 48 to 128 contacts. The EEPROM read / write lines are configured to couple to the chassis of the wireless test module. The WTM-side hot swap connector further includes a jumper harness configured to couple to the wireless test module. The hot-swap connector on the WTM side allows for the wireless test module to be replaced with another one if it malfunctions, while automatically updating address information in real time.

[0008] According to some embodiments, the front-end hot-swap connector is further operable to attach the adjustable front end of the wireless inspection module to the chassis of the wireless inspection module. The front-end hot-swap connector is further operable to detach the adjustable front end of the wireless inspection module from the chassis of the wireless inspection module. The front-end hot-swap connector is further operable to transfer data to the wireless inspection module when the chassis and the adjustable front end of the wireless inspection module are mated. The front-end hot-swap connector is a universal connector located at the end of the adjustable front end of the wireless inspection module that is attached to the WTM hot-swap connector located at the end of the chassis of the wireless inspection module. The female connector includes a plurality of contacts ranging from 48 to 128 contacts. The front-end hot-swap connector further includes a plurality of connectors configured to couple to wire jumpers of the aircraft connector. The wireless inspection module is further operable to wirelessly communicate with a central computer system using a wireless transceiver to transfer data stored in the EEPROM. The data on the EEPROM is automatically incorporated into the inspection software of the central computer system without human data entry. The front-end hot-swap connector also allows for the wireless test module to be swapped in with another if it malfunctions, while automatically updating address information in real time.

[0009] According to some embodiments, the system includes a battery pack for the wireless inspection module. The battery pack module includes a wireless charging battery, a wireless battery pack holder capable of receiving the wireless charging battery, an injection-molded pogo pin holder with a plurality of pogo pins, and a wireless charging receiver operable to wirelessly charge the wireless charging battery. The injection-molded pogo pin holder is coupled to the wireless battery pack holder using a set of fasteners. The injection-molded pogo pin holder is capable of coupling to the wireless inspection module. The battery pack module includes a steel retractable spring plunger with a pull ring that can be attached to the WTM using a second set of screws to hold the battery pack module together. The battery pack includes a magnet attached to the wireless charging receiver that can lock onto the WTM. The wireless charging receiver includes a 5-volt (V) Qi-standard wireless charging receiver with a magnetic plate that fits the magnet. The wireless battery pack holder is a three-dimensional (3D) printed part with a shape that allows the wireless battery pack holder to slide over the end of the wireless inspection module. The WTM is operable to perform one or more tests to verify the electrical wiring harness according to a plurality of test commands received from the computer system. The one or more tests are selected from a plurality of tests including a continuity check, a voltage insulation check, a diode polarity check, and a resistance measurement check. The WTM is operable to wirelessly communicate with the computer system using Wi-Fi, Bluetooth, or Zigbee. The WTM includes an electrical connector that can mate with a wiring harness connector of the electrical wiring harness.

[0010] According to some embodiments, a system includes a computer system and a computer-implemented method for operating multiple wireless test modules of WHAMS. The computer-implemented method can use a computer server to access multiple electrical wiring harnesses, test criteria, and WHAMS. Each of the multiple electrical wiring harnesses is connected to a respective endpoint of a wireless test module of WHAMS. The computer-implemented method can generate a test plan for the multiple electrical wiring harnesses based on the test criteria and select multiple wireless test modules using the test plan and WHAMS. In particular, the test plan includes a map of the multiple electrical wiring harnesses, multiple harness connections associated with each of the multiple wireless test modules, a hookup file, and one or more electrical tests associated with the multiple electrical wiring harnesses. The hookup file specifies the multiple wireless test modules assigned to the multiple harness connections. For example, the test plan can be generated with additional harness information related to splices, passive devices, and discarded lost leads. As another example, the test plan can be generated to check wires and unused pins in a network configuration for each of the multiple electrical wiring harnesses. The computer-implemented method may use multiple wireless test modules to perform one or more tests on multiple electrical wiring harnesses according to multiple test commands. The one or more tests may be selected from multiple tests including a continuity check, a voltage insulation check, a time domain reflectometry (TDR) test, a fiber optic test, a diode polarity check, and a resistance measurement check. The computer-implemented method may use multiple WTMs to wirelessly communicate test results to a computer server for display. The computer-implemented method may implement a WTM board support package for applying core operating applications to the multiple wireless test modules to perform one or more tests on the multiple electrical wiring harnesses according to the multiple test commands. The computer-implemented method may implement a custom power controller suite to manage multiple batteries for the multiple wireless test modules.The computer-implemented method can implement a bidirectional testing approach to perform one or more electrical tests on a plurality of electrical wiring harnesses according to a plurality of test commands. The computer-implemented method can evaluate the status of the test results through a color-coded report by highlighting the test results using different colors. The computer-implemented method can wirelessly communicate with a plurality of wireless test modules to update one or more smart test adapters and / or software packages associated with each of the plurality of wireless test modules with part number and pin configuration data of the one or more smart test adapters.

[0011] According to some embodiments, a system includes a system and computer-implemented method for operating a large or small module of a wireless test module. The system can include a wireless transceiver, an electrical wiring harness, and a wireless test module. The wireless test module can be physically coupled to the electrical wiring harness. The wireless test module includes a chassis and a variable front end connected to the chassis using a hot-swap connector. The chassis includes a plurality of electrical relays designed for high-voltage solid-state multiplexing and a rechargeable battery. In particular, the chassis includes a central processing and memory block and circuitry operable to determine measurements for manufacturing and debugging the electrical wiring harness. The variable front end includes an electrical connector that can be coupled to a wiring harness connector of the electrical wiring harness. For example, the electrical connector can accommodate a connector with up to 128 pins. As another example, the electrical connector can accommodate a connector with up to 48 pins. The variable front end is a removable portion of the wireless test module. The variable front end includes a hot-swap interface that allows for quick replacement with a different connector.

[0012] According to some embodiments, the wireless test module is operable to wirelessly receive a plurality of test commands from a computer system according to an automated test plan using a wireless transceiver. The wireless test module is further operable to perform one or more tests on the electrical wiring harness according to the plurality of test commands using a variable front end. The one or more tests are selected from a plurality of tests including a continuity check, a voltage insulation check, a TDR test, a fiber optic test, a diode polarity check, and a resistance measurement check. The wireless test module is further operable to wirelessly transmit test results to the computer system using the wireless transceiver. The wireless test module has a shape selected from a plurality of shapes including a prismatic shape, a pyramidal shape, a cylindrical shape, and a spherical shape. The wireless test module is further operable to wirelessly communicate with the computer system using Wi-Fi, Bluetooth, or Zigbee. The wireless test module is further operable to apply a pick-by-light function for the initial hardware selection and harness connection process.

[0013] According to some embodiments, the wireless test module is further operable to apply an internal power source to one or more wires of the electrical wiring harness to perform tests on the electrical wiring harness, where the internal power source is a high-voltage or low-voltage source. The wireless test module is further operable to replace an inoperable chassis 122 with another available unit in the event of a malfunction. The wireless test module is further operable to generate a low-voltage output of approximately 2.4 volts (V) for resistance / continuity tests. The wireless test module is further operable to measure resistance with an accuracy of 10% ±1 Ω for resistances in the range of 1 Ω-50 Ω. The wireless test module is further operable to measure resistance with an accuracy of 5% ±1 Ω for resistances in the range of 51 Ω-250 Ω. The wireless test module is further operable to measure resistance with an accuracy of 10% ±1 Ω for resistances in the range of 251 Ω-1 MΩ. The wireless test module is further operable to generate a voltage output in the range of 100 V to 500 V for high-voltage tests. The wireless test module is further operable to measure resistance with a high voltage to an accuracy in the range of 6% and 10%. The wireless test module is further operable to identify a variable front end.

[0014] According to some embodiments, a system includes an apparatus for charging a WHAMS. The apparatus includes a charging cart, a mobile aluminum frame, a plurality of light-emitting diode (LED) indicators, and a plurality of charging slots. The WHAMS includes a plurality of wireless test modules. Each of the plurality of charging slots is associated with a respective wireless test module of the WHAMS. The charging cart is operable to charge the plurality of wireless test modules of the WHAMS. The mobile aluminum frame is capable of supporting the charging cart. The plurality of LED indicators are operable to identify the status of the plurality of wireless test modules during setup and storage of the WHAMS.

[0015] According to some embodiments, the charging cart further includes a power supply operable to provide 1500 watts (W) of power for charging multiple wireless inspection modules in parallel. The charging cart is a double-deck charging cart with multiple charging slots ranging from 150 to 200. The charging cart is a single-deck charging cart with multiple charging slots ranging from 50 to 100. The charging cart is a mini charging cart with multiple charging slots ranging from 20 to 30. The charging cart includes a support structure assembled from multiple sheets and pipes, the support structure including one or more decks welded onto the charging cart to allocate the multiple charging slots. The multiple charging slots are keyed slots to accept multiple WTMs and ensure proper placement of the multiple WTMs. The charging cart is connected to the frame using bolts. Each of the multiple LED indicators includes a red LED and a green LED. Each of the multiple LED indicators lights red to indicate that a specific WTM associated with the respective LED indicator is currently charging. Each of the multiple LED indicators lights up green to indicate and locate the specific WTM associated with the respective LED indicator before testing. Each of the multiple LED indicators turns off to indicate that the specific WTM associated with the respective LED indicator has finished charging. Each of the multiple charging slots uses a four-pogo pin layout to charge the multiple wireless test modules. The four-pogo pin layout includes a 5 volt (V) pin, a ground pin, a green LED pin, and a red LED pin.

[0016] According to some embodiments, a system includes a computer system and a calibration instrument. The calibration instrument is operable to calibrate a wireless test module of a WHAMS. The wireless test module includes a plurality of field effect transistors (FETs). The plurality of FETs can be optically isolated moffets. The calibration instrument includes a plurality of resistors. The calibration instrument is operable to evaluate a resistance calibration value by measuring first and second resistance values ​​of the plurality of FETs in a plurality of internal measurement tests for the wireless test module. The calibration instrument is operable to perform a resistance accuracy test (RAT) for the wireless test module using the plurality of resistors of the calibration instrument. The RAT can select a resistor from the plurality of resistors of the calibration instrument and a test associated with the WTM, where the resistor is associated with a target resistance value. The RAT can measure a plurality of calibration coefficients using the calibration instrument and the test. The RAT can determine a measured resistance value using the plurality of calibration coefficients. The RAT can store the measured resistance value and the target resistance value in a database on a computer server. The plurality of FETs includes a high-side FET having a high-side resistance and a low-side FET having a low-side resistance. The test is selected from a plurality of tests including a continuity check, a voltage isolation check, a diode polarity check, and a resistance measurement check. The first resistance value of the FET evaluates a high-side resistance associated with the high-side FET. The second resistance value of the FET evaluates the sum of both the high-side resistance associated with the high-side FET and the low-side resistance associated with the low-side FET. The first resistance value is in a range of 80 Ω to 90 Ω, and the second resistance value is in a range of 120 Ω to 140 Ω. The plurality of resistors have a plurality of resistance values ​​in a range of 1 Ω to 50 MΩ. The plurality of calibration factors for the continuity test include a source-side high-side calibration index, a sink-side high-side calibration factor, and an initial resistance value. The measured resistance value for the continuity test is determined by subtracting the source-side high-side calibration index and the sink-side high-side calibration factor from the initial resistance value. The calibration instrument is further operable to perform a plurality of RATs for the WTM using the plurality of resistors of the calibration instrument.The calibration instrument is further operable to store the plurality of calibration coefficients and the RAT history associated with the RAT in a database on a computer server. The calibration instrument is further operable to perform controlled periodic calibrations on the WHAMS to detect potential failure modes using FET resistance drift over time.

[0017] Technical advantages of certain embodiments include providing improved systems and methods for inspecting electrical wiring harnesses utilized in aircraft, automobiles, or other vehicles and devices. The disclosed wireless harness automated measurement system and method offers a unique combination of hardware flexibility and portability for application at all stages of electrical wiring harness inspection. Instead of typical bulky inspection cabinets with live-wire adapters, the disclosed embodiments utilize multiple wireless inspection modules that physically couple to the electrical wiring harness under test and then wirelessly transmit inspection results to a central computer. This provides a wireless, scalable architecture that ensures maximum hardware utilization. The wireless communication capabilities of the wireless inspection modules open the door to electrical inspection in environments previously difficult to access with live-wire inspection systems (e.g., cabinet-type electrical relay box inspection systems with live-wire inspection cable adapters).

[0018] Additionally, minimal equipment requirements to initiate an inspection lower the barrier to entry and improve system efficiency. The disclosed embodiments provide a simplified information entry format that ensures rapid, automated inspection planning with little or no manual intervention by an operator. Other technical advantages will be readily apparent to those skilled in the art from the following figures, description, and claims. Additionally, while certain advantages have been enumerated above, various embodiments may include all, some, or none of the enumerated advantages.

[0019] For a more complete understanding of the disclosed embodiments, and their features and advantages, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which: [Brief explanation of the drawings]

[0020] [Figure 1] 1 illustrates an automatic wireless harness measurement system, according to some embodiments. [Figure 2A] 2 illustrates inspection of an electrical wiring harness by the automatic wireless harness measurement system of FIG. 1, according to some embodiments. [Figure 2B] 2 illustrates inspection of an electrical wiring harness by the automatic wireless harness measurement system of FIG. 1, according to some embodiments. [Figure 3] 2 illustrates a wireless inspection module that can be used in the automatic wireless harness measurement system of FIG. 1, according to some embodiments. [Figure 4] 4 illustrates an exploded view of the wireless inspection module of FIG. 3 according to some embodiments. [Figure 5] 4 illustrates an internal view of the wireless inspection module of FIG. 3, according to some embodiments. [Figure 6] FIG. 4 is a functional block diagram of the wireless inspection module of FIG. 3, according to some embodiments. [Figure 7A] 4 illustrates a WTM-side hot-swap connector that mates with the variable front end of FIG. 3 according to some embodiments. [Figure 7B] 4 illustrates a front-end hot-swap connector that couples to the wireless inspection module of FIG. 3 according to some embodiments. [Figure 7C] 4 illustrates a front-end hot-swap connector that couples to the wireless inspection module of FIG. 3 according to some embodiments. [Figure 8A] 4 illustrates an exemplary variable front end that can be attached to the wireless inspection module of FIG. 3, according to some embodiments. [Figure 8B] 4 illustrates an exemplary variable front end that can be attached to the wireless inspection module of FIG. 3, according to some embodiments. [Figure 8C] 4 illustrates an exemplary variable front end that can be attached to the wireless inspection module of FIG. 3, according to some embodiments. [Figure 9A] 1 illustrates a battery pack for a wireless inspection module, according to some embodiments. [Figure 9B] 1 illustrates a battery pack for a wireless inspection module, according to some embodiments. [Figure 9C] 1 illustrates a battery pack for a wireless inspection module, according to some embodiments. [Figure 10] 9A-9C illustrate injection molded pogo pin holders for the battery pack of FIGS. 9A-9C, according to some embodiments. [Figure 11A] 1 illustrates a charging cart system for storing multiple wireless inspection modules, according to some embodiments. [Figure 11B] 1 illustrates a charging cart system for storing multiple wireless inspection modules, according to some embodiments. [Figure 11C] 1 illustrates a charging cart system for storing multiple wireless inspection modules, according to some embodiments. [Figure 11D] 1 illustrates a charging cart system for storing multiple wireless inspection modules, according to some embodiments. [Figure 11E] 1 illustrates a charging cart system for storing multiple wireless inspection modules, according to some embodiments. [Figure 11F] 1 illustrates a charging cart system for storing multiple wireless inspection modules, according to some embodiments. [Figure 12] 11A-11F illustrate further details of the charging cart of FIGS. 11A-11F, according to some embodiments. [Figure 13] 11A-11F illustrate further details of the charging cart of FIGS. 11A-11F, according to some embodiments. [Figure 14A] 11A-11F illustrate further details of the charging cart of FIGS. 11A-11F, according to some embodiments. [Figure 14B] 11A-11F illustrate further details of the charging cart of FIGS. 11A-11F, according to some embodiments. [Figure 14C] 11A-11F illustrate further details of the charging cart of FIGS. 11A-11F, according to some embodiments. [Figure 14D] 11A-11F illustrate further details of the charging cart of FIGS. 11A-11F, according to some embodiments. [Figure 15]1 illustrates a calibration fixture for a wireless inspection module, according to some embodiments. [Figure 16A] 16 illustrates an internal measurement test using the calibration fixture of FIG. 15 according to some embodiments. [Figure 16B] 16 illustrates an internal measurement test using the calibration fixture of FIG. 15 according to some embodiments. [Figure 17] 16 illustrates a resistance accuracy test using the calibration fixture of FIG. 15 according to some embodiments. [Figure 18A] 2 illustrates an example application interface for operating software for inspecting multiple electrical wiring harnesses with the automated wireless harness measurement system of FIG. 1 in accordance with certain embodiments. [Figure 18B] 2 illustrates an example application interface for operating software for inspecting multiple electrical wiring harnesses with the automated wireless harness measurement system of FIG. 1 in accordance with certain embodiments. [Figure 19] 1 is a flow chart illustrating an exemplary method for testing a wireless test module, according to certain embodiments. [Figure 20] 1 illustrates an exemplary computer system that can be utilized to implement aspects of the various techniques presented herein, according to certain embodiments. DETAILED DESCRIPTION OF THE INVENTION

[0021] Electrical wiring harnesses are used in many different industries and vehicles. For example, large, complex electrical wiring harnesses with numerous wires and connectors are used in the aerospace industry to produce aircraft. As another example, electrical wiring harnesses are used in the automotive industry to produce automobiles. Electrical wiring harnesses for vehicles such as aircraft and automobiles typically must be rigorously and thoroughly inspected to ensure that there are no defects in the electrical wiring harness components, such as connectors or wires. For example, electrical wiring harnesses are inspected to ensure that there are no shorted wires, swapped connector pins, damaged wires, etc.

[0022] Typically, electrical wiring harnesses are tested using large cabinet-style electrical relay boxes with hard-wired test cable adapters that physically connect to connectors on both the electrical wiring harness under test and the electrical relay box. While electromechanical operations are performed in a centralized cabinet, the hard-wired test cable adapters function as extension cords for the unique mating connectors to reach the electrical wiring harness under test. However, such systems can cause problems in certain situations. For example, using cabinet-style test machines for harness testing, including setup, testing, repair (harness and tooling), and analysis, can be inefficient. For example, typical cabinet-style test machines are large, heavy, and relatively fixed. They rely on highly customized test cable adapter sets and cannot be efficiently scaled to meet changing electrical testing needs. As another example, operators typically spend hundreds of hours using cabinet-style test machines to test harnesses on aircraft, such as fault-response systems to ensure product quality in the aerospace, military, and transportation / rail industries. As another example, a typical cabinet type test machine must test various independent test cable sets and appropriate fixtures for tooling the wire harness templates.

[0023] To address these and other issues with typical systems for inspecting electrical wiring harnesses, the present disclosure provides a wireless harness automatic measurement system and method. Particular disclosed embodiments utilize one or more wireless test modules (WTMs), each physically and electrically coupled to a connector of an electrical wiring harness under test. The one or more wireless test modules are utilized in a wireless harness automatic measurement system (WHAMS) for a mobile inspection solution to verify electrical harnesses, alleviating the inefficiencies of traditional cable-based inspection using cabinet-type inspection machines. The wireless test modules transmit and receive electrical test signals via one or more wires in the electrical wiring harness and then, unlike current live-wire solutions, wirelessly report the test results to a central computer system, such as a laptop. That is, each wireless test module is not physically connected to the central computer system, but instead communicates wirelessly with it. This allows the wireless test modules to be transported to the location of the electrical wiring harness without worrying about moving the central computer system or large relay cabinets. This improves productivity and flexibility when inspecting electrical wiring harnesses. The wireless test module may be of any suitable shape (e.g., cylindrical, prismatic, spherical, pyramidal, etc.). In certain embodiments, the wireless test module is similar in size and / or shape to a typical flashlight. This small outer size allows a technician to easily carry multiple wireless test modules and attach them to electrical wiring harnesses under test, which may be located physically remotely (e.g., in an adjacent room or on a floor) from the central computing system.

[0024] Each wireless test module includes two main parts: a chassis and a front end. The wireless test module chassis houses the electronics and components (e.g., battery, relay, etc.) for performing electrical tests on electrical wiring harnesses (e.g., continuity checks, voltage insulation checks, TDR tests, fiber optic tests, diode polarity checks, resistance measurement checks, etc.). The wireless test module's removable front end houses a specific mating connector that connects to the electrical wiring harness connector and can be quickly replaced with a common interface on the front of the wireless test module. Wireless test modules are interchangeable and not dedicated to any particular wiring harness or system. The wireless harness automated test system's configuration allows for the creation of a catalog of front ends to meet various electrical connector needs while minimizing the number of wireless test modules required to maximize hardware utilization. The hardware commonality of the wireless test module chassis also facilitates replacement in the event of a failure. If one wireless test module becomes inoperable, simply replace the inoperable wireless test module chassis with another available unit, allowing critical testing activities to continue without delay. As a result, the test operator can complete the test of the electrical wiring harness without having to troubleshoot or repair the test equipment.

[0025] The disclosed wireless harness automated measurement system and method offers a unique combination of hardware flexibility and portability applicable to all phases of electrical wiring harness inspection. Certain disclosed embodiments provide a wireless, scalable architecture that ensures maximum hardware utilization. The wireless communication capabilities of the wireless inspection module open the door to electrical inspection in environments previously difficult to access with live-wire inspection systems (e.g., cabinet-type electrical relay box inspection systems with live-wire inspection cable adapters). Furthermore, minimal equipment requirements to initiate an inspection lower the barrier to entry and improve system efficiency. Certain disclosed embodiments provide a simplified information entry format that ensures rapid, automated inspection planning with little or no manual intervention by the operator.

[0026] To facilitate a better understanding of the present disclosure, examples of specific embodiments are provided below. The following examples should not be construed as limiting or defining the scope of the present disclosure. The embodiments of the present disclosure and their advantages can be best understood by referring to the included figures, in which like numbers are used to indicate like and corresponding elements.

[0027] The entire WHAMS system

[0028] 1 illustrates an automated wireless harness measurement system 100 according to some embodiments. The automated wireless harness measurement system 100 includes an electrical wiring harness under test 110, one or more wireless test modules 120 (e.g., 120A, 120B, 120C, and 120D), a central computer system 130, and a wireless interface 140. Although a specific number of wireless test modules 120 are shown in FIG. 1, in other embodiments, any number of wireless test modules 120 may be utilized.

[0029] Generally, the wireless harness automatic measurement system 100 utilizes one or more wireless test modules 120 to test the functionality of the electrical wiring harness 110. Each wireless test module 120 has a variable front end 126 (e.g., 126A, 126B, 126C, 126D) that includes at least one connector that physically and electrically couples to a wiring harness connector 115 (e.g., 115A, 115B, 115C, 115D) of the electrical wiring harness 110 under test. The wireless test modules 120 send and receive electrical test signals over one or more wires 111 of the electrical wiring harness 110 to perform tests such as continuity checks (e.g., misplaced pins in the wiring harness connector 115, shorted pins within the wiring harness connector 115, etc.), voltage insulation checks, diode polarity checks, and resistance measurement checks. Second, unlike typical solutions that are hard-wired in large relay cabinets, wireless test modules 120 wirelessly report test results 160 to central computer system 130 using wireless transceivers 121 (e.g., 121A, 121B, 121C, 121D). That is, each wireless test module is not physically connected to the central computer system, but instead communicates wirelessly with central computer system 130 using a wireless protocol such as Zigbee, Bluetooth, or Wi-Fi. The small dimensions of wireless test modules 120, combined with their ability to wirelessly communicate with central computer system 130, allow a technician to easily carry multiple wireless test modules 120 and couple them to wiring harness connectors 115 of electrical wiring harnesses 110 under test, even when electrical wiring harnesses 110 are physically located remotely from central computer system 130.

[0030] The electrical wiring harness 110 is a bundle of electrical wires 111. The electrical wiring harness 110 includes one or more wiring harness connectors 115 coupled to one or more electrical wires 111. For example, the electrical wiring harness 110 of FIG. 1 includes four wiring harness connectors 115 (115A-115D). The wiring harness connectors 115 may be any suitable electrical connector and may include any number of pins or electrical contacts. Examples of wiring harness connectors 115 include signal connectors, power connectors, etc. The electrical wiring harness 110 may be installed in any device or vehicle, such as an aircraft, automobile, watercraft, spacecraft, etc. The wireless harness automatic measurement system 100 may be utilized to inspect the electrical wiring harness 110 either before or after the electrical wiring harness 110 is installed in the device, aircraft, or vehicle of interest.

[0031] Each wireless inspection module 120 (120A-120D) is a portable inspection device that physically connects to a wiring harness connector 115 of an electrical wiring harness 110, performs one or more electrical tests on the electrical wiring harness 110 as instructed by the central computer system 130, and / or wirelessly transmits inspection commands 150 from the electrical tests back to the central computer system 130. Existing inspection systems for electrical wiring harnesses include large, bulky relay cabinets with live wiring inspection adapters that connect to the wiring harness connectors 115. Such systems are difficult to transport, not easily adaptable, and not easily scalable. However, by utilizing wireless inspection modules 120 that have small overall dimensions and are easily portable, the wireless harness automatic measurement system 100 can be utilized to inspect electrical wiring harnesses 110 located remotely (e.g., in another room or on another floor). Additionally, the wireless harness automated measurement system 100 can utilize any number of wireless inspection modules 120 to inspect the electrical wiring harness 110, thereby increasing the adaptability and scalability of the wireless harness automated measurement system 100 compared to existing live wiring inspection relay cabinets.

[0032] Each wireless test module 120 includes a wireless transceiver 121, a chassis 122 (e.g., 122A, 122B, 122C, and 122D), and a variable front end 126. The wireless transceiver 121 enables the wireless test module 120 to communicate wirelessly with the central computer system 130 (either directly or via a wireless interface 140) using any suitable wireless protocol (e.g., Zigbee, Bluetooth, Wi-Fi, etc.). The chassis 122 is the main body of the wireless test module 120 and houses components such as a battery, relay, processor, memory, etc. The variable front end 126 is a removable portion of the wireless test module 120 that includes an electrical connector configured to mate with the wiring harness connector 115 of the electrical wiring harness 110. For example, if the wiring harness connector 115A is a typical three-pronged male electrical plug, the variable front end 126 may include a three-pronged female electrical plug. As another example, if the wiring harness connector 115A is a male coaxial electrical connector, the variable front end 126 may include a female coaxial electrical connector. Details regarding the wireless inspection module 120 and its components are described in more detail below with reference to Figures 2-8C.

[0033] The central computer system 130 can be any suitable computing system in any suitable physical form. By way of example, and not limitation, the central computer system 130 can be an embedded computer system, a system-on-chip (SOC), a single-board computer system (SBC) (e.g., a computer-on-module (COM) or system-on-module (SOM)), a desktop computer system, a laptop or notebook computer system, a mainframe, a network of computer systems, a mobile phone, a personal digital assistant (PDA), a server, a tablet computer system, an augmented / virtual reality device, or a combination of two or more of these. Where appropriate, the central computer system 130 can include one or more computer systems, be single or distributed, span multiple locations, span multiple machines, span multiple data centers, or reside in a cloud, which can include one or more cloud components in one or more networks. Where appropriate, the central computer system 130 can perform one or more steps of one or more methods described or illustrated herein without substantial spatial or temporal limitations. By way of example, and not limitation, central computer system 130 may perform one or more steps of one or more methods described or illustrated herein in real time or in batch mode. Central computer system 130 may, where appropriate, perform one or more steps of one or more methods described or illustrated herein at different times or in different locations. A specific example of central computer system 130 is described in connection with FIG. 20.

[0034] Wireless interface 140 is any suitable device capable of providing wireless communication between central computer system 130 and wireless inspection module 120. In some embodiments, wireless interface 140 is a separate device that is communicatively coupled to central computer system 130 (e.g., wired, wirelessly coupled, or physically plugged into central computer system 130). In other embodiments, wireless interface 140 is built into or integrated into central computer system 130. In some embodiments, wireless interface 140 is a Zigbee transceiver module, a WI-FI router, or a Bluetooth transceiver.

[0035] Test command 150 is one or more signals, operations, commands, etc., wirelessly transmitted from central computer system 130 to wireless test module 120. Test command 150 is utilized by wireless test module 120 to perform one or more electrical tests on electrical wiring harness 110. The electrical tests may be, for example, a continuity check (e.g., misplaced pins on wiring harness connector 115, shorted pins on wiring harness connector 115, damaged wires 111, etc.), a voltage insulation check, a diode polarity check, a resistance measurement check, etc. In some embodiments, test command 150 is determined by central computer system 130 according to a test plan for electrical wiring harness 110. An example of test command 150 is described in connection with Figures 18A and 18B.

[0036] Test results 160 are one or more signals, values, pass / fail indicators, etc. that are wirelessly transmitted from wireless test module 120 (either directly or via wireless interface 140) to central computer system 130. Test results 160 are the results from one or more electrical tests performed by wireless test module 120 on electrical wiring harness 110. Test results 160 also include status signals and other metadata not directly related to harness test results. An example of test results 160 is described in connection with FIG. 18A.

[0037] 2A-2B illustrate various examples of steps for inspecting an electrical wiring harness 110 by the wireless harness automatic measurement system 100, according to some embodiments. In FIG. 2A, two wireless inspection modules 120, a source wireless inspection module 120A and a destination wireless inspection module 120B, are utilized to perform the inspection steps on the electrical wiring harness 110. In this example, the source wireless inspection module 120A is physically coupled to a first wiring harness connector 115A, and the destination wireless inspection module 120B is physically coupled to a second wiring harness connector 115B. In this scenario, two electrical wires 111, a first electrical wire 111A and a second electrical wire 111B, are utilized during the inspection. The second electrical wire 111B is used as a return line in this example. Both electrical wires 111A and 111B are physically and electrically coupled to both source wireless inspection module 120A and destination wireless inspection module 120B via wiring harness connectors (e.g., wiring harness connectors 115A and 115B in FIG. 1). Source wireless inspection module 120A introduces current flow into first electrical wire 111A, and destination wireless inspection module 120B internally connects first electrical wire 111A to second electrical wire 111B, for example, using an electrical relay. Source wireless inspection module 120A can then measure the voltage and current across first electrical wire 111A and second electrical wire 111B to perform various electrical tests as described herein. Destination wireless inspection module 120B also measures the current and voltage to ensure that the current is actually reaching destination wireless inspection module 120B. The destination wireless test module 120B includes a pin multiplexing component, such as a high-voltage capable solid-state multiplexing block 616, which is configured to provide connections by transmitting signals over one or more transmission paths for various switching and digital control applications.

[0038] 2A, options other than the second electrical wire 111B may be used for the electrical return path or ground. For example, an electrical shield within the electrical wiring harness 110 may be used for the electrical return path or ground. As another example, an electrical jumper (e.g., an electrical wire) may be physically connected to both the source wireless inspection module 120A and the destination wireless inspection module 120B and used as the electrical return path or ground.

[0039] In FIG. 2B , a single wireless test module 120A is utilized to perform testing of the electrical wiring harness 110. In this example, the wireless test module 120A is physically coupled to a first wiring harness connector (e.g., wiring harness connector 115A of FIG. 1 ), and a loopback connector (or other similar device) 202 is physically coupled to a second wiring harness connector (e.g., wiring harness connector 115B of FIG. 1 ). In this scenario, two electrical wires 111 are utilized during testing: a first electrical wire 111A and a second electrical wire 111B. The second electrical wire 111B is used as a return line in this example. Both electrical wires 111A and 111B are physically and electrically coupled to the wireless test module 120A and are coupled to each other using a loopback device. The wireless test module 120A introduces a current flow into the first electrical wire 111A, which is returned to the wireless test module 120A on the second electrical wire 111B. The wireless test module 120A can then measure the voltage and current across the first electrical wire 111A and the second electrical wire 111B to perform various electrical tests as described herein.

[0040] 1, 2A, and 2B, wireless harness automatic measurement system 100 utilizes central computer system 130 and one or more wireless inspection modules 120 to inspect electrical wiring harness 110. First, one or more wireless inspection modules 120 are physically connected to one or more wiring harness connectors 115 of electrical wiring harness 110. For example, as shown in FIG. 2A, source wireless inspection module 120A is physically coupled to first wiring harness connector 115A, and destination wireless inspection module 120B is physically coupled to second wiring harness connector 115B. In another example, as shown in FIG. 2B, wireless inspection module 120A is physically coupled to first wiring harness connector 115A, and loopback connector (or other similar device) 202 is physically coupled to second wiring harness connector (e.g., wiring harness connector 115B of FIG. 1). Central computer system 130 then transmits inspection commands 150 to one or more wireless inspection modules 120 according to the automated inspection plan. Details and examples of automated inspection plans used to inspect electrical wiring harness 110 are described in more detail below. In some embodiments, inspection commands 150 are transmitted to one or more wireless inspection modules 120 using wireless interface 140. Inspection commands 150 may be transmitted using any suitable wireless protocol, such as Wi-Fi, Bluetooth, or Zigbee.

[0041] After receiving the test command 150 using the wireless transceiver 121, the wireless test module 120 performs one or more tests on the electrical wiring harness 110 according to the test command 150 received from the central computer system 130. The electrical tests may be, for example, a continuity check (e.g., misplaced pins on the wiring harness connector 115, shorted pins on the wiring harness connector 115, damaged electrical wires 111, etc.), a voltage insulation check, a diode polarity check, a resistance measurement check, etc. For example, the wireless test module 120 may enable / disable one or more internal electrical relays and apply current from an internal power source to one or more electrical wires 111 of the electrical wiring harness 110 to perform the continuity check on the electrical wiring harness 110. Each wireless test module 120 may vary the voltage and current of one or more connected electrical wires 111 according to the received test command 150. After performing one or more tests on the electrical wiring harness 110 in accordance with the test commands 150 received from the central computer system 130, the wireless test modules 120 wirelessly transmit test results 160 back to the central computer system 130 (either directly or via the wireless interface 140). Once the test results 160 are received by the central computer system 130, the central computer system 130 may display the test results 160 received from the one or more wireless test modules 120 on an electronic display.

[0042] WHAMS Wireless Inspection Module

[0043] In some embodiments, the wireless inspection module is the primary electrical inspection hardware of the WHAMS. The wireless inspection module is a cylindrical, wireless-enabled communication and inspection node that can perform various electrical inspections by mating with individual electrical connectors on aircraft or other electrical harnesses. The wireless inspection module can communicate with a wireless transceiver that is powered by the central computer system 130. As a result, the central computer system 130 sends various types of commands to the wireless inspection module for performing and reporting inspections. The wireless inspection module can operate alone or in a scalable network of multiple wireless inspection modules for use on large harness assemblies.

[0044] FIG. 3 illustrates a wireless test module 120 that can be used in the wireless harness automatic measurement system of FIG. 1 , according to some embodiments. Each wireless test module 120 includes a wireless transceiver 121 (shown in FIG. 1 ), a chassis 122, and a variable front end 126. The wireless test module 120 is the primary electrical test hardware of the WHAMS. In some embodiments, conventional electrical harness test hardware includes one or more large charging cabinets and extension cables with unique test adapters at the ends. The one or more charging cabinets can be configured to house hundreds of relays and other electrical components used to perform various types of tests required to verify the functionality of an electrical harness. In particular, an individual charging cabinet can test thousands of test points and can be expanded by connecting multiple charging cabinets. However, the one or more charging cabinets can be configured to be expandable in large increments of test points. For example, the one or more charging cabinets can be configured to be deployable for harness configurations requiring fewer than a predetermined number of test points. As a result, optimizing the cabinet configuration of one or more charging cabinets to reduce costs is challenging, especially for compact electrical harness assemblies with low pin count connectors. Typically, one or more charging cabinets include multiple connectors with various pin counts, types, and units for most of the work to be completed.

[0045] In some embodiments, one or more charging cabinets use a universal connector interface panel for plugging in multiple test adapter cables. The multiple test adapter cables are double-ended and have unique lengths, which increases the weight and manufacturing costs of conventional electrical harness test hardware. Therefore, conventional electrical harness test hardware is difficult to quickly transport and deploy for use in a multi-build environment.

[0046] In some embodiments, the wireless inspection module 120 is configured to use a smaller charging cabinet. Specifically, the wireless inspection module 120 has a portable and rapidly configurable cabinet configuration, which allows the wireless inspection module 120 to fit within a tight footprint for complete, closed-loop wireless functionality for electrical harness inspection. The wireless inspection module 120 is battery-powered and operates independently from other wireless inspection modules based on a personalized architecture. Thus, the wireless inspection module 120 can perform one or more tests that are no longer tied to an immediate power source or a cabled inspection adapter. As a result, the wireless inspection module 120 can provide more efficient performance for inspecting various harness sizes and reduce the non-recurring engineering (NRE) required to launch new inspection adapters.

[0047] In some embodiments, the wireless test module 120 is a cylindrical, wireless-enabled communication and test node. The chassis 122 can be a circuit card assembly (CCA) chassis housing multiple electronic components. In the event of a malfunction, the wireless test module 120 can replace an inoperable chassis 122 with another available unit. In some embodiments, the variable front end 126 includes the electrical connector 302 (and possibly a backshell), a plastic adapter (such as the hot-swap interface 124 connecting the electrical connector 302 to the chassis 122), and a wire harness (e.g., jumper harness 708 in FIG. 7A ) connecting the electrical connector 302 to the chassis 122. The variable front end 126 is a removable portion of the wireless test module 120. The wireless test module 120 can be configured to automatically identify a test adapter, such as the variable front end 126, that is connected to the wireless test module 120. The variable front end 126 can be coupled to a wiring harness connector of an electrical wiring harness using the electrical connector 302. Thus, wireless test module 120 can be configured to physically couple to an electrical wiring harness to perform one or more tests on the electrical wiring harness (e.g., a continuity check, a voltage insulation check, a TDR test, a fiber optic test, a diode polarity check, a resistance measurement check, etc.). In particular, wireless test module 120 can be configured to wirelessly receive a plurality of test commands (e.g., test command 150 of FIG. 1 ) from an automated test plan from a central computer system (e.g., central computer system 130 of FIG. 1 ) using wireless transceiver 121. Wireless test module 120 is configured to perform one or more tests on the electrical wiring harness according to the test commands from the automated test plan from the central computer system using variable front end 126. Wireless test module 120 is configured to wirelessly communicate test results to the central computer system using wireless transceiver 121.

[0048] FIG. 4 shows an exploded view of the wireless inspection module 120 of FIG. 3 , according to some embodiments. The wireless inspection module 120 is a modular, common duplicate part for easy unit replacement to facilitate repairs and eliminate system downtime. The variable front end 126 (shown in FIG. 1 ) can be customized, while the chassis 122 remains consistent. For example, the variable front end 126 can include a front-end hot-swap connector 404 that can be quickly replaced with a variety of connectors. The chassis 122 can be configured to house multiple electronic components, which allows the wireless inspection module 120 to wirelessly communicate with a central computer system (e.g., the central computer system 130 of FIG. 1 ) using Wi-Fi, Bluetooth, or Zigbee. The wireless inspection module 120 can communicate with inspection software and a wireless transceiver (e.g., the wireless transceiver 121 of FIG. 1 ) using the Zigbee communication protocol. Thus, the wireless inspection module 120 provides a portable, modular electrical harness inspection machine that does not use a cabled inspection adapter to communicate with the central computer system.

[0049] 5 shows an internal view of the wireless test module 120 of FIG. 3 , according to some embodiments. The wireless test module 120 can include a wide variety of mating electrical connectors 406. For example, the wireless test module 120 can accommodate electrical connectors 406 with up to 128 pins. In another example, the wireless test module 120 can accommodate electrical connectors 406 with up to 48 pins. The electrical connectors 406 can be integrated within the wireless test module 120 and can couple to wiring harness connectors of an electrical wiring harness.

[0050] FIG. 6 illustrates a functional block diagram 600 of the wireless test module 120 of FIG. 3 , according to some embodiments. The wireless test module includes multiple electronic components, such as a radio block 602, a charging and powering block 604, a central processing and memory block 606, a lithium-ion rechargeable battery 608, a high-voltage supply 610, a low-voltage supply 612, an analog measurement circuit 614, and a high-voltage capable solid-state multiplexing block 616. The high-voltage capable solid-state multiplexing block 616 is connected to the variable front end of the wireless test module (e.g., variable front end 126 of FIG. 3 ). In certain embodiments, the central processing and memory block 606 of the wireless test module is combined with circuits such as the analog measurement circuit 614 so that the wireless test module is designed to perform measurements typically performed when manufacturing and debugging cable harnesses. In some embodiments, the wireless test module includes multiple electrical relays designed for the high-voltage capable solid-state multiplexing block 616. In certain embodiments, the wireless test module includes a lithium-ion rechargeable battery 608 (e.g., a 3400 milliampere-hour (mAh) lithium-ion rechargeable battery) that eliminates the need for a charging cabinet with a cable. As a result, the wireless test module can be configured to perform low-current, high-voltage tests and to communicate wirelessly with a central computer system (e.g., central computer system 130 of FIG. 1) while under battery power.

[0051] In some embodiments, the wireless inspection module is configured to perform various electrical inspections by using multiple electronic components to mate with multiple individual electrical connectors of aircraft and automotive electronic wiring harnesses. For example, the wireless inspection module can use the central processing and memory block 606 and analog measurement circuitry 614 to perform measurements during inspection of aircraft and automotive electronic wiring harnesses. Similarly, the wireless inspection module can use the central processing and memory block 606 to apply pick-by-light functionality for the initial hardware selection and harness hookup process. As another example, the wireless inspection module can use the wireless block 602 to communicate with a wireless transceiver powered by a control laptop, such as a central computer system, which transmits various types of inspection commands (e.g., inspection command 150 of FIG. 1 ) to the wireless inspection module for execution and reporting of the inspections. As another example, the wireless inspection module can apply an internal power source to one or more wires of an electrical wiring harness to perform inspections on the electrical wiring harness. The internal power supply may include a high voltage supply 610 and / or a low voltage supply 612 .

[0052] In some embodiments, a wireless test module (e.g., wireless test module 120 of FIG. 1 ) includes a power button that allows a user to turn the wireless test module on, off, or reset it. The wireless test module can be configured to use a mini-USB connector, the wireless test module's charging port, and the charging and powering block 604 to charge the wireless test module. Similarly, the wireless test module can be configured to use the mini-USB connector as a software debug port for fast updates of one or more software packages of the wireless test module. In particular, the wireless test module's charging port can interface with multiple pogo pins located in each slot of the WHAMS charging cart. The multiple pogo pins can also be used for the wireless test module's battery pack. When the wireless test module is powered off and power is applied to the charging port, the wireless test module can be configured to power on and begin charging. The wireless test module can include multiple light-emitting diode (LED) indicators to visually facilitate communication with the user. For example, the LED indicators can be orange and located on the end of the wireless test module 120.

[0053] In some embodiments, a wireless test module (e.g., wireless test module 120 of FIG. 1 ) can be configured to operate independently or within a scalable network of wireless test modules for use on large harness assemblies. Specifically, a wireless test module can be configured to generate a low-voltage output of approximately 2.4 volts (V) for resistance / continuity testing. Similarly, a wireless test module can be configured to generate a voltage output in the range of 100 V to 500 V for high-voltage testing with an output voltage tolerance of ±3% ±2 V. As a result, a wireless test module can be configured to measure resistance with an accuracy of 10% ±1 Ω for resistances in the range of 1 Ω to 50 Ω. A wireless test module can be configured to measure resistance with an accuracy of 5% ±1 Ω for resistances in the range of 51 Ω to 250 Ω. A wireless test module can be configured to measure resistance with an accuracy of 10% ±1 Ω for resistances in the range of 251 Ω to 1 million (M) Ω. The wireless test module can be configured to measure resistance with a high voltage to an accuracy of 6% to 10%. For example, the accuracy of resistance measurements with a high voltage of 100V is 10% for resistances in the range of 1 MΩ to 50 MΩ. As another example, the accuracy of resistance measurements with a high voltage of 500V is 6% for resistances in the range of 1 MΩ to 50 MΩ.

[0054] WHAMS Hot Swap Connectors

[0055] In some embodiments, the WHAMS is configured to perform one or more electronic tests related to Functional Automated Check (FAC) on multiple electronic wiring harnesses for vehicles, such as aircraft and automobiles. The variety of connectors on vehicles is vast. The WHAMS can test every connector on the vehicle using multiple wireless test modules. Because vehicles are tested individually, the multiple wireless test modules can use hot-swap connectors to disconnect connectors from the multiple wireless test modules, reducing manufacturing costs and increasing the flexibility of the WHAMS.

[0056] FIG. 7A illustrates a WTM-side hot-swap connector 402 that can be coupled to a variable front end (e.g., the variable front end of FIG. 3 ) according to some embodiments. A wireless inspection module (e.g., wireless inspection module 120 of FIG. 1 ) includes a pair of hot-swap connectors, such as WTM-side hot-swap connector 402 and front-end hot-swap connector 404 of FIG. 4 , located between the wireless inspection module chassis and the variable front end of the wireless inspection module. A WHAMS can use multiple wireless inspection modules, including multiple types of connectors for FACs, during inspection of multiple electrical wiring harnesses. Specifically, it can accommodate all unique connectors in FACs for vehicles such as aircraft and automobiles. A conventional WHAMS includes multiple connectors permanently attached to a wireless inspection module that includes all processing functions. Because at least one wireless inspection module is required for each unique connector, conventional WHAMS can incur high manufacturing costs for inspecting multiple electrical wiring harnesses. The hot-swap connectors can significantly reduce manufacturing costs and increase the flexibility of the WHAMS by decoupling the hot-swap connectors from the wireless inspection modules. The number of wireless inspection modules will be determined based on the number of inspections required for WHAMS.

[0057] In some embodiments, the WTM-side hot-swap connector 402 is a custom-designed universal connector. The WTM-side hot-swap connector 402 can be located at the end of the wireless test module chassis and attached to another custom-designed universal connector, such as a front hot-swap connector, located at the end of the variable front end that mates with the wireless test module. Thus, the WTM-side hot-swap connector 402 can attach the variable front end of the wireless test module to the wireless test module chassis. Similarly, the WTM-side hot-swap connector 402 can remove the variable front end of the wireless test module from the wireless test module chassis. The WTM-side hot-swap connector 402 is operable to transfer data to and from the wireless test module when the wireless test module chassis and the variable front end of the wireless test module are mated. The WTM-side hot-swap connector 402 can automatically update address information in real time to replace a malfunctioning wireless test module with another wireless test module if the wireless test module is malfunctioning.

[0058] In some embodiments, the WTM-side hot-swap connector 402 includes an alignment peg 702, a slip ring 704, an electrically erasable programmable read-only memory (EEPROM) read / write line 706, a jumper harness 708, and a female connector, such as a surface-mount female connector 710. The alignment peg 702 is configured to mate with the variable front end of the wireless test module. The slip ring 704 is configured to secure the wireless test module in place for quick and reliable connection, thereby allowing for quick attachment and detachment of the variable front end from the wireless test module. The EEPROM read / write line 706 is integrated on the circuit board and allows for reading and writing data to the wireless test module. The EEPROM read / write line 706 can be configured to couple to the chassis of the wireless test module. The wireless test module is operable to wirelessly communicate with a central computer system using a wireless transceiver to transfer data stored in an EEPROM (e.g., EEPROM 726 in FIG. 7B) associated with EEPROM read / write lines 706. Jumper harness 708 is configured to couple to the wireless test module. Surface mount female connector 710 includes a number of contacts ranging from 48 contacts to 128 contacts. For example, surface mount female connector 710 may include 100 contacts.

[0059] 7B and 7C illustrate a front-end hot-swap connector 404 that couples to the wireless test module 120 of FIG. 3 , according to some embodiments. The front-end hot-swap connector 404 can be located at the end of the wireless test module's variable front end and attach to another custom-designed universal connector, such as a WTM hot-swap connector, located at the end of the wireless test module's chassis. Thus, the front-end hot-swap connector 404 can attach the wireless test module's variable front end to the wireless test module's chassis. Similarly, the front-end hot-swap connector 404 can detach the wireless test module's variable front end from the wireless test module's chassis. The front-end hot-swap connector 404 is operable to transfer data to and from the wireless test module when the wireless test module's chassis and the wireless test module's variable front end are mated. The front-end hot-swap connector 404 can automatically update address information in real time to swap in another wireless test module if the wireless test module malfunctions.

[0060] In some embodiments, the front-end hot-swap connector 404 includes an alignment peg 722, threads 724, an EEPROM 726, multiple connectors 728, and a male connector, such as a surface-mount male connector 730. The alignment peg 722 is configured to mate with the chassis of the wireless inspection module. The threads 724 are configured to mate with a slip ring (e.g., slip ring 704 in FIG. 7A ) to secure the wireless inspection module in place for a quick and reliable connection. As a result, the variable front end can be quickly attached and detached from the wireless inspection module. Upon attachment, the variable front end is securely held in place by the slip ring and threads 724. An EEPROM 726 is integrated on the circuit board and can store data for the wireless inspection module. The wireless inspection module is operable to wirelessly communicate with a central computer system using a wireless transceiver to transfer data stored in the EEPROM 726. The data on the EEPROM 726 can be automatically incorporated into the inspection software of the central computer system without human data entry. The plurality of connectors 728 are configured to mate with wire jumpers to aircraft connectors. The surface mount male connector 730 includes a plurality of contacts ranging from 48 contacts to 128 contacts. For example, the surface mount male connector 730 may include 100 contacts.

[0061] 8A-8C illustrate an exemplary variable front end 802 that may be attached to the wireless inspection module 120 of FIG. 3, according to some embodiments. In particular, the variable front end 802 of FIGS. 8A-8C may be coupled to a wiring harness connector, such as an aircraft connector (e.g., wiring harness connector 115 of FIG. 1), at various pins.

[0062] WHAMS Battery Pack

[0063] In some embodiments, the wireless inspection module may use a portable rechargeable battery pack to provide additional power when the WHAMS wireless inspection module draws power during a low battery condition during an inspection. The portable rechargeable battery pack is configured to extend the battery life of the WHAMS wireless inspection module if the WHAMS wireless inspection module is left uncharged for an extended period of time.

[0064] 9A-9C illustrate a battery pack 900 for a wireless inspection module, according to some embodiments. The battery pack 900 provides a portable charging solution for the wireless inspection module to provide additional power to the wireless inspection module during testing when the battery level is low. The battery pack 900 includes a wireless charging battery, a wireless battery pack holder 902, an injection-molded pogo pin holder 904, and a wireless charging receiver 906. The wireless battery pack holder 902 is capable of accommodating the wireless charging battery. In certain embodiments, the wireless battery pack holder 902 is a three-dimensional (3D) printed part with a shape that allows the wireless battery pack holder 902 to slide onto the end of the wireless inspection module. Thus, the wireless battery pack holder 902 can house multiple components necessary for the battery pack 900 to function.

[0065] In some embodiments, the injection-molded pogo pin holder 904 includes a plurality of pogo pins (e.g., pogo pins 1002 in FIG. 10 ). The injection-molded pogo pin holder 904 is coupled to the wireless battery pack holder 902 using a first set of fasteners (e.g., screws). Similarly, the injection-molded pogo pin holder 904 can be coupled to a wireless inspection module. The wireless charging receiver 906 is operable to wirelessly charge the wireless charging battery. Thus, the battery pack 900 is configured to charge the wireless inspection module by contacting the plurality of pogo pins with a compatible wireless charging battery pack. In particular, the battery pack includes a steel retractable spring plunger 908, which includes a pull ring that can be attached to the wireless inspection module using a second set of fasteners (e.g., screws) to hold the battery pack 900 together. The battery pack 900 includes a magnet 910 attached to the wireless charging receiver 906. The magnet 910 can lock the battery pack 900 to the wireless test module. In a particular embodiment, the wireless charging receiver 906 includes a 5 volt (V) Qi-standard wireless charging receiver 912, which includes a magnetic plate that fits over the magnet 910.

[0066] In some embodiments, the battery pack 900 is configured to extend the battery life of the wireless test module, which may be left uncharged for long periods of time. For example, the battery pack 900 can be coupled to the wireless test module to provide additional power for performing one or more electrical tests on the electrical wiring harness (e.g., a continuity check, a voltage insulation check, a TDR test, a fiber optic test, a diode polarity check, a resistance measurement check, etc.). In particular, the wireless test module can include an electrical connector that can mate with a wiring harness connector of the electrical wiring harness. The wireless test module can be operable to perform one or more tests to verify the electrical wiring harness according to a plurality of test commands received from a central computer system. In particular, the wireless test module can be operable to wirelessly communicate with the central computer system using Wi-Fi, Bluetooth, or Zigbee.

[0067] 10 illustrates an injection-molded pogo pin holder 904 for the battery pack of FIGS. 9A-9C, according to some embodiments. The injection-molded pogo pin holder 904 can include multiple pogo pins 1002 that can be secured (e.g., screwed) to the wireless battery pack holder.

[0068] WHAMS Charging Cart

[0069] In some embodiments, the WHAMS can use a mobile charging cart to charge multiple wireless inspection modules in parallel. The mobile charging cart is configured to hold and charge the multiple wireless inspection modules and to locate the multiple wireless inspection modules when needed for inspection. As a result, the mobile charging cart can ensure that the multiple wireless inspection modules are fully charged during production use. Similarly, the mobile charging cart can locate the multiple wireless inspection modules through a pick-by-flight feature that lights up the multiple wireless inspection modules when they are needed for inspection.

[0070] 11A-11F illustrate a charging cart system 1100 for storing multiple wireless test modules, according to some embodiments. The charging cart system 1100 is a bulk charging device configured to hold and charge multiple wireless test modules for use in production. The charging cart system 1100 includes three sizes: (1) a double-deck charging cart 1160 as shown in FIG. 11A , (2) a single-deck charging cart 1170 as shown in FIG. 11B , and (3) a mini charging cart 1180 as shown in FIG. 11C . FIG. 11A illustrates how the double-deck charging cart 1160 can hold multiple charging slots in the range of 150-200 slots. FIG. 11B illustrates how the single-deck charging cart 1170 can hold multiple charging slots in the range of 50-100 slots. FIG. 11C illustrates how the mini charging cart 1180 can hold multiple charging slots in the range of 20-30 slots. For example, the double-deck charging cart 1160 can hold 174 charging slots. As another example, the single-deck charging cart 1170 can hold 87 charging slots. As another example, the mini charging cart 1180 can hold 25 charging slots.

[0071] In some embodiments, the charging cart system 1100 includes a mobile aluminum frame 1102, a charging cart 1150, multiple LED indicators 1104, and multiple charging slots 1106. In particular, FIGS. 11D-11F show a charging cart 1160, which includes a bottom front 1108, a bottom center 1110, a bottom rear 1112, a left side 1114, a right side 1116, a back sheet 1118, a front sheet 1120, and multiple pipes 1122. These components can be assembled using polyvinyl chloride (PVC) sheeting and PVC pipes to support the charging cart. The PVC sheeting can be 0.5-inch thick Type 1 PVC sheeting. The PVC pipes can be 2-inch diameter Schedule 40 PVC pipes.

[0072] FIG. 11E shows an aluminum frame 1102. A charging cart 1150 is coupled to the aluminum frame 1102 using fasteners (e.g., bolts). The LED indicators 1104 in FIG. 11A are operable to identify the status of the wireless test modules during testing of the WHAMS. The charging slots 1106 in FIG. 11A are operable to charge the wireless test modules. Each of the charging slots is associated with a respective LED indicator 1104. In some embodiments, the charging cart can charge more than 100 wireless test modules in parallel using a power supply operable to provide 1500 watts (W) of power. As another example, the charging cart can use a find-by-light feature to locate the wireless test modules and illuminate one or more wireless test modules used for testing. As a result, the charging cart can include a support structure assembled from PVC sheets and PVC pipes. The support structure can include one or more decks, such as sheet assemblies 1124 of FIG. 11F, welded onto the charging cart to allocate multiple charging slots. The multiple charging slots are keyed slots that receive multiple wireless inspection modules and ensure proper placement of the multiple wireless inspection modules. FIG. 11F shows how each sheet assembly 1124 can include a back sheet 1118, a front sheet 1120, and multiple PVC pipes 1122.

[0073] Figures 12-14D show details of the charging cart system 1100 of FIGS. 11A-11F according to some embodiments. FIG. 12 shows how the charging cart can be configured to charge the wireless inspection module 120 attached to the charging slot 1106 using the injection molded pogo pin block 1204. Specifically, the injection molded pogo pin block 1204 can include a 4-pin layout 1300 as shown in FIG. 13 for charging the wireless inspection module 120 and a visual indication using the LED ring 1206, and the visual indication can include a plurality of red LEDs and a plurality of green LEDs alternating along the LED ring 1206. The LED ring 1206 can include a ring cover 1202 (e.g., a transparent polycarbonate LED ring cover).

[0074] FIG. 13 shows the 4-pin layout 1300 for the injection molded pogo pin block 1204 of FIG. 12. The 4-pin layout 1300 includes a power pin 1302, a ground pin 1304, and a plurality of LED pins 1306. The power pin 1302 can be a 5V pin. The plurality of LED pins 1306 can include red LED pins and green LED pins. As a result, the charging cart is configured to charge the wireless inspection module using the injection molded pogo pin block and provide a visual indication to assist in locating the wireless inspection module.

[0075] FIGS. 14A and 14B show a layout 1400 of multiple charging slots 1106 on the deck of the charging cart system 1100 of FIGS. 11A-C. Each of the multiple charging slots 1106 is associated with a respective injection-molded pogo pin block 1204 and a respective LED ring 1206. FIG. 14C shows a 1500 W single output power supply operable to power multiple wireless test modules within the charging cart. FIG. 14D shows multiple LED indicators 1104 that can help identify the status of each wireless test module and identify the location of the module at any given time. Specifically, each of the multiple LED indicators illuminates red to indicate that the particular wireless test module associated with the respective LED indicator is currently charging. Each of the multiple LED indicators illuminates green to indicate and identify the particular wireless test module associated with the respective LED indicator prior to testing. Each of the multiple LED indicators turns off to indicate that the particular wireless test module associated with the respective LED indicator has finished charging. For example, a red LED 1402 indicates that the particular wireless test module associated with the red LED 1402 is currently charging. As another example, a green LED 1404 indicates and locates the particular wireless test module associated with the green LED 1404 prior to testing. As another example, an unlit LED 1406 indicates that the particular wireless test module associated with the unlit LED 1406 has finished charging.

[0076] Calibration of WHAMS

[0077] Certain embodiments relate to a calibration method for calibrating the wireless test module 120 of FIG. 1 . Calibrating the wireless test module of a WHAMS is important to accurately read resistance measurements when performing one or more electrical tests on an electrical wiring harness (e.g., a continuity check, a voltage insulation check, a TDR test, a fiber optic test, a diode polarity check, a resistance measurement check, etc.). Prior to a WHAMS test, the wireless test module undergoes a controlled, periodic calibration process to ensure it can accurately read resistance. In particular, the wireless test module may include multiple field-effect transistors (FETs). The multiple FETs may be optically isolated moffets. If the wireless test module is not properly calibrated, the internal resistance measurements for the multiple FETs of the wireless test module may drift over time.

[0078] FIG. 15 illustrates a calibration fixture 1500 for a wireless test module, according to some embodiments. The calibration fixture 1500 includes a switch board 1502, a connector 1504, and a ground cable 1506. In a particular embodiment, the switch board 1502 includes a plurality of switches 1508. The connector 1504 is used to attach the calibration fixture 1500 to the wireless test module. The ground cable 1506 is used to connect the calibration fixture 1500 directly to earth ground. A calibration method can use the calibration fixture 1500 to apply a controlled periodic calibration process in an automated manner to record the internal resistance of each of a plurality of FETs. The controlled periodic calibration process can include one or more of the following five operations: (1) performing an internal measurement test; (2) performing a resistance accuracy test (RAT); (3) saving calibration coefficients; (4) saving RAT history; and (5) recalling updated calibration coefficients during testing. Calibration instrument 1500 is configured to short out the wireless test module in the internal measurement test and the RAT to provide measurements for the internal resistance of the wireless test module in the internal measurement test and for the resistors in the RAT. As a result, the resistors can be periodically measured and recorded with a calibrated ohmmeter such as calibration instrument 1500. The calibration method can determine whether there is a resistor shift by comparing the measurements of the resistors in the RAT to the original calibration standard.

[0079] 16A and 16B illustrate an internal measurement test 1600 using the calibration fixture 1500 of FIG. 15 , according to some embodiments. The wireless test module 120 includes a relay using multiple FETs, such as a high-side FET 1602 and a low-side FET 1604. The high-side FET 1602 has a high-side resistance. The low-side FET 1604 has a low-side resistance. Similarly, the calibration fixture 1500 includes a first switch 1606 and a second switch 1608. The calibration method can use the first switch 1606 and / or the second switch 1608 to measure different “on” resistance components for the relays of the wireless test module 120.

[0080] 16A shows that first switch 1606 is turned on and second switch 1608 is turned off. The calibration method measures a first resistance value of a plurality of FETs from a first internal measurement test for wireless test module 120 when performing calibration of wireless test module 120 using calibration instrument 1500. The first resistance value measures the resistance for a first path along high-side FET 1602 of wireless test module 120 and calibration instrument 1500. Thus, the first resistance value is related to the resistance of high-side FET 1602, contact resistance, and trace / wiring resistance on the calibration board. For example, the first resistance value can be in the range of 80 Ω to 90 Ω.

[0081] 16B shows that first switch 1606 is turned off and second switch 1608 is turned on. The calibration method measures second resistance values ​​of the plurality of FETs from a second internal measurement test for wireless test module 120 when performing calibration of wireless test module 120 using calibration instrument 1500. The second resistance value estimates the resistance for a second path along high-side FET 1602 and / or low-side FET 1604 of wireless test module 120 and calibration instrument 1500. Thus, the second resistance value is related to the resistance of high-side FET 1602, the resistance of low-side FET 1604, contact resistance, and trace / wiring resistance on the calibration substrate. For example, the first resistance value can be in the range of 120 Ω to 140 Ω. As a result, the first resistance value of the FETs estimates the high-side resistance associated with high-side FET 1602. The second resistance value of the FET evaluates to the sum of both the high-side resistance associated with the high-side FET 1602 and the low-side resistance associated with the low-side FET 1604 .

[0082] In some embodiments, the calibration method determines a resistance calibration value by subtracting a first resistance value of the plurality of FETs from a second resistance value of the plurality of FETs. The resistance calibration value is a low-side calibration value. For example, the resistance calibration value may be in a range of 40 Ω to 50 Ω. The calibration method may compare the resistance calibration value to a predetermined value. For example, if the predetermined value of the low-side FET 1604 is 45 Ω, the calibration method may determine that the resistance calibration value matches this predetermined value. As a result, the calibration method is configured to perform a RAT using the plurality of resistors of the calibration instrument 1500. As another example, if the predetermined value of the low-side FET 1604 is 60 Ω, the calibration method may determine that the resistance calibration value does not match the predetermined value. The calibration method may determine a failed result of a controlled periodic calibration process for the wireless test module 120.

[0083] FIG. 17 illustrates a resistance accuracy test 1700 using the calibration instrument 1500 of FIG. 15 , according to some embodiments. The resistance accuracy test 1700 is configured to verify multiple resistors in the calibration instrument 1500. For example, the multiple resistors can have resistance values ​​ranging from 1 Ω to 50 MΩ. Specifically, the calibration instrument 1500 can use multiple pins to adjust the resistance of the calibration instrument 1500. All pins perform the RAT at a value of 1 Ω, and one pin performs the RAT at a higher value. The calibration method selects a resistor 1702 from the multiple resistors in the calibration instrument 1500 and selects a test, such as a continuity test, associated with the wireless test module 120. The selected resistor 1702 is associated with a target resistance value, such as 2 Ω. The calibration method measures multiple calibration factors using the calibration instrument 1500 and the test. For example, the multiple calibration factors for the continuity test include a source-side high-side calibration index, a sink-side high-side calibration coefficient, and an initial resistance value.

[0084] In some embodiments, the calibration method uses multiple calibration coefficients to determine the measured resistance value. For example, the measured resistance value for a continuity test is determined by subtracting a source-side high-side calibration index and a sink-side high-side calibration coefficient from the initial resistance value. As a result, the calibration means compares the measured resistance value to a target resistance value. If the measured resistance value matches the target resistance value, the calibration method determines a pass. If the measured resistance value does not match the target resistance value, the calibration means determines a fail. As a result, the calibration method can store the measured resistance value and the target resistance value in a database on a central computer server. Similarly, the calibration method can store multiple calibration coefficients and a RAT history associated with the RAT in a database on a central computer server. Thus, the calibration method can perform multiple RATs on the wireless test module 120 using multiple resistors in the calibration instrument 1500 to detect potential failure modes using FET resistance drift over time.

[0085] WHAMS Operating Software

[0086] Some embodiments relate to a control method for managing multiple wireless test modules of a WHAMS for multiple electrical wiring harnesses. The multiple wireless test modules of the WHAMS can communicate wirelessly with a central computer system. Specifically, the control method is applied during testing of the WHAMS using multiple operational components: (1) a wireless test module board support component, (2) a custom power controller component, and (3) a test generation, execution, and module management component. The wireless test module board support component is configured to apply a core operational application to the multiple wireless test modules using a wireless test module board support package. Specifically, the core operational application can implement a bidirectional test technique to perform one or more electrical tests (e.g., continuity check, voltage insulation check, TDR test, fiber optic test, diode polarity check, resistance measurement check, etc.) on the multiple electrical wiring harnesses in accordance with multiple test commands received from the central computer system.

[0087] In some embodiments, the custom power controller component is configured to implement a custom power controller suite to manage multiple batteries for multiple wireless test modules. In some embodiments, the test generation, execution, and module management component is configured to implement one or more algorithms to generate a test plan and / or a graphic user interface (GUI) for executing various system functions. In particular, the test plan may include a map of multiple electrical wiring harnesses, multiple harness connections associated with each of multiple wireless test modules, a hookup file, and one or more electrical tests associated with the multiple electrical wiring harnesses. For example, the hookup file defines multiple wireless test modules assigned to the multiple harness connections. As another example, the test plan may be generated with additional harness information related to splices, passive devices, and resignations of lost leads. In particular, the test plan may be generated to check the wires and unused pins in a network configuration for each of the multiple electrical wiring harnesses. Thus, the test generation, execution, and module management component may interpret a wire list of the multiple electrical wiring harnesses and generate a test plan based on test criteria received from a user. In particular, the test generation, execution, and module management component is configured to determine a grounding mechanism for testing each electrical wiring harness and to analyze each electrical wiring harness using the input data.

[0088] In some embodiments, the control method uses a central computer system to access a plurality of electrical wiring harnesses, test criteria, and WHAMS. The control method generates a test plan for the plurality of electrical wiring harnesses based on the test criteria and selects a plurality of wireless test modules using the test plan and WHAMS. The control method generates a plurality of test instructions based on the test plan and the plurality of wireless test modules. The control method performs one or more tests on the plurality of electrical wiring harnesses according to the plurality of test instructions using the plurality of wireless test modules. The control method wirelessly transmits test results using the plurality of wireless test modules to the central computer system 130 for display. Furthermore, the control method can be used to wirelessly communicate with the plurality of wireless test modules and update one or more smart test adapters and / or software packages associated with each of the plurality of wireless test modules with part number and pin configuration data of the one or more smart test adapters.

[0089] 18A and 18B includes a first user interface for test plan generation 1806. The first user interface 1806 can be implemented to define multiple harness features, monitor the creation of the test plan, and send warnings of potential errors in the conversion.

[0090] In some embodiments, the application interface 1800 includes a second user interface 1808 for executing a test plan. The second user interface 1808 can be implemented to allow a user to visually inspect the status of an electronic wiring harness through a color-coded report. For example, passed tests are highlighted in green, and failed tests are highlighted in a different color, such as red, orange, or yellow, based on the failure status. In particular, a user can interact with the second user interface 1808 to manage one or more tests for multiple electrical wiring harnesses based on various criteria, such as relevant source and destination reference designators, test status, and test type. As a result, the second user interface 1808 provides a flexible solution for executing test plans based on various test conditions. After test plan execution, the second user interface 1808 generates a final consumable report that can be digitally saved and post-processed to extract data for further use in troubleshooting or data analysis.

[0091] In some embodiments, the application interface 1800 includes a third user interface 1810 for calibrating the wireless test modules. The third user interface 1810 can be implemented to allow a user to control the calibration hardware of the WHAMS to automatically calibrate the wireless test modules of the WHAMS. Thus, the third user interface 1810 can be applied to verify the internal relays of the wireless test modules and their correction values.

[0092] In some embodiments, the application interface 1800 includes a fourth user interface 1812 for built-in-test (BIT) calibration. The fourth user interface 1812 can be implemented for calibrating test types and module capabilities. For example, the fourth interface 1812 can be implemented to check the health of multiple wireless test modules of a WHAMS. As another example, the fourth interface 1812 can be implemented to allow a user to define parameters to improve module efficiency and establish appropriate voltages for the wireless test modules to perform one or more tests, such as high and low voltage continuity, voltage insulation checks, data bus polarity and diode polarity checks, and resistance measurement checks.

[0093] In some embodiments, application interface 1800 includes a fifth user interface 1814 for maintaining and updating module software. Fifth user interface 1814 can be implemented to allow a user to wirelessly update one or more software packages for multiple wireless inspection modules. Fifth user interface 1814 can be utilized to facilitate easy migration of new functionality to the floor with minimal touch interaction.

[0094] In some embodiments, application interface 1800 includes a sixth user interface 1816 for test debugging and general module troubleshooting. Sixth user interface 1816 can be implemented to build one-shot tests for either electronic radio harness troubleshooting or module functionality troubleshooting. The one-shot tests can be created based on selected electronic wiring harness data by modifying multiple parameters of the one-shot test for better performance.

[0095] In some embodiments, the application interface 1800 includes a seventh user interface 1816 for test debugging and general module troubleshooting. The seventh user interface 1816 can be implemented to build a one-shot test for either electronic radio harness troubleshooting or module functionality troubleshooting. The one-shot test can be created based on selected electronic wiring harness data by modifying multiple parameters of the one-shot test for better performance.

[0096] In some embodiments, application interface 1800 includes an eighth user interface 1818 for programming smart inspection adapters, such as hot-swap front ends, with their respective part number and pin configuration data. Once programmed, eighth user interface 1818 can be implemented to identify the front ends connected to each wireless inspection module and relay that information back to application interface 1800. As a result, eighth user interface 1818 can be implemented to dynamically build a module network to monitor harness inspections based on the connectors attached to each wireless inspection module.

[0097] 18A and 18B illustrate an example application interface 1800 for operating software for inspecting a plurality of electrical wiring harnesses with the wireless harness automated metering system of FIG. 1 , according to certain embodiments. The wireless harness automated metering system includes a plurality of wireless inspection modules. Each of the plurality of wireless inspection modules is connected to a respective electronic wiring harness for inspection. FIG. 18A illustrates a first inspection plan for a calibration check based on a first table 1824 for a first of the plurality of wireless inspection modules 1802. Specifically, the first inspection plan is generated to evaluate the status 1804 of the inspection results through a color-coded report. For example, passed inspections are highlighted in green, and failed inspections are highlighted in red, orange, or yellow based on the failure status.

[0098] FIG. 18B illustrates a second test plan for high-voltage insulation in a second table 1826 for a second plurality of wireless test modules 1822. The control method can automatically build a map of the plurality of electrical wiring harnesses for testing. The control method can determine one or more connections available to each of the second plurality of wireless test modules 1822. As a result, the control method can systematically build multiple tests for each of the second plurality of wireless test modules 1822 to verify the insulation or continuity of those connections. For example, the control method can generate multiple continuity tests for each of the plurality of electrical wiring harnesses. The control method can verify that source and destination reference designators are assigned to the wireless test modules. As another example, the control method can generate an insulation check for each of the plurality of electrical wiring harnesses. Similarly, a second test plan can be applied to check all presumably unused pins on the electrical connectors of the plurality of electrical wiring harnesses to ensure there are no shorts or miswired harnesses.

[0099] In some embodiments, the application interface 1800 can be used to invoke additional modules to increase the number of possible paths for creating ground circuits for testing. Specifically, the control method can be used to perform one or more electrical tests on multiple electrical wiring harnesses, such as high- and low-voltage continuity, voltage insulation checks, data bus and diode polarity checks, and resistance measurement checks. Accordingly, the control method can use the application interface 1800 to allow a user to monitor the health and functionality of multiple wireless test modules in the WHAMS. Specifically, the control method can determine test conditions for the WHAMS based on the health and functionality of the multiple wireless test modules. Similarly, the control method can select multiple actions to schedule tests of multiple electronic wiring harnesses, such as module identification, power-off, and harness connection. The control method can take into account global network changes, such as available wireless channels and the deployment of different harnesses for different tests.

[0100] 19 shows a flow diagram illustrating an example method 1900 for testing wireless inspection modules, according to certain embodiments. Method 1900 may begin at step 1910, where a plurality of electrical wiring harnesses, inspection criteria, and a Wireless Harness Automated Measurement System (WHAMS) are accessed using a computer server. In some embodiments, the WHAMS includes a plurality of wireless inspection modules. In some embodiments, each of the plurality of electrical wiring harnesses is connected to a respective wireless inspection module of the WHAMS.

[0101] In step 1920, a test plan is generated for the plurality of electrical wiring harnesses. For example, the test plan may include one or more electrical tests (e.g., continuity checks, voltage insulation checks, TDR tests, fiber optic tests, diode polarity checks, resistance measurement checks, etc.) for the plurality of electrical wiring harnesses. As another example, the test plan may include a map of the plurality of electrical wiring harnesses, a plurality of harness connections associated with each of a plurality of wireless test modules.

[0102] In step 1930, a plurality of wireless test modules (WTMs) are determined using the test plan and WHAMS. For example, the plurality of wireless test modules are selected based on various test conditions. As another example, the plurality of wireless test modules are appropriately calibrated using a calibration tool.

[0103] At step 1940, a plurality of test orders are generated based on the test plan and the plurality of wireless test modules. In some embodiments, each of the plurality of wireless test modules is operable to wirelessly receive one or more of the plurality of test orders from the computer system. The plurality of test orders may be one or more signals, actions, commands, etc.

[0104] In step 1950, one or more tests are performed on the plurality of electrical wiring harnesses using the plurality of test modules according to the plurality of test commands. Upon receiving the plurality of test commands, the plurality of wireless test modules are configured to automatically perform one or more electrical tests (e.g., continuity check, voltage insulation check, TDR test, fiber optic test, diode polarity check, resistance measurement check, etc.) on the plurality of electrical wiring harnesses.

[0105] At step 1960, the test results are transmitted to the computer system by wirelessly communicating with the computer system using the plurality of WTMs. In some embodiments, the test results are collected by the computer system for one or more electrical tests and displayed on a user interface for a user to visually inspect the status of the plurality of electronic wiring harnesses through a color-coded report. For example, a passing test is highlighted in green, and a failing test is highlighted in a different color, such as red, orange, or yellow, based on the failing status. After step 1960, method 1900 may end.

[0106] FIG. 20 illustrates an exemplary computer system 2000. In particular embodiments, one or more computer systems 2000 perform one or more steps of one or more methods described or illustrated herein. In particular embodiments, one or more computer systems 2000 provide functionality described or illustrated herein. In particular embodiments, software executing on one or more computer systems 2000 performs one or more steps of one or more methods described or illustrated herein or provides functionality described or illustrated herein. Particular embodiments include one or more portions of one or more computer systems 2000. As used herein, references to a computer system encompass computing devices, and vice versa, where appropriate. Furthermore, references to a computer system may encompass one or more computer systems, where appropriate.

[0107] The present disclosure contemplates any suitable number of computer systems 2000. The present disclosure contemplates the computer system 2000 taking any suitable physical form. By way of example, and not limitation, the computer system 2000 may be an embedded computer system, a system-on-chip (SOC), a single-board computer system (SBC) (e.g., a computer-on-module (COM) or system-on-module (SOM)), a desktop computer system, a laptop or notebook computer system, a kiosk, a mainframe, a mesh computer system, a mobile phone, a personal digital assistant (PDA), a server, a tablet computer system, an augmented / virtual reality device, or a combination of two or more of these. Where appropriate, the computer system 2000 may include one or more computer systems that are single or distributed, may span multiple locations or multiple machines, or may reside in a cloud that may include one or more cloud components in one or more networks. Where appropriate, one or more computer systems 2000 may perform one or more steps of one or more methods described or illustrated herein without substantial spatial or temporal limitations. By way of example, and not limitation, one or more computer systems 2000 may perform one or more steps of one or more methods described or illustrated herein in real time or in batch mode. Where appropriate, one or more computer systems 2000 may perform one or more steps of one or more methods described or illustrated herein at different times or in different locations.

[0108] In a particular embodiment, computer system 2000 includes a processor 2002, memory 2004, storage 2006, an input / output (I / O) interface 2008, a communication interface 2010, and a bus 2012. Although this disclosure describes and illustrates a particular computer system having a particular number of particular components in a particular arrangement, any suitable computer system having any suitable number of any suitable components in any suitable arrangement is contemplated.

[0109] In particular embodiments, processor 2002 includes hardware for executing instructions, such as those making up a computer program. By way of example, and not limitation, to execute instructions, processor 2002 may retrieve (or fetch) instructions from an internal register, an internal cache, memory 2004, or storage 2006, decode and execute them, and then write one or more results to an internal register, an internal cache, memory 2004, or storage 2006. In particular embodiments, processor 2002 may include one or more internal caches for data, instructions, or addresses. This disclosure contemplates that processor 2002 includes any suitable number of any suitable internal caches, where appropriate. By way of example, and not limitation, processor 2002 may include one or more instruction caches, one or more data caches, and one or more translation lookaside buffers (TLBs). Instructions in the instruction cache may be copies of instructions in memory 2004 or storage 2006, and the instruction cache may speed up retrieval of these instructions by processor 2002. Data in the data cache may be copies of data in memory 2004 or storage 2006 for instructions executing in processor 2002 to operate on, either for access by subsequent instructions executing in processor 2002 or for writes to memory 2004 or storage 2006, or for results of previous instructions executed by processor 2002 or other suitable data. The data cache may speed up read or write operations by processor 2002. The TLB may speed up virtual address translation for processor 2002. In particular embodiments, processor 2002 may include one or more internal registers for data, instructions, or addresses. This disclosure contemplates processor 2002 including any suitable number of any suitable internal registers, where appropriate.Where appropriate, processor 2002 may include one or more arithmetic logic units (ALUs), or may be a multi-core processor, or may include one or more processors 2002. While this disclosure describes and illustrates a particular processor, any suitable processor is contemplated.

[0110] In particular embodiments, memory 2004 includes a main memory for storing instructions to be executed by processor 2002 or data on which processor 2002 operates. By way of example, and not limitation, computer system 2000 may load instructions into memory 2004 from storage 2006 or another source (e.g., another computer system 2000). Processor 2002 may then load the instructions from memory 2004 into an internal register or cache. To execute the instructions, processor 2002 may retrieve the instructions from the internal register or cache and decode them. During or after execution of the instructions, processor 2002 may write one or more results (which may be intermediate or final results) to the internal register or cache. Processor 2002 may then write one or more of those results to memory 2004. In particular embodiments, processor 2002 executes only instructions in one or more internal registers, internal caches, or memory 2004 (rather than storage 2006 or some other location) and operates only on data in one or more internal registers, internal caches, or memory 2004 (rather than storage 2006 or some other location). One or more memory buses (each of which may include an address bus and a data bus) may connect processor 2002 to memory 2004. Bus 2012 may include one or more memory buses, as described below. In particular embodiments, one or more memory management units (MMUs) reside between processor 2002 and memory 2004 to facilitate accesses to memory 2004 requested by processor 2002. In particular embodiments, memory 2004 includes random access memory (RAM). This RAM may be volatile memory, where appropriate. This RAM may be dynamic RAM (DRAM) or static RAM (SRAM), where appropriate. Moreover, where appropriate, this RAM may be single-ported or multi-ported RAM, and this disclosure contemplates any suitable RAM.Memory 2004 may, where appropriate, comprise one or more memories 2004. Although this disclosure describes and illustrates particular memory, any suitable memory is contemplated.

[0111] In particular embodiments, storage 2006 includes mass storage for data or instructions. By way of example, and not limitation, storage 2006 may include a hard disk drive (HDD), a floppy disk drive, flash memory, an optical disk, a magneto-optical disk, magnetic tape, or a universal serial bus (USB) drive, or a combination of two or more of these. Storage 2006 may include removable or non-removable (or fixed) media, where appropriate. Storage 2006 may be internal or external to computer system 2000, where appropriate. In particular embodiments, storage 2006 is non-volatile semiconductor memory. In particular embodiments, storage 2006 includes read-only memory (ROM). Where appropriate, this ROM may be mask-programmed ROM, programmable ROM (PROM), erasable PROM (EPROM), electrically erasable PROM (EEPROM), erasable and programmable ROM (EAROM), or flash memory, or a combination of two or more of these. This disclosure contemplates mass storage 2006 taking any suitable physical form. Storage 2006 may include, where appropriate, one or more storage control units that facilitate communication between processor 2002 and storage 2006. Where appropriate, storage 2006 may include one or more storages 2006. While this disclosure describes and illustrates particular storage, any suitable storage is contemplated.

[0112] In particular embodiments, I / O interface 2008 includes hardware, software, or both that provide one or more interfaces for communication between computer system 2000 and one or more I / O devices. Computer system 2000 may include one or more of these I / O devices, where appropriate. One or more of these I / O devices may enable communication between a person and computer system 2000. By way of example, and without limitation, an I / O device may include a keyboard, keypad, microphone, monitor, mouse, printer, scanner, speaker, still camera, stylus, tablet, touch screen, trackball, video camera, another suitable I / O device, or a combination of two or more of these. An I / O device may include one or more sensors. This disclosure contemplates any suitable I / O devices and any suitable I / O interface 2008 therefor. Where appropriate, I / O interface 2008 may include one or more device or software drivers that enable processor 2002 to drive one or more of these I / O devices. I / O interface 2008 may, where appropriate, include one or more I / O interfaces 2008. While this disclosure describes and illustrates particular I / O interfaces, any suitable I / O interface is contemplated.

[0113] In particular embodiments, communication interface 2010 includes hardware, software, or both that provide one or more interfaces for communicating (e.g., wirelessly) between computer system 2000 and one or more other devices or systems. By way of example, and not limitation, communication interface 2010 may include a network interface controller (NIC) or network adapter for communicating with an Ethernet or other wire-based network, or a wireless NIC (WNIC) or wireless adapter for communicating with a wireless network, such as a Wi-Fi network. This disclosure contemplates any suitable network and any suitable communication interface 2010 therefor. By way of example, and not limitation, computer system 2000 may communicate with one or more portions of an ad-hoc network, a personal area network (PAN), a local area network (LAN), a wide area network (WAN), a metropolitan area network (MAN), or the Internet, or a combination of two or more of these. One or more portions of one or more of these networks may be wired or wireless. As an example, computer system 2000 may communicate with a wireless PAN (WPAN) (e.g., a BLUETOOTH WPAN, etc.), a Wi-Fi network, a Wi-MAX network, a cellular telephone network (e.g., a Global System for Mobile Communications (GSM) network, a Long Term Evolution (LTE) network, or a 5G network, etc.), or other suitable wireless network, or a combination of two or more thereof. Computer system 2000 may include any suitable communication interface 2010 for any of these networks, where appropriate. Communication interface 2010 may include one or more communication interfaces 2010, where appropriate. This disclosure describes and illustrates a particular communication interface, but any suitable communication interface is contemplated.

[0114] In particular embodiments, bus 2012 includes hardware, software, or both that connects components of computer system 2000 to one another. By way of example, and not limitation, bus 2012 may include an Accelerated Graphics Port (AGP) or other graphics bus, an Enhanced Industry Standard Architecture (EISA) bus, a Front Side Bus (FSB), a HyperTransport (HT) interconnect, an Industry Standard Architecture (ISA) bus, an InfiniBand interconnect, a Low Pin Count (LPC) bus, a memory bus, a MicroChannel Architecture (MCA) bus, a Peripheral Component Interconnect (PCI) bus, a PCI Express (PCIe) bus, a Serial Advanced Technology Attachment (SATA) bus, a Video Electronics Standards Association Local (VLB) bus, or another suitable bus, or a combination of two or more of these. Bus 2012 may include one or more buses 2012, where appropriate. While this disclosure describes and illustrates a particular bus, any suitable bus or interconnect is contemplated.

[0115] As used herein, computer-readable non-transitory storage medium(s) may comprise, where appropriate, one or more semiconductor-based or other integrated circuits (ICs) (e.g., field programmable gate arrays (FPGAs) or application-specific ICs (ASICs)), hard disk drives (HDDs), hybrid hard drives (HHDs), optical disks, optical disk drives (ODDs), magneto-optical disks, magneto-optical drives, floppy diskettes, floppy disk drives (FDDs), magnetic tapes, solid-state drives (SSDs), RAM drives, secure digital cards or drives, any other suitable computer-readable non-transitory storage media, or any suitable combination of two or more of these. Computer-readable non-transitory storage media may, where appropriate, be volatile, non-volatile, or a combination of volatile and non-volatile.

[0116] As used herein, "or" is inclusive and not exclusive, unless expressly indicated otherwise or indicated otherwise by context. Thus, unless expressly indicated otherwise herein or indicated otherwise by context, "A or B" means "A, B, or both." Furthermore, "and" is jointly and severally, unless expressly indicated otherwise or indicated otherwise by context. Thus, as used herein, "A and B" means "A and B, jointly or severally," unless expressly indicated otherwise or indicated otherwise by context.

[0117] The scope of the present disclosure encompasses all changes, substitutions, variations, alterations, and modifications to the exemplary embodiments described or illustrated herein that would be apparent to one skilled in the art. The scope of the present disclosure is not limited to the exemplary embodiments described or illustrated herein. Furthermore, although the present disclosure describes and illustrates each embodiment herein as including particular components, elements, features, functions, operations, or steps, any of these embodiments may include any combination or permutation of any of the components, elements, features, functions, operations, or steps described or illustrated anywhere herein that would be apparent to one skilled in the art. Furthermore, references within the scope of a claim to a device or system, or a component of a device or system, being adapted to, arranged to, having, configured to, enabled to, operative to, or being operative in a particular function encompass such device, system, or component, or such particular function, so long as such device, system, or component is so adapted, arranged, having, configured to, enabled, operative, or operative, regardless of whether such device, system, or component is activated, turned on, or unlocked. Furthermore, although this disclosure may describe or illustrate particular embodiments as providing certain advantages, the particular embodiment may provide none, some, or all of these advantages.

[0118] The embodiments disclosed herein are merely examples, and the scope of the present disclosure is not limited thereto. Particular embodiments may include all, some, or none of the components, elements, features, functions, operations, or steps of the embodiments disclosed herein. Particular embodiments are disclosed in claims, particularly those directed to methods, storage media, systems, and computer program products. In such cases, any feature recited in one claim category, e.g., a method, may also be claimed in another claim category, e.g., a system. Dependency or retroactivity within the claims is merely a matter of formality. However, just as any combination of multiple claims and their features may be disclosed and claimed regardless of selective dependency within the claims, any subject matter resulting from intentional retroactivity (e.g., multiple dependency) to any preceding claims may also be claimed. Subject matter that may be claimed includes not only the combination of features provided within the claims, but also any other combination of features within the claims, and each feature described in a claim may be combined with any other feature or combination of features within the claims. Furthermore, any of the embodiments and features described or illustrated herein may be claimed in an individual claim and / or in any combination with any of the embodiments or features described or illustrated herein or among the features within the scope of the claims. [Explanation of symbols]

[0119] 100 Wireless Harness Automatic Measuring System 110 Electrical wiring harness 111 Electric wire 115A-D Wiring Harness Connector 120A-D Wireless Inspection Module 121A-D Radio Transceiver 122A-D chassis 126A-D Variable Front End 130 Central Computer System 140 Wireless Interface 150 Inspection Order 160 Test Results

Claims

1. A radio transceiver; An electrical wiring harness; a wireless test module (WTM) capable of being physically coupled to the electrical wiring harness, the WTM comprising a chassis and a variable front end connected to the chassis using a hot swap connector; A system comprising: The WTM is wirelessly receiving a plurality of test commands from a computer system according to an automated test plan using the wireless transceiver; performing one or more tests on the electrical wiring harness in accordance with the plurality of test commands using the variable front end; wirelessly transmitting test results to the computer system using the wireless transceiver; It is operable as follows: system.

2. The system of claim 1 , wherein the WTM has a shape selected from a plurality of shapes consisting of a prism shape, a pyramid shape, a cylinder shape, and a sphere shape.

3. the variable front end includes an electrical connector capable of being coupled to a wiring harness connector of the electrical wiring harness; the variable front end being a removable portion of the WTM; The system of claim 1 , wherein the variable front end includes a hot swap interface for rapid exchange with different connectors.

4. The system of claim 3 , wherein the electrical connector supports up to a 128-pin connector.

5. The system of claim 3 , wherein the electrical connector supports up to a 48-pin connector.

6. The chassis includes: A number of electrical relays designed for high voltage solid state multiplexing; A rechargeable battery and The system of claim 1 .

7. The one or more tests include: Continuity check, Voltage insulation check, Time Domain Reflectometry (TDR) inspection, Optical fiber inspection, Diode polarity check, and Resistance measurement check, The system of claim 1 , wherein the test is selected from a plurality of tests including:

8. The system of claim 1 , wherein the WTM is operable to communicate wirelessly with the computer system using WI-FI, Bluetooth, or Zigbee.

9. The system of claim 1 , wherein the chassis includes a central processing and memory block and circuitry operable to determine measurements for manufacturing and debugging of the electrical wiring harness.

10. The system of claim 1 , wherein the WTM is operable to apply pick-by-write functionality to the initial hardware selection and harness connection process.

11. the WTM is operable to apply an internal power source to one or more wires of the electrical wiring harness to perform testing of the electrical wiring harness; the internal power supply is a high voltage source; The internal power supply is a low voltage power supply. The system of claim 1 .

12. The system of claim 1 , wherein the WTM is capable of replacing an inoperable chassis with another available unit in the event of a failure.

13. The system of claim 1 , wherein the WTM is operable to generate a low voltage output of approximately 2.4 volts (V) for resistance / continuity testing.

14. The system of claim 1 , wherein the WTM is operable to measure resistance with an accuracy of 10%±1Ω for resistances in the range of 1Ω-50Ω.

15. The system of claim 1 , wherein the WTM is operable to measure resistance with an accuracy of 5%±1Ω for resistances in the range of 51Ω-250Ω.

16. The system of claim 1 , wherein the WTM is operable to measure resistance with an accuracy of 10% ±1Ω for resistances in the range of 251Ω-1MΩ.

17. The system of claim 1 , wherein the WTM is operable to generate a voltage output in the range of 100V to 500V for high voltage testing.

18. 20. The system of claim 17, wherein the WTM is operable to measure resistance with an accuracy in the range of 6% to 10% using high voltage.

19. The system of claim 1 , wherein the WTM is operable to identify the variable front end.

20. 1. A computer-implemented method, comprising: receiving, wirelessly with a wireless transceiver, a plurality of test commands from a computer system according to an automated test plan; performing, using a wireless test module (WTM) to perform one or more tests on the electrical wiring harness according to the plurality of test commands; wirelessly transmitting test results to the computer system using the wireless transceiver; 4. A computer-implemented method comprising:

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