System and method for operating wireless harness automated measurement system

Abstract

To provide a system and method for operating a wireless harness automated measurement system.SOLUTION: A computer-implemented method accesses, using a computer server, a plurality of electrical wiring harnesses, testing criteria, and a wireless harness automated measurement system (WHAMS). The computer-implemented method generates a test plan for the plurality of electrical wiring harnesses based on the testing criteria. The computer-implemented method selects a plurality of wireless test modules (WTMs) using the test plan and the WHAMS. The computer-implemented method generates a plurality of test instructions based on the test plan and a plurality of WTMs. The computer-implemented method performs, using the plurality of WTMs, one or more tests on the plurality of electrical wiring harnesses according to the plurality of test instructions. The computer-implemented method wirelessly communicates, using the plurality of WTMs, test results to the computer server for display.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] FIELD OF THE DISCLOSURE This disclosure relates generally to Wireless Harness Automatic Measurement System (WHAMS) operating software implementations and, more particularly, to WHAMS automated implementation systems and methods. [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 must be rigorously and thoroughly inspected 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, a system includes a computer system and a plurality of wireless inspection modules. Each wireless inspection module includes a wireless transceiver and is capable of being physically coupled to the electrical wiring harness. The computer system is operable to transmit 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 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 can be physically coupled to the electrical wiring harness. The wireless inspection module includes a wireless transceiver. The computer system is operable to transmit 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 perform one or more inspections 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 a 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 capable of mating 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 capable of mating 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, an alignment peg 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 an Electrically Erasable Programmable Read Only Memory (EEPROM) read / write line integrated on a circuit board operable to read / write data 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 test 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 hot swap connector is further operable to attach the adjustable front end of the wireless test module to a chassis of the wireless test module. The WTM 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 hot swap connector is further operable to transfer data to the wireless test module when the chassis of the wireless test module and the adjustable front end of the wireless test module are mated. The WTM hot swap connector is a universal connector located at an end of the chassis of the wireless test module, the universal connector being attached to the front end hot swap connector located at an 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 number of contacts ranging from 48 contacts to 128 contacts. The EEPROM read / write lines are configured to couple to the chassis of the wireless test module. The WTM 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 the wireless test module to be replaced with another one if it does not function properly, while automatically updating the 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 of the wireless inspection module 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 side hot swap connector located at the end of the chassis of the wireless inspection module. The female connector includes a number of contacts ranging from 48 contacts to 128 contacts. The front end hot swap connector further includes a number 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 the wireless test module is not functioning properly, while automatically updating the 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 with 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 with 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 be locked to the WTM. The wireless charging receiver includes a 5 volt (V) Qi compliant 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 an 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 capable of mating 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 a plurality of wireless test modules of the WHAMS. The computer-implemented method can use a computer server to access a plurality of electrical wiring harnesses, test criteria, and the WHAMS. Each of the plurality of electrical wiring harnesses is connected to a respective end point of the wireless test module of the WHAMS. The computer-implemented method can generate a test plan for the plurality of electrical wiring harnesses based on the test criteria and select the plurality of wireless test modules using the test plan and the WHAMS. In particular, the test plan includes a map of the plurality of electrical wiring harnesses, a plurality of harness connections associated with each of the plurality of wireless test modules, a hook-up file, and one or more electrical tests associated with the plurality of electrical wiring harnesses. The hook-up file defines the plurality of wireless test modules assigned to the plurality of harness connections. For example, the test plan is generated with additional harness information related to splices, passive devices, and lost lead discards. As another example, the test plan is generated to check wires and unused pins in a network configuration for each of the plurality of electrical wiring harnesses. The computer-implemented method can use the wireless test modules to perform one or more tests on the electrical wiring harnesses according to the test instructions. The one or more tests are selected from a number of 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 can use the WTMs to wirelessly communicate test results to a computer server for display. The computer-implemented method can implement a WTM board support package to apply core operational applications to the wireless test modules to perform one or more tests on the electrical wiring harnesses according to the test instructions. The computer-implemented method can implement a custom power controller suite to manage batteries for the wireless test modules.The computer-implemented method can implement a bi-directional inspection technique to perform one or more electrical tests on the plurality of electrical wiring harnesses according to the plurality of inspection instructions. The computer-implemented method can evaluate the status of the inspection results through a color-coded report by highlighting the inspection results using different colors. The computer-implemented method can wirelessly communicate with the plurality of wireless inspection modules to update the one or more smart inspection adapters and / or software packages associated with each of the plurality of wireless inspection modules with part number and pin configuration data of the one or more smart inspection 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 may include a wireless transceiver, an electrical wiring harness, and a wireless test module. The wireless test module is capable of being physically coupled to the electrical wiring harness. The wireless test module includes a chassis and a variable front end connected to the chassis with 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 capable of being coupled to a wiring harness connector of the electrical wiring harness. For example, the electrical connector accommodates a connector with up to 128 pins. As another example, the electrical connector accommodates 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 is quickly interchangeable for a different connector.

[0012] According to some embodiments, the wireless inspection module is operable to wirelessly receive a plurality of inspection commands according to an automated inspection plan from a computer system using a wireless transceiver. The wireless inspection module is further operable to perform one or more inspections on the electrical wiring harness according to the plurality of inspection commands using a variable front end. The one or more inspections are selected from a plurality of inspections including a continuity check, a voltage insulation check, a TDR inspection, a fiber optic inspection, a diode polarity check, and a resistance measurement check. The wireless inspection module is further operable to wirelessly communicate the inspection results to the computer system using the wireless transceiver. The wireless inspection module has a shape selected from a plurality of shapes including a prism shape, a pyramidal shape, a cylindrical shape, and a spherical shape. The wireless inspection module is further operable to wirelessly communicate with the computer system using WI-FI, Bluetooth, or Zigbee. The wireless inspection module is further operable to apply a pick-by-light function for early 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 source or a low voltage source. The wireless test module is further operable to replace an inoperable chassis 122 with another available unit in case of a malfunction. The wireless test module is further operable to generate a low voltage output of about 2.4 volts (V) for resistance / continuity testing. 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 100V to 500V for high voltage testing. The wireless test module is further operable to measure resistance with an accuracy in the range of 6% and 10% using high voltage. The wireless test module is further operable to identify the 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 number of light emitting diode (LED) indicators, and a number of charging slots. The WHAMS includes a number of wireless testing modules. Each of the number of charging slots is associated with a respective wireless testing module of the WHAMS. The charging cart is operable to charge the number of wireless testing modules of the WHAMS. The mobile aluminum frame is capable of supporting the charging cart. The number of LED indicators are operable to identify a status of the number of wireless testing modules during setup and storage of the WHAMS.

[0015] According to some embodiments, the charging cart further includes a power source operable to provide 1500 watts (W) of power for charging the wireless test modules in parallel. The charging cart is a double deck charging cart with a plurality of charging slots ranging from 150 to 200. The charging cart is a single deck charging cart with a plurality of charging slots ranging from 50 to 100. The charging cart is a mini charging cart with a plurality of charging slots ranging from 20 to 30. The charging cart includes a support structure assembled from a plurality of sheets and pipes, the support structure including one or more decks welded onto the charging cart to allocate the plurality of charging slots. The plurality of charging slots are keyed slots to receive the plurality of WTMs and ensure that the plurality of WTMs are properly positioned. The charging cart is connected to the frame using bolts. Each of the plurality of LED indicators includes a red LED and a green LED. Each of the plurality of LED indicators is illuminated red to indicate that a particular WTM associated with the respective LED indicator is currently charging. Each of the plurality of LED indicators illuminates green to indicate and locate the particular WTM associated with the respective LED indicator prior to testing. Each of the plurality of LED indicators turns off to indicate the particular WTM associated with the respective LED indicator has finished charging. Each of the plurality of charging slots uses a four pogo pin layout to charge the plurality of 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, the system includes a computer system and a calibration instrument. The calibration instrument is operable to calibrate a wireless test module of the 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 a first resistance value and a second resistance value 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 factors using the calibration instrument and the test. The RAT can determine a measured resistance value using the plurality of calibration factors. 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 insulation check, a diode polarity check, and a resistance measurement check. A first resistance value of the FET evaluates a high-side resistance associated with the high-side FET. A second resistance value of the FET evaluates a sum of both a high-side resistance associated with the high-side FET and a 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 has 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 tool is further operable to store the plurality of calibration coefficients and the RAT history relating to the RAT in a database on the computer server. The calibration tool 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 wireless harness automatic measurement system and method of the present disclosure provide a unique combination of hardware flexibility and mobility 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 harnesses to be inspected and then wirelessly transmit the 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 pave the way for electrical inspection in environments that have been difficult to utilize with live-wire inspection systems (e.g., cabinet-type electrical relay box inspection systems with live-wire inspection cable adapters).

[0018] Additionally, the minimal equipment requirements to initiate an inspection lowers the barrier to entry for testing and improves the efficiency of the system. The disclosed embodiments provide simplified information entry formats that ensure rapid and automated inspection planning with little or no manual effort 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 description of the drawings]

[0020] [Figure 1] 1 illustrates a wireless harness automatic measurement system according to some embodiments. [Figure 2A] 2 illustrates inspection of an electrical wiring harness by the wireless harness automatic measurement system of FIG. 1 according to some embodiments. [Figure 2B] 2 illustrates inspection of an electrical wiring harness by the wireless harness automatic measurement system of FIG. 1 according to some embodiments. [Diagram 3] 2 illustrates a wireless inspection module that may be utilized in the wireless harness automatic 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. [Diagram 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 depict an injection molded pogo pin holder for the battery pack of FIG. 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 depict further details of the charging cart according to some embodiments. [Figure 13] 11A-11F depict further details of the charging cart according to some embodiments. [Figure 14A] 11A-11F depict further details of the charging cart according to some embodiments. [Figure 14B] 11A-11F depict further details of the charging cart according to some embodiments. [Figure 14C] 11A-11F depict further details of the charging cart according to some embodiments. [Figure 14D] 11A-11F depict further details of the charging cart 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 wireless harness automated gauging 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 wireless harness automated gauging system of FIG. 1 in accordance with certain embodiments. [Figure 19] 4 is a flow diagram illustrating an example method for testing a wireless test module, in accordance with 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 PREFERRED EMBODIMENTS

[0021] Electrical wiring harnesses are utilized in many different industries and vehicles. For example, large, complex electrical wiring harnesses with numerous wires and connectors are utilized in the aerospace industry to produce aircraft. As another example, electrical wiring harnesses are utilized 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 components of the electrical wiring harness, 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 connection test cable adapters that physically connect to the connectors of both the electrical wiring harness under test and the electrical relay box. While the electromechanical operations are performed in a centralized cabinet, the hard-wired cable adapters act as extension cords for the unique mating connectors to reach the electrical wiring harness under test. However, such a system can cause problems in certain situations. For example, using cabinet-style test machines for harness testing, such as setup, testing, repair (harness and tooling), and analysis, is inefficient. Typical cabinet-style test machines are large, heavy, and relatively fixed, and they rely on highly customized test cable adapter sets and cannot be efficiently scaled to meet changing electrical testing needs. As another example, in aircraft-specific harness testing, such as fault response systems to ensure product quality in the aerospace, military, and transportation / rail industries, operators typically spend hundreds of hours using cabinet-style test machines. 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. Certain disclosed embodiments utilize one or more wireless test modules (WTMs), each of which physically and electrically couples to a connector of an electrical wiring harness to be inspected. 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, which mitigates the inefficiencies of traditional cable-based inspection using cabinet-type inspection machines. The wireless test modules transmit and receive electrical inspection signals through one or more wires of the electrical wiring harness, and then wirelessly report the inspection results to a central computer system, such as a laptop, unlike current live-wire solutions. That is, each wireless test module is not physically connected to the central computer system, but instead communicates wirelessly with the central computer system. 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 increases productivity and flexibility in inspecting electrical wiring harnesses. In some embodiments, the wireless test modules are cylindrical in shape, similar in size and shape to a typical flashlight. This small external 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 the next room or on the 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 the electrical wiring harness (e.g., continuity check, voltage insulation check, TDR test, fiber optic test, diode polarity check, resistance measurement check, etc.). The removable front end of the wireless test module houses a specific mating connector that connects to the connector of the electrical wiring harness and can be quickly replaced with a common interface on the front of the wireless test module. The wireless test modules are interchangeable and are not dedicated to any particular wiring harness or system. The configuration of the wireless harness automatic measurement system allows a catalog of front ends to be created to suit the needs of various electrical connectors while minimizing the number of wireless test modules required to maximize hardware utilization. The hardware commonality of the wireless test module chassis also allows for easy replacement in the event of a failure. In the event that one wireless test module becomes inoperable, the inoperable wireless test module chassis can simply be replaced with another available unit to continue critical testing activities without delay. As a result, a test operator can complete an inspection of an 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 mobility 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 that have been difficult to access with live-wire inspection systems (e.g., cabinet-type electrical relay box inspection systems with live-wire inspection cable adapters). Additionally, the minimal equipment requirements to initiate an inspection lowers the barrier to entry and increases the efficiency of the system. Certain disclosed embodiments provide a simplified information entry format that ensures fast and automated inspection planning with little or no manual effort by the operator.

[0026] In order to facilitate a better understanding of the present disclosure, examples of specific embodiments are given 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 its 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] FIG 1 illustrates a wireless harness automated measurement system 100 in accordance with some embodiments. The wireless harness automated measurement system 100 includes an electrical wiring harness to be inspected 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 particular number of wireless test modules 120 are illustrated in FIG 1, in other embodiments, any number of wireless test modules 120 may be utilized.

[0029] In general, 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 being tested. 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., pins in the wiring harness connector 115 in the wrong position, pins shorted within the wiring harness connector 115, etc.), voltage insulation checks, diode polarity checks, and resistance measurement checks. Secondly, unlike typical solutions that are hard-wired into large relay cabinets, the wireless test modules 120 wirelessly report the test results 160 to the 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 wirelessly communicates with the central computer system 130 using a wireless protocol such as Zigbee, Bluetooth, or WI-FI. The small outer dimensions of the wireless test modules 120, together with their ability to wirelessly communicate with the central computer system 130, allow a technician to easily carry multiple wireless test modules 120 and couple them to the wiring harness connectors 115 of the electrical wiring harness 110 under test, even when the electrical wiring harness 110 is physically located away from the 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 can be any suitable electrical connector and can include any number of pins or electrical contacts. Examples of wiring harness connectors 115 include signal connectors, power connectors, and the like. The electrical wiring harness 110 can be installed in any device or vehicle, such as, for example, an aircraft, an automobile, a watercraft, a spacecraft, and the like. The wireless harness automatic measurement system 100 can 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 the wiring harness connector 115 of the electrical wiring harness 110 and performs one or more electrical tests on the electrical wiring harness 110 as commanded 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 and bulky relay cabinets with live wiring inspection adapters that connect to the wiring harness connectors 115. Such systems are difficult to transport, are not easily adaptable, and are not easily scalable. However, by utilizing the 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 that are located far away (e.g., in another room or 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 physical 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 wirelessly communicate (directly or via a wireless interface 140) with a central computer system 130 using any suitable wireless protocol (e.g., Zigbee, Bluetooth, WI-FI, etc.). The chassis 122 is the body of the wireless test module 120 and houses components such as a battery, relays, 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 can 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 can 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 may be any suitable computing system in any suitable physical form. By way of example, and not by way of limitation, the central computer system 130 may be an embedded computer system, a system on a 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 may 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 may include one or more cloud components in one or more networks. Where appropriate, the central computer system 130 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, the 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. The central computer system 130 may perform one or more steps of one or more methods described or illustrated herein at different times or in different locations, where appropriate. A particular example of the central computer system 130 is described in connection with FIG. 20.

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

[0035] The test command 150 is one or more signals, operations, commands, etc., that are wirelessly transmitted from the central computer system 130 to the wireless test module 120. The test command 150 is utilized by the wireless test module 120 to perform one or more electrical tests on the electrical wiring harness 110. The electrical tests can be, for example, a continuity check (e.g., a pin of the wiring harness connector 115 is in a wrong position, a pin of the wiring harness connector 115 is shorted, the wire 111 is damaged, etc.), a voltage insulation check, a diode polarity check, a resistance measurement check, etc. In some embodiments, the test command 150 is determined by the central computer system 130 according to a test plan for the electrical wiring harness 110. An example of the test command 150 is described in connection with FIGS. 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 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 show various examples of steps of inspecting an electrical wiring harness 110 by a wireless harness automatic measurement system 100 according to some embodiments. In FIG. 2A, two wireless inspection modules 120 are utilized to perform the inspection steps on the electrical wiring harness 110, namely, a source wireless inspection module 120A and a destination wireless inspection module 120B. 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 are utilized during the inspection, namely, 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 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 to the first wire 111A, and destination wireless inspection module 120B internally connects the first wire 111A to the second wire 111B, for example, using an electrical relay. Source wireless inspection module 120A can then measure voltage and current across the first wire 111A and the second wire 111B to perform various electrical tests as described herein. Test results 160 also include status signals and other metadata not directly related to harness test results. 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 across one or more transmission paths for various switching and digital control applications.

[0038] 2A , options other than the second wire 111B can be used for the electrical return path or ground. For example, an electrical shield in the electrical wiring harness 110 can be used for the electrical return path or ground. As another example, an electrical jumper (e.g., an electrical wire) can 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 inspection module 120A is utilized to perform inspection of the electrical wiring harness 110. In this example, the wireless inspection module 120A is physically coupled to a first wiring harness connector (e.g., wiring harness connector 115A in 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 in FIG. 1). In this scenario, two wires 111 are utilized during inspection: a first wire 111A and a second wire 111B. The second wire 111B is used as a return line in this example. Both wires 111A and 111B are physically and electrically coupled to the wireless inspection module 120A and are coupled to each other using a loopback device. The wireless inspection module 120A introduces a current flow into the first wire 111A, which is returned to the wireless inspection module 120A on the second wire 111B. The wireless test module 120A can then measure the voltage and current across the first wire 111A and the second wire 111B to perform various electrical tests as described herein.

[0040] In operation, and with reference to Figures 1, 2A and 2B, the wireless harness automatic measurement system 100 utilizes a central computer system 130 and one or more wireless test modules 120 to test an electrical wiring harness 110. First, one or more wireless test modules 120 are physically connected to one or more wiring harness connectors 115 of the electrical wiring harness 110. For example, as shown in Figure 2A, a source wireless test module 120A is physically coupled to a first wiring harness connector 115A, and a destination wireless test module 120B is physically coupled to a second wiring harness connector 115B. In another example, as shown in Figure 2B, a wireless test module 120A is physically coupled to a first wiring harness connector 115A, and a loopback connector (or other similar device) 202 is physically coupled to a second wiring harness connector (e.g., wiring harness connector 115B in Figure 1). The central computer system 130 then transmits test commands 150 to the one or more wireless test modules 120 according to the automated test plan. Details and examples of the automated test plans used to test the electrical wiring harness 110 are described in more detail below. In some embodiments, the test commands 150 are transmitted to the one or more wireless test modules 120 using the wireless interface 140. The test 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 test can be, for example, a continuity check (e.g., a pin of the wiring harness connector 115 is in a wrong position, a pin of the wiring harness connector 115 is shorted, a wire 111 is damaged, etc.), a voltage insulation check, a diode polarity check, a resistance measurement check, etc. For example, the wireless test module 120 can enable / disable one or more internal electrical relays and apply a current from an internal power source to one or more wires 111 of the electrical wiring harness 110 to perform a continuity check of the electrical wiring harness 110. Each wireless test module 120 can vary the voltage and current of one or more connected wires 111 according to the received test command 150. After performing one or more tests on the electrical wiring harness 110 according to the test commands 150 received from the central computer system 130, the wireless test modules 120 wirelessly transmit (either directly or via the wireless interface 140) the test results 160 back to the central computer system 130. 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 inspection module 120 that can be utilized in the wireless harness automated measurement system of FIG. 1, according to some embodiments. Each wireless inspection module 120 includes a wireless transceiver 121 (shown in FIG. 1), a chassis 122, and a variable front end 126. The wireless inspection module 120 is the primary electrical inspection hardware of the WHAMS. In some embodiments, conventional electrical harness inspection 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 the 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 are configured to be expandable in large increments of test points. For example, the one or more charging cabinets are configured to be deployable for harness configurations that require a certain number of test points or less. As a result, optimizing the cabinet configuration of one or more charging cabinets to reduce costs is difficult, especially for small 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, which are double ended and unique in length, adding weight and manufacturing costs to conventional electrical harness test hardware, making conventional electrical harness test hardware difficult to rapidly 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. In particular, the wireless inspection module 120 has a portable and quickly configurable cabinet configuration, which allows the wireless inspection module 120 to be housed within a tight exterior dimension for full and 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 inspections 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 a new inspection adapter.

[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 that houses multiple electronic components. The wireless test module 120 can replace the inoperable chassis 122 with another available unit in case of failure. 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 that connects the electrical connector 302 to the chassis 122), and a wire harness (e.g., jumper harness 708 in FIG. 7A ) that makes the connection from the electrical connector 302 to the chassis 122. The variable front end 126 is a removable part 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, the wireless test module 120 can be configured to physically couple to the electrical wiring harness to perform one or more tests on the electrical wiring harness (e.g., continuity check, voltage insulation check, TDR test, fiber optic test, diode polarity check, resistance measurement check, etc.). In particular, the wireless test module 120 can be configured to wirelessly receive a number of test commands (e.g., test commands 150 of FIG. 1 ) from an automated test plan from a central computer system (e.g., central computer system 130 of FIG. 1 ) using the wireless transceiver 121. The 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 the variable front end 126. The wireless test module 120 is configured to wirelessly communicate the test results to the central computer system using the wireless transceiver 121.

[0048] FIG. 4 illustrates an exploded view of the wireless inspection module 120 of FIG. 3 according to some embodiments. The wireless inspection module 120 is a common duplicate part of the module to facilitate replacement of units to facilitate repair 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 the inspection software and wireless transceiver (e.g., the wireless transceiver 121 of FIG. 1) using Zigbee communication protocol. Thus, the wireless inspection module 120 provides a portable and modular electrical harness inspection machine that does not use a cabled inspection adapter to communicate with a central computer system.

[0049] 5 illustrates an internal view of the wireless inspection module 120 of FIG. 3, according to some embodiments. The wireless inspection module 120 can include a wide variety of mating electrical connectors 406. For example, the wireless inspection module 120 can accommodate electrical connectors 406 with up to 128 pins. In another example, the wireless inspection module 120 can accommodate electrical connectors 406 with up to 48 pins. The electrical connectors 406 can be integrated within the wireless inspection module 120 and coupled to a wiring harness connector 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 source 610, a low voltage source 612, an analog measurement circuit 614, and a high voltage compatible solid state multiplexing block 616. The high voltage compatible solid state multiplexing block 616 is connected to the variable front end of the wireless test module (e.g., the 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 that are typically made when manufacturing and debugging cable harnesses. In some embodiments, the wireless test module includes multiple electrical relays designed for the high voltage compatible solid state multiplexing block 616. In certain embodiments, the wireless test module includes a lithium ion rechargeable battery 608 (e.g., a 3400 milliamp hour (mAh) lithium ion rechargeable battery) that eliminates the need for a charging cabinet with cables. As a result, the wireless test module can be configured to perform low current, high voltage testing and to wirelessly communicate with a central computer system (e.g., central computer system 130 of FIG. 1) under battery power.

[0051] In some embodiments, the wireless inspection module is configured to perform various electrical inspections 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 the 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 central computer system, such as a control laptop, which transmits various types of inspection commands (e.g., the inspection command 150 of FIG. 1 ) to the wireless inspection module for performing and reporting the inspections. As another example, the wireless inspection module can apply an internal power source to one or more wires of the 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, the wireless test module (e.g., wireless test module 120 of FIG. 1) includes a power button that allows a user to turn on, off, or reset the wireless test module. The wireless test module can be configured to use a mini USB connector, a charging port of the wireless test module, and a 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 to rapidly update one or more software packages of the wireless test module. In particular, the charging port of the wireless test module can interface with multiple pogo pins located in each slot of the WHAMS charging cart. Multiple pogo pins can also be used for the battery pack of the wireless test module. 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 visual communication with the user. For example, the LED indicators are orange and located at 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. In particular, 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 100V to 500V for high voltage testing with an output voltage tolerance of ±3%±2V. As a result, a wireless test module can be configured to measure resistance with an accuracy of 10%±1Ω for resistances in the range of 1Ω to 50Ω. A wireless test module can be configured to measure resistance with an accuracy of 5%±1Ω for resistances in the range of 51Ω to 250Ω. A wireless test module can be configured to measure resistance with an accuracy of 10%±1Ω for resistances in the range of 251Ω to 1 million (M)Ω. The wireless test module can be configured to measure resistance with a high voltage with an accuracy in the range of 6% to 10%. For example, the accuracy of resistance measurement with a high voltage of 100V is 10% for resistances in the range of 1MΩ to 50MΩ. As another example, the accuracy of resistance measurement with a high voltage of 500V is 6% for resistances in the range of 1MΩ to 50MΩ.

[0054] WHAMS Hot Swap Connectors

[0055] In some embodiments, the WHAMS is configured to perform one or more electronic tests for Functional Automated Check (FAC) on electronic wiring harnesses for vehicles, such as aircraft and automobiles. The types of connectors on vehicles are numerous. The WHAMS can test every connector on the vehicle using wireless test modules. Since vehicles are tested individually, the wireless test modules can use hot swap connectors to disconnect connectors from the 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., 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 located between a wireless inspection module chassis and a wireless inspection module variable front end, such as WTM side hot swap connector 402 and front end side hot swap connector 404 of FIG. 4. A WHAMS can use multiple wireless inspection modules including multiple types of connectors for FACs during inspection of multiple electrical wiring harnesses. In particular, all unique connectors in FACs for vehicles such as aircraft and automobiles can be accommodated. A conventional WHAMS includes multiple connectors permanently attached to a wireless inspection module that includes all processing functions. Since at least one wireless inspection module is required for each unique connector, a conventional WHAMS may incur high manufacturing costs to inspect 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 chassis of the wireless test module and is 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 chassis of the wireless test module. Similarly, the WTM side hot swap connector 402 can remove the variable front end of the wireless test module from the chassis of the wireless test module. The WTM side hot swap connector 402 is operable to transfer data to and from the wireless test module when the chassis of the wireless test module and the variable front end of the wireless test module are mated. The WTM side hot swap connector 402 can replace the wireless test module with another wireless test module if the wireless test module is not functioning properly, while automatically updating the address information in real time.

[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 a quick and reliable connection. Thus, the variable front end can be quickly attached and detached from the wireless test module. The EEPROM read / write line 706 is integrated on the circuit board and can read / write data of 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. A jumper harness 708 is configured to couple to the wireless test module. The surface mount female connector 710 includes a number of contacts ranging from 48 contacts-128 contacts. For example, the surface mount female connector 710 can include 100 contacts.

[0059] 7B and 7C show 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 is attached to another custom-designed universal connector located at the end of the wireless test module's chassis, such as a WTM hot swap connector. 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 remove 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 replace the wireless test module with another wireless test module when the wireless test module is not functioning properly, while automatically updating the address information in real time.

[0060] In some embodiments, the front end hot swap connector 404 includes an alignment peg 722, threads 724, an EEPROM 726, a number of connectors 728, and a male connector, such as a surface mount male connector 730. The alignment peg 702 is configured to mate with a 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. When attached, 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] Figures 8A-8C illustrate an exemplary variable front end 802 that may be attached to the wireless inspection module 120 of Figure 3, according to some embodiments. In particular, the variable front end 802 of Figures 8A-8C may be coupled to a wiring harness connector, such as an aircraft connector (e.g., wiring harness connector 115 of Figure 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 test in a low battery condition. 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 show 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 in low battery level conditions. 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 housing 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 required 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 that 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 inspection 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 inspection module, which may be left uncharged for long periods of time. For example, the battery pack 900 can be coupled to the wireless inspection module to provide additional power to perform one or more electrical tests on the electrical wiring harness (e.g., continuity check, voltage insulation check, TDR test, fiber optic test, diode polarity check, resistance measurement check, etc.). In particular, the wireless inspection module can include an electrical connector that can mate with a wiring harness connector of the electrical wiring harness. The wireless inspection module is operable to perform one or more tests to verify the electrical wiring harness according to a number of test commands received from a central computer system. In particular, the wireless inspection module is 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 of 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 they are 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 function that lights up the multiple wireless inspection modules that are called when they are needed for inspection.

[0070] 11A-11F illustrate a charging cart system 1100 for storing multiple wireless inspection modules, according to some embodiments. The charging cart system 1100 is a bulk charging device configured to hold and charge multiple wireless inspection 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, a double deck charging cart 1160 can hold 174 charging slots. As another example, a single deck charging cart 1170 can hold 87 charging slots. As another example, a 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, a number of LED indicators 1104, and a number of 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 side left 1114, a side right 1116, a back sheet 1118, a front sheet 1120, and a number of pipes 1122. These components can be assembled with polyvinyl chloride (PVC) sheets and PVC pipes to support the charging cart. The PVC sheets can be 0.5 inch thick Type 1 PVC sheets. 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). A plurality of LED indicators 1104 in FIG. 11A are operable to identify the status of the plurality of wireless test modules during testing of the WHAMS. A plurality of charging slots 1106 in FIG. 11A are operable to charge the plurality of wireless test modules. Each of the plurality of charging slots is associated with a respective one of the plurality of LED indicators 1104. In some embodiments, the charging cart can charge more than 100 wireless test modules in parallel using a power source operable to provide 1500 watts (W) of power. As another example, the charging cart can locate the plurality of wireless test modules using a find by light function and light up one or more wireless test modules used for testing. As a result, the charging cart can include a support structure assembled with a plurality of PVC sheets and PVC pipes. The support structure can include one or more decks, such as sheet assemblies 1124 of FIG. 11F, that are 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 that the multiple wireless inspection modules are properly positioned. FIG. 11F shows how each sheet assembly 1124 can include a back sheet 1118, a front sheet 1120, and multiple PVC pipes 1122.

[0073] 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 test module 120 attached to the charging slot 1106 using an injection molded pogo pin block 1204. In particular, the injection molded pogo pin block 1204 can include a four-pin layout 1300 as shown in FIG. 13 for charging the wireless test module 120 and a light indicator using an LED ring 1206, the light indicator including multiple red LEDs and multiple green LEDs alternating along the LED ring 1206. The LED ring 1206 can include a ring cover 1202 (e.g., a clear polycarbonate LED ring cover).

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

[0075] 14A and 14B show a layout 1400 of a plurality of charging slots 1106 on the deck of the charging cart system 1100 of FIGS. 11A-C. Each of the plurality of 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 a plurality of wireless test modules in the charging cart. FIG. 14D shows a plurality of LED indicators 1104 that can help identify the state of each wireless test module as well as help identify where the module is located at any given time. In particular, each of the plurality of LED indicators illuminates red to indicate that the particular wireless test module associated with the respective LED indicator is currently charging. Each of the plurality of 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 plurality of 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. It is important to calibrate the wireless test module of the WHAMS in order to accurately read resistance measurements when performing one or more electrical tests on the electrical wiring harness (e.g., continuity check, voltage insulation check, TDR test, fiber optic test, diode polarity check, resistance measurement check, etc.). Prior to testing of the WHAMS, the wireless test module will undergo a controlled periodic calibration process to ensure that 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 number 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 directly connect the calibration fixture 1500 to earth. The 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 the multiple FETs. The controlled periodic calibration process can include one or more of the following five operations: (1) perform an internal measurement test; (2) perform a resistance accuracy test (RAT); (3) save the calibration coefficients; (4) save the RAT history; and (5) recall the 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 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 tool 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 tool 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 the first switch 1606 is turned on and the 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 the wireless test module 120 when performing a calibration of the wireless test module 120 using the calibration tool 1500. The first resistance value measures a resistance for a first path along the high side FET 1602 of the wireless test module 120 and the calibration tool 1500. Thus, the first resistance value is related to the resistance of the high side FET 1602, the contact resistance, and the trace / wiring resistance on the calibration board. For example, the first resistance value may be in the range of 80 Ω to 90 Ω.

[0081] FIG. 16B shows that the first switch 1606 is turned off and the second switch 1608 is turned on. The calibration method measures a second resistance value of the plurality of FETs from a second internal measurement test for the wireless test module 120 when performing a calibration of the wireless test module 120 using the calibration tool 1500. The second resistance value measures a resistance for a second path along the high-side FET 1602 and / or low-side FET 1604 of the wireless test module 120 and the calibration tool 1500. Thus, the second resistance value is related to the resistance of the high-side FET 1602, the resistance of the low-side FET 1604, the contact resistance, and the trace / wiring resistance on the calibration board. 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 FET measures a high-side resistance associated with the 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 range from 40Ω to 50Ω. 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 45Ω, the calibration method may determine that the resistance calibration value matches the predetermined value. As a result, the calibration method is configured to perform a RAT using the plurality of resistors of the calibration tool 1500. As another example, if the predetermined value of the low-side FET 1604 is 60Ω, the calibration method may determine that the resistance calibration value does not match the predetermined value. The calibration method determines 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 tool 1500 of FIG. 15 according to some embodiments. The resistance accuracy test 1700 is configured to verify a plurality of resistors of the calibration tool 1500. For example, the plurality of resistors can have resistance values ​​ranging from 1 Ω to 50 MΩ. In particular, the calibration tool 1500 can use a plurality of pins to adjust the resistance value of the calibration tool 1500. All pins perform RAT at a value of 1 Ω, and one pin performs RAT at a higher value. The calibration method selects a resistor 1702 from the plurality of resistors of the calibration tool 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 a plurality of calibration coefficients using the calibration tool 1500 and the test. For example, the plurality of calibration coefficients 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 factors to determine the measured resistance. For example, the measured resistance 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. As a result, the calibration means compares the measured resistance to the target resistance. If the measured resistance matches the target resistance, the calibration means determines the test is passed. If the measured resistance does not match the target resistance, the calibration means determines the test is failed. As a result, the calibration method can store the measured resistance and the target resistance in a database in a central computer server. Similarly, the calibration method can store multiple calibration factors and a RAT history related to the RAT in a database in a central computer server. Thus, the calibration method can perform multiple RATs for the wireless test module 120 using multiple resistors in the calibration tool 1500 to detect potential failure modes using the resistance of the FET drifting over a period of time.

[0085] WHAMS Operating Software

[0086] Some embodiments relate to a control method for managing a plurality of wireless test modules of a WHAMS on a plurality of electrical wiring harnesses. The plurality of wireless test modules of the WHAMS can wirelessly communicate with a central computer system. In particular, the control method is applied during testing of the WHAMS using a plurality of 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 plurality of wireless test modules using a wireless test module board support package. In particular, the core operational application can implement a bi-directional 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 plurality of electrical wiring harnesses according to a plurality of 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 can include a map of multiple electrical wiring harnesses, multiple harness connections associated with each of the multiple wireless test modules, a hook-up file, and one or more electrical tests associated with the multiple electrical wiring harnesses. For example, the hook-up file specifies multiple wireless test modules assigned to the multiple harness connections. As another example, the test plan is generated with additional harness information related to splices, passive devices, and resignment of lose leads. In particular, the test plan is generated to check 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 can interpret the wire lists of the multiple electrical wiring harnesses and generate a test plan based on the test criteria received from the 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 analyze each electrical wiring harness using the input data.

[0088] In some embodiments, the control method uses a central computer system to access the plurality of electrical wiring harnesses, the test criteria, and the 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 the 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 communicates test results using the plurality of wireless test modules to the central computer system 130 for display. Additionally, 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 a number of 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 the test plan. The second user interface 1808 can be implemented for a user to visually inspect the status of the electronic wiring harness through a color-coded report. For example, a passed test is highlighted in green, and a failed test is highlighted in a different color, such as red, orange, or yellow, based on its failure status. In particular, a user can interact with the second user interface 1808 to manage one or more tests on a plurality of electrical wiring harnesses based on various criteria, such as relevant source and destination reference designators, test status, and type of test. As a result, the second user interface 1808 provides an adaptable solution for executing the test plan based on various test conditions. After the test plan is executed, the second user interface 1808 generates a final consumable report, which is digitally stored 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 calibration of test types and module capabilities. For example, the fourth interface 1812 can be implemented to check the health of multiple wireless test modules of the 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 to 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, the application interface 1800 includes a fifth user interface 1814 for maintaining and updating module software. The fifth user interface 1814 may be implemented to allow a user to wirelessly update one or more software packages for multiple wireless inspection modules. The fifth user interface 1814 may be utilized to facilitate easy migration of new functionality to the floor with minimal touch effort.

[0094] In some embodiments, the application interface 1800 includes a sixth user interface 1816 for test debugging and general module troubleshooting. The sixth 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 the data of a selected electronic wiring harness 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 debugging tests 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 the data of a selected electronic wiring harness by modifying multiple parameters of the one-shot test for better performance.

[0096] In some embodiments, the 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, the eighth user interface 1818 can be implemented to identify the front ends connected to each wireless inspection module and relay that information back to the application interface 1800. As a result, the eighth user interface 1818 can be implemented to dynamically build a module network to monitor harness inspection 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 in the wireless harness automatic measurement system of FIG. 1 according to certain embodiments. The wireless harness automatic measurement 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 of a calibration check based on a first table 1824 for a first plurality of wireless inspection modules 1802. In particular, the first inspection plan is generated to evaluate the status 1804 of the inspection results through a color-coded report by highlighting the inspection results using different colors. For example, the passed inspections are highlighted in green, and the failed inspections are highlighted in red, orange, or yellow based on their fail status.

[0098] FIG. 18B illustrates a second test plan for high voltage insulation on the second table 1826 for the 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 a plurality of tests for each of the second plurality of wireless test modules 1822 to check the insulation or continuity of those connections. For example, the control method can generate a plurality of 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, the second test plan is applied to check all presumably unused pins for the electrical connectors of the plurality of electrical wiring harnesses to ensure that there are no shorts or miswires in the harness.

[0099] In some embodiments, the application interface 1800 can be used to call additional modules to increase the number of possible paths for creating ground circuits for testing. In particular, the control method can be used to perform one or more electrical tests on a number of electrical wiring harnesses, such as high and low voltage continuity, voltage insulation checks, data bus polarity and diode polarity checks, and resistance measurement checks. Thus, the control method can use the application interface 1800 for a user to monitor the health and functionality of a number of wireless test modules of the WHAMS. In particular, the control method can determine the test conditions of the WHAMS based on the health and functionality of a number of wireless test modules. Similarly, the control method can select multiple actions to schedule the testing of a number of 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 turning on 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] At 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 the plurality of wireless test modules.

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

[0103] At step 1940, a plurality of test instructions 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 instructions from the computer system. The plurality of test instructions may be one or more signals, actions, commands, etc.

[0104] At 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 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 multiple electronic wiring harnesses 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 failed status. After step 1960, the method 1900 may end.

[0106] FIG. 20 illustrates an exemplary computer system 2000. In certain embodiments, one or more computer systems 2000 perform one or more steps of one or more methods described or illustrated herein. In certain embodiments, one or more computer systems 2000 provide functionality described or illustrated herein. In certain 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. Certain embodiments include one or more portions of one or more computer systems 2000. References herein to a computer system encompass computing devices, where appropriate, and vice versa. Additionally, references to a computer system may encompass one or more computer systems, where appropriate.

[0107] This disclosure contemplates any suitable number of computer systems 2000. This disclosure contemplates computer system 2000 taking any suitable physical form. By way of example, and not limitation, computer system 2000 may be an embedded computer system, a system on a chip (SOC), a single board computer system (SBC) (e.g., a computer on module (COM) or a 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, computer system 2000 may include one or more computer systems that may be single or distributed, across multiple locations or across multiple machines, or across multiple data centers, 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 by way of 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, the processor 2002 includes hardware for executing instructions, such as those that make up a computer program. By way of example, and not by way of limitation, to execute instructions, the 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, the processor 2002 may include one or more internal caches for data, instructions, or addresses. This disclosure contemplates that the processor 2002 may include any suitable number of any suitable internal caches, where appropriate. By way of example, and not by way of limitation, the 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 the processor 2002. Data in the data cache may be copies of data in memory 2004 or storage 2006 for instructions executing in the processor 2002 to operate on results of previous instructions executed by the processor 2002 or other suitable data for access by subsequent instructions executing in the processor 2002 or for writing to the memory 2004 or storage 2006. The data cache may speed up read or write operations by the processor 2002. The TLB may speed up virtual address translation for the processor 2002. In certain embodiments, the processor 2002 may include one or more internal registers for data, instructions, or addresses. This disclosure contemplates the processor 2002 including any suitable number of any suitable internal registers, where appropriate.Where appropriate, the 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. Although this disclosure describes and illustrates a particular processor, any suitable processor is contemplated.

[0110] In a particular embodiment, memory 2004 includes a main memory for storing instructions that processor 2002 executes or data that processor 2002 operates on. By way of example, and not limitation, computer system 2000 may load instructions into memory 2004 from storage 2006 or another source (such as, for example, another computer system 2000). Processor 2002 may then load instructions from memory 2004 into an internal register or cache. To execute instructions, processor 2002 may retrieve instructions from the internal register or cache and decode them. During or after execution of 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, the processor 2002 executes only instructions in one or more internal registers or internal caches or memory 2004 (and not in storage 2006 or some other location) and operates only on data in one or more internal registers or internal caches or memory 2004 (and not in 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 the processor 2002 to the memory 2004. The bus 2012 may include one or more memory buses, as described below. In particular embodiments, one or more memory management units (MMUs) reside between the processor 2002 and the memory 2004 to facilitate accesses to the memory 2004 requested by the processor 2002. In particular embodiments, the 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 - 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, a flash memory, an optical disk, a magneto-optical disk, a 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 a non-volatile semiconductor memory. In particular embodiments, storage 2006 includes read-only memory (ROM). Where appropriate, this ROM may be a mask programmed ROM, a programmable ROM (PROM), an erasable PROM (EPROM), an electrically erasable PROM (EEPROM), an erasable re-writeable ROM (EAROM), or a 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 one or more storage control units that facilitate communications between processor 2002 and storage 2006, where appropriate. Storage 2006 may include one or more storages 2006, where appropriate. This disclosure contemplates any suitable storage, although particular storage is described and illustrated.

[0112] In certain 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, as appropriate. One or more of these I / O devices may enable communication between a person and computer system 2000. By way of example, and not 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 include one or more I / O interfaces 2008, where appropriate. Although this disclosure describes and illustrates a particular I / O interface, any suitable I / O interface is contemplated.

[0113] In certain embodiments, the communication interface 2010 includes hardware, software, or both that provide one or more interfaces for communicating (e.g., wirelessly, etc.) between the computer system 2000 and one or more other devices or systems. By way of example, and not by way of limitation, the 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 by way of limitation, the 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 of these. Computer system 2000 may include any suitable communication interface 2010 for any of these networks, as appropriate. Communication interface 2010 may include one or more communication interfaces 2010, as appropriate. This disclosure contemplates any suitable communication interface, although particular communication interfaces are described and illustrated.

[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, as appropriate. Although this disclosure describes and illustrates a particular bus, any suitable bus or interconnect is contemplated.

[0115] As used herein, a computer-readable non-transitory storage medium(s) may include, 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. A computer-readable non-transitory storage medium may be volatile, non-volatile, or a combination of volatile and non-volatile, where appropriate.

[0116] As used herein, "or" is inclusive and not exclusive, unless expressly indicated otherwise or indicated otherwise by context. Thus, "A or B" means "A, B, or both," unless expressly indicated otherwise or indicated otherwise by context. 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, modifications, and alterations to the exemplary embodiments described or illustrated herein that would be understood by 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 certain 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 understood by one skilled in the art. Furthermore, references within the scope of the claims to devices or systems, or components of devices or systems, being adapted, arranged, having, configured, enabled, operable, or operative to perform a particular function encompass such devices, systems, or components, or such particular functions, whether or not they are activated, turned on, or unlocked, so long as they are so adapted, arranged, having, configured, enabled, operative, or operative. Furthermore, although particular embodiments may be described or illustrated in this disclosure 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 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 relating to methods, storage media, systems, and computer program products, where 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 in the claims is merely selected for formal reasons. However, any subject matter resulting from intentional retroactivity (especially multiple dependency) to any preceding claims may also be claimed, just as any combination of claims and their features may be disclosed and claimed regardless of the dependency selected in the claims. Subject matter that may be claimed includes not only the combination of features provided in the claims, but also any other combination of features within the claims, and each feature described in the claims may be combined with any other feature or combination of other features within the claims. Furthermore, any of the embodiments and features described or illustrated in this specification may be claimed in an individual claim and / or in any combination with any of the embodiments or features described or illustrated in this specification or within the scope of the claims. [Explanation of symbols]

[0119] 100 Wireless Harness Automatic Measurement 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. 1. A computer-implemented method comprising: accessing a plurality of electrical wiring harnesses, inspection criteria, and a Wireless Harness Automated Measurement System (WHAMS) using a computer server; generating an inspection plan for the plurality of electrical wiring harnesses based on the inspection criteria; selecting a number of Wireless Test Modules (WTMs) using the test plan and the WHAMS; generating a plurality of test orders based on the test plan and the plurality of WTMs; performing, with the plurality of WTMs, one or more tests on the plurality of electrical wiring harnesses according to the plurality of test commands; using the plurality of WTMs to wirelessly transmit test results to the computer server for display; 4. A computer-implemented method comprising:

2. 2. The computer-implemented method of claim 1, further comprising implementing a WTM board support package for applying core operational applications to the plurality of WTMs to perform the one or more tests on the plurality of electrical wiring harnesses in accordance with the plurality of test instructions.

3. The computer-implemented method of claim 1 , further comprising implementing a custom power controller suite to manage a plurality of batteries of the plurality of WTMs.

4. The computer-implemented method of claim 1 , further comprising implementing a bi-directional inspection technique for performing the one or more electrical tests on the plurality of electrical wiring harnesses in accordance with the plurality of inspection commands.

5. the test plan includes a map of the plurality of electrical wiring harnesses, a plurality of harness connections associated with each of the plurality of WTMs, a hookup file, and a plurality of tests associated with the plurality of electrical wiring harnesses; The computer-implemented method of claim 1 , wherein the hookup file defines the WTMs assigned to the harness connections.

6. The inspection plan is generated with additional harness information regarding splices, passives, and discarded lost leads; The computer-implemented method of claim 1 , wherein the test plan is generated to check wires and unused pins in a network configuration for each of the plurality of electrical wiring harnesses.

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 computer-implemented method of claim 1 , wherein the test is selected from a plurality of tests including:

8. 10. The computer-implemented method of claim 1, further comprising evaluating the status of the test results through a color-coded report by highlighting the test results with different colors.

9. The computer-implemented method of claim 1 , further comprising wirelessly communicating with the plurality of WTMs to update software packages.

10. 2. The computer-implemented method of claim 1, further comprising wirelessly communicating with a plurality of wireless test modules to update the one or more smart test adapters 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.

11. one or more processors; one or more computer-readable non-transitory storage media; A system comprising: The one or more computer-readable non-transitory storage media, when executed by the one or more processors, cause one or more components of the system to: accessing a plurality of electrical wiring harnesses, inspection criteria, and a Wireless Harness Automated Measurement System (WHAMS) using a computer server; generating an inspection plan for the plurality of electrical wiring harnesses based on the inspection criteria; selecting a number of Wireless Test Modules (WTMs) using the test plan and the WHAMS; generating a plurality of test orders based on the test plan and the plurality of WTMs; performing, with the plurality of WTMs, one or more tests on the plurality of electrical wiring harnesses according to the plurality of test commands; using the plurality of WTMs to wirelessly transmit test results to the computer server for display; [0033] system.

12. The system of claim 11 , further comprising implementing a WTM board support package for applying core operational applications to the plurality of WTMs to perform the one or more tests on the plurality of electrical wiring harnesses in accordance with the plurality of test instructions.

13. The system of claim 11 , further comprising implementing a custom power controller suite to manage a plurality of batteries of the plurality of WTMs.

14. The system of claim 11 , further comprising implementing a bi-directional inspection technique for performing the one or more electrical tests on the plurality of electrical wiring harnesses in accordance with the plurality of inspection commands.

15. the test plan includes a map of the plurality of electrical wiring harnesses, a plurality of harness connections associated with each of the plurality of WTMs, a hookup file, and a plurality of tests associated with the plurality of electrical wiring harnesses; The system of claim 11 , wherein the hookup file defines the WTMs assigned to the harness connections.

16. The inspection plan is generated with additional harness information regarding splices, passives, and discarded lost leads; The system of claim 11 , wherein the test plan is generated for each of the plurality of electrical wiring harnesses to check wires and unused pins in a network configuration.

17. 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 11, wherein the test is selected from a plurality of tests including:

18. 12. The system of claim 11, further comprising evaluating the status of the test results through a color-coded report by highlighting the test results with different colors.

19. The system of claim 11 , further comprising wirelessly communicating with the plurality of WTMs to update software packages.

20. A non-transitory computer-readable medium that, when executed by a processor, using a computer server to receive the wire list, the inspection criteria, and the Wireless Harness Automatic Measurement System (WHAMS); Generating an inspection plan for a plurality of wire harnesses; selecting a plurality of wireless test modules (WTMs) using said test plan and said WHAMS; generating a plurality of test instructions based on the test plan and the plurality of WTMs; performing one or more tests on the plurality of electrical wiring harnesses according to the plurality of test commands using the plurality of WTMs; using the plurality of WTMs to wirelessly transmit test results to the computer server for display; 23. A non-transitory computer-readable medium comprising instructions configured to:

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