System and method for calibration of wireless harness automatic measurement system

Abstract

To achieve a rigorous and thorough test of an electrical wiring harness by calibrating a wireless harness automatic measurement system (WHAMS) with computer assistance.SOLUTION: A method (1700) performed by a computer is used for calibrating a wireless test module (WTM) of the WHAMS using a computer server and a calibration jig (1500). The WTM (120) includes multiple field-effect transistors (FETs). The calibration jig has multiple resistors (1702). In this method, first and second resistance values of the multiple FETs are measured using the calibration jig from first and second internal measurement tests for the WTM. A resistance calibration value is obtained by subtracting the first resistance value from the second resistance value. Multiple calibration factors are measured to obtain a measurement resistor value for the corresponding resistor of the calibration jig to obtain a target resistor value.SELECTED DRAWING: Figure 17

Description

[Technical field]

[0001] FIELD OF THE DISCLOSURE This disclosure relates generally to calibration of a Wireless Harness Automatic Measurement System (WHAMS), and more particularly to hardware and routines associated with a WHAMS calibration system and method. [Background technology]

[0002] Electrical wiring harnesses (also called wire harnesses or wiring harnesses) are used in a wide variety of industries and vehicles. For example, large and complex electrical wiring harnesses containing numerous wires and connectors are used by the aerospace industry in the manufacture of aircraft. As another example, electrical wiring harnesses are used by the automotive industry in the manufacture of automobiles. Electrical wiring harnesses for vehicles, such as aircraft and automobiles, must typically be rigorously and thoroughly tested to ensure that the connectors or wires of the electrical wiring harness are free of defects. For example, electrical wiring harnesses are tested to ensure that there are no shorts in the wires or wires, no replacement of connector pins, no damage to the wires, and other issues. Summary of the Invention [Problem to be solved by the invention]

[0003] SUMMARY OF THE PRESENT EMBODIMENT It is an object of the present invention to provide a system and method for calibrating a wireless harness automatic measurement system for rigorous and thorough testing of electrical wiring harnesses during aircraft and automobile manufacturing. [Means for solving the problem]

[0004] According to some embodiments, the system includes a computer system and a plurality of wireless test modules. Each wireless test module includes a wireless transceiver, and the wireless test modules can be physically coupled to the electrical wiring harness. The computer system is operable to send test instructions to the plurality of wireless test modules according to an automatic test plan. Each wireless test module is operable to wirelessly receive one or more of the plurality of test instructions from the computer system using the wireless transceiver, and to perform one or more tests on the electrical wiring harness according to the one or more instructions received from the computer system. Each wireless test module is further operable to wirelessly transmit test results to the computer system using the wireless transceiver.

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

[0006] In some embodiments, the system includes a hot-swap connector that couples a chassis of the wireless test module to a variable front-end of the wireless test module. The variable front-end of the wireless test module can be mated to an aircraft connector. The hot-swap connector includes a WTM-side hot-swap connector and a front-end-side hot-swap connector disposed between the chassis of the wireless test module and the variable front-end of the wireless test module. The WTM-side hot-swap connector can be mated to the front-end-side hot-swap connector to couple the chassis of the wireless test module to the variable front-end of the wireless test 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 test module, a slip ring configured to secure the wireless test module in place, and an Electrically Erasable Programmable Read Only Memory (EEPROM) read / write wire mounted on a circuit board and operable to read / write data to the aircraft connector. The front-end hot-swap connector has 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 mounted on a circuit board and operable to store data for the aircraft connector.

[0007] According to some embodiments, the WTM side hot swap connector is further operable to attach the adjustable front end of the wireless test module to the chassis of the wireless test module. The WTM side hot swap connector is further operable to remove the adjustable front end of the wireless test module from the chassis of the wireless test module. The WTM side hot swap connector is further operable to transfer data to the wireless test module when the chassis of the wireless test module and the adjustable front end of the wireless test module are mated. The WTM side hot swap connector is a universal connector located at an end of the chassis of the wireless test module, and the universal connector is attached to the front end side 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 computer system using the wireless transceiver to transfer data stored on the EEPROM associated with the EEPROM read / write wire. The female connector includes a plurality of contacts ranging from 48 to 128. The EEPROM read / write wire is configured to couple to the chassis of the wireless test module. The WTM-side hot-swap connector further includes a jumper harness configured to couple to the wireless test module, the WTM-side hot-swap connector operable to switch to a different wireless test module with address information automatically updated in real-time in the event of a malfunction of the wireless test module.

[0008] According to some embodiments, the front-end hot-swap connector is further operable to attach the adjustable front-end of the wireless test module to the chassis of the wireless test module. The front-end hot-swap connector is further operable to remove the adjustable front-end of the wireless test module from the chassis of the wireless test module. The front-end 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 front-end hot-swap connector is a universal connector located at an end of the adjustable front-end of the wireless test module, which is attached to the WTM hot-swap connector located at an end of the chassis of the wireless test module. The male connector includes a plurality of connectors ranging from 48 to 128. The front-end hot-swap connector further includes a plurality of connectors configured to couple to wire jumpers of the aircraft connector. The wireless test module is further operable to wirelessly communicate with a computer system using the wireless transceiver to transfer data stored on the EEPROM. The data on the EEPROM is automatically incorporated into the test software of the central computer system without human data entry. The front-end side hot-swap connector is further operable to switch to a different wireless test module with address information automatically updated in real-time in case of a wireless test module malfunction.

[0009] According to some embodiments, the system includes a battery pack module for the wireless test module. The battery pack module includes a wireless charging battery, a wireless battery pack holder capable of housing the wireless charging battery, an injection molded pogo pin holder including a plurality of pogo pins, and a wireless charging receiver operable to wirelessly charge the wireless charging battery. The injection molded pogo pin holder is coupled to the wireless battery pack holder using a set of screws. The injection molded pogo pin holder is operable to couple to the wireless test module. The battery pack module includes a steel retractable spring plunger including a pull ring operable to hold the battery pack modules together by attachment of the WTM using a second set of screws. The battery pack module includes a magnet attached to the wireless charging receiver that is latchable onto the WTM. The wireless charging receiver is a 5 volt (V) Qi standard wireless charging receiver that includes a magnet plate that is compatible with the magnet. The wireless battery pack holder is a three-dimensional (3D) printed part with a shape that allows the wireless battery pack holder to slide over the end of the WTM. 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 isolation check, a diode polarity check, and a resistance measurement check. The WTM can wirelessly communicate with the computer system using Wi-Fi, Bluetooth, or Zigbee. The WTM includes an electrical connector that can be coupled to a wiring harness connector of the electrical wiring harness.

[0010] According to some embodiments, the system includes a computer-implemented method for operating a computer system and a plurality of wireless test modules of the WHAMS. The computer-implemented method can access a plurality of electrical wiring harnesses, test criteria, and the WHAMS using a computer server. Each of the plurality of electrical wiring harnesses is connected to an endpoint of each of the wireless test modules of the WHAMS. The computer-implemented method can create 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 a plurality of 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 created with additional harness information of splices, passive devices, and loose lead resignments. As another example, the test plan is created to check wires and unused pins in a network configuration for each of the plurality of electrical wiring harnesses. The computer-implemented method may 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 isolation check, a time domain reflectometry (TDR) test, a fiber optic test, a diode polarity check, and a resistance measurement check. The computer-implemented method may use the WTMs to wirelessly transmit test results to a computer server for display. The computer-implemented method may implement a WTM board support package to apply the core operating applications of the wireless test modules to perform one or more tests on the electrical wiring harnesses according to the test instructions. The computer-implemented method may embody a custom power controller suite to manage the batteries of the wireless test modules.The computer-implemented method can perform one or more tests on the plurality of electrical wiring harnesses according to a plurality of test instructions using a bi-directional test approach. The computer-implemented method can evaluate the status of the test results through a color-coded report by highlighting the test results using different colors. The computer-implemented method can wirelessly communicate with the plurality of wireless test modules to update a software package and 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.

[0011] According to some embodiments, the 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 may be physically coupled to the electrical wiring harness. The wireless test module has a chassis and a variable front end coupled to the chassis using a hot-swap connector. The chassis includes a plurality of electrical relays and a rechargeable battery designed to enable high voltage capability solid state multiplexing. In particular, the chassis includes a central processing and memory block and circuitry operable to determine measurements for manufacturing and debugging the electrical wiring harness. The variable front end includes an electrical connector that can be coupled to a wiring harness connector of the electrical wiring harness. For example, the electrical connector supports up to 128 pin connectors. As another example, the electrical connector supports up to 48 pin connectors. 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 different connectors.

[0012] In some embodiments, the wireless test module is operable to wirelessly receive a plurality of test instructions from the computer system according to an automatic test plan using the wireless transceiver. The wireless test module is further operable to perform one or more tests on the electrical wiring harness according to the plurality of test instructions using the variable front end. The one or more tests are selected from a plurality of tests including a continuity check, a voltage isolation check, a TDR test, a fiber optic test, a diode polarity check, and a resistance measurement check. The wireless test module is further operable to wirelessly transmit test results to the computer system using the wireless transceiver. The wireless test module has a shape selected from a plurality of shapes including a prism shape, a pyramid shape, a cylinder shape, and a sphere shape. The wireless test module can further wirelessly communicate with the computer system using Wi-Fi, Bluetooth, or Zigbee. The wireless test module can further apply a pick-by-light function for initial hardware selection and harness hook-up 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 testing of the electrical wiring harness, the internal power source being a high voltage source or a low voltage source. The wireless test module is further operable to replace the inoperative chassis with another available unit in case of malfunction. The wireless test module is further operable to produce a low voltage output of about 2.4 volts (V) for resistance / continuity testing. The wireless test module is further capable of measuring resistance with an accuracy of 10% ±1 ohm when the resistance is in the range of 1 ohm to 50 ohms. The wireless test module is further capable of measuring resistance with an accuracy of 5% ±1 ohm when the resistance is in the range of 51 ohms to 250 ohms. The wireless test module is further capable of measuring resistance with an accuracy of 10% ±1 ohm when the resistance is in the range of 251 ohms to 1 megaohm. The wireless test module may further be operable to produce a voltage output in the range of 100V to 500V for high voltage testing. The wireless test module may further be operable to measure resistance with an accuracy in the range of 6% to 10% using the high voltage. The wireless test module may further be operable to identify a variable front end.

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

[0015] According to some embodiments, the charging cart further includes a power source capable of providing 1500 watts (W) of power to charge the wireless test modules in parallel. The charging cart is a double deck charging cart with a number of charging slots ranging from 150 to 200. The charging cart is a single deck charging cart with a number of charging slots ranging from 50 to 100. The charging cart is a mini charging cart with a number of 4 charging slots ranging from 20 to 30. The charging cart has a base assembled with a number of sheets and pipes, the base being made of one or more decks that are welded onto the charging cart and allocate the number of charging slots. The number of charging slots are keyed slots that receive the number of WTMs so that the number of WTMs are accurately positioned. The charging cart is coupled to the frame using bolts. Each of the number of LED indicators includes a red LED and a green LED. Each of the number of LED indicators turns red to indicate that an identified WTM associated with the LED is currently charging. Each of the plurality of LED indicators turns green to indicate the identified WTM associated with the LED is in place before testing. Each of the plurality of LED indicators turns off to indicate the identified WTM associated with the LED is finished charging. Each of the plurality of charging slots uses a four pogo pin layout to charge the plurality of WTMs. 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 jig. The calibration jig 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 may be optically isolated MOFFETS. The calibration jig includes a plurality of resistors. The calibration jig is operable to measure 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 jig is operable to perform a resistance accuracy test (RAT) on the wireless test module using the plurality of resistors of the calibration jig. The RAT may select a resistor from the plurality of resistors of a test associated with the calibration jig and the WTM, the resistor being associated with a target resistance value. The RAT may measure a plurality of calibration factors using the calibration jig and the test. The RAT may determine a measured resistance value using the plurality of calibration factors. The RAT may 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 with a high-side resistance and a low-side FET with a low-side resistance. The test is selected from a plurality of tests including a continuity check, a voltage isolation check, a diode polarity check, and a resistance measurement check. A first resistance value of the FET indicates a magnitude of a high-side resistance associated with the high-side FET. A second resistance value of the FET indicates a combined magnitude 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 ranges from 80 ohms to 90 ohms, and the second resistance value ranges from 120 ohms to 140 ohms. The plurality of resistors has a plurality of resistance values ​​ranging from 1 ohm to 50 megaohms. The plurality of calibration factors for the continuity test include a source side high-side calibration index value, a sink side high-side calibration factor, and an initial resistance value. A measured resistance value for the continuity test is determined by subtracting the source side high-side calibration factor and the sink side high-side calibration factor from the initial resistance value.The calibration jig may further be operable to perform multiple RATs on the WTM using multiple resistors in the calibration jig. The calibration jig may further be operable to store a RAT history associated with the multiple calibration factors and the RATs in a database on a computer server. The calibration jig may further be operable to perform controlled periodic calibrations on the WHAMS to detect potential failure modes using resistance of FET drift over a period of time.

[0017] A technical advantage of certain embodiments is the provision of an improved system and method for testing electrical wiring harnesses used in aircraft, automobiles, or other vehicles and devices. The wireless harness automatic measurement system and method of the present invention provides a unique combination of hardware versatility and mobility for application at all stages of electrical wiring harness testing. Instead of typical bulky test cabinets with hardwired adapters, the disclosed embodiments utilize one or more wireless test modules that physically couple to the electrical wiring harness during testing and then wirelessly transmit results back to a central computer. This results in a wireless and scalable architecture that ensures maximum utilization of the hardware. The wireless communication capabilities of the wireless test modules open the door to electrical testing in environments that were previously difficult to access by hardwired test systems (e.g., cabinet-type electrical relay box systems with hardwired test cable adapters).

[0018] Additionally, minimal equipment requirements to initiate testing lowers the barrier to entry and increases the efficiency of the system. The disclosed embodiments provide a simple information entry format that ensures rapid and automated test plan creation with little or no tasks required by the 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 described above, various embodiments may include all, some, or none of the above-described advantages.

[0019] For a more complete understanding of the present invention, and the advantages thereof, 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] FIG. 1 illustrates a wireless harness automatic measurement system according to some embodiments. [Figure 2A] 2 illustrates how an electrical wiring harness is tested by the wireless harness automatic measurement system of FIG. 1 according to some embodiments. [Figure 2B] 2 illustrates how an electrical wiring harness is tested by the wireless harness automatic measurement system of FIG. 1 according to some embodiments. [Diagram 3] 2 illustrates a wireless test module that can be utilized by the wireless harness automatic measurement system of FIG. 1 according to some embodiments. [Figure 4] 4 is an exploded view of the wireless test module of FIG. 3 according to some embodiments. [Diagram 5] 4 is an internal view of the wireless test module of FIG. 3 according to some embodiments. [Figure 6] 4 is a functional block diagram of the wireless test module of FIG. 3 according to some embodiments. [Figure 7A]4 illustrates a WTM-side hot-swap connector coupled to the tunable front-end of FIG. 3 according to some embodiments. [Figure 7B] 4 illustrates a front-end hot-swap connector coupled to the wireless test module of FIG. 3 according to some embodiments. [Figure 7C] 4 illustrates a front-end hot-swap connector coupled to the wireless test module of FIG. 3 according to some embodiments. [Figure 8A] 4 illustrates an example tunable front end that can be attached to the wireless test module of FIG. 3 according to some embodiments. [Figure 8B] 4 illustrates an example tunable front end that can be attached to the wireless test module of FIG. 3 according to some embodiments. [Figure 8C] 4 illustrates an example tunable front end that can be attached to the wireless test module of FIG. 3 according to some embodiments. [Figure 9A] FIG. 2 illustrates a battery pack for a wireless test module according to some embodiments. [Figure 9B] FIG. 2 illustrates a battery pack for a wireless test module according to some embodiments. [Figure 9C] FIG. 2 illustrates a battery pack for a wireless test module according to some embodiments. [Figure 10] 9A-9C according to some embodiments. FIG. [Figure 11A] FIG. 1 illustrates a charging cart system for storing multiple wireless test modules according to some embodiments. [Figure 11B] FIG. 1 illustrates a charging cart system for storing multiple wireless test modules according to some embodiments. [Figure 11C] FIG. 1 illustrates a charging cart system for storing multiple wireless test modules according to some embodiments. [Figure 11D]FIG. 1 illustrates a charging cart system for storing multiple wireless test modules according to some embodiments. [Figure 11E] FIG. 1 illustrates a charging cart system for storing multiple wireless test modules according to some embodiments. [Figure 11F] FIG. 1 illustrates a charging cart system for storing multiple wireless test modules according to some embodiments. [Figure 12] 11A-11F show details of the charging cart according to some embodiments. [Figure 13] 11A-11F show details of the charging cart according to some embodiments. [Figure 14A] 11A-11F show details of the charging cart according to some embodiments. [Figure 14B] 11A-11F show details of the charging cart according to some embodiments. [Figure 14C] 11A-11F show details of the charging cart according to some embodiments. [Figure 14D] 11A-11F show details of the charging cart according to some embodiments. [Figure 15] FIG. 2 illustrates a calibration jig for a wireless test module according to some embodiments. [Figure 16A] 16 illustrates an internal measurement test using the calibration jig of FIG. 15 according to some embodiments. [Figure 16B] 16 illustrates an internal measurement test using the calibration jig of FIG. 15 according to some embodiments. [Figure 17] 16 illustrates a resistance accuracy test using the calibration jig of FIG. 15 according to some embodiments. [Figure 18A] 2 illustrates an example application interface of operating software that enables testing of multiple electrical wiring harnesses by the wireless harness automatic measurement system of FIG. 1 in accordance with certain embodiments. [Figure 18B]2 illustrates an example application interface of operating software that enables testing of multiple electrical wiring harnesses by the wireless harness automatic measurement 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] FIG. 1 illustrates an example computer system that can be utilized to implement aspects of the various techniques provided herein, according to certain embodiments. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] Electrical wiring harnesses are utilized in a wide variety of industries and vehicles. For example, large and complex electrical wiring harnesses containing numerous wires and connectors are utilized by the aerospace industry in the manufacture of aircraft. As another example, electrical wiring harnesses are utilized by the automotive industry in the manufacture of automobiles. Electrical wiring harnesses for vehicles, such as aircraft and automobiles, must typically be rigorously and thoroughly tested to ensure that there are no defects in the connectors or wires of the electrical wiring harness. For example, electrical wiring harnesses are tested to ensure there are no shorts in the wires or wires, no replacement of connector pins, no damage to the wires, and other issues.

[0022] Typically, electrical wiring harnesses are tested using large cabinet-type electrical relay boxes with hard-wired interface connection test cable adapters that physically connect to both the connectors of the electrical wiring harness under test and the electrical relay box. The electrical machine operations occur in a centralized cabinet, while the hard-wired cable adapters act as extension cords for the unique mating connectors to reach the electrical wiring harness under test. However, such systems can be problematic in certain situations. For example, it is inefficient to use cabinet-type test machines during harness testing, such as for setup, testing, repair (harness and tools), and during breakdowns. Typical cabinet-type test machines are large, heavy, and relatively difficult to move, and such cabinet-type test machines utilize highly customized test cable adapter sets, so they cannot be efficiently scaled to meet changing electrical testing needs. As another example, operators typically spend hundreds of hours using cabinet-type test machines, such as troubleshooting systems, during harness testing per aircraft to ensure product quality in the aerospace, defense, and transportation / rail industries. As another example, a typical cabinet type test machine requires testing jigs that fit into the fabrication tooling to test various independent sets of test cables and wire harness form boards.

[0023] To solve these and other problems with typical systems for testing 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 the electrical wiring harness under test. One or more wireless test modules are utilized in a Wireless Harness Automatic Measurement System (WHAMS) for a mobile testing solution that verifies electrical harnesses while mitigating the inefficiencies of traditional cable-based testing using cabinet-type test machines. The wireless test modules transmit and receive electrical test signals over one or more wires of the electrical wiring harness, and then wirelessly report test results back to a central computer system, e.g., a laptop, unlike current hardwired 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 electrical wiring harness installation site without having to worry about how to move the central computing system or bulky relay cabinets. This increases productivity and effectiveness when testing electrical wiring harnesses. In some embodiments, the wireless test modules are cylindrical in shape and similar in dimensions to a typical flashlight. This small form factor allows a technician to easily carry multiple wireless test modules and attach them to electrical wiring harnesses under test that may be physically located far away (e.g., in the next room or on the floor) from the central computing system.

[0024] Each wireless test module has 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 isolation check, diode polarity check, resistance measurement check, etc.). The removable front end of the wireless test module has a specific mating connector that can be connected to the connector of the electrical wiring harness and is quickly interchangeable with a common interface provided 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 configured to meet various demands for electrical connectors while minimizing the number of wireless test modules required for maximum hardware utilization. The hardware commonality of the wireless test module chassis also allows for easy replacement in case of malfunction. If one wireless test module becomes inoperative, critical test activities can continue without delay by simply replacing the inoperative wireless test module chassis with another available unit. As a result, a test operator can complete testing of an electrical wiring harness without the need for test equipment troubleshooting or repair.

[0025] The wireless harness automatic measurement system and method of the present invention provides a unique combination of hardware versatility and mobility to be adaptable at every stage of electrical wiring harness testing. Certain disclosed embodiments provide a wireless and scalable architecture that ensures maximum utilization of hardware. The wireless communication capabilities of the wireless test modules open the door to electrical testing in environments that were previously difficult to access by hardwired test systems (e.g., cabinet-type electrical relay box systems with hardwired test cable adapters). Furthermore, minimizing the equipment requirements to initiate a test lowers the test entry barrier and increases the efficiency of the system. Certain disclosed embodiments provide a simplified information entry format that ensures fast and automated test plan creation with little or no manual effort required by the operator.

[0026] To facilitate a better understanding of the present invention, the following examples of certain embodiments are given. The following examples should in no way be read as limiting or defining the scope of the present invention. The embodiments of the present invention and its advantages are best understood by referring to the accompanying drawings, in which the same reference numerals are used to indicate the same or corresponding parts.

[0027] WHAMS Overall System 1 illustrates some embodiments of a wireless harness automatic measurement system 100. The wireless harness automatic measurement system 100 includes an electrical wiring harness under test 110, one or more wireless test modules 120 (e.g., 120A, 120B, 120C, 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, other embodiments may utilize any number of wireless test modules 120.

[0028] 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 has at least one connector that physically and electrically couples to a wiring harness connector 115 (e.g., 115A, 115B, 115C, 115D) of the wireless test module 120 under test. The wireless test module 120 transmits and receives electrical test signals through one or more wires 111 of the electrical wiring harness 110 to perform tests such as continuity checks (e.g., whether pins of the wiring harness connector 115 are in the wrong place, whether pins of the wiring harness connector 115 are shorted, etc.), voltage isolation checks, diode polarity checks, and resistance measurement checks. In this case, unlike typical solutions that are hardwired into bulky relay cabinets, the wireless test modules 120 wirelessly report test results 160 back to the central computer system 130 using wireless transceivers (e.g., 121A, 121B, 121C, 121D). That is, each wireless test module 120 is not physically connected to the central computer system 130, but instead communicates wirelessly with the central computer system 130 using a wire protocol, e.g., Zigbee, Bluetooth, or Wi-Fi. The small form factor of the wireless test modules allows a technician to easily carry multiple wireless test modules 120 and attach them to wiring harness connectors 115 on the electrical wiring harness 110, even when the electrical wiring harness 110 is physically located far from the central computing system 130.

[0029] The electrical wiring harness 110 is a bundle of electrical wires 111. The electrical wiring harness 110 has one or more wiring harness connectors 115 coupled to one or more of the electrical wires 111. For example, the electrical wiring harness 110 of FIG. 1 has four wiring harness connectors 115: 115A-115D. The wiring harness connectors 115 may be any suitable electrical connector and may have 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 may be installed in any device or vehicle, such as an aircraft, automobile, watercraft, spacecraft, and the like. The wireless automatic measurement system 100 may be utilized to test the electrical wiring harness 110 either before or after it is installed in its intended device, aircraft, or vehicle.

[0030] Each wireless test module 120 (120A-120D) is a portable test device that makes a physical connection to the wiring harness connector 115 of the electrical wiring harness 110, performs one or more electrical tests on the electrical wiring harness 110 as commanded by the central computer system 130, and / or wirelessly communicates test commands 150 from the electrical tests back to the central computer system 130. Existing test systems for electrical wiring harnesses include large, bulky relay cabinets with hard-wired test adapters that connect to the wiring harness connectors 110. Such systems are difficult to transport, not easy to adapt, and not easy to scale. However, by utilizing the wireless test modules 120 that have a small form factor and are easy to carry, the wireless harness automatic measurement system 100 can be used to test electrical wiring harnesses 110 located at long distances (e.g., in another room or floor). Additionally, any number of wireless test modules 120 can be utilized by the wireless harness automatic measurement system 100 to test the electrical wiring harness 110, thereby increasing the adaptability and scalability of the wireless harness automatic measurement system 100 compared to existing hardwired test relay cabinets.

[0031] Each wireless test module 120 includes a wireless transceiver 121, a chassis 122 (e.g., 122A, 122B, 122C, 122D), and a configurable front-end 126. The wireless transceiver 121 allows the wireless test module 120 to wirelessly communicate (either directly or via a wireless interface 140) with a central computer system 130 using any suitable wireless protocol (e.g., Zigbee, Bluetooth, or Wi-Fi, etc.). The chassis 122 is the main body of the wireless test module 120, which houses components such as a battery, relays, processor, memory, etc. The configurable front-end 126 is a removable portion of the wireless test module 120, which includes an electrical connector configured to mate with a wiring harness connector 115 of the electrical wiring harness 110. For example, if the wiring harness connector 115A is a typical three-prong plug, the variable front end 126 may include a three-prong female electrical plug. As another example, if the wiring harness connector 115A is a male coaxial electrical connector, the variable front end 126 may include a female coaxial electrical connector. Details regarding the wireless test module 120 and its components are described in more detail below with reference to Figures 2-8C.

[0032] The central computer system 130 may be any suitable computing system in any suitable physical form. By way of example, and without 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 mesh-connected computer system, a mobile phone, a personal digital assistant (PDA), a server, a tablet computer system, an augmented / virtual reality device, or a combination of two or more of these. Where appropriate, the central computer system 130 may include one or more computer systems or may be distributed, spanning multiple locations, spanning multiple machines, spanning multiple data centers, or residing in a cloud, which may include one or more cloud components in one or more networks. Where applicable, the central computer system 130 may perform one or more steps of one or more methods described or illustrated herein without substantial space or time constraints. 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, as appropriate. A particular example of the central computer system 130 is described with reference to FIG.

[0033] The wireless interface 140 is any suitable device capable of providing wireless communication between the central computer system 130 and the wireless test module 120. In some embodiments, the wireless interface 140 is a separate device that is communicatively coupled (e.g., wired, wirelessly coupled, or physically plugged) to the central computer system 140. In other embodiments, the wireless interface 140 is located within 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.

[0034] The test instructions 150 are 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 instructions 150 are utilized by the wireless test module 120 to perform one or more electrical tests on the electrical wiring harness 110. The electrical tests consist in performing tests such as, for example, continuity checks (e.g., whether pins of the wiring harness connector 115 are in the wrong place, whether pins of the wiring harness connector 115 are shorted, whether the wires 111 are damaged, etc.), voltage isolation checks, diode polarity checks, and resistance measurement checks, etc. In some embodiments, the test instructions 150 are defined by the central computer system 130 according to a test plan for the electrical wiring harness 110. An example of the test instructions 150 is described with reference to FIGS. 18A and 18B.

[0035] Test results 160 are one or more signals, values, pass / fail indicators, etc. that are wirelessly communicated (either directly or via wireless interface 140) from wireless test module 120 to central computer system 130. Test results 160 are the results of one or more electrical tests performed on electrical wiring harness 110 by wireless test module 120. Test results 160 further include status and other signal metadata not directly associated with harness test results. An example of test results 160 is described with reference to FIG. 18A.

[0036] 2A and 2B show various examples of testing an electrical wiring harness 110 by a wireless harness automatic measurement system 100 according to some embodiments. In FIG. 2A, two wireless test modules 120, namely, a source wireless test module 120A and a destination wireless test module 120B, are utilized to perform tests on the electrical wiring harness 110. In this example, the source wireless test module 120A is physically coupled to a first wiring harness connector 115A, and the destination wireless test module 120B is physically coupled to a second wiring harness connector 115B. Two wires 151, namely, a first wire 111A and a second wire 111B, are utilized during testing in this scenario. The second wire 111B is used as a return line in this example. Both the wire 111A and the wire 111B are physically and electrically coupled to both the source wireless test module 120A and the destination wireless test module 120B via wiring harness connectors (e.g., wireless wiring harness connectors 115A, 115B in FIG. 1). The source wireless test module 120A sends a current flow to the first wire 111A, and the destination wireless test module 120B internally connects the first wire 111A to the second wire 111B, for example, using an electrical relay. The source wireless test module 120A can then measure the voltage and current passing through the first wire 111A and the second wire 111B to perform various electrical tests as described herein. The destination wireless test module 120B also measures the current and voltage to ensure that the current actually reaches the destination wireless test module 120B. The destination wireless test module 120B has a pin multiplexing component, such as a high voltage capability solid state multiplexing block 616, configured to enable connections by routing signals over one or more channels in a variety of switching and digital control applications.

[0037] 2A example, options other than the second wire 111B may be utilized for the electrical return path or ground. For example, an electrical shield within the electrical wiring harness 110 may be utilized for the electrical return path or ground. As another example, an electrical jumper (e.g., an electrical wire) may be physically connected to both the source wireless test module 120A and the destination wireless test module 120B and may be used as the electrical return path or ground.

[0038] In FIG. 2B, a single wireless test module 120A is utilized to perform testing on the electrical wiring harness 110. In this example, the wireless test module 120A is physically coupled to a first wiring harness connector (e.g., wiring harness connector 115A 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). Two wires 111, namely, the first wire 111A and the second wire 111B, are utilized for testing in this scenario. The second wire 111B is used as a return line in this example. Both the wire 111A and the wire 111B are physically and electrically coupled to the wireless test module 120A and are coupled to each other using a loopback device. The wireless test module 120A sends a flow of electrical current down the first wire 111A, which is returned to the wireless test 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.

[0039] In principle of operation, referring to FIG. 1, FIG. 2A, and FIG. 2B, the wireless harness automatic measurement system 100 utilizes a central computer system 130 and one or more wireless test modules 120 to test the electrical wiring harness 110. First, the one or more wireless test modules 120 are physically connected to one or more wireless wiring connectors 115 of the electrical wiring harness 110. For example, as shown in FIG. 2A, the source wireless test module 120A is physically coupled to the first wiring harness connector 115A, and the destination wireless test module 120B is physically coupled to the second wiring harness connector 115B. As another example, as shown in FIG. 2B, the source wireless test module 120A is physically coupled to the first wiring harness connector 115A, and a loopback connector (or other similar device) is physically coupled to the second wiring harness connector 115B. The central computer system 130 then sends test commands 150 to one or more wireless test modules 120 according to the automatic test plan. Details and examples of automatic test plans used to test the electrical wiring harness 110 are described in more detail below. In some embodiments, the test commands 150 are sent to the one or more wireless test modules 120 using the wireless interface 140. The test commands 150 may be sent using any suitable wireless protocol, such as Wi-Fi, Bluetooth, or Zigbee.

[0040] After receiving the test command 150 using the wireless transceiver 121, the wireless test module 120 performs one or more tests on the wiring harness connector 115 according to the received test command 150 from the central computer 130. The electrical tests may be, for example, a continuity check (e.g., whether the pins of the wiring harness connector 115 are in the wrong place, whether the pins of the wiring harness connector 115 are shorted, etc., whether the wires 111 are damaged, etc.), a voltage isolation check, a diode polarity check, and a resistance measurement check. For example, the wireless test module 120 may activate / deactivate one or more internal electrical relays and allow current to flow from an internal power source to one or more wires 111 of the electrical wiring harness 110 in order to perform a continuity check on the electrical wiring harness 110. Each wireless test module 120 may vary the voltage and current applied to one or more connecting wires 111 according to the received test command 150. After performing one or more tests on the electrical wiring harness 110 in accordance with the central computer system 130's received test orders 150, the wireless test modules 120 return test results 160 to the central computer system 130 by wireless transmission (either directly or via the wireless interface 140). Once the test results 160 are received by the central computer system 130, the central computer system 130 may display the test results 160 received from the one or more wireless test modules 120 on an electronic display.

[0041] WHAMS Wireless Test Module In some embodiments, the wireless test module is the primary electrical test hardware of the WHAMS. The wireless test module is a cylindrical wirelessly enabled communication and test node that can perform various electrical checkouts by mating with separate electrical connectors on the aircraft or other electrical harnesses. The wireless test module can communicate with a radio transceiver that is powered by the central computer system 130. The central computer system 130 then sends various commands to the wireless test module to enable tests to be performed and reported. The wireless test module can operate by itself or in a scalable network of multiple wireless test modules for use on a large harness assembly.

[0042] FIG. 3 illustrates wireless test modules 120 that can be utilized by the wireless harness automatic measurement system of FIG. 1 according to some embodiments. Each wireless test module 120 includes a wireless transceiver 121 (shown in FIG. 1), a chassis 122, and a variable front end 126. The wireless test modules 120 are the primary electrical test hardware of the WHAMS. In some embodiments, traditional electrical harness test hardware includes one or more large charging cabinets and long cables with unique test adapters on the ends. The one or more charging cabinets may be configured to house hundreds of relays and other electrical components used to perform different test types required for functional electrical harness validation. In particular, an individual charging cabinet can test thousands of test points and is expandable by connecting multiple charging cabinets together. However, the one or more charging cabinets are configured to be scalable with many small test points. For example, the one or more charging cabinets are configured to be deployable for harness configurations that require less than or equal to a given number of test points. As a result, it is difficult to optimize the charging cabinet configuration to reduce costs, especially for miniature electrical harness assemblies that include a high degree of diversity in low pin count (LPC) charging cabinets. Typically, the charging cabinet has multiple connectors with different pin counts, styles, and units for the majority of the tasks being completed.

[0043] In some embodiments, one or more large charging cabinets use a panel of universal connector interfaces into which multiple test adapter cables plug. The multiple test adapters are double ended and unique lengths, which increases the weight and manufacturing costs of traditional electrical harness test hardware. Thus, traditional electrical harness test hardware is difficult to transport and deploy in an agile manner to enable multi-build environments.

[0044] In some embodiments, the wireless test module 120 is configured to use a smaller charging cabinet. Specifically, the wireless test module 120 has a portable and rapidly configurable cabinet form that can accommodate the wireless test module 120 in a tight form factor to provide full and closed-loop wireless capability for electrical harness testing. The wireless test module 120 is battery powered and operates separately and independently from other wireless test modules based on a separate architecture. Thus, the wireless test module 120 can perform one or more tests that are no longer tethered to an instant power source or a cabled test adapter. As a result, the wireless test module 120 can provide higher performance in testing harnesses of various sizes and can reduce the non-recurring engineering (NRE) required to bring up new test adapters.

[0045] In some embodiments, the wireless test module 120 is a cylindrical wirelessly enabled communication and test node. The chassis 122 may be a circuit card assembly (CCA) chassis housing multiple electronic components. In the case of malfunction, the wireless test module 120 allows the inoperable chassis 122 to be replaced with another operable unit. In some embodiments, the variable front end 126 includes an electrical connector 302 (and optionally a backshell), a plastic adapter (e.g., hot swap interface 124 connecting the electrical connector 302 to the chassis 122), and a wire harness (e.g., jumper harness 708 of FIG. 7A) that connects 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 may be configured to automatically identify a test adapter, e.g., the variable front end 126, connected to the wireless test module 120. The variable front end 126 may use the electrical connector 302 to couple to a wiring harness connector of an electrical wiring harness. Thus, the wireless test module 120 may be configured to physically couple to the electrical wiring harness for performing one or more electrical tests (e.g., continuity check, voltage isolation check, diode polarity check, resistance measurement check, etc.) on the electrical wiring harness. Specifically, the wireless test module 120 may be configured to wirelessly receive a plurality of test instructions (e.g., test instructions 150 of FIG. 1 ) using the wireless transceiver 121 in accordance with an automated test plan from a central computer system (e.g., central computer system 130 of FIG. 1 ). The wireless test module 120 is configured to perform one or more tests on the electrical wiring harness using the configurable front end 126 in accordance with the plurality of test instructions and based on the automated test plan from the central computer system. The wireless test module 120 is configured to wirelessly transmit test results to the central computer system using the wireless transceiver 121.

[0046] FIG. 4 is an exploded view of the wireless test module 120 of FIG. 3 according to some embodiments. The wireless test module 120 is a common duplicate module piece that allows for easy 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 the same. For example, the variable front end 126 can have front end hot swap connectors 404 that can be quickly interchanged for different connectors. The chassis 122 can be configured to house multiple electronic components that enable the wireless test module 120 to wirelessly communicate with a central computer system (e.g., central computer system 130 of FIG. 1) using Wi-Fi, Bluetooth, or Zigbee. The wireless test module 120 can communicate with test software and a wireless transceiver (e.g., wireless transceiver 121 of FIG. 1) using Zigbee communication protocol. Thus, the wireless test module 120 provides a mobile and modular electrical harness tester that does not use cabled test adapters to communicate with a central computer system.

[0047] 5 is an internal view of the wireless test module 120 of FIG. 3 in accordance with some embodiments. The wireless test module 120 may have a wide variety of mating electrical connectors 406. For example, the wireless test module 120 may support up to 120 pin electrical connectors 406. As another example, the wireless test module 120 may support up to 48 pin electrical connectors 406. The electrical connectors 406 may be incorporated into the wireless test module 120 to couple to wiring harness connectors of an electrical wiring harness.

[0048] FIG. 6 is 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 wireless block 602, a charging and power lock 604, a central processing and memory block 606, a rechargeable lithium ion battery 608, a high voltage source 610, a low voltage source 612, an analog measurement circuitry 614, and a high voltage capability solid state multiplexing block 616. The high voltage capability solid state multiplexing block 616 is connected to a configurable front end of the wireless test module (e.g., the configurable front end 126 of FIG. 3). In some embodiments, the central processing and memory block 606 of the wireless test module is combined with circuitry, such as the analog measurement circuitry 614, such that the wireless test module is typically designed to capture measurements taken during the manufacture and debugging of cable harnesses. In some embodiments, the wireless test module includes multiple electrical relays designed for the high voltage capability solid state multiplexing block 616. In some embodiments, the wireless test module includes a rechargeable lithium ion battery 608 (e.g., a 3400 milliamp-hour (mAh) rechargeable lithium ion battery), which eliminates the need for a cabled charging cabinet. As a result, the wireless test module may 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.

[0049] In some embodiments, the wireless test module is configured to use multiple electronic components to perform various electrical checkouts by mating with multiple separate electrical connectors of an aircraft or automotive electronic wiring harness. For example, the wireless test module can use the central processing and memory block 606 and the analog measurement circuitry 614 to acquire measurements during testing of the aircraft or automotive electronic wiring harness. Similarly, the wireless test module can use the central processing and memory block 606 to apply a pick-by-light function for the initial hardware selection and harness hook-up process. As another example, the wireless test module can use the wireless block 602 to communicate with a control laptop, e.g., a wireless transceiver powered by a central computer system, which sends various types of test commands (e.g., test commands 150 of FIG. 1 ) to the wireless test module for test execution and reporting. As another example, the wireless test module can apply an internal power source to one or more wires of the electrical wiring harness to perform tests on the electrical wiring harness. The internal power supply may include a high voltage supply 610 and / or a low voltage supply 612 .

[0050] In some embodiments, the wireless test module (e.g., wireless test module 120 of FIG. 1) has a power button (power switch) to allow a user to turn on, turn off, or reset the wireless test module. The wireless test module may be configured to use the mini USB connector, the wireless test module's charging port, and the charging and power block 604 to charge the wireless test module. Similarly, the wireless test module may 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 wireless test module's charging port may interface with a number of pogo pins located within each slot of the WHAMS charging cart. The number of pogo pins may also be used for the wireless test module's battery pack. When the wireless test module is powered off and power is applied to the charging port, the wireless test module may be configured to power on and begin charging. The wireless test module may have a number of light emitting diode (LED) indicators to visually facilitate visual communication with the user. For example, the LED indicator is colored orange and is located on the end of the wireless test module 120 .

[0051] In some embodiments, the wireless test module (wireless test module 120 of FIG. 1) may be configured to operate independently or in a scalable network of wireless test modules for use on a large harness assembly. Specifically, the wireless test module may be configured to generate a low voltage output of approximately 2.4 volts (V) for parallel / continuity testing. Similarly, the wireless test module may be configured to generate a voltage output in the range of 100V to 500V for high voltage testing with a tolerance of ±3% ±2V on the output voltage. As a result, the wireless test module may be configured to measure resistance with an accuracy of 10% ±1 ohm for resistances in the range of 1 ohm to 50 ohms. The wireless test module may be configured to measure resistance with an accuracy of 5% ±1 ohm for resistances in the range of 51 ohms to 250 ohms. The wireless test module may be configured to measure resistance with an accuracy of 10% ±1 ohm for resistances in the range of 251 ohms to 1 million (M) ohms. The wireless test module may be configured to measure resistance with an accuracy in the range of 6% to 10% using a high voltage. For example, resistance measurement accuracy using a 100V high voltage is 10% for resistances in the range of 1M ohms to 50M. As another example, resistance measurement accuracy using a 500V high voltage is 6% for resistances in the range of 1M ohms to 50M.

[0052] WHAMS Hot-Swap Connectors In some embodiments, the WHAMS is configured to perform one or more electronic tests for Functional Automated Check (FAC) on electronic wiring harnesses for a vehicle, such as an aircraft or automobile. The variety of connector types on a vehicle is limitless. The WHAMS may use wireless test modules to test every unique connector on the vehicle. Since the vehicle is tested in a disassembled, component state, the wireless test modules may use hot-swappable connectors to isolate the connectors from the wireless test modules to reduce manufacturing costs and increase versatility of the WHAMS.

[0053] FIG. 7A illustrates a WTM-side hot-swap connector 402 operable to couple to a variable front-end (e.g., variable front-end 126 of FIG. 3) according to some embodiments. A wireless test module (e.g., wireless test module 120 of FIG. 1) has a pair of hot-swap connectors, such as WTM-side hot-swap connector 402 and front-end-side hot-swap connector 404 of FIG. 4, disposed between a chassis of the wireless test module and a variable front-end of the wireless test module. The WHAMS can use multiple wireless test modules with several types of connectors for FAC during testing of multiple electrical wiring harnesses. In particular, every unique connector is considered in the FAC for vehicles such as aircraft and automobiles. A traditional WHAMS includes multiple connectors permanently attached to a wireless test module that includes all of the processing functions. Since at least one wireless test module is required for each unique connector, the traditional WHAMS may incur high manufacturing costs for testing multiple electrical wiring harnesses. The hot-swappable connectors can significantly reduce the manufacturing cost of the WHAMS and increase its versatility by isolating the hot-swappable connectors from the wireless test modules. The number of wireless test modules is determined based on the number of tests required for the WHAMS.

[0054] In some embodiments, the WTM side hot-swappable connector 402 is a custom-designed universal connector. The WTM side hot-swappable connector 402 may be located on the edge of the wireless test module chassis attached to another custom-designed universal connector, e.g., a front-side hot-swappable connector, located at the end of the adjustable front-end that mates with the wireless test module. Thus, the WTM side hot-swappable connector 402 can attach the wireless test module adjustable front-end to the wireless test module chassis. Similarly, the WTM side hot-swappable connector 402 can remove the wireless test module adjustable front-end from the wireless test module chassis. The WTM side hot-swappable connector 402 is operable to transmit data to and from the wireless test module when the wireless test module chassis and the wireless test module adjustable front-end are mated. The WTM side hot-swappable connector 402 is operable to switch to a different wireless test module with address information automatically updated in real time in case of wireless test module malfunction.

[0055] In some embodiments, the WTM-side hot-swap connector 402 includes an alignment peg 702, a slip ring 704, an electrically erasable programmable read-on-memory (EEPROM) read / write wire 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 a variable front end of a wireless test module. The slip ring 704 is configured to fix the wireless test module in a fixed position that allows for quick and reliable connection. Thus, the variable front end can be quickly attached and detached from the wireless test module. The EEPROM read / write wire 706 may be integrated on a circuit board for reading and writing data of the wireless test module. The EEPROM read / write wire 706 may be configured to couple to a chassis of the wireless test module. The wireless test module is operable to wirelessly communicate with a central computer system using a wireless transceiver, thereby transmitting data stored in an EEPROM (e.g., EEPROM 726 in FIG. 7B) associated with EEPROM read / write wire 706. Jumper harness 708 is configured to couple to the wireless test module. Surface mount female connector 710 has a number of contacts ranging from 48 to 128. For example, surface mount female connector 710 may have 100 contacts.

[0056] 7B and 7C show a front-end hot-swap connector 404 coupled to the wireless test module 120 of FIG. 3 according to some embodiments. The front-end hot-swap connector 404 is a custom-designed universal connector located on the end of the wireless test module's adjustable front-end, which is attached to another custom-designed universal connector, e.g., a WTM hot-swap connector, located on the end of the wireless test module's chassis. Thus, the front-end hot-swap connector 404 can serve to attach the wireless test module's adjustable front-end to the wireless test module's chassis. Similarly, the front-end hot-swap connector 404 can remove the wireless test module's adjustable front-end from the wireless test module's chassis. The front-end hot-swap connector 404 can operate to transfer data to and from the wireless test module when the wireless test module's chassis and the wireless test module's adjustable front-end are mated. The front-end hot-swap connector 404 can operate to switch to a different wireless test module with address information automatically updated in real time in the event of a wireless test module malfunction.

[0057] In some embodiments, the front-end hot-swap connector 404 includes an alignment peg 722, a screw thread 724, an EEPROM 726, a number of connectors 728, and a male connector, such as a surface-mount male connector 730. The alignment peg 722 is configured to mate with a chassis of a wireless test module. The screw thread 724 is configured to mate with a slip ring (e.g., slip ring 704 in FIG. 7A) to secure the wireless test module in place for quick and reliable connection. As a result, the variable front-end can be quickly attached and detached from the wireless test module. Once attached, the variable front-end is held securely in place with the slip ring and screw thread 724. The EEPROM 726 can be implemented on a circuit board to store data of the wireless test module. The wireless test module is operable to wirelessly communicate with a central computer system using a wireless transceiver, thereby transmitting data stored on the EEPROM 726. The data on EEPROM 726 can be automatically loaded into the test software of the central computer system without human data entry. The plurality of connectors 728 are configured to couple to aircraft connectors by wire jumpers. The surface mount male connector 730 has a plurality of contacts ranging from 48 to 128. For example, the surface mount male connector 730 may have 100 contacts.

[0058] Figures 8A-8C illustrate an example adjustable front end 802 that can be mounted on the wireless test module 120 of Figure 3 in accordance with some embodiments. Specifically, the adjustable front end 802 of Figures 8A-8C can be coupled to a wiring harness connector with various pins (e.g., wiring harness connector 115 of Figure 1), such as an aircraft connector.

[0059] WHAMS Battery Pack In some embodiments, the wireless test module may use a portable rechargeable battery pack to provide extra power when the WHAMS wireless test module runs out of power during testing in a low battery condition. The portable charging pack is configured to extend battery life for the WHAMS wireless test module when the wireless test module remains in a non-charging state for an extended period of time.

[0060] 9A-9C show a battery pack 900 for a wireless test module according to some embodiments. The battery pack 900 provides a portable charging solution for the wireless test module to provide extra power to the wireless test module during low battery levels during testing. 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 904 can accommodate the wireless charging battery. In some embodiments, the wireless battery pack holder 904 is a three-dimensional (3D) printed part with a shape that allows the wireless battery pack holder 902 to slide over the end of the wireless test module. Thus, the wireless battery pack holder 904 can accommodate multiple components required to make the battery pack 900 functional.

[0061] In some embodiments, the injection molded pogo pin holder 904 has a number 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 is coupleable to a wireless test module. The wireless charging receiver 906 is operable to wirelessly charge a wireless charging battery. Thus, the battery pack 900 is configured to charge the wireless test module by contacting the number of pogo pins with a compatible wireless charging battery pack. Specifically, the battery pack has a steel retractable spring plunger 908 with a pull ring that can hold the battery pack 900 together by coupling to the wireless test module using a second set of fasteners (e.g., screws). The battery pack 900 includes a magnet 910 attached to the wireless charging receiver 906. The magnet 910 is operable to latch the battery pack 900 onto the wireless test module. In some embodiments, the wireless charging receiver 906 includes a 5 Volt (V) Qi standard wireless charging receiver 912 that includes a magnet plate that is compatible with the magnet 910.

[0062] In some embodiments, the battery pack 900 is configured to extend battery life for the wireless test module of the WHAMS when the wireless test module remains in a non-charging state for an extended period of time. For example, the battery pack 900 can be coupled to the wireless test module to provide excess power to perform one or more electrical tests (e.g., continuity check, voltage isolation check, diode polarity check, resistance measurement check, etc.) on the electrical wiring harness. In particular, the wireless test module can have an electrical connector that can mate with a wiring harness connector of the electrical wiring harness. The wireless test module can perform one or more tests to verify the electrical wiring harness according to receiving test instructions from the central computer 130. In particular, the wireless test module can wirelessly communicate with the central computer system using Wi-Fi, Bluetooth, or Zigbee.

[0063] Figure 10 illustrates an injection molded pogo pin holder 904 for the battery pack of Figures 9A-9C according to some embodiments. The injection molded pogo pin holder 904 can have a number of pogo pins 1002 that can be fastened (e.g., screwed) to a wireless battery holder.

[0064] WHAMS charging cart In some embodiments, the WHAMS may use a mobile charging cart to charge multiple wireless test modules in parallel. The mobile charging cart is configured to hold and charge the multiple wireless test modules and to position the multiple wireless test modules when needed for testing. As a result, the mobile charging cart can ensure that the multiple wireless test modules are fully charged at the point of product use. Similarly, the mobile charging cart can locate the multiple wireless test modules with a pick by flight function that lights up the multiple wireless test modules that are called upon when needed for testing.

[0065] 11A-11F illustrate a charging cart system 1100 for storing multiple wireless test modules, according to some embodiments. The charging cart system 1100 is a bulk charging device configured to hold and charge multiple wireless test modules for manufacturing applications. The charging cart system 1100 has 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 a number of charging slots ranging from 150 to 200. FIG. 11B illustrates how the single deck charging cart 1170 can hold a number of charging slots ranging from 50 to 100. FIG. 11C illustrates how the mini charging cart 1180 can hold a number of charging slots ranging from 20 to 30. 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.

[0066] 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 having a bottom front 1108, a bottom middle 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 may be assembled using polyvinyl chloride (PVC) sheets and PVC pipes to support the charging cart. The PVC sheets may be 0.5 inch (1.27 cm) thick Type 1 PVC sheets. The PVC pipes may be Schedule 40 PVC pipes with a diameter of 2 inches (5.08 cm).

[0067] FIG. 11E shows an aluminum frame 1102. A charging cart 1150 is coupled to the aluminum frame 1102 using fasteners (e.g., bolts). The LED indicators of FIG. 11A are operable to identify the status of the wireless test modules during testing of the WHAMS. The charging slots of FIG. 11A are operable to charge the wireless test modules. Each of the charging slots is associated with a respective one of the LED indicators 1104. In some embodiments, the charging cart can charge more than 100 wireless test modules in parallel using a power source capable of providing 1500 watts (W). As another example, the charging cart can locate the wireless test modules with a find by light function, which lights up one or more wireless test modules used for testing. As a result, the charging cart can have a base constructed by a number of PVC sheets and PVC pipes. The foundation may include one or more decks, such as the seat assembly 1124 of FIG. 11F, that are welded to the charging cart to allocate multiple charging slots. The multiple charging slots are keyed slots to receive multiple wireless test modules so that the multiple wireless test modules are precisely positioned. FIG. 11F shows how each seat assembly 1124 can include a back sheet 1118, a front sheet 1112, and multiple PVC pipes 1122.

[0068] 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 mounted in the charging slot 1106 using an injection molded pogo pin block 1204. Specifically, the injection molded pogo pin block 1204 can have a four-pin layout 1300 as shown in FIG. 13 for charging the wireless test module 120 and a light indication using an LED ring 1206 with multiple red LEDs and multiple green LEDs in alternating order along the LED ring 1206. The LED ring 1206 can have a ring cover 1202 (e.g., a clear polycarbonate ring cover).

[0069] 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 1202, a ground pin 1304, and a number of LED pins 1306. The power pin 1202 may be a 5V pin. The number of LED pins 1306 may include a red LED pin and a green LED pin. As a result, the charging cart is configured to charge the wireless test modules using the injection molded pogo pin blocks while providing a light indication to help locate the wireless test modules.

[0070] 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-11C. 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 1500W single output power supply operable to provide power to a plurality of wireless test modules in the charging cart. FIG. 14D shows a plurality of LED indicators 1104 that can help identify the status of the corresponding wireless test module as well as help locate where the wireless test module is at any given time. Specifically, each of the plurality of LED indicators turns red to indicate that the identified wireless test module associated with the corresponding LED designation is currently charging. Each of the plurality of LED indicators turns green to indicate an identified wireless test module associated with the corresponding LED indicator that should be located before testing. Each of the plurality of LED indicators turns off to indicate that an identified wireless test module associated with the corresponding LED indicator has finished charging. For example, a red LED 1402 indicates that an identified wireless test module associated with the red LED 1402 is currently charging. As another example, a green LED 1404 indicates an identified wireless test module associated with the green LED 1404 that should be located before testing. As another example, a light-off LED 1406 indicates that an identified wireless test module associated with the light-off LED 1406 has finished charging.

[0071] WHAMS calibration Some embodiments relate to a calibration method for calibrating the wireless test module 120 of Fig. 1. At the time one or more electrical tests (e.g., continuity check, voltage isolation check, diode polarity check, resistance measurement check, etc.) are to be performed on an electrical wiring harness, it is essential to calibrate the wireless test module of the WHAMS in order to accurately read the resistance measurements. Before testing the WHAMS, the wireless test module is subjected to a controlled periodic calibration process, which allows the wireless test module to accurately read the resistance. Specifically, the wireless test module may have a number of field effect transistors (FETs). The number of FETs may be optically blocked MOFFETS. If the wireless test module is not properly calibrated, the measurements of the internal resistance of the number of FETs of the wireless test module may drift over time.

[0072] 15 illustrates a calibration jig 1500 for a wireless test module according to some embodiments. The calibration jig 1500 includes a switch board 1502, a connector 1504, and a ground cable 1506. In some embodiments, the switch board 1502 includes a number of switches 1508. The connector 1504 is used to attach the calibration jig 1500 to the wireless test module. The ground cable 1506 is used to connect the calibration jig 1500 directly to earth. The calibration method can apply a controlled periodic calibration process using the calibration jig 1500 in an automated manner to record the internal resistance of each of the multiple FETs. The controlled periodic calibration process may include one or more of the following five operations: (1) performing an internal measurement test; (2) performing a resistance accuracy test (RAT); (3) storing calibration factors; (4) storing RAT history; and (5) recalling updated calibration factors at the time of testing. The calibration jig 1500 is configured to short the wireless test module in the internal measurement test and the RAT to perform measurements of the internal resistance of the multiple resistors in the wireless test module and the RAT in the internal measurement test. As a result, the multiple resistors may be measured and recorded periodically by a calibrated ohmmeter, for example, the calibration jig 1500. The calibration method may determine whether there is a resistor shift by comparing the measurements of the multiple resistors in the RAT with the original calibration standard.

[0073] 16A and 16B show an internal measurement test 1600 using the calibration jig 1500 of FIG. 15 according to some embodiments. The wireless test module 120 has a relay with multiple FETs, for example, 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 jig 1500 has a first switch 1606 and a second switch 1608. The calibration method can use the first switch 1606 and the second switch 1608 to measure different "on" resistance components of the relay of the wireless test module 120.

[0074] 16A illustrates a state in which the first switch 1606 is turned on and the second switch 1608 is turned off. When the calibration method uses the calibration jig 1500 to calibrate the wireless test module 120, the calibration method measures a first resistance value of the plurality of FETs from a first internal measurement test for the wireless test module 120. The first measurement value indicates the amount of resistance added to the high-side FET 1602 of the wireless test module 120 and a first path along the calibration jig 1500. Thus, the first resistance value is related to the resistance of the high-side FET 1602, the contact resistance, and the trace / wire resistance on the calibration board. For example, the first resistance value may be in the range of 80 ohms to 90 ohms.

[0075] FIG. 16B illustrates a state in which the first switch 1606 is turned off and the second switch 1608 is turned on. When the calibration method uses the calibration jig 1500 to calibrate the wireless test module 120, the calibration method measures second resistance values ​​of the plurality of FETs from a second internal measurement test for the wireless test module 120. The second measurement is indicative of a magnitude of resistance added to the high-side FET 1602 of the wireless test module 120 and / or a first path along the calibration jig 1500. Thus, the second resistance value is associated with the resistance of the high-side FET 1602, the resistance of the low-side FET 1604, the contact resistance, and the trace / wire resistance on the calibration board. For example, the first resistance value may be in the range of 120 ohms to 140 ohms. As a result, the first measurement of the FETs is indicative of a magnitude of high-side resistance associated with the high-side FET 1602. The second resistance value of the FET represents the combined magnitude 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 .

[0076] In some embodiments, the calibration method determines a resistance calibration value by subtracting a first resistance value of the plurality of FETs from a second resistance value of the plurality of FETs. The resistance calibration value is a low-side calibration value. For example, the resistance calibration value may be in a range of 40 ohms to 50 ohms. The calibration method may compare the resistance calibration value to a predetermined value. For example, if the predetermined value for the low-side FET 1604 is 45 ohms, the calibration method may determine that the resistance calibration value meets the predetermined value. As a result, the calibration method is configured to perform the RAT using the plurality of resistors of the calibration jig 1500. As another example, if the predetermined value for the low-side FET 1604 is 60 ohms, the calibration method may determine that the resistance calibration value does not meet the predetermined value. The calibration method determines that a test result has failed for the controlled periodic calibration process for the wireless test module 120.

[0077] FIG. 17 illustrates a resistance accuracy test 1700 using the calibration jig 1500 of FIG. 15 according to some embodiments. The resistance accuracy test 1700 is configured to verify a plurality of resistors of the calibration jig 1500. For example, the plurality of resistors may have resistance values ​​ranging from 1 ohm to 50M ohms. Specifically, the calibration jig 1500 may use a plurality of pins to adjust the resistance value of the calibration jig 1500. All pins perform RAT at a value of 1 ohm and one pin performs RAT at a higher value. The calibration method selects a resistor 1702 from the plurality of resistors of the calibration jig 1500 and selects a test associated with the wireless test module 120, e.g., a continuity test. The selected resistor 1702 is associated with a target resistance value, e.g., 2 ohms. The calibration method uses the calibration jig 1500 and the test to measure a plurality of calibration factors. For example, the calibration factors for a continuity test include a source side high side calibration index value, a sink side high side calibration factor, and an internal resistance value.

[0078] In some embodiments, the calibration method uses multiple calibration factors to determine the measured resistance value. For example, the measured resistance value for the continuity test is determined by subtracting a source side high side calibration index value and a sink side high side calibration factor from the internal resistance value. The calibration method then compares the measured resistance value to a target resistance value. If the measured resistance value matches the target resistance value, the calibration method determines that the test has passed. If the measured resistance value does not match the target resistance value, the calibration method determines that the test has failed. The calibration method may then store the measured resistance value and the target resistance value in a central computer data server. Similarly, the calibration method may store the multiple calibration factors and the RAT-related RAT history in a database in the central computer server. Thus, the calibration method may perform multiple RATs on the wireless test module 120 using multiple resistors in the calibration jig 1500 to detect potential failure modes using FET resistance drifting over a period of time.

[0079] WHAMS Operating Software Some embodiments relate to a control method for managing a plurality of wireless test modules of a WHAMS for a plurality of electrical wiring harnesses. The plurality of wireless test modules of the WHAMS can wirelessly communicate with a central computer system. Specifically, the control method is applied during testing of the WHAMS using a plurality of operational components, namely: (1) a wireless test module board support component, (2) a custom power controller component, and (3) a test creation, execution, and module management component. The wireless test module board support component is configured to use a wireless test module board support package to apply a core operational application for the plurality of wireless test modules. Specifically, the core operational application may implement a two-way test approach to perform one or more electrical tests (e.g., continuity check, voltage isolation check, diode polarity check, resistance measurement check, etc.) for the plurality of electrical wiring harnesses according to a plurality of test instructions received from the central computer system.

[0080] In some embodiments, the custom power controller component is configured to implement the custom power controller suite to manage multiple batteries for multiple wireless test modules. In some embodiments, the test creation, execution, and module management component is configured to create a test plan and / or a graphic user interface (GUI) for executing one or more algorithms to perform various system functions. Specifically, the test plan may 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 defines multiple wireless test modules assigned to the multiple harness connections. As another example, the test plan is created with additional harness information for splices, passive devices, and loose lead resignments. Specifically, the test plan is created to check wires and unused pins in a network topology for each of the multiple electrical wiring harnesses. Thus, the test creation, execution, and module management component can interpret the wire list for a plurality of electrical wiring harnesses and create a test plan based on the test criteria received from the user. Specifically, the test creation, execution, and module management component is configured to use the input data to define a grounding mechanism for testing each electrical wiring harness and to analyze each electrical wiring harness.

[0081] In some embodiments, the control method accesses the plurality of electrical wiring harnesses, the test criteria, and the WHAMS using a central computer system. The control method creates a test plan for the plurality of electrical wiring harnesses based on the test criteria, and selects the 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 based on the plurality of wireless test modules. The control method wirelessly transmits test results using the plurality of wireless test modules to the central computer system 130 for display. Additionally, the control method may be used to wirelessly communicate with the plurality of wireless test modules to update a software package associated with each of the plurality of wireless test modules and / or the one or more smart test adapters with part number and pin configuration data of the one or more smart test adapters.

[0082] 18A and 18B includes a first user interface 1806 for test plan creation. The first user interface 1806 can be implemented to define multiple harness features, monitor the test plan creation status, and translate and send warnings regarding potential errors.

[0083] In some embodiments, the application interface 1800 includes a second user interface 1808 for execution of a test plan. The second user interface 1808 may be embodied for a user to visually inspect the status of the electronic wiring harness with a color-coded report. For example, a pass of a test is highlighted in green, and a fail of a test is highlighted in a different color, e.g., red, orange, or yellow, based on the fail status in case of a fail of a test result. Specifically, a user interfaces with the second user interface 1808 to manage one or more tests on a plurality of electrical wiring harnesses based on various criteria, e.g., source and destination reference index values ​​involved, test status, type of test, etc. As a result, the second user interface 1808 is a versatile solution for executing a test plan based on various test conditions. After execution of the test plan, the second user interface 1808 generates a final consumable report that is digitally stored and post-processed to extract data for further use in troubleshooting or data analysis.

[0084] In some embodiments, the application interface 1800 includes a third user interface 1810 for calibration of the wireless test modules. The third user interface 1810 may be implemented for a user to control the calibration hardware of the WHAMS and to automatically calibrate the wireless test modules of the WHAMS. Thus, the third user interface 1810 may be utilized to verify the relays of the wireless test modules and their compensation values.

[0085] 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 functions. 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 for a user to specify parameters for enhancing module efficiency and defining suitable voltages for the wireless test modules to perform one or more tests, such as high and low voltage continuity checks, voltage isolation checks, data bus and diode polarity checks, resistance measurement checks, etc.

[0086] In some embodiments, the application interface 1800 includes a fifth user interface 1814 for module software maintenance and updates. The fifth user interface 1814 may be embodied for a user to wirelessly update one or more software packages on the wireless test modules. The fifth user interface 1814 may be utilized to facilitate a smooth transition of new features to the floor with minimal touch effort.

[0087] In some embodiments, the application interface 1800 includes a sixth user interface 1816 for test debugging and global troubleshooting. The sixth user interface 1816 can be embodied to build one-off tests to either troubleshoot the electronic wiring harness or troubleshoot module functionality. The one-off tests can be created based on the data of a selected electronic wiring harness by varying multiple parameters of a single test to obtain better performance.

[0088] In some embodiments, the application interface 1800 includes a seventh user interface 1816 for test debugging and global troubleshooting. The seventh user interface 1816 can be embodied to build one-off tests to either troubleshoot the electronic wiring harness or troubleshoot module functionality. The one-off tests can be created based on the data of a selected electronic wiring harness by varying multiple parameters of a single test to obtain better performance.

[0089] In some embodiments, the application interface 1800 includes an eighth user interface 1818 for programming smart test adapters, such as hot-swappable 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 associated with the wireless test modules and relay this information back to the application interface 1800. As a result, the eighth user interface 1818 can be implemented to dynamically build a module network and monitor harness test status based on the connectors attached to the corresponding wireless test modules.

[0090] 18A and 18B illustrate an example application interface 1800 of operating software for testing a plurality of electrical wiring harnesses by the wireless harness automatic measurement system of FIG. 1 according to certain embodiments. The wireless harness automatic measurement system includes a plurality of wireless test modules. Each of the plurality of wireless test modules is respectively connected to each of the electronic wiring harnesses for testing. FIG. 18A illustrates a first test plan of a calibration check on a first table 1824 for a first plurality of wireless test modules 1802. In particular, the first test plan is created to evaluate the status 1804 of the test results by a color-coded report. For example, a test pass is highlighted in green, and a test fail is highlighted in red, orange, or yellow based on the test fail status.

[0091] FIG. 18B illustrates a second test plan of high voltage isolation on a second table 1826 for a second plurality of wireless test modules 1822. The control method can automatically build a map of the plurality of electrical wiring harnesses for testing. The control method can determine one or more connections available to each of the second plurality of wireless test modules 1822. As a result, the control method can systematically build a plurality of tests to verify the isolation or continuity of the connections for each of the second plurality of test modules 1822. For example, the control method can create a plurality of continuity tests for each of the plurality of electrical wiring harnesses. The control method can verify the source and destination reference index values ​​assigned to the wireless test modules. As another example, the control method can generate an isolation check for each of the plurality of electrical wiring harnesses. Similarly, the second test plan is utilized to check all presumably unused pins of the electrical connectors of the plurality of electrical wiring harnesses to ensure that no harness shorts or miswires occur.

[0092] In some embodiments, the application interface 1800 can be used to request additional modules to augment the multiple possible routes to create a ground circuit for testing. In particular, the control method can be used to perform one or more electrical tests on multiple electrical wiring harnesses, such as high and low voltage continuity checks, voltage isolation checks, data bus polarity and diode polarity checks, resistance measurement checks, and the like. Thus, the control method can use the application interface 1800 for a user to monitor the health and functionality status of multiple wireless test modules of the WHAMS. In particular, the control method can define WHAMS test conditions based on the health and functionality status of multiple wireless test modules. Similarly, the control method can select multiple actions for scheduling multiple electrical wiring harness tests, such as module identification, power off, and harness hookup. The control method can take into account global scale network changes, such as operational wireless channels and loading of different harnesses for different tests.

[0093] 19 is a flow diagram illustrating an example method 1900 of testing wireless test modules according to certain embodiments. Method 1900 may begin at step 1910, where a plurality of electrical wiring harnesses, test standards, and a wireless harness automatic measurement system (WHAMS) are accessed by using a computer server. In some embodiments, the WHAMS includes a plurality of wireless test modules. In some embodiments, each of the plurality of electrical wiring harnesses is respectively connected to each of the wireless test modules of the WHAMS.

[0094] At step 1920, a test plan is created for the plurality of electrical wiring harnesses. For example, the test plan may include one or more electrical tests (e.g., continuity checks, voltage isolation checks, diode polarity checks, resistance measurement checks, etc.) for the plurality of electrical wiring harnesses. As another example, the test plan may include a plurality of electrical wiring harnesses, a plurality of harness connections associated with each of a plurality of wireless test modules.

[0095] In step 1930, the test plan and the WHAMS are used to determine the wireless test modules (WTMs). For example, the wireless test modules are selected based on various test conditions. As another example, a calibration jig is used to properly calibrate the wireless test modules.

[0096] 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 can wirelessly receive one or more of the plurality of test instructions from the computer system. The plurality of test instructions can be one or more signals, operations, commands, etc.

[0097] At step 1950, one or more tests are performed on the plurality of electrical wiring harnesses using the plurality of wireless test modules according to the plurality of test instructions. Upon receiving the plurality of test instructions, the plurality of wireless test modules are configured to automatically perform one or more electrical tests (e.g., continuity checks, voltage isolation checks, diode polarity checks, resistance measurement checks, etc.) on the plurality of electrical wiring harnesses.

[0098] At step 1960, the test results are sent to the computer system by wirelessly communicating with the computer system using the plurality of WTMs. In some embodiments, the test results are collected by the computer system for one or more electrical tests and displayed on a user interface for a user to visually inspect the status of the plurality of electronic wiring harnesses in a color-coded report. For example, a test pass is highlighted in green and a test failure is highlighted in red, orange, or yellow based on the test failure status. After step 1960, the method 1900 may end.

[0099] 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 perform functions described or illustrated herein. In certain embodiments, software running on one or more computer systems 2000 performs one or more steps of one or more methods described or illustrated herein or performs functions described or illustrated herein. Certain embodiments include one or more portions of one or more computer systems 2000. References herein to a computer system may include computing devices, where appropriate, and vice versa. Further, references to a computer system may include one or more computer systems, where appropriate.

[0100] The present invention contemplates any suitable number of computer systems 2000. The present invention contemplates computer system 2000 taking any suitable physical form. By way of example, and not of 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 system on module (SOM)), a desktop computer system, a laptop or notebook computer system, an interactive kiosk, 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. Computer system 2000 may include one or more computer systems 2000, may be unitary or distributed, may span multiple locations, may span multiple machines, may span multiple data centers, or may reside in a cloud, which may include one or more cloud components in one or more networks. Optionally, one or more computer systems 2000 may perform one or more steps of one or more methods described or illustrated herein without substantial space or time constraints. By way of example, and not 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. 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 from one another, as appropriate.

[0101] In a particular embodiment, computer system 2000 includes a processor 2002, a memory 2004, a storage device 2006, an input / output (I / O) interface 2008, a communications interface 2010, and a bus 2012. Although this disclosure describes and illustrates a particular computer system including a particular number of particular components in a particular arrangement, this disclosure contemplates any suitable computer system including any suitable number of any suitable components in any suitable arrangement.

[0102] In particular embodiments, the processor 2002 includes hardware for executing instructions, such as instructions 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) the instructions from an internal register, an internal cache, memory 2004, or storage device 2006, may compound and execute the instructions, and may then write one or more results to the internal register, internal cache, memory 2004, or storage device 2006. In particular embodiments, the processor 2002 may include one or more internal caches for data, instructions, or addresses. This disclosure contemplates the processor 2002 including any suitable number of any suitable internal caches, as 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). The 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 1032. The data in the data cache may be copies of data in memory 2004 or storage 2006 for instructions executing at the processor 2002 to work on, may be the results of previous instructions executed at the processor 1032 to be accessible by the next instruction executing at the processor 2002 or to be written to memory 2004 or storage 2006, or may be other suitable data. 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 1032. In a particular embodiment, the processor 2002 may include one or more internal registers for data, instructions, or addresses. The present invention contemplates the processor 2002 including any suitable number of any suitable internal registers, as appropriate.Processor 2002 may include an arithmetic logic unit (ALU), where appropriate, may be a multi-core processor, or may include one or more processors 2002. Although this disclosure describes and illustrates a particular processor, this disclosure contemplates any suitable processor.

[0103] In a particular embodiment, memory 2004 includes a main memory that stores instructions for processor 2002 to execute or data for operating processor 2002. By way of example, and not limitation of the present invention, computer system 2000 may load instructions into memory 2004 from storage device 2006 or another source (e.g., another computer system 2000). Processor 2002 may then load the instructions from memory 2004 into an internal register or cache. To execute instructions, processor 2002 may retrieve instructions from the internal register or cache and compound the instructions. During or after execution of instructions, processor 2002 may write one or more results (which may be intermediate or final results) to an internal register or cache. Processor 2002 may then write one or more of the results to memory 2004. In particular embodiments, the processor 2002 executes only instructions in one or more internal registers or caches or memory 2004 (as opposed to storage device 2006 or elsewhere) and operates only on data in one or more internal registers or caches or memory 2004 (as opposed to storage device 2006 or elsewhere). One or more memory buses (each of which may include an address bus and a data bus) may couple 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 memory 2004 and facilitate accesses to memory 2004 requested by the processor 2002. In particular embodiments, the memory 2004 includes random access memory (RAM). The RAM may be volatile memory, as appropriate. The RAM may be dynamic RAM (DRAM) or static RAM (SRAM), as appropriate. Moreover, this RAM may be single-ported or multi-ported RAM, where appropriate, and this disclosure contemplates any suitable RAM.The memory 2004 may, where appropriate, include one or more memories 2004. Although this disclosure describes and illustrates a particular memory, this disclosure contemplates any suitable memory.

[0104] In certain embodiments, storage 2006 includes mass storage for data or instructions. By way of example, and not of limitation to the present invention, 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, as appropriate. Storage 2006 may be internal or external to computer system 2000, as appropriate. In certain embodiments, storage 2006 is a non-volatile solid-state memory. In certain embodiments, storage 2006 includes a read-only memory (ROM), which may be a mask program ROM, a programmable ROM (PROM), an erasable PROM (EPROM), an electrically erasable PROM (EEPROM), an electrically eraseable and re-writeable ROM (EAROM), or a flash memory, as appropriate, or a combination of two or more of these. This disclosure contemplates mass storage device 2006 taking any suitable physical form. Storage device 2006 may optionally include one or more storage control units that facilitate communication between processor 2002 and storage device 2006. Storage device 2006 may optionally include one or more storage devices 2006. Although this disclosure describes and illustrates a particular storage device, this disclosure contemplates any suitable storage device.

[0105] 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 2006 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 of limitation, the I / O devices may include a keyboard, keypad, microphone, monitor, mouse, printer, scanner, speaker, still camera, stylus, tablet, touch screen, trackball, video camera, another suitable I / O port, or a combination of two or more of these. The I / O devices may include one or more sensors. This disclosure contemplates any suitable I / O devices and any suitable I / O devices for these I / O devices in interface 2008. I / O interface 2008 may include one or more devices or software drivers that enable processor 2002 to drive one or more of these I / O devices, as appropriate. I / O interface 2008 may, where appropriate, include one or more I / O interfaces 2008. Although this disclosure describes and illustrates a particular I / O interface, this disclosure contemplates any suitable I / O interface.

[0106] In certain embodiments, the communication interface 2010 includes hardware, software, or both that provide one or more interfaces for communication (e.g., wireless communication) 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 a 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 include 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), a Wi-Fi network, a Wi-MAX network, a cellular network, (e.g., a Global System for Mobile Communications (GSM) network, a Long Term Evolution (LTE) network, or a 5G network), or other suitable wireless network, or a combination of two or more thereof. Computer system 2000 may include any suitable communication interface 2010 for any of these networks, as appropriate. Communication interface 2010 may include one or more communication interfaces 2010, as appropriate. Although this disclosure describes and illustrates particular communication interfaces, this disclosure contemplates any suitable communication interface.

[0107] In particular embodiments, bus 2012 includes hardware, software, or both that couple together components of computer system 2000. By way of example, and not limitation of the present invention, bus 2012 may include an Accelerated Graphics Port (AGP) or other graphics bus, an Enhanced Extended Industry Standard Architecture (EISA) bus, a Front Side Bus (FSB), a HyperTransport (HT) interconnect, an Industry Standard (ISA) bus, an InfiniBand (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 (BESA) Local Bus (VLB), 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, this disclosure contemplates any suitable bus or interconnect.

[0108] As used herein, one or more storage media or media may include, as appropriate, one or more semiconductor-based or other integrated circuits (ICs) (e.g., field programmable gate arrays (EPGAs) 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, as appropriate.

[0109] In this specification, "or" is inclusive and not exclusive, unless expressly indicated otherwise or the context indicates otherwise. Thus, in this specification, "A or B" means "A, B, or both" unless expressly indicated otherwise or the context indicates otherwise. Furthermore, "and" is a word that indicates both jointly and severally, unless expressly indicated otherwise or the context indicates otherwise. Thus, in this specification, "A and (and) B" means "A and (and) B, jointly or severally," unless expressly indicated otherwise or the context indicates otherwise.

[0110] The scope of the present invention includes all changes, substitutions, variations, alterations, and modifications to the exemplary embodiments described or illustrated herein, as would be understood by one of ordinary skill in the art. The scope of the present invention is not limited to the exemplary embodiments described or illustrated herein. Furthermore, although the present invention is described and illustrated herein in each embodiment as including certain components, elements, features, functions, acts, or steps, any of these embodiments may include any combination or permutation of any of the components, elements, features, functions, acts, or steps described or illustrated elsewhere herein, as would be understood by one of ordinary skill in the art. Furthermore, in the appended claims, a statement that an apparatus or system, or a component of an apparatus or system is adapted to, arranged to, capable of, configured to, implemented to, operable to, or operative to perform a particular function includes the apparatus, system, or component, regardless of whether the particular function is implemented, operated, or exerted, so long as the apparatus, system, or component is so adapted, arranged, capable, configured, implemented, operable, or operative. Additionally, although the present disclosure describes or illustrates particular embodiments as providing certain advantages, the particular embodiment may provide none of these advantages, or may provide some or all of these advantages.

[0111] The embodiments disclosed herein are merely examples, and the scope of the present invention is not limited to these embodiments. A particular embodiment may include all, some, or none of the components, elements, features, functions, acts, or steps of the embodiments disclosed herein. Certain embodiments are disclosed in the claims, particularly those relating to methods, storage media, systems, and computer program products, in which case any feature mentioned in one claim category, e.g., the method category, may also be claimed in another claim category, e.g., the system category. The dependency or "said" statements in the claims are selected for formality reasons only. However, any inventive subject matter resulting from the intentional "said" statements to any previous claims may also be claimed, and thus any combination of the claimed inventions and features of such inventions may be disclosed and claimed notwithstanding the selected dependency in the claims. Claimable subject matter includes not only combinations of features recited in the claims, but also any other combination of features in the claims, in which case each feature recited in the claims may be combined with any other feature or combination of features in the claims. Furthermore, any of the embodiments and features described or illustrated herein may be claimed in a separate claim and / or in any combination with any of the embodiments or features described or illustrated herein or any of the claimed inventive features. [Explanation of symbols]

[0112] 100 Wireless Harness Automatic Measurement System (WHAMS) 110 Electrical Wiring Harness 120 Test Modules 130 Central Computer System 140 Wireless Interface 1500 Calibration Jig 1700 Resistor Accuracy Test 1702 resistor

Claims

1. 1. A computer-implemented method for calibrating a Wireless Test Module (WTM) of a Wireless Harness Automatic Measurement System (WHAMS), comprising: accessing the WTM and the calibration jig using a computer server; The WTM includes a plurality of field effect transistors (FETs); the calibration jig having a plurality of resistors; measuring a first resistance value of the plurality of FETs from a first internal measurement test on the WTM using the calibration jig; measuring second resistance values ​​of the plurality of FETs from a second internal measurement test on the WTM using the calibration jig; determining a resistance calibration value by subtracting the first resistance values ​​of the plurality of FETs from the second resistance values ​​of the plurality of FETs; performing a resistor accuracy test (RAT) using the plurality of resistors of the calibration jig, the RAT comprising: selecting a resistor from the plurality of resistors of the calibration jig and selecting a test associated with the WTM, the resistor being associated with a target resistor value; measuring a plurality of calibration factors using said calibration jig and said test; determining a measured resistor value using the plurality of calibration factors; The computer-implemented method includes storing the measured resistor value and the target resistor value in a database of the computer server.

2. The plurality of FETs include a high side FET having a high side resistor; and 2. The computer-implemented method of claim 1 further comprising a low-side FET having a low-side resistor.

3. the plurality of FETs are optically isolated MOSFETs; the first resistance value of the FET is a magnitude of the high side resistor associated with the high side FET; 3. The computer-implemented method of claim 2, wherein the second resistance value of the FET is a magnitude of the sum of both the high side resistance associated with the high side FET and the low side resistance associated with the low side FET.

4. the first resistance value is in the range of 80 ohms to 90 ohms; 4. The computer-implemented method of claim 3, wherein the second resistance value is in the range of 120 ohms to 140 ohms.

5. 2. The computer-implemented method of claim 1, wherein the plurality of resistors has a plurality of resistor values ​​ranging from 1 ohm to 50 megaohms.

6. the plurality of calibration factors for continuity testing include a source side high side calibration index value, a sink side high side calibration factor, and an initial resistor value; 2. The computer-implemented method of claim 1, wherein the post-measurement resistor value for the continuity test is determined by subtracting the high side calibration index value on the source side and the high side calibration factor on the sink side from an initial resistor value.

7. The computer-implemented method of claim 1 , further comprising: performing a RAT on the WTM multiple times using the resistors of the calibration jig.

8. 8. The computer-implemented method of claim 7, further comprising storing the plurality of calibration factors and a RAT history associated with the RAT in the database on the computer server.

9. The test is selected from a plurality of tests, the plurality of tests comprising: Continuity check, Voltage isolation check, Diode polarity check, and The computer-implemented method of claim 1 further comprising a resistance measurement check.

10. 2. The computer-implemented method of claim 1, further comprising performing controlled periodic calibration of the WHAMS to detect potential failure modes using the resistance of the FETs drifting over time.

11. 1. A system for calibrating a Wireless Test Module (WTM) of a Wireless Harness Automatic Measurement System (WHAMS), comprising: One or more computing devices having at least one processor and memory, the processor comprising: accessing said WTM and calibration jig using a computer server; The WTM includes a plurality of field effect transistors (FETs); the calibration jig having a plurality of resistors; measuring a first resistance value of the plurality of FETs from a first internal measurement test on the WTM using the calibration jig; measuring second resistance values ​​of the plurality of FETs from a second internal measurement test on the WTM using the calibration jig; determining a resistance calibration value by subtracting the first resistance values ​​of the plurality of FETs from the second resistance values ​​of the plurality of FETs; and performing a Resistor Accuracy Test (RAT) using the plurality of resistors of the calibration jig, the RAT comprising: selecting a resistor from the plurality of resistors of the calibration jig and selecting a test associated with the WTM, the resistor being associated with a target resistor value; measuring a plurality of calibration factors using said calibration jig and said test; determining a measured resistor value using the plurality of calibration factors; storing the measured resistor value and the target resistor value in a database on the computer server.

12. The plurality of FETs include a high side FET having a high side resistor; and The system of claim 11 further comprising a low-side FET having a low-side resistor.

13. the plurality of FETs are optically isolated MOSFETs; the first resistance value of the FET is a magnitude of the high side resistor associated with the high side FET; 13. The system of claim 12, wherein the second resistance value of the FET is a magnitude of the sum of both the high side resistance associated with the high side FET and the low side resistance associated with the low side FET.

14. the first resistance value is in the range of 80 ohms to 90 ohms; The system of claim 13 , wherein the second resistance value is in the range of 120 ohms to 140 ohms.

15. The system of claim 11 , wherein the plurality of resistors has a plurality of resistor values ​​ranging from 1 ohm to 50 megaohms.

16. the plurality of calibration factors for continuity testing include a source side high side calibration index value, a sink side high side calibration factor, and an initial resistor value; The system of claim 11 , wherein the measured resistor value for the continuity test is determined by subtracting the high side calibration index value on the source side and the high side calibration factor on the sink side from an initial resistor value.

17. The system of claim 11 , wherein the processor is further configured to perform multiple RATs on the WTM using the multiple resistors of the calibration jig.

18. 20. The system of claim 17, wherein the processor is further configured to store the plurality of calibration factors and a RAT history associated with the RAT in the database of the computer server.

19. The test is selected from a plurality of tests, the plurality of tests comprising: Continuity check, Voltage isolation check, Diode polarity check, and The system of claim 11 including a resistance measurement check.

20. 12. The system of claim 11, wherein the processor further comprises performing a controlled periodic calibration of the WHAMS to detect potential failure modes using the resistance of the FET drifting over time.

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