Cable harness test system and method for testing a cable harness

Abstract

A cable harness test system (7) for testing cable harnesses (4) having a plurality of plugs (6) has: a test field (14) having a plurality of test pins and test contacts provided on the test pins, an adjustment system (10) which has at least one robot arm (11) for an automated adjustment and for placing the test field (14) on a plug (6) to be tested, test electronics (15), and a control device (16) for actuating the adjustment system (10) and the test electronics (15).

Description

[0001] Cable harness testing system and procedure for testing a cable harness

[0002] The invention relates to a cable harness testing system and a method for testing a cable harness, in particular cable harnesses in the automotive sector.

[0003] State of the art

[0004] These wiring harness testing systems are used to test the wiring harnesses of electronic end products, particularly vehicles, but also aircraft, household appliances such as washing machines and dryers, and treatment equipment in the health and wellness sector. Wiring harnesses, also called cable assemblies or cable sets, consist of numerous cables and connectors, for example, with 300 connectors, where each end of a cable is fitted with a connector. The wiring harnesses are generally tested before installation in the final product to prevent subsequent defects. The test typically checks for electrical continuity and proper mechanical construction of the connectors. In addition to electrical cables with connectors, the wiring harness may also contain, for example, fiber optic cables or data cables.

[0005] The wiring harness is generally tested on a test bench with test modules. These modules are arranged on the test bench such that each module is assigned to a connector. The connectors and their respective test modules are then manually plugged into each other. A test bench control unit can then initiate central test routines, in particular a continuity test by applying a test voltage and / or injecting a test current. Each test module is equipped with an adapter or molded part designed for precise insertion into the connector, generally having a contour complementary to the connector.

[0006] Such test modules and test benches enable the reliable testing of cable harnesses. However, the effort required to configure the test bench and manually insert the test modules into the respective connectors is relatively high. Appropriate adapters must also be developed and kept on hand for each connector.

[0007] EP 3 460 495 B1 discloses such a test table with several test modules, wherein the table positions of the test module are stored in module memories. EP 1 149 292 B1 discloses another test system with individual test modules, each having an adapter with a connector receptacle whose configuration is adapted to its corresponding connector. EP 2 044 449 B1 discloses a test device with a contoured adapter plate, a plane adjustable relative to the adapter plate by, for example, a pneumatic lifting cylinder, and test pins, wherein a needle body of each test pin is received in the adjustable plane and a spring-loaded test needle is received in the needle body for contacting a connector contact of a connector under test. The test needle allows for testing of the locking mechanism and the electrical contact of the connector contact.

[0008] EP 4 279 937 A2 discloses a device for testing and / or assembling a cable harness, with an automated robot for maintaining the test table. The cable harness with its interfaces is mounted on a test and / or assembly device with a mounting surface that has an interface for testing a cable harness. The invention is based on the objective of creating a cable harness testing system and a method for testing a cable harness that enable reliable testing with minimal effort.

[0009] This task is solved by a cable harness testing system and a method according to the independent claims. The dependent claims describe preferred embodiments.

[0010] The cable harness testing system thus comprises at least one test field with multiple test pins and test contacts provided on the test pins, wherein each test contact is designed to connect to a connector contact of a connector of a cable harness under test, and the multiple test pins are spaced apart from each other within the test field. An adjustment system with at least one robot arm is provided for automated adjustment, in particular relative adjustment, and for positioning the test field against a connector under test. Furthermore, test electronics are electrically connected to the test contacts and are designed to perform at least one, preferably several, electrical test routines on the test contacts. The adjustment system is controlled by a single- or multi-part control unit, preferably by means of adjustment signals, which also control the test electronics by means of control signals.

[0011] This alone offers several advantages. A single test field can be used for multiple different connectors, reducing manufacturing costs and increasing flexibility. One test field can be used successively to test different connectors within a cable harness. A particular advantage is that automated testing is possible by simply aligning the test field and the connector, preferably without the need for a mechanically locking adapter in or with the connector. This eliminates the need for manual positioning and, in particular, the manual assembly of a test module with a form-fitting adapter into the respective connectors, significantly reducing processing effort and increasing automation.

[0012] A significant cost advantage is also achieved through the use of test fields on, for example, test heads that no longer require form-fitting adapters for precise insertion into the respective connectors. This eliminates manufacturing costs and unnecessary material expenditure for connectors that might not be used in other cable harnesses and subsequent connector systems. Furthermore, the development of specific test tables, each adapted to the respective cable harness and requiring the test modules to be fixed in precisely positioned locations, is generally no longer necessary, as the robot arm allows for suitable adjustment.

[0013] The test field and / or the test head can be designed without being directly adapted to a specific connector type and / or without a contour, and thus be suitable for contacting and testing various connectors. The test field is therefore preferably non-specific and generalized in such a way that it can be flexibly attached to different connectors or connector contacts.

[0014] The test pins can advantageously be spaced apart from each other in a test field plane. When the test field and the connector are pressed together, suitable test pins of the test field thus come into contact with the connector contacts to enable the subsequent electrical test, i.e., one or more test routines. Since the test field is preferably non-specific or designed only for a subset of connectors, the arrangement and number of its test pins may not be adapted to the specific connector.

[0015] This reveals that one or more test pins may not be relevant for the respective plug; however, these non-relevant test pins can, for example, give way and be pressed in, so that they remain passive and do not hinder either the insertion process or the subsequent electrical test.

[0016] The test electronics can perform one or more of the following steps in the electrical test routine:

[0017] - Applying electrical voltages to the individual test contacts

[0018] - Measuring electrical voltages at the individual test contacts,

[0019] - Injecting a test current into the individual test contacts

[0020] - Measuring a test current through the individual test contacts, e.g. also with direct current and / or alternating current of different frequency and current intensity,

[0021] - Measuring electrical resistance and / or impedance,

[0022] - Measuring capacity,

[0023] - Measuring data and / or frequency signals transmitted via the test contacts and test pins.

[0024] This allows for diverse testing, including the measurement and evaluation of data transmission quality.

[0025] In addition to the electrical test field, at least one optical test contact may be provided for contacting an optical fiber in the connector under investigation.

[0026] The adjustment system can, in particular, have several robot arms that can be adjusted independently of each other. Each robot arm can, for example, have or accommodate one or more test fields, including uniform test fields. This allows for automated measurement of a cable harness at multiple connectors, especially at opposite connectors on the same cable, with simultaneous and / or sequential adjustment of the robot arms.

[0027] According to one embodiment, each test field, e.g., each test field, is equipped with its own test electronics, so that preferably each test field has its own decentralized test electronics, resulting in a modular design. Alternatively, the test electronics can centrally control the multiple test fields.

[0028] According to an advantageous design, the one- or multi-part control device is designed to carry out a test procedure in which the test fields are adjusted and positioned relative to the plugs by the robot arms, with subsequent control of at least one part of the test contacts with one or more test routines and for the evaluation of a test result.

[0029] The control device may, depending on the test, in particular

[0030] - output one or more indicator signals, e.g. for a successful or failed test procedure,

[0031] - output one or more evaluation signals for a proper or faulty test procedure,

[0032] - if a fault is detected, perform a repeat test and / or a supplementary test of a test contact, e.g. an electrical test with different electrical properties.

[0033] The test routines can be performed automatically after electrical contact is detected, thus advantageously eliminating the need for user activation of each test routine. The control unit can therefore start the electrical test immediately after detecting electrical contact between the plug contacts of a connector and the test contacts of the test field.

[0034] The control unit can both store the test results and, advantageously, also display them directly, i.e., output display signals. In particular, upon detection of a fault, a display signal, e.g., visual and / or audible, can be output, so that, for example, a user can subsequently examine the connector or the indicated fault directly. It is also recognized that, with the system according to the invention with automated contacting, false-positive measurement results will generally not occur, i.e., the indication of a through-hole between the contacts of two opposing connectors, even though no through-hole exists.

[0035] If the cable is properly configured, but the automated contacting has not been performed correctly, false-negative test results may initially be displayed, indicating that no contact is detected; however, in these rare cases, a user can subsequently perform a retest, e.g., directly at the connector. Thus, the invention also demonstrates that, surprisingly, automated testing is enabled directly through automated test fields without reducing safety.

[0036] The control unit can both store the test results and, advantageously, also display them directly, i.e., output display signals. In particular, upon detection of a fault, a display signal, e.g., visual and / or audible, can be output, so that, for example, a user can subsequently examine the connector or the indicated fault directly. It is also recognized that, with the system according to the invention with automated contacting, false-positive measurement results will generally not occur, i.e., the indication of a through-hole between the contacts of two opposing connectors, even though no through-hole exists.

[0037] If the cable is properly configured, but the automated contacting has not been performed correctly, false-negative test results may initially be displayed, indicating that no contact is detected; however, in these rare cases, a user can subsequently perform a retest, e.g., directly at the connector. Thus, the invention also demonstrates that, surprisingly, automated testing is enabled directly through automated test fields without reducing safety.

[0038] According to one embodiment, the cable harness test system can have different test fields for contacting different connectors, in particular with different numbers and / or arrangements and / or adjustability of the test pins or test contacts and / or different designs of the test pins or test contacts. Thus, a large number of connectors, even of different designs, can be tested by adjusting a suitable test field for each connector, whereby, for example, only a few test fields are provided for less common contacts.

[0039] According to an advantageous embodiment, at least one test pin in the test field is designed to be resiliently compliant in the opposite direction to the insertion direction, enabling insertion without contacting a connector contact and / or for passive function during a test routine. Thus, a test field can be used without precise adaptation to the connector under test, in particular even a non-specific test field, where the irrelevant test pins yield resiliently and / or elastically when they do not come into contact with a connector, i.e., a connector housing.

[0040] Instead of passive spring compliance, a test pin tensioning device can also be provided for one or more test contacts to actively adjust at least one test pin against the insertion direction relative to the test field and / or relative to the other test pins. This allows for controlled adjustment that is gentle on the test contact.

[0041] According to an advantageous embodiment, test pin adjustment means are provided for adjusting at least one test pin, in particular in a lateral direction and / or in a direction other than the insertion direction, in particular

[0042] = to change the relative distances of the test pins, and / or

[0043] = to change the arrangement of the test pins of the test field, and / or = in a lateral test field plane perpendicular to the insertion direction, and / or = to the relative adjustment of the several test pins in a lateral test field plane, and / or = for an adjustment of one test pin at a time in a one-dimensional direction, e.g. obliquely opposite a grid arrangement of the test field.

[0044] This further increases flexibility and adaptability to different connectors, whereby even small adjustments, e.g. with simple adjustment means such as piezo actuators or stepper motors, enable a high variety of different grids and arrangements of contacts.

[0045] According to an advantageous embodiment, an optical system, e.g., a camera system with one or more optical means, e.g., one or more cameras, is provided; the optical system can preferably be used for the optical inspection of connectors, in particular for the optical detection of a connector's contour, and / or for positioning the test field relative to the connector, and / or for adapting the test field to the connector. Thus, the shape of the contour can be detected and evaluated. The optical system can have several stereoscopically arranged optical means, e.g., cameras, and / or at least one adjustable optical means, e.g., a camera. This allows for stereoscopic and / or superimposed detection and evaluation. The optical means can also be adjustable by a robot arm, in particular by another robot arm or a robot arm that also holds a test head or a connector.Furthermore, for example, additional lighting can be provided so that the optical system can detect the connector under suitable illumination or at different angles. It has been shown that the optical evaluation of the connector contour is sufficiently reliable even without manual insertion by a user. Thus, according to the invention, an optical system, e.g., a camera system, can be used for multiple functions, resulting in a synergistic effect.

[0046] The multiple robot arms can each have their own testing electronics and be controlled by a central control unit. Alternatively, a single central testing electronics unit can be used for all the test areas. This allows for a modular design that can be expanded and adapted at any time.

[0047] The relative adjustment between the test field and the connector can be done in different ways, so that a flexible solution can be chosen.

[0048] According to one embodiment, at least one test field is mounted on a test head that can be adjusted by at least one robot arm. The test head is advantageously free of contours and / or designed to allow the test field to be positioned against the connector without mechanical locking. Thus, the connector of the cable harness can be mounted on, for example, a mounting plate or a mounting table and advantageously fixed in place, so that the test head with the test field is adjusted towards the connector and the test field is pressed against the connector to achieve electrical contact.

[0049] According to a further embodiment, at least one connector is picked up by a holding device provided on a robot arm, e.g., grasped by a gripper provided on the robot arm, and guided to the test area and pressed against it to achieve contact. Thus, the connector is preferably not completely fixed; the test area can be positioned at a suitable location, e.g., on the mounting plate next to the cable harness, or even next to the mounting plate for the cable harness, and advantageously fixed. In principle, the test area can also be additionally guided against the connector. Instead of a mechanical gripper, the holding device can, for example, also magnetically grasp the connector.

[0050] The positions of the connector and the test field can be preset; however, the connector can also be detected in real time by, for example, an optical system, such as a camera system. The optical system can output image signals to the control unit for evaluation of the image signals and assessment of proper installation. Thus, the test head can also be automatically guided and pressed against the detected connector. In the embodiment where the connector is repositioned, the connector can be...

[0051] B. located by a camera system and subsequently captured and guided by the gripper of the robot arm.

[0052] In principle, the automated adjustment can initially be initiated by a user. For example, a user can position the wiring harness and, if necessary, additionally mark the position of the connector and / or pre-align the test head, so that the automated test can then be carried out by relative adjustment and contact. With such a setup, the manual effort is therefore very low, allowing several tests to be performed quickly in succession.

[0053] Thus, according to the invention, suitable signals are advantageously transmitted between the devices, in particular an adjustment signal from the control device to the adjustment system and a control signal to the test electronics, furthermore, the electrical test is carried out by the test electronics by outputting and detecting test signals, i.e. a test voltage and / or a test current, wherein the test electronics then outputs a measurement signal to the control device, which in turn outputs a display signal to the display device.

[0054] This also includes a procedure for testing a cable harness that is fully or largely automated, with the following steps:

[0055] Providing a cable harness test system with preferably an adjustment system and at least one test field, positioning a cable harness, relative adjustment of the test field and the at least one connector, placing the test field against the connector and making electrical contact with the test contacts and the connector contacts of the connector, whereby a pre-positioning followed by an insertion process can first take place,

[0056] Performing the test routine and / or the electrical measurement, e.g. by applying and / or measuring a current and / or a voltage at the test contacts, in particular at opposite plugs of individual cables, evaluating the measurement and assessing the test process, in particular with subsequent storage and / or output of display signals and / or error signals.

[0057] This also includes, in particular, a method for testing different connectors and / or different cable harnesses using one or more standardized test fields. Specifically, the connector and the test field can differ in...

[0058] - a different number of test contacts compared to the plug contacts, i.e., in particular with a higher number of test contacts, since the passive test contacts give way elastically, and / or

[0059] - in a different arrangement relative to each other.

[0060] The invention is explained in more detail below with reference to the accompanying drawings, which illustrate several embodiments. The drawings show:

[0061] Fig. 1 shows a cable harness test system according to a first embodiment with an adjustment of the test field to the connectors;

[0062] Fig. 2 Front views of two test fields and a connector to be tested;

[0063] Fig. 3 shows an insertion process and the measurement of a plug using a camera system;

[0064] Fig. 4 shows a test field with adjustable test pins according to one embodiment;

[0065] Fig. 5 shows a test field with adjustable test pins according to a further embodiment; Fig. 6 shows a cable harness test system according to a further embodiment with an adjustment of the connector to the test field; and

[0066] Fig. 7 shows a flowchart of a method according to the invention.

[0067] Figure 1 shows a test setup 1 with a mounting plate 2 on which a cable harness 4 with individual cables 5 and connectors 6 at the ends of the cables 5 is mounted, as well as a cable harness test system 7 for testing the cable harness 4. The cable harness 4 is attached to the mounting plate 2 by means of fixing means 8, e.g., clips. Preferably, the connectors 6 are fixed in place. An adjustment system 10 has two robot arms 11, each designed for three-dimensional adjustment, for which purpose the robot arms 11 can be articulated in three dimensions. Each robot arm 11 adjusts a test head 12, on the front of which a test field 14 is formed.

[0068] Furthermore, a test electronics unit 15 is provided for each test field 14. This unit is contacted with the test field 14 and controls the test field 14 with a test signal S4 for test routines. Alternatively, a single test electronics unit 15 can be provided for all test fields 14. A control unit 16 serves, on the one hand, to control the adjustment system 10 by means of adjustment signals S1 and, on the other hand, to control the one or more test electronics units 15 by means of control signals S2, as well as to receive and evaluate the measurement signals S3 from the test electronics units 15. The control unit 16 and the one or more test electronics units 15 can be designed separately or integrated. In this embodiment, a central control unit 16 is provided for controlling the adjustment system 10, which also receives and evaluates the measurement signals S3 from the test electronics units 15.In principle, a control unit can also be assigned to each individual test electronics unit and interact accordingly with a central control unit.

[0069] In the illustrated embodiment, two robot arms 11, each equipped with a probe 12, are provided to simultaneously contact and test the connectors 6 at both ends of a cable 5 of the cable harness 6. This allows, in particular, testing of the contact and continuity, i.e., signal transmission between the connectors 6. The control unit 16 then receives the measurement data or signals S3 and evaluates the test process. In this embodiment, the connectors 6 can be sufficiently rigidly fixed by the fixing means 8, so that only the probe 12(s) need to be adjusted.

[0070] Figure 2 shows front views and end views of a connector 6 and two test fields 14. In this embodiment, the connector 6 has six connector contacts 22 in a specific arrangement. The connector 6 has a connector housing 24 with, for example, a receiving contour 25 as a recess, as can also be seen in the perspective view of Figure 3, where the contour 25 generally ensures the unambiguous and friction-fit or locking reception of the suitable mating connector. The connector contacts 22 of the connector 6 can be designed as protruding pins and / or as pin receptacles for receiving a pin, depending on the type of connector 6. Similarly, the contour 25 can also be designed as a recess in the housing 24, or the housing 24 can define the contour 25 on its outer surface, i.e., as an outer contour.

[0071] The test field 14, which is guided by the probe head 12 against the connector 6, has a suitable number of test contacts 26 that are intended to contact the connector contacts 22 during an insertion process in the z-direction. For this purpose, the test field 14 has a sufficient number of test contacts 26, and in particular, the test field 14 can have a higher number of test contacts 26 than the number of connector contacts 22 of the connector 6, as can be seen in Figure 2. The test contacts 26 are advantageously designed as elastically spring-loaded test pins, as can be seen in Figure 3, which shows an insertion process in the z-direction. The test contacts 26 are thus arranged next to each other in the XY plane, so that the probe head 12 with the test field 14 is moved in the Z-direction, i.e., the insertion direction, for contacting. According to the perspective view of Figure 3, the test contacts 26 are provided on test pins 27 and are oriented in the -Z direction, i.e.into the test head 12, elastically adjustable. Thus, the test head 12 with the test field 14 can be moved in the Z-direction into or against the connector 6, so that the test contacts 26 provided for this purpose contact the corresponding connector contacts 22; the test pins 27 with the non-relevant test contacts 26a, i.e., in Figure 2 the middle horizontal row with three test contacts 26a arranged next to each other, thus yields elastically when they come into contact with the housing 24 or between the connector contacts 22, in order to enable an insertion process or contacting.

[0072] As an alternative to passive compliance, a test pin puller 29 can also be provided, as indicated in the lower left of test field 14 in Fig. 3, for active adjustment of at least one test pin 27 against the insertion direction z relative to test field 14 and / or relative to the other test pins 27. This allows for controlled adjustment that is gentle on the test contact 26.

[0073] The shape or contour of the probe head 12 is preferably not adapted to individual connectors 6, but rather designed for universal use with various connectors 6. Thus, the probe head 12 can, for example, successively probe the individual connectors 6. In this case, the probe area 14 can be sufficiently small to be inserted into the contour 25 or recess of the connector 6. However, this is not strictly necessary. A larger probe area 14, as shown on the left in Figure 2, can also be guided against the connector 6 by ensuring that the non-relevant probe contacts 26a are sufficiently flexible in the -Z direction.

[0074] In Figure 2, some test contacts 26 are therefore marked as non-relevant test contacts 26a; however, in principle all test contacts 26 are initially provided as equally important and electrically controllable, so that it is only when used with the respective connector 6 that it is determined which test contacts 26 are not relevant.

[0075] According to the invention, optical fibers can also be tested, wherein the connector 6 then provides corresponding receptacles for an optical fiber as connector contacts 22, and the mating contacts 26 on the test head 12 are also designed as optical fibers.

[0076] Figures 4 and 5 show embodiments of test fields 4 with test contacts 26 that are adjustable in the XY plane and / or the surface of the test field 14, respectively. Here, some or all of the test contacts 26 can be actively adjusted in the X-direction and / or in the Y-direction to adapt to the pattern of the plug contacts 22 of the plug 6. Generally, only small adjustment ranges p of a few millimeters are required to adapt the test fields 14 to a multitude of plugs 6. Figure 4 shows an adjustment of the test contacts 26 in the X-direction and Y-direction. Figure 5 shows a motorized adjustment of a test field 14 with four test contacts 26, where the test contacts 26 are each adjustable in only one direction d, e.g., in an oblique direction. Thus, with minimal effort, a large number of test fields 14 or a large number of relative arrangements of test contacts 26 can be achieved by appropriately controlling individual test pin adjustment means 28.The test pin adjustment means 28 can be designed, for example, with piezo adjustments or stepper motors.

[0077] As indicated in Figure 3, the connector 6 can advantageously be additionally measured for correct three-dimensional formation, in particular a proper contour 25, by an optical system, in particular a camera system 30. The camera system 30 can, for example, have several individual cameras 32 as optical means for a stereoscopic examination, or a single camera 32 can be mechanically adjusted to enable a three-dimensional image or three-dimensional capture of the contour 25. Furthermore, the camera system can have active illumination, e.g., at an oblique angle, to capture the three-dimensional structure. The camera system 30 thus outputs image signals S6 to the control unit 16 for evaluation.

[0078] Figure 6 shows an embodiment in which the connector 6 is adjusted to the test field 14. Thus, an adjustment system 10 with one or more robot arms 11 can again be provided, wherein, for example, a gripper 35 is mounted on the robot arm 11, which grasps a connector 6 and guides it to the test field 14. The test field 14 can be fixed or can also be positioned additionally, for example, by another robot arm 11. The robot arm 11 thus adjusts the connector 6 in front of the test field 14 and presses it against the test field 14, so that the test electronics 15 can again perform a test routine via the test field 14. In this embodiment as well, the proper three-dimensional design of the connector 6, in particular the contour 25, can again be examined and evaluated by a camera system 30 with one or more cameras 32. In this embodiment, a larger test field 14 can be provided, which, for example,It has several sections, each intended for the respective plug 6.

[0079] Thus, the method according to the invention as shown in Figure 7 comprises the following steps, the order of which may be changed if necessary:

[0080] After starting in ST0, step ST1 involves the provision and arrangement of both the cable harness 4 and the cable harness test system 7 with the adjustment system 10, which has one or more robot arms 11, and thus also one or more test heads 12 and test fields 14. In the embodiment of Figure 1, the cable harness 4 is first sufficiently fixed to the mounting plate 2 by the fixing means 8, whereby the individual connectors 6 can also be fixed in such a way that the test heads 12 can subsequently be adjusted against them. In the embodiment of Figure 6, the cable harness 4 is received in such a way that the individual connectors 6 are adjustable; here, the cable harness 6 can, for example, be roughly fixed to a mounting plate 2 or rest freely. Furthermore, in the embodiments of the test fields 14 according to Figures 4 and 5, the patterns of the test contacts 26 can be set.

[0081] In step ST2, the test fields 14 are subsequently adjusted and positioned or pre-positioned relative to the connectors 6, so that in the embodiment of Figure 1, the robot arm 11 guides the test head 12 with the test field 14 to the connector 6. In the embodiment of Figure 6, a gripper 35 thus picks up a connector 6 and guides it to the test field 14.

[0082] According to step ST3, a preliminary optical inspection can then be carried out using the camera system 30 of Fig. 3, in which the individual connectors 6 are examined and evaluated for proper shaping, in particular the shape of the contour 25. For this step ST3 of the optical inspection, the cameras 32 can be adjusted, for example, by the robot arm 11, or the cameras 32 are mounted in the same robot arm 11 as the test heads 12 of the subsequent inspection step. A measurement signal for the optical inspection is then output, if necessary, which can indicate, in particular, proper inspection or a defect. The procedure can also be carried out without step ST2 of the optical inspection.

[0083] In step ST4, the physical contact between the plug contacts 22 and test contacts 26 is made. In the embodiment shown in Figure 1, the robot arm 11 guides the test head 12 with the test field 14 against the plug 6, so that the test contacts 26 come into contact with the plug contacts 22. Any potentially irrelevant test contacts 26a yield elastically upon contact and are therefore no longer relevant. In the embodiment shown in Figure 6, the gripper 35 presses the plug 6 against the test field 14. Steps ST2 and ST4 can also be performed directly one after the other or as a continuous adjustment.

[0084] In step ST5, one or more electrical test routines are performed. The electrical test routine can perform one or more of the following steps: applying electrical voltages to the individual test contacts and / or measuring electrical voltages at the individual test contacts 26, injecting a test current I into the individual test contacts 26 and / or measuring a test current I through the individual test contacts 26, e.g., also with direct current and / or alternating current of different frequencies and current intensities. Capacitive measurements can also be performed. Thus, an electrical contact test is performed, particularly as a continuity test, whereby proper contact or continuity can be assessed by individually applying electrical voltage to the test contacts 26 and measuring the currents through the test contacts 26, especially also from opposing probes 12 with test fields 14.

[0085] In a proper electrical test, in step ST6, the control unit 16 outputs a display signal S5 to a display unit 38, which can visually display the test result; if necessary, an error can also be indicated audibly.

[0086] Advantageously, the procedure is then reset to the point before step ST2 so that the subsequent connector 6 can be tested. This allows connector 6 and / or test field 14 to be adjusted, contacted, and subsequently tested. This loop can thus be repeated until the entire wiring harness 4 has been measured. The output of the display signal S5 S1 can only occur after the entire wiring harness has been tested. Reference numeral list

[0087] 1 Test setup

[0088] 2 Mounting plate

[0089] 4 Wiring harness

[0090] 5 cables

[0091] 6 plugs

[0092] 7 Cable harness test system

[0093] 8 Fixatives

[0094] 10 adjustment system

[0095] 11 robot arm

[0096] 12 probe

[0097] 14 Test field

[0098] 15 Test electronics,

[0099] 16 Control unit, in particular for controlling the adjustment system 10 and for electrically supplying power to the test field 14

[0100] 22 plug contacts of plug 6

[0101] 24 Connector housing of connector 6

[0102] 25 Contour in the connector housing 24

[0103] 26 test contacts of test field 14

[0104] 26a passive test contacts

[0105] 27 Test pin, elastic or spring-loaded, with test contact

[0106] 28 test pin adjustment devices for adjusting the test pins 27 in the test field plane XY

[0107] 29 Test pin puller for adjusting a test pin 27 against the insertion direction Z

[0108] 30-camera system

[0109] 32 camera

[0110] 35 Gripper 38 Display device p Adjustment travel d Adjustment direction Z Insertion direction

[0111] XY test field level

[0112] 51 Adjustment signal to adjustment system 10

[0113] 52 Control signal to test electronics 15 S3 Measurement signal

[0114] 54 Test signal, e.g. voltage or current

[0115] 55 Display signal

[0116] 56 Image signal

Claims

Patent claims 1. Cable harness test system (7) for testing cable harnesses (4) with multiple connectors (6), wherein the cable harness test system (7) comprises: - a test field (14) with several test pins (27) and test contacts (26) provided on the test pins (27), wherein the test contacts (26) are each designed to contact a plug contact (22) of a plug (6) of a cable harness (4) to be tested, and wherein the several test pins (27) are spaced apart from each other in the test field (14), - an adjustment system (10) comprising at least one robot arm (11) for automated adjustment and for positioning the test field (14) against a plug (6) to be tested, - a test electronics (15) which is electrically connected to the test contacts (26) and is configured to perform an electrical test routine on the test contacts (26), and - a control device (16) for controlling the adjustment system (10) by means of adjustment signals (S1) and for controlling the test electronics (15) by means of control signals (S2).

2. Cable harness test system (7) according to claim 1, characterized in that the test electronics (15) is configured to output test signals (S4) to the test contacts (26) in the electrical test routine and to perform one or more of the following steps: - Applying electrical voltages to the individual test contacts (26), - Measuring electrical voltages at the individual test contacts (26), - Injecting a test current (I) into the individual test contacts (26), - Measuring a test current (I) through the individual test contacts (26), - Measuring electrical resistance and / or impedance, - Measuring capacity, - Measuring data and / or frequency signals transmitted via the test contacts (26) and test pins (27) are transferred.

3. Cable harness testing system (7) according to one of the preceding claims, characterized in that the adjustment system (10) has several robot arms (11) which are independently adjustable.

4. Cable harness testing system (7) according to claim 3, characterized in that - for each test field (14) a test electronics (15) is provided, or - a central test electronics (15) that controls several test fields (4).

5. Cable harness testing system (7) according to one of the preceding claims, characterized in that the control device (16) is configured to perform a test procedure in which the test fields (14) are adjusted and positioned relative to the connectors (6) by the robot arms (11), with subsequent control of at least a part of the test contacts (26) with one or more test routines and evaluation of a test result.

6. Cable harness testing system (7) according to one of the preceding claims, characterized in that the control device (16) outputs and / or stores an evaluation signal and / or fault signal and / or display signal (S5) depending on a test or execution and evaluation of a test routine, in particular display signals for a proper or faulty test procedure.

7. Cable harness test system (7) according to one of the preceding claims, characterized in that the cable harness test system (7) has several different test fields (14) for contacting different connectors (6), in particular with: different number and / or arrangement and / or adjustability of the test pins (27) or test contacts (26), and / or different design of the test pins (27) or test contacts 8. Cable harness test system (7) according to one of the preceding claims, characterized in that at least one test pin (27) in the test field (14) is resiliently designed in the opposite direction of insertion (Z) for an insertion process without contacting a plug contact (22) and / or for a passive function during a test routine.

9. Cable harness test system (7) according to one of the preceding claims, characterized in that a test pin pulling means (29) is provided for an active adjustment of at least one test pin (27) against the insertion direction (z) relative to the test field (14) and / or relative to the other test pins (27).

10. Cable harness testing system (7) according to one of the preceding claims, characterized in that test pin adjustment means (28) are provided for lateral adjustment of at least one test pin (27) = to change the relative distances of the test pins (27), and / or = to change the arrangement of the test pins (27) of the test field (14), and / or = in a lateral test field plane (X, Y) perpendicular to the insertion direction (z) and / or = for the relative adjustment of the multiple test pins (27) in a lateral test field plane (X, Y), and / or = for adjusting each of a test pin (27) in a one-dimensional direction, e.g. diagonally opposite a grid arrangement of the test field (14).

11. Cable harness testing system (7) according to one of the preceding claims, characterized in that an optical system, in particular a camera system (30), with at least one optical means, e.g. a camera (32), is further provided, - for the optical inspection of plugs (6), in particular the optical detection of a contour (25) of a plug (6), and / or - for positioning the test field (14) relative to the connector (6), and / or - to adapt the test field (14) to the connector (6).

12. Cable harness testing system (7) according to claim 11, characterized in that the optical system (30) comprises - several stereoscopically arranged optical means, e.g. cameras (32) and / or - at least one adjustable optical device, e.g. a camera (32), and / or - a lighting device for illuminating a plug from at least one lighting angle.

13. Cable harness testing system (7) according to one of the preceding claims, characterized in that a test head (12) is mounted on at least one robot arm (11) on which the test field (14) is mounted or formed, wherein the test head (12) is advantageously free of a contour and / or is designed to allow the test field (14) to be placed on the connector (6) without mechanical locking.

14. Cable harness testing system (7) according to one of the preceding claims, characterized in that a receiving means, e.g. gripper (35), for receiving a plug (6) is provided on at least one robot arm (11), wherein the control device (16) is set up and configured to control the robot arm (11) in such a way that it detects a plug (6) and leads it to the test field (14), in particular a fixed test field (14), and presses it against the test field (14) for contacting and for carrying out a test routine.

15. Method for testing a cable harness (8), comprising at least the following steps: - Providing a cable harness testing system (7) which includes an adjustment system (10), - Positioning a cable harness (4) which has at least one cable (5) and connectors (6) provided on the cable, - relative adjustment of a test field (14) having several test pins (27) with test contacts (26) relative to the plug (6), and - Attaching the test field (14) to the connector (6) - electrical contacting of the test contacts (26) of the test field (14) with plug contacts (22) of the plug (6), - Performing an electrical test routine on the test contact (26) with a measurement of at least one electrical property, - Evaluation of the measurement and assessment of the testing process.

16. Method according to claim 15, characterized in that during the measurement a test field (14) and a plug (6) are contacted together, wherein the plug contacts (22) of the plug (6) and the test contacts (26) of the test field (14) - a different number, and / or - have a different arrangement relative to each other, in particular with at least one passive test contact (26a) of the test field (14) that does not contact a plug contact (22).

17. Method according to one of claims 15 or 16, characterized in that the robot arm (11 ) adjusts a test head (12) with the test field (14) against the plug (6), and / or the robot arm (11 ) has or receives a gripper (35) for gripping and guiding a plug (6) and adjusts it against the test field (14).

18. Method according to one of claims 15 to 17, characterized in that - a robot arm (11 ) is adjusted so that a test field (11 ) is successively used to test several plugs, and / or - several robot arms (11 ) with at least one test head (12) each are adjusted simultaneously or successively to perform at least one electrical test routine on opposite plugs (6) of a common cable (5).

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