Adaptive Voltage Harness Testing System
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Solution Overview
Problem
Existing high voltage harness testing systems are inadequate for early and preventative detection of connector faults, often mistaking voltage fluctuations due to load resistance as arc faults and require complex external components and skilled manual re-wiring for testing.
Innovation Solution
A wire harness testing system that includes a voltage sensor, controller, and indication device, which measures voltage drops, adaptively updates reference voltages based on operating characteristics, and generates fault notices with warning signals, reducing the need for external components and skilled personnel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external smart connectors and additional wirings are used to perform the test, then arc fault detection capability is improved, but device complexity increases
Solution Approach 1:
The patent merges the testing functions directly into the existing connector structure, eliminating the need for external smart connectors and additional wirings. The controller integrates multiple testing capabilities (voltage measurement, current measurement, arc detection) into a single unified system that communicates with the existing connector components, thereby reducing device complexity while maintaining arc fault detection capability.
Solution Approach 2:
The patent extracts the testing functionality from external components and relocates it to the existing connector structure. By using the existing connector's inherent electrical connections and integrating the controller within the harness assembly, the system removes the need for separate external testing devices, thus simplifying the overall system architecture.
2Measurement precision
If manual re-wiring and connection of external components is required, then testing accuracy is improved, but ease of operation deteriorates
Solution Approach 1:
The system performs self-testing by utilizing the existing electrical connections and components within the harness assembly. The controller automatically measures voltage and current through the existing connector pathways without requiring manual intervention for wiring or connection setup, thereby maintaining testing accuracy while significantly improving ease of operation.
Solution Approach 2:
The controller is designed to perform multiple testing functions (voltage measurement, current measurement, arc detection, connector engagement verification) through a single integrated unit that interfaces with the existing connector structure. This multi-functional approach eliminates the need for separate testing equipment and manual re-wiring procedures, making the system both accurate and easy to operate.
3Measurement precision
If adaptive reference voltages are used to account for load variations, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The controller implements a feedback mechanism where it continuously monitors the actual voltage and current measurements through the existing connector pathways. Based on these real-time measurements, the controller dynamically adjusts the reference voltage values to account for variations in load characteristics, sensor precision, and operating conditions. This feedback-based adaptation improves voltage measurement accuracy without requiring complex external calibration equipment.
Solution Approach 2:
The reference voltage values are made dynamic rather than static, allowing the system to automatically adapt to changing operating conditions such as different load types, temperature variations, and sensor drift. The controller adjusts these reference values in real-time based on the measured electrical parameters, thereby maintaining high measurement precision across varying operational scenarios without adding significant complexity.
Data Source
AI summary
A wire harness testing system is disclosed. The wire harness testing system includes a voltage sensor configured to measure a voltage at a location associated with an electric load, wherein the electric load is connected with at least one wire harness. The wire harness testing system also includes a controller electrically coupled to the voltage sensor. The controller is configured to receive a wire harness test request. The controller is further configured to determine a voltage drop based on a voltage sensor measurement and a reference voltage and compare the voltage drop with a threshold. The controller is also configured to adaptively update the reference voltage with the voltage measurement responsive to a voltage drop below the threshold, and generate a fault notice responsive to a voltage drop above the threshold. The wire harness testing system further includes at least one indication device configured to provide a warning signal based on the fault notice generated by the controller.