Wireless Battery Pack Holder With Pogo Pins for Mobile Harness Testing

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Solution Overview

Problem

Traditional electrical wiring harness testing systems are inefficient due to their bulky, immobile nature and reliance on hard-wired adaptors, making them difficult to scale and adapt to changing testing needs, especially in environments where mobility and flexibility are required.

Innovation Solution

The implementation of wireless harness automated measurement systems (WHAMS) that utilize wireless test modules with hot-swap connectors and wireless charging, allowing for wireless communication and testing of electrical wiring harnesses, enabling mobility and scalability by eliminating the need for physical connections to a central computer system.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional hard-wired testing systems are used, then stable electrical connections can be maintained, but the system becomes bulky and immobile

Engineering Contradiction:

Improveconnection stabilityVSAvoidmobility

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent replaces the mechanical hard-wired connection system with a wireless communication system. The testing module communicates with the wiring harness through wireless signals (Bluetooth, Wi-Fi, or other wireless protocols) instead of physical electrical connections, eliminating the need for bulky cables and connectors while maintaining reliable data transmission for testing operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a wireless communication module as an intermediary between the testing device and the wiring harness. This intermediary enables indirect communication through electromagnetic waves, replacing direct physical contact while maintaining the functional relationship needed for testing, thus achieving mobility without sacrificing connection reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If wireless test modules are used, then mobility and flexibility are improved, but power supply becomes more complex

Engineering Contradiction:

ImprovemobilityVSAvoidpower supply system

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent implements a dynamic power management system that automatically switches between wired power supply (when connected to a power source) and wireless power supply (when mobile). The system adjusts its power acquisition mode based on operational needs, allowing the testing module to remain mobile while simplifying the overall power supply architecture through intelligent adaptation.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The testing module is designed with multi-functional power acquisition capabilities, able to accept power through multiple pathways (wired connection, wireless charging, or internal battery). This universal power interface reduces the complexity of the power supply system by consolidating multiple power sources into a single adaptable platform.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If hot-swap connectors are implemented, then adaptability to different connectors is improved, but connector complexity increases

Engineering Contradiction:

Improveconnector compatibilityVSAvoidconnector structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent divides the connector system into two separate components: a universal interface on the testing module and interchangeable adapter connectors on the wiring harness side. This segmentation allows the main testing module to remain simple while achieving broad compatibility through standardized adapters, reducing overall system complexity while maintaining high adaptability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of making the testing module connector complex to accommodate all wire harness types, the patent inverts the approach by making the wire harness connector adaptable to a simple universal interface. The complexity is shifted to the adapter side rather than the core testing device, simplifying the main module while achieving versatility.

Inventive Principle:

Principle #13The other way round (Inversion)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach enhances testing efficiency and flexibility by allowing wireless test modules to be easily carried and deployed, reducing equipment requirements, and enabling fast automated test plan creation with minimal manual intervention, thus improving the scalability and adaptability of electrical wiring harness testing.

Implementation Method 1

a wireless charging receiver operable to wirelessly charge the wireless charging battery

Methodology Applied

Scientific EffectWireless charging: Electromagnetic Induction

Data Source

PatentEP4528891A1Systems and methods for a battery pack of a wireless harness automated measurement system

Publication Date: 2025.03.26 LOCKHEED MARTIN CORP

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Figure 2A~2B
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AI summary

According to some embodiments, a system includes a wireless charging battery, a wireless battery pack holder (902), an injected molded pogo pin holder (904) comprising a plurality of pogo pins, and a wireless charging receiver (906). The wireless battery pack holder (902) is operable to contain the wireless charging battery. The injected molded pogo pin holder (904) is coupled to the wireless battery pack holder (902) using a set of screws. The injected molded pogo pin holder (904) is operable to couple to a wireless test module (WTM). The wireless charging receiver (905) is operable to wirelessly charge the wireless charging battery.