Modular Cable Harness Testing with Variant-Specific Adapter Carriers
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Solution Overview
Problem
The complex and labor-intensive process of handling and testing various variants of cable harnesses, which involves manual handling, transportation, and plugging into test connections, makes the testing process inefficient and prone to errors.
Innovation Solution
A modular testing system with transport devices equipped with contour receptacles and adapter carriers that accommodate different variants of cable harness connectors, allowing for automated transportation and testing, using adapters to connect the harnesses to a standardized testing device, eliminating the need for manual handling and plugging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual handling and transportation of cable harnesses is used, then flexibility in handling different variants is maintained, but handling complexity and labor intensity increase significantly
Solution Approach 1:
The patent introduces transport devices as intermediary carriers that automatically hold and transport cable harnesses from the assembly workbench to the test station. These transport devices include holding elements that securely grip the harnesses, eliminating the need for manual carrying and reducing handling complexity while maintaining operational flexibility.
Solution Approach 2:
The patent extracts the transportation function from the manual handling process by introducing dedicated transport devices. The transport devices are equipped with holding elements that automatically secure the cable harnesses, separating the transportation task from manual operations and reducing the complexity of handling different harness variants.
2Adaptability or versatility
If manual connection to test terminals is used, then adaptability to different connector variants is maintained, but testing time and productivity decrease
Solution Approach 1:
The patent employs universal test terminals and adapter carriers that can accommodate different connector variants through standardized interfaces. The test terminals are designed with universal connection capabilities, allowing automated testing of various cable harness configurations without requiring manual reconfiguration, thus maintaining adaptability while increasing testing speed.
Solution Approach 2:
The patent implements dynamic adapter carriers that can be automatically exchanged or reconfigured based on the specific cable harness variant being tested. This dynamic adaptability allows the testing system to quickly adjust to different connector types through automated mechanisms rather than manual intervention, enhancing both productivity and versatility.
3Device complexity
If standardized test terminals are used, then testing process is simplified, but adaptability to different cable harness variants is reduced
Solution Approach 1:
The patent introduces adapter carriers as intermediary components between the standardized test terminals and the various cable harness connectors. These adapter carriers provide a standardized interface on one side (connecting to test terminals) and variant-specific interfaces on the other side (connecting to different harness types), thus maintaining system simplicity while enhancing variant compatibility.
Solution Approach 2:
The patent segments the connection system into modular components: standardized test terminals, interchangeable adapter carriers, and variant-specific connector interfaces. This segmentation allows the core testing system to remain simple and standardized while adapting to different harness variants through interchangeable adapter modules, resolving the contradiction between simplicity and versatility.
4Productivity
If automated transport devices are introduced, then handling efficiency is improved, but system complexity and initial investment increase
Solution Approach 1:
The patent segments the automated transport system into modular, functionally independent components: transport devices with holding elements, positioning mechanisms, and integration interfaces with the assembly workbench and test station. This modular segmentation allows the automated handling function to be implemented without requiring complete system redesign, thus improving productivity while limiting the increase in overall system complexity.
Data Source
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AI summary
The invention relates to a modular test system (12) for the automated testing of different variants of cable harnesses (18), comprising several transport devices (14) designed to receive and transport the respective cable harnesses (18) arranged on building boards (10); different variants of contour fixtures (20) attachable to the transport devices (14) for receiving different variants of connectors (22) of the cable harnesses (18); at least one test device (16) with several test terminals (24) for indirectly connecting the test device (16) to respective connector outputs (26) of the connectors (22) of the cable harnesses (18);Different variants of adapters (28) for connecting the test device (16) to the different variants of the connectors (22) of the cable harnesses (18), each having a variant-specific input (30) for establishing a plug connection with the respective connector outputs (26) of the variants of the connectors (22) and with a respective output (32) for establishing a plug connection with the test terminals (24) of the test device (16); at least one adapter carrier (34) on which the different variants of the adapters (28) can be attached at different positions on the adapter carrier (34) specific to the cable harness. The invention further relates to a method for the automated testing of different variants of cable harnesses (18).