Parallel Insulation Testing for Cable Harness Networks
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Solution Overview
Problem
Current insulation testing methods for cable harnesses are time-consuming and inefficient, as they require sequential measurement of each network, involving multiple plug contacts and extensive effort.
Innovation Solution
The method involves dividing cable harness networks into two groups, with one group connected to GND and the other checked for current flow, allowing for parallel testing using small, independent measuring units, reducing testing time and effort by regrouping networks in each measurement step to ensure all connections are correctly insulated.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sequential measurement of each network is performed, then measurement precision is ensured, but testing time increases significantly
Solution Approach 1:
The patent divides the cable harness networks into multiple groups that can be tested in parallel. Each group is assigned to a separate measuring unit, allowing simultaneous insulation testing of multiple networks without sequential measurement, thus reducing total testing time while maintaining accuracy through systematic group-based measurement.
Solution Approach 2:
The patent transitions from sequential one-dimensional measurement to parallel multi-dimensional measurement by introducing multiple measuring units that operate simultaneously on different network groups. This dimensional expansion from single-measurement-to-multiple-measurements enables concurrent testing without compromising precision.
2Reliability
If multiple connectors are involved in each measurement step, then comprehensive testing is achieved, but device complexity increases
Solution Approach 1:
The patent segments the testing system into multiple independent measuring units, each responsible for specific network groups. This segmentation reduces the complexity of individual measurement devices while achieving comprehensive testing through the coordinated operation of multiple simplified units rather than one complex sequential system.
Solution Approach 2:
Each measuring unit is designed with universal functionality to test multiple networks within its assigned group. The measuring units can accommodate different connector configurations and network arrangements, providing multi-functional capability that reduces overall system complexity while maintaining comprehensive testing coverage.
3Productivity
If parallel testing is implemented, then productivity increases, but measurement precision may be compromised
Solution Approach 1:
The patent segments networks into distinct groups that are tested in parallel by independent measuring units. Each group is isolated during measurement, ensuring that parallel testing does not introduce interference between networks. This segmentation maintains measurement precision while enabling simultaneous testing of multiple networks, thereby increasing productivity.
Solution Approach 2:
The patent introduces group-based measurement structures as intermediaries between individual networks and the measuring units. These group structures act as mediators that organize parallel measurements systematically, ensuring that each network is tested with appropriate isolation and control mechanisms, thus maintaining precision while achieving parallel processing for higher throughput.
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 significantly reduces testing times in cable harness production by enabling parallel use of existing testing equipment, ensuring accurate insulation testing and completeness checks across networks.
Implementation Method 1
Applying a first electrical potential to a first contact of the group of electrical contacts of each electrical network of the first network group and applying a second electrical potential, which differs from the first electrical potential, to the remaining contacts of the group of electrical contacts of each electrical network of the first network group and to all electrical contacts of the group of electrical contacts of each electrical network of the second network group
Implementation Method 2
testing the electrical contacts of the second network group connected to the second electrical potential for current flow
Data Source
Figure 1
Figure 2a~2c
Figure 3
AI summary
The disclosure relates to a method for the insulation testing of a plurality of electrical networks (11, 12, 13, 14) of a cable harness among themselves, wherein each network comprises a group of electrical contacts which are interconnected via electrical conductors.The procedure comprises the following: grouping the networks into a first network group (21) and a second network group (22) according to a grouping scheme; applying a first potential (141) to a first contact (112) of each network of the first network group (21) and applying a second potential (142) to the remaining contacts of each network of the first network group (21) as well as to all contacts of each network of the second network group (22); checking the contacts of the second network group (22) connected to the second potential (142) for current flow; and detecting electrical isolation between the networks of the second network group (22) and the networks of the first network group (21) if the checking of the contacts of the second network group (22) connected to the second potential (142) has shown that no current flows.