Cable Harness Testing Device Using Frequency Discrimination
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Solution Overview
Problem
The complexity of modern vehicle wiring harnesses makes it difficult to accurately check and ensure correct connections among numerous electrical networks, as existing methods are prone to errors and can only test one network at a time, failing to recognize overlapping signals.
Innovation Solution
A device and method that use a signal generator to feed AC voltage with specific frequencies into each network, allowing simultaneous testing of all connections by distinguishing individual frequencies, and a test unit to determine if frequencies are present at correct and incorrect contacts, thereby identifying errors and coupling factors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If DC voltage is applied to check individual electrical networks, then the presence of voltage can be measured at all connections, but the checking process becomes very complex and prone to errors, and only one network can be checked at a time
Solution Approach 1:
The patent changes the parameter of the test signal from DC voltage to AC voltage with different frequencies for different electrical networks. This allows multiple networks to be tested simultaneously by using frequency discrimination, thereby reducing testing complexity while maintaining measurement accuracy. Each network is assigned a unique frequency, enabling the test system to distinguish and measure multiple networks at the same time without confusion.
Solution Approach 2:
The patent employs periodic AC test signals with different frequencies for different electrical networks. By using periodic signals rather than continuous DC voltage, the system can encode multiple networks with distinct frequency characteristics, allowing simultaneous testing without the complexity and error-proneness associated with DC voltage measurement methods.
2Measurement precision
If DC voltage is applied to check individual electrical networks, then voltage presence can be measured, but overlapping electrical networks cannot be recognized
Solution Approach 1:
The patent changes the test signal parameter from DC voltage to AC voltage with unique frequencies for each network. This frequency encoding allows the system to distinguish between overlapping electrical networks by identifying their respective frequency signatures. When networks are accidentally connected together, the frequency analysis reveals the presence of multiple frequencies, enabling detection of overlapping connections that would be indistinguishable with DC voltage.
3Productivity
If multiple electrical networks are tested simultaneously with DC voltage, then testing speed increases, but overlapping networks cannot be distinguished and errors increase
Solution Approach 1:
The patent assigns different frequency parameters to test signals for different electrical networks, enabling simultaneous testing while maintaining the ability to distinguish between networks. The frequency discrimination capability allows the system to process multiple networks in parallel without sacrificing accuracy, as each network's response can be independently identified by its unique frequency signature even when networks are accidentally connected.
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
Enables quick and error-free verification of all connections in a wiring harness, allowing for efficient detection of correct connections and identification of overlapping signals, reducing manual errors and increasing testing speed.
Implementation Method 1
A device (100) and corresponding method for testing a wiring harness (150) with a multiplicity of electrical networks (151, 152), which are formed by connecting elements (153, 154) with individual contacts (155-158), which are coupled to one another by lines (160, 161). The device (100) has a signal generator (101) which is designed to generate a test signal (102, 103) with a predetermined frequency. Furthermore, the device (100) has a coupling device (104) which is designed to contact at least one of the networks (151, 152) via one of the contacts (155-158) of the network (151, 152) and to feed the test signal (102, 103) into the corresponding network (151, 152).
Implementation Method 2
Finally, the device (100) has a test unit (106), which is designed to contact the further contacts (157, 158) of the at least one network (151, 152) and to check whether the test signal (102, 103) with the respective frequency is present at the further contacts (157, 158). The test unit (106) is designed to determine the frequencies which are contained in the signals (107, 108) which are present at the contacts (157, 158).
Data Source
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AI summary
The present invention discloses a device (100, 200) for testing a cable harness (150) with a plurality of networks (151, 152, 251, 252, 265) formed by connecting elements (153, 154, 253, 254, 266) with individual contacts (155, 156, 157, 158, 255, 256, 257, 270, 271, 272, 273) coupled to one another by lines (160, 161), comprising a signal generator (101, 201) configured to generate at least one test signal (102, 103, 202, 203, 210) with a predetermined frequency, and a coupling device (104, 105) configured to connect at least one of the to contact networks (151, 152, 251, 252, 265) via one of the contacts (155, 156, 157, 158, 255, 256, 257, 270, 271, 272, 273) of the network (151, 152, 251, 252, 265) and to feed the test signal (102, 103, 202, 203, 210) into the corresponding network (151, 152, 251, 252, 265), and with a test unit (106, 206) which is designed to contact the other contacts (155, 156,157, 158, 255, 256, 257, 270, 271, 272, 273) of at least one network (151, 152, 251, 252, 265) to contact and check whether the test signal (102, 103, 202, 203, 210) at the respective frequency is present at the other contacts (155, 156, 157, 158, 255, 256, 257, 270, 271, 272, 273). Furthermore, the present invention discloses a corresponding method and a manufacturing method.