Cable Harness Testing via Voltage-Current Signature Analysis
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Solution Overview
Problem
The increasing complexity of cable harnesses in vehicle electrical systems makes testing inefficient and requires complex mathematical calculations, which are impractical due to the combination of resistors, capacitors, inductors, and semiconductors.
Innovation Solution
A method and device that apply an alternating voltage signal to networks within the cable set, measure current and voltage, compare these signatures to predetermined target voltage-current characteristics, and output an error message if deviations exceed a threshold, allowing for efficient detection of faults without complex mathematical calculations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If complex mathematical calculations are used to test cable harnesses with multiple electrical assemblies, then measurement precision can be improved, but device complexity and calculation time increase significantly
Solution Approach 1:
The patent extracts only the essential characteristic - the voltage-current signature - from the complex electrical behavior of cable harnesses with multiple assemblies. Instead of attempting to model and calculate all electrical interactions mathematically, the invention measures the actual I/U characteristic curve directly, extracting the fingerprint-like signature that uniquely identifies the cable harness configuration and detects deviations without complex computations.
Solution Approach 2:
The patent replaces the mechanical/mathematical system of complex circuit analysis and mathematical calculations with a direct electrical measurement approach. By using an I/U characteristic curve measurement, the invention substitutes elaborate mathematical modeling with a straightforward electrical signature comparison, eliminating the need for complex calculation algorithms while maintaining high measurement precision.
2Reliability
If traditional testing methods are used for complex cable harnesses, then comprehensive testing coverage can be achieved, but testing time and effort increase
Solution Approach 1:
The patent changes the measurement parameter from individual component testing to holistic I/U characteristic curve measurement. By measuring the overall voltage-current relationship of the entire cable harness assembly rather than testing each electrical component separately, the invention achieves comprehensive testing coverage in a single measurement, dramatically reducing testing time while maintaining reliability through the unique signature comparison approach.
Solution Approach 2:
The patent merges multiple testing functions into a single I/U characteristic measurement. Instead of performing separate tests for different electrical assemblies and connections, the invention combines all testing into one comprehensive signature measurement that captures the electrical characteristics of the entire cable harness system, thereby achieving thorough testing coverage without the time penalty of multiple individual tests.
3Adaptability or versatility
If multiple electrical assemblies are integrated into the cable harness, then functionality and versatility are improved, but difficulty of detecting and measuring faults increases
Solution Approach 1:
The patent creates an electrical signature copy or fingerprint of the cable harness I/U characteristic curve under known good conditions. This signature serves as a reference template that can be stored and compared against future measurements. By copying and storing the characteristic signature, the invention enables easy fault detection through simple comparison operations, regardless of how complex the cable harness configuration with multiple electrical assemblies may be.
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 simplifies the testing process, reduces the time and cost of testing, and effectively detects damage to electronic components, such as ESD protection diodes, by analyzing voltage-current characteristics.
Implementation Method 1
applying an alternating voltage signal to the networks, in particular those which have electrical assemblies
Implementation Method 2
measuring the current and the voltage for each, or in each of the networks to which the alternating voltage signal is applied
Implementation Method 3
comparing voltage-current characteristics of the respective networks created on the basis of the respective measured current and the respective measured voltage
Data Source
Figure 1~2
Figure 3
AI summary
The present invention relates to a method for testing a cable set (150, 250) having a number of networks (157, 158, 159, 160), at least one of the networks (157, 158, 159, 160) having a number of electrical assemblies (161, 162), comprising the steps of: - applying (S1) an alternating voltage signal (102, 202) to the networks (157, 158, 159, 160); - measuring (S2) the current and the voltage for each of the networks (157, 158, 159, 160) to which the alternating voltage signal (102, 202) is applied; - comparing (S3) voltage-current characteristic curves of the relevant networks (157, 158, 159, 160) that have been created on the basis of the relevant measured current and the relevant measured voltage with a specified target voltage-current characteristic curve (106, 206) for the relevant network (157, 158, 159, 160); and - outputting (S4) an error message (107, 207) if one of the voltage-current characteristic curves created on the basis of the relevant measured current and the relevant measured voltage deviates from the corresponding target voltage-current characteristic curve (106, 206) by more than a specified threshold value. The present invention also relates to a corresponding testing device (100, 200).