Cable Set Testing With Coded Signals for Simultaneous Wire Verification
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Solution Overview
Problem
The existing methods for testing cable sets in the automotive industry, particularly wiring harnesses with numerous individual wires, are time-consuming and expensive due to the need for successive resistance measurements of each wire.
Innovation Solution
A method and device for testing cable sets that apply simultaneously coded test signals to multiple conductors, allowing simultaneous testing of several wires, ensuring unique signal assignment and rapid, reliable functionality verification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If successive resistance measurements are performed on each wire individually, then measurement precision is ensured, but testing time increases significantly
Solution Approach 1:
Multiple individual resistance measurements are merged into a single simultaneous measurement by connecting multiple wires in parallel and applying a common test voltage. The individual resistances are calculated from the measured total current and individual voltage drops, achieving the same measurement precision as individual measurements but in parallel, thus reducing total testing time significantly.
Solution Approach 2:
The method uses periodic switching of the test voltage application across different wire groups in a systematic sequence. By periodically applying test voltage to different combinations of wires and measuring the corresponding currents, all individual wire resistances can be determined through mathematical evaluation, enabling simultaneous testing without interference.
2Productivity
If multiple wires are tested simultaneously using identical test signals, then testing time is reduced, but signal differentiation becomes impossible
Solution Approach 1:
Instead of using identical test signals for all wires, the method applies different voltage levels or signal characteristics to different wires or wire groups. This local differentiation of test signal quality allows the receiving unit to distinguish which current corresponds to which wire, maintaining signal assignment information while enabling simultaneous testing of multiple wires.
Solution Approach 2:
The test voltage parameter is varied across different wires or measurement cycles. By changing the voltage level or other electrical parameters of the test signal applied to different wires, the system can identify and differentiate the current contribution from each individual wire, preserving the ability to track individual wire performance while testing multiple wires simultaneously.
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
Significantly reduces testing time and ensures accurate, error-free verification of cable functionality by using differently coded test signals, enabling efficient and rapid testing of entire cable sets.
Implementation Method 1
a test signal is applied to one cable end of each individual cable by a transmitting unit and is detected at the other cable end by a receiving unit
Implementation Method 2
a resistance measurement is carried out for each cable to check the conductivity and thus functionality
Data Source
Figure 1~2
Figure 3
AI summary
In the method and device for testing a cable set (4), which is intended in particular for a vehicle and which has a plurality of individual wires (10) each with two wire ends (18), a test signal (P) is applied to one wire end (18) of each individual wire (10) by a transmitting unit (14) and detected at the other wire end (18) by a receiving unit (16), whereby several wires (10) are tested simultaneously and differently coded test signals (P) are applied for this purpose. This achieves a fast and reliable test of the entire cable set 4.