Capacitive Cable Harness Testing for Open-End Wire Detection
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Solution Overview
Problem
Conventional cable harness testers require plug connections on both sides of wires, making it time-consuming and labor-intensive to test cable harnesses with open wires, especially those with connectors on only one side, as they need to contact individual wires for testing.
Innovation Solution
A method and device that use capacitive sensing to detect the presence of wires within a cable harness by applying a test signal and measuring the electrical potential, allowing for contactless line detection and identification of shielded cables, without the need for physical contact with the second ends of the wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional cable harness testers are used to test cable harnesses with open wires, then individual wire contact is achieved, but testing time and labor effort increase significantly
Solution Approach 1:
The patent replaces the mechanical contact-based testing system with a capacitive sensing system. Instead of physically contacting each wire with test probes, the system uses an electrode that forms capacitors with wires through non-contact or minimal-contact means, enabling simultaneous detection of multiple wires and dramatically reducing testing time while maintaining detection accuracy
2Reliability
If plug connections are required on both sides of wires for testing, then contact resistance measurement is enabled, but device complexity and handling effort increase
Solution Approach 1:
The patent extracts the requirement for dual-side plug connections and replaces it with a single-side electrode placement approach. The capacitive sensing method only requires the electrode to be placed on one side of the cable harness, forming capacitors with wires that pass through or near the electrode, thereby simplifying the testing setup while still enabling reliable wire detection and connection verification
Solution Approach 2:
The electrode serves multiple functions: it forms capacitors with multiple wires simultaneously, enables detection of both shielded and non-shielded cables, and provides a universal testing interface that works with different cable harness configurations without requiring separate test setups for each type
3Measurement precision
If individual wire contact is performed for testing, then precise wire identification is achieved, but testing effort and time consumption increase
Solution Approach 1:
The patent merges the detection of multiple wires into a single capacitive sensing operation. By placing one electrode that can form capacitors with multiple wires simultaneously, the system combines what would otherwise require multiple separate contact measurements into a single unified testing step, maintaining wire identification accuracy while reducing testing duration
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 efficient and rapid testing of cable harnesses with open ends by determining the presence of all lines in a bundle, reducing testing time and effort, and effectively identifying both individual wires and shielded cables without the need for extensive handling or additional connections.
Implementation Method 1
An electrode (16) is placed on a test section (18). The arrangement is such that the electrode forms a respective capacitor with each of the lines (4) of the line bundle (20) in the test section (18)
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
In a method for checking a cable harness (2), a test section (18) of the cable harness (2) with at least one conductor (4a-f) is selected, an electrode (16) is arranged on the test section (18) which forms capacitors (Ca-c) with the conductors (4a-c), a test lead is selected and a test signal (P) is applied, a reference potential (R) is applied to all other conductors, a characteristic value (K) is determined on the basis of the electrical potential (M) of the electrode (16), and a decision (E) is made as to whether the test lead is located in the test section (18) if the characteristic value (K) fulfills a test criterion (T), or not.A measuring device (12) for checking the cable harness (2) with a plurality of coupling elements (14a-f) for contacting the lines (4a-f) includes the electrode (16) and a control and evaluation unit (22) which is connected to the coupling elements (14a-f) in order to selectively provide the test signal (P) or the reference potential (R) there, and which is connected to the electrode (16), and which carries out the method according to the invention, and which has an output interface (24) for the decision (E).