Connectorized Cable Assembly Using Database-Guided Connection Mapping
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Solution Overview
Problem
Existing automated testing equipment (ATE) and handheld testers face limitations in agility and efficiency due to the need for numerous customized interface cables and test programs, which leads to delays and increased costs in maintenance and repair of connectorized electrical equipment, especially in urgent situations where parts are not readily available.
Innovation Solution
A system utilizing a centralized database for universal connector and test program management, enabling rapid creation and deployment of interface cables and test programs through a GUI-oriented approach, with features like 3D printing and augmented/virtual reality for on-site assembly and repair, allowing remote access and validation of parts and programs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ATE is used with customized interface cables for each connector type, then test coverage and reliability are improved, but device complexity and time to deploy increase significantly
Solution Approach 1:
The patent implements a universal interface cable design that can connect to multiple different connector types through a single standardized connector. This universal cable incorporates a database-driven configuration system that allows the same physical cable to be programmed for different connector types, eliminating the need for multiple specialized cables while maintaining full test coverage across diverse electrical equipment.
Solution Approach 2:
The invention changes the configuration parameters of the interface cable through software programming rather than physical redesign. By storing connector-specific parameters (pin layouts, electrical characteristics, signaling protocols) in a database and loading the appropriate configuration before use, the system achieves adaptability to different connector types without changing the physical cable structure, thus reducing complexity while maintaining reliability.
2Loss of time
If interface cables are built in advance and stored at the location, then urgent maintenance can be performed immediately, but engineering costs and opportunity costs increase
Solution Approach 1:
The system performs preliminary actions by pre-configuring the universal interface cable with standard connector types and pre-loading test programs into the ATE before maintenance is needed. The cable is prepared in advance with a library of connector configurations stored in its database, allowing immediate deployment to various locations without requiring custom cable construction for each specific maintenance task, thus reducing both time loss and manufacturing costs.
Solution Approach 2:
Instead of building custom physical cables for each connector type, the invention creates virtual copies of connector configurations stored in a database. These digital representations contain all the necessary electrical and mechanical parameters, allowing the same physical cable to be programmed to match different connector types. This copying approach eliminates the need for expensive custom cable manufacturing while enabling immediate maintenance response.
3Ease of operation
If handheld testers are used for testing, then agility and ease of operation are improved, but productivity and scope of work are limited
Solution Approach 1:
The patent merges the advantages of handheld testers (portability, ease of operation) with the capabilities of automated test equipment (high throughput, comprehensive testing). The universal interface cable integrates both a portable form factor and automated test program execution, allowing technicians to perform complex multi-point tests using a single handheld device that can be quickly reconfigured for different equipment types without sacrificing productivity.
Solution Approach 2:
The system introduces dynamic reconfigurability to the handheld tester through the universal interface cable. The cable can dynamically change its configuration by loading different connector types from a database based on the specific equipment being tested. This dynamic adaptation allows the handheld device to maintain high productivity across diverse applications while preserving operational flexibility, as the same physical device can adapt to different testing scenarios without physical reconfiguration.
Data Source
AI summary
There is described a method for assembling or repairing an electrical cable in an environment. The method comprises obtaining a unique identifier of an origin connector of the electrical cable to be assembled or repaired. A computing device receives a reading of the unique identifier of the origin connector of the electrical cable to be assembled or repaired and identifies a connection between the origin connector of the electrical cable to be assembled or repaired and a destination electrical component. At the computing device, there is made a determination of the connection that was identified with a connectivity list required for the electrical cable, from a database, to determine a next step of the assembling or the repairing which depends on the connection identified by the computing device.