Connectorized Equipment Testing With Modular Interface Cables
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Solution Overview
Problem
Existing automated test equipment (ATE) and handheld testers face limitations in agility and efficiency due to the need for customized interface cables and test programs, leading to delays and increased costs in electrical equipment maintenance and manufacturing, especially in environments where immediate action is required.
Innovation Solution
A system utilizing a centralized database with a universal connector database and graphical user interface (GUI) to rapidly create and validate interface cables and test programs, enabling remote operation and tracking, and employing 3D printing and augmented/virtual reality for on-site assembly and repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If customized interface cables are used to connect to various connection points of the subject under test, then the ability to perform tests on diverse equipment is improved, but the time required to prepare and deploy the cables increases
Solution Approach 1:
The interface cable is divided into modular segments with standardized connectors. Each segment can be independently configured and connected to match different connection points on the subject under test, enabling rapid reconfiguration without requiring custom cables for each scenario.
Solution Approach 2:
The cable system transitions from static, fixed configurations to dynamic, reconfigurable connections. The modular design allows the cable topology to be dynamically adjusted based on the specific testing requirements and equipment being tested, significantly reducing preparation time.
2Adaptability or versatility
If a large number of customized interface cables are maintained for different SUT types, then the coverage of test capabilities is improved, but the complexity of cable management and inventory increases
Solution Approach 1:
A universal interface cable design with standardized connectors and modular segments serves multiple testing scenarios. The same basic cable platform can be configured for different SUT types by simply changing the connector types and topology, eliminating the need to maintain separate cable inventories for each application.
Solution Approach 2:
Instead of maintaining physically different cables for each application, the system changes parameters such as connector types, wire configurations, and topological arrangements while using the same fundamental cable platform. This allows diverse test capabilities to be achieved through software configuration rather than physical variety.
3Reliability
If interface cables are built in advance and stored at the location of the SUT, then immediate availability for urgent repairs is improved, but the costs of engineering, building, and storing the cables increase
Solution Approach 1:
Instead of building complete customized cables in advance, the system pre-configures modular components and connector types in a standardized library. When urgent repairs are needed, the required cable configuration can be rapidly assembled from these pre-prepared modular elements, achieving both speed and cost efficiency.
Solution Approach 2:
The system uses virtual templates and configurations that can be rapidly instantiated. Rather than physically storing multiple customized cables, the infrastructure stores digital blueprints and modular physical components that can be quickly assembled to match any required configuration, reducing both storage costs and engineering overhead.
Data Source
AI summary
There is described a method for testing connectorized electrical equipment in an environment. The method comprises obtaining a unique identifier of an origin connector of the connectorized electrical equipment to be tested. A computing device receives a reading of the unique identifier of the origin connector of the connectorized electrical equipment to be tested and identifies a connection between the origin connector of the connectorized electrical equipment to be tested 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 connectorized electrical equipment, from a database, to determine a next step of the testing which depends on the connection identified by the computing device.