Engine Test Box Replicating Vehicle Electrical Interfaces

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Solution Overview

Problem

Testing diesel engines removed from vehicles poses challenges due to the absence of electrical interfaces, making it difficult to ensure all power and control connections are present for effective testing, leading to risks when reinstalling the engine.

Innovation Solution

An engine test box with a box-like enclosure featuring various electrical connections and adapters that mimic the vehicle's electrical infrastructure, allowing for the connection of essential components like the ECM connector, starter solenoid, and throttle control, enabling testing outside the vehicle with all necessary interfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the engine is removed from the vehicle for major overhaul, then the engine can be accessed and worked on, but the electrical interfaces and control connections are lost

Engineering Contradiction:

ImproveAccessibility of engine for overhaulVSAvoidPresence of electrical interfaces

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent introduces an intermediary testing system that mediates between the removed engine and the vehicle's electrical infrastructure. This system includes a power supply unit, control unit, and various connectors that replicate the vehicle's electrical environment, allowing the engine to be tested outside the vehicle while maintaining all necessary electrical connections through portable equipment.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If complicated temporary wiring is put in place to maintain electrical interfaces, then the electrical connections can be preserved, but the complexity and risk increase

Engineering Contradiction:

ImprovePresence of electrical interfacesVSAvoidComplexity of temporary wiring

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines multiple separate electrical connection functions into an integrated testing system. The power supply unit, control unit, data communication interfaces, and various connectors are merged into a coordinated system that manages all electrical connections through a unified control architecture, reducing the complexity of temporary wiring while maintaining all necessary interfaces.

Inventive Principle:

Principle #5Merging (Combining)

3Productivity

If the engine is reinstalled without proper testing, then the engine is back in service quickly, but the risk of damage or malfunction increases

Engineering Contradiction:

ImproveSpeed of engine return to serviceVSAvoidRisk of damage or malfunction

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent implements preliminary testing actions before the engine is reinstalled into the vehicle. The testing system performs comprehensive electrical and functional tests on the removed engine, including power supply verification, control signal validation, and system integration checks, ensuring all components are functioning correctly before the engine returns to service.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11460374B1Engine testing mechanism

Publication Date: 2022.10.04 COPE DAVID M

AI summary

An engine testing system has a control box having a plurality of internal components such as switches for starting and stopping the engine, a switch to enable or disable the fuel injectors, a voltage meter, circuit breakers and fuses that supply power to auxiliary circuits, and the like. The testing system further has two large spring-loaded clamps, which are attached to heavy gauge cables, which allow for the connection of a battery.