Modular Cable Harness Testing System for Aircraft Wiring
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Solution Overview
Problem
Current methods for testing aircraft wiring harnesses are inefficient, leading to production bottlenecks and delayed detection of defects such as damage or faulty wiring during aircraft component assembly.
Innovation Solution
A modular, lightweight, and flexible wiring harness test system that can be temporarily attached to aircraft components during cabling, utilizing microcomputers and interface simulation devices to detect defects in real-time, reducing the need for external test stations and enabling immediate error correction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external test stations are used for testing wiring harnesses, then testing can be performed, but production time is increased and production bottlenecks occur
Solution Approach 1:
The test system is segmented into multiple portable test kits that can be distributed to different workstations throughout the production process. Each test kit contains the necessary interface simulation devices and test equipment to perform local testing, eliminating the need for centralized external test stations and reducing production bottlenecks.
Solution Approach 2:
Testing is performed at multiple stages during the wiring process rather than only after completion. Interface simulation devices are connected to individual cable strands as they are installed, allowing defects to be detected and corrected immediately during assembly rather than requiring time-consuming post-assembly testing.
2Reliability
If heavy external test stations are used, then comprehensive testing is possible, but device portability and flexibility are reduced
Solution Approach 1:
The monolithic external test station is divided into multiple lightweight, portable test kits. Each kit contains only the essential components needed for testing specific portions of the wiring harness, making them easy to move and position at different workstations while maintaining comprehensive testing capability through the distributed network of test kits.
Solution Approach 2:
The essential testing functionality is extracted from the heavy external test station and embodied in compact, portable interface simulation devices. These extracted core functions are sufficient for performing comprehensive wiring tests without requiring the bulk and weight of traditional external test stations.
3Reliability
If testing is performed after wiring completion, then all wiring can be tested, but defect detection is delayed
Solution Approach 1:
Testing actions are performed preliminarily at multiple intermediate stages during the wiring process. Interface simulation devices are connected to cable strands as they are installed, allowing defects to be detected and corrected immediately rather than waiting until the end of the wiring process. This preliminary testing approach maintains complete defect detection while significantly reducing detection time.
Solution Approach 2:
The system provides immediate feedback about wiring defects through the portable test kits. When a defect is detected, the information is communicated instantly to the workers, allowing for real-time correction. This continuous feedback loop ensures complete defect detection while eliminating the time delay associated with post-assembly testing.
Data Source
Figure 1~3
AI summary
A cable harness test system comprises a cable test device (4) which has a microcomputer (P) and a plurality of first test point connections for connecting first endpoints (2) of a plurality of electrical conductors (1) of a cable harness and is designed to inject line test signals at the first test point connections into the plurality of electrical conductors (1) of the cable harness, as well as a plurality of interface simulation devices (5, 6) which each have a plurality of second test point connections for connecting second endpoints (3) of the plurality of electrical conductors (1) of the cable harness and are each designed to send line test signals received by the cable test device (4) at the second test point connections back through the plurality of electrical conductors (1) of the cable harness to the cable test device (4).