Modular Cable Harness Test Bench for Fast Reconfiguration
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Solution Overview
Problem
Existing test benches are often specific to a single type of cable harness, requiring costly and time-consuming modifications to accommodate different harness geometries and sizes, limiting their adaptability.
Innovation Solution
A modular test bench system with a base frame, test attachments, and extension frames that can be configured to fit various cable harness types, featuring a central test unit for power and communication, allowing quick adaptation to different harness geometries and sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If test benches are designed specifically for one or a few cable harness types, then testing reliability and precision are improved, but adaptability to other cable harness types deteriorates
Solution Approach 1:
The test bench is divided into modular components including a base frame, interchangeable test attachments, and extension frames. Each test attachment can be selectively mounted on the base frame to accommodate different cable harness geometries, allowing the same physical structure to serve multiple testing purposes without compromising reliability.
Solution Approach 2:
The base frame serves as a universal platform that can accommodate various test attachments designed for different cable harness types. The central test unit provides universal power and communication capabilities that work with all test attachments, enabling one test bench system to perform multiple testing functions reliably.
2Adaptability or versatility
If test benches are modified to accommodate different cable harness geometries, then adaptability is improved, but manufacturing cost and time increase
Solution Approach 1:
Instead of manufacturing completely different test benches for each cable harness type, the system segments the test bench into a reusable base frame and interchangeable test attachments. This allows the expensive base frame to be manufactured once and reused, while only the relatively inexpensive test attachments need to be manufactured for different geometries.
Solution Approach 2:
The test bench configuration can be dynamically changed by swapping test attachments on the base frame. This dynamic reconfigurability eliminates the need for costly remanufacturing when adapting to new cable harness geometries, as the same base frame can quickly accommodate different test attachments.
3Measurement precision
If test benches are designed with fixed configurations for specific cable harness types, then testing precision is maintained, but ease of reconfiguration deteriorates
Solution Approach 1:
The test bench is segmented into a stable base frame that maintains precise positioning and a set of interchangeable test attachments that can be easily swapped. This segmentation allows the precision features to remain in the base frame while the test attachments provide the necessary geometric variations for different cable harness types.
Solution Approach 2:
Test attachments are pre-configured with the specific geometric features needed for different cable harness types before being mounted on the base frame. This preliminary preparation ensures that when a test attachment is installed, the testing precision is immediately available without requiring on-site modifications or complex setup procedures.
Data Source
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AI summary
The test bench system (2) is used for testing cable harnesses and is modularly designed for easy adaptation to different cable harnesses. It can be set up in different test bench configurations and has a base frame (4) which includes a central test unit (26). The test bench system (2) further comprises: - several different types of test attachments (8) which can be optionally mounted on the base frame (4) to form the different test bench configurations and whose test modules (18A) are each connected to the central test unit (26) when mounted; and/or - at least one extension frame (6) which can be mounted laterally on the base frame (4) to form the different test bench configurations, wherein a test attachment (8) is mounted on the at least one extension frame (6) when mounted.whose test modules (18A) are connected to the central test unit (26) in the assembled state,