Modular Test Device for Electric Components
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing test devices for electrical components, such as those in motor vehicles, become complex and error-prone when testing complete systems with many components, requiring extensive wiring and adaptation to various voltage and current levels, making them difficult to handle and prone to errors.
Innovation Solution
A modular test device with integrated stimulation and load devices, controlled via a selector switch, allows for easy connection and adjustment of stimulus signals and load levels, featuring digital-to-analog converters, level adjustment devices, and a bus concept for efficient communication between modules, reducing the need for additional devices and minimizing cabling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If individual wiring and separate test arrangements are used for each component, then the test arrangement can be adapted to the specific test object, but the test arrangement becomes extensive and confusing with increased complexity
Solution Approach 1:
The patent implements a universal test module design that can be configured for different test objects through software settings rather than physical reconfiguration. The test module includes reconfigurable wiring patterns, adjustable voltage/current levels, and programmable test sequences that adapt to various electrical components (sensors, actuators, control units) without requiring separate dedicated test arrangements for each component type.
Solution Approach 2:
The patent combines multiple test functions into a single integrated test module that includes stimulus generation, signal measurement, load simulation, and evaluation capabilities. This consolidation eliminates the need for multiple separate test devices and extensive interconnections, reducing overall system complexity while maintaining comprehensive test coverage for complete systems with multiple electrical components.
2Adaptability or versatility
If adaptation devices are coupled to achieve desired test voltages or current levels, then the test arrangement can be adapted to voltage or current levels, but the interconnection becomes complicated and error-prone
Solution Approach 1:
The patent employs dynamically adjustable voltage and current sources within the test module that can be programmed to output any required level through software control. This eliminates static adaptation devices and hardwired voltage dividers, allowing flexible adaptation to different test requirements without adding physical complexity or creating error-prone interconnections.
Solution Approach 2:
The patent replaces physical adaptation devices (voltage dividers, current transformers, manual switches) with electronically controlled digital-to-analog converters and programmable power supplies. This substitution of mechanical/electrical adaptation hardware with software-controlled electronic systems simplifies the interconnection architecture and reduces the potential for wiring errors.
3Reliability
If a complete system with many electrical components is tested, then comprehensive system testing is achieved, but the test arrangement becomes extensive and confusing
Solution Approach 1:
The patent designs the test module as a universal platform capable of testing multiple types of electrical components (sensors, actuators, control units, relays) within a single integrated system. The module can simultaneously or sequentially test various components in a complete vehicle system through programmable test sequences, eliminating the need for separate dedicated test arrangements for each component while maintaining comprehensive system testing capability.
Solution Approach 2:
The patent merges stimulus generation, signal measurement, load simulation, and evaluation functions into a single integrated test module that can handle complete system testing. This consolidation allows comprehensive testing of multiple electrical components without requiring extensive separate test arrangements and complex interconnections between multiple specialized devices.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The modular design simplifies the testing process, reduces cabling effort, and allows flexible adaptation to test requirements, providing a robust and efficient means to simulate various conditions and measure outputs without the need for external devices, thus enhancing test accuracy and ease of use.
Implementation Method 1
The stimulation device expediently contains a digital-to-analog converter. Thus, for example, digital default values can be entered via the control connection, which the digital-to-analog converter converts to analog values
Implementation Method 2
Furthermore, it is advantageous if the stimulation device has an output level adjustment device for adjusting the at least one stimulus signal. With the level adjustment device, for example, a low voltage or current level can be converted to a higher level
Implementation Method 3
A short-circuit switch is advantageous for one or more of the test modules, with which a short circuit can be generated at the test connection arrangement. The short-circuit switch can expediently be connected to the test connection arrangement with the aid of the selector switch
Implementation Method 4
For measurement purposes, it is possible, on the one hand, for measurement connections to be provided, for example, on a front side or at another point of a respective test module. However, a measuring device that is on board a respective test module is also advantageous
Implementation Method 5
It is advantageous if the measuring device also includes an analog/digital converter
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The test unit, for electrical components (13c) especially in a motor vehicle, has test modules with connections to link the component to a connection (54) for a central control (24). The control activates selective switches (25a-25c) to switch off selectively a load and/or at least one stimulus signal at a test connection (27). At least one test module (18) has an internal stimulation signal generating unit and an on-board power supply is linked to the test connection.