Modular Wiring Harness Testing via Reconfigurable TDR Switching
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Solution Overview
Problem
Current wiring harness testing systems are impractical and costly due to the need for re-designing testing equipment for each different configuration, failing to accurately and reliably test the electrical characteristics of various wiring harnesses with diverse numbers of wires and connector types.
Innovation Solution
A modular wiring harness testing apparatus with re-configurable time-domain reflectometer (TDR) engines and switching networks, along with body holder receptacles, allows for flexible testing of multiple wiring harness configurations by impedance-matching delivery paths, accommodating different connector types and sizes, and enabling accurate detection of impedance anomalies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If TDR testing board is re-designed for each wiring harness configuration, then compatibility with particular wiring harness is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent implements a universal testing board design that can accommodate multiple wiring harness configurations through a standardized switching network interface. The testing board maintains fixed architecture while the switching network dynamically reconfigures to match different harness types, enabling one board to serve multiple functions across various connector configurations (e.g., 6-pin, 12-pin, 24-pin connectors).
Solution Approach 2:
The patent employs dynamic reconfiguration of the switching network using electronically controlled switches that can be programmed to establish different connection patterns. This allows the testing system to adapt to different wiring harness configurations in real-time without physical hardware changes, transitioning from static board designs to dynamic, software-controlled connectivity.
2Measurement precision
If TDR testing board is re-designed for each wiring harness configuration, then accurate testing of specific configuration is improved, but loss of time and productivity decrease
Solution Approach 1:
The patent pre-programs multiple switching network configurations into the testing system's memory before operation. When a specific wiring harness type is to be tested, the system retrieves and activates the pre-configured switching pattern corresponding to that harness type, eliminating the need for time-consuming manual reconfiguration or physical board redesign during the testing process.
Solution Approach 2:
The system dynamically switches between pre-configured testing patterns through electronic control, allowing rapid transition between different wiring harness configurations. This dynamic switching capability maintains measurement precision for each specific configuration while reducing setup time from hours of board redesign to seconds of software configuration.
3Ease of manufacture
If continuity tester is used for wiring harness testing, then manufacturing process simplicity is improved, but measurement precision of electrical characteristics deteriorates
Solution Approach 1:
The patent introduces a switching network as an intermediary component between the simple continuity tester and the wiring harness under test. This switching network enables the basic tester to access multiple test points and configurations without requiring the tester itself to be complex, maintaining ease of manufacture while achieving comprehensive electrical characteristic measurement through intelligent signal routing.
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 system enables efficient and reliable testing of various wiring harness configurations, detecting impedance anomalies and electrical faults, while simplifying maintenance and updates, allowing for parallel continuity tests and fault detection across multiple circuits.
Implementation Method 1
Time-domain reflectometer (TDR) systems can be used to characterize and locate faults in conductive cables such as those used in a wiring harness. To test a wiring harness a signal is sent down a pair of wires and the reflection of this signal is evaluated to find a fault.
Implementation Method 2
a signal is sent down a pair of wires and the reflection of this signal is evaluated to find a fault
Implementation Method 3
Each connector system is impedance-matched with the body holder receptacle and the switching network to define a delivery path having a uniform impedance to deliver the test pulses to and from one of the wiring harnesses.
Data Source
AI summary
Modular wiring harness testing systems and apparatus are provided for testing wiring harnesses such as those used in the automotive industry. The testing apparatus is configurable (or re-configurable) to test a plurality of different types of wiring harnesses that have different configurations in terms of the number of wires, number of circuits and/or the number, size or type of connectors.