Parallel Cable Harness Testing for Electrical and Sealing Checks
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Solution Overview
Problem
Current methods for functional testing of high-voltage cable harnesses require separate test stations for connector sealing, lead-through sealing, and electrical properties, leading to high time, personnel, and cost expenditures.
Innovation Solution
A method and device for functional testing using a test system with multiple test nests, allowing simultaneous execution of electrical and sealing tests on multiple cable harnesses, thereby reducing idle time for operators and optimizing test device configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate test stations are used for connector sealing, lead-through sealing, and electrical tests, then each test can be performed with dedicated equipment, but the total testing time and operator idle time increase significantly
Solution Approach 1:
The patent combines multiple separate test stations (connector sealing test, lead-through sealing test, electrical test) into a single integrated test system with multiple test nests. This allows simultaneous execution of different tests on multiple cable harnesses, eliminating operator idle time while maintaining dedicated testing capabilities for each test type.
Solution Approach 2:
The test system is divided into multiple independent test nests (first test nest, second test nest, etc.), each capable of performing complete test sequences. This segmentation allows parallel processing of multiple cable harnesses while maintaining the reliability of individual test stations through functional duplication.
2Extent of automation
If multiple test stations are arranged separately, then each test can be performed automatically, but the space requirement and device complexity increase
Solution Approach 1:
Multiple test stations are merged into a single integrated test system where connector sealing test device, lead-through sealing test device, and electrical test device coexist in one structure. This reduces spatial requirements and operational complexity while maintaining automatic testing capabilities across all test types.
Solution Approach 2:
The test system is designed as a universal platform that can perform connector sealing tests, lead-through sealing tests, and electrical tests across multiple test nests. Each test nest is equipped with all necessary testing capabilities, allowing any cable harness to undergo complete testing sequences without requiring transfer between separate stations.
3Device complexity
If sequential testing is performed on single cable harness, then test equipment can be simple, but the productivity and output per time unit decrease
Solution Approach 1:
The test system segments testing into multiple parallel test nests, allowing simultaneous testing of multiple cable harnesses. Each nest maintains relatively simple equipment structure while the collective system achieves high productivity through parallel processing of multiple units.
Solution Approach 2:
While one cable harness is being tested in a test nest, the operator can simultaneously prepare or test other cable harnesses in other nests. This eliminates idle time and ensures continuous productive action, with the system maintaining simple equipment per nest while achieving high overall throughput.
Data Source
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AI summary
The invention refers to a method and device for functional testing of cable harnesses, in particular high-voltage cable harnesses, comprising a test system (2) which is equippable with a cable harness (A, B, C), with a cable harness (A, B, C) having a plurality of components to be tested, and with the test system (2) having at least one test device (6, 7) with which different, preferably automatically running, functional tests, in particular electrical tests and/or sealing tests as functional tests, are executable for the components of a cable harness (A, B, C) to be tested. According to the invention, the test system (2) comprises several test nests, preferably of essentially the equal design, which are sequentially equipped with a cable harness (A, B, C), in particular by one and the same operator, so that at least one functional test is performed at least temporarily simultaneously on several cable harnesses (A, B, C).