Electronic Slave Connector for Automated Test Equipment Harness Validation
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Solution Overview
Problem
Current automated testing equipment (ATE) for wire harnesses requires extensive customization and preparation of interface cables and test programs, making the testing process time-consuming, costly, and inefficient due to the complexity of unique electrical circuits in manufacturing and maintenance environments.
Innovation Solution
The use of electronic slave connectors with EEPROMs that allow ATE to interrogate and read connection information without direct linking, enabling the creation of generic interface cables and eliminating the need for specific test programs, and allowing for precise resistance measurements by bypassing EEPROMs to connect directly to ground.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fully customized interface cables and specific test programs are used for each SUT configuration, then the ATE can validate the integrity of electrical circuits, but the preparation time and cost increase significantly
Solution Approach 1:
The patent applies universality by designing interface cables with generic connectors that can mate with multiple different SUT configurations without requiring customization. The electronic identifiers (EEPROMs) embedded in the connectors enable a single generic cable design to adapt to various SUT types, eliminating the need for custom cable preparation for each configuration.
Solution Approach 2:
The electronic identifiers in the connector perform self-identification, allowing the ATE to automatically determine the SUT configuration without requiring pre-programmed test procedures. The system self-configures by reading the EEPROM data, which provides information about the connector layout and required test parameters, eliminating manual test program creation.
2Reliability
If customized interface cables are prepared for each SUT configuration, then accurate circuit testing is achieved, but the cost and complexity of cable preparation increase
Solution Approach 1:
The patent uses electronic identifiers (EEPROMs) that store copied information about the connector layout and configuration. Instead of physically customizing each cable for different SUT configurations, the configuration data is copied into the EEPROM, allowing a single physical cable design to represent multiple configurations through digital information storage.
Solution Approach 2:
The electronic identifier acts as an intermediary between the physical connector and the ATE testing system. It mediates the configuration information transfer, allowing the ATE to understand the SUT setup without requiring complex physical cable variations. The EEPROM serves as the intermediary that bridges the gap between standardized hardware and customized test requirements.
3Reliability
If extensive test programs are created for each SUT configuration, then complete circuit validation is achieved, but the time and cost of program development increase
Solution Approach 1:
The configuration information is prepared in advance and stored in the electronic identifiers during connector manufacturing. This preliminary action eliminates the need for real-time program development during testing. The ATE simply reads the pre-stored configuration data and automatically generates the appropriate test sequence, significantly reducing setup time and increasing productivity.
Solution Approach 2:
The test system transitions from static, pre-programmed test procedures to dynamic, adaptive testing. The ATE dynamically generates test programs based on the configuration data read from the EEPROM, allowing the same hardware to efficiently handle diverse SUT configurations without requiring separate fixed test programs for each type.
Data Source
AI summary
The present document describes a connector for use with a harness under test by an automated test equipment (ATE). The harness is electrically connected to a reference. The connector comprises connection points having a layout, namely a connector layout, electronic identifiers and a switch. Each one of the electronic identifiers is connected to a respective one of the connection points. The switch is either for connecting the ATE to the reference via the electronic identifiers, either for connecting the ATE to the reference while bypassing the electronic identifiers.