SSTDR Wire Fault Location Using Design Data Integration
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Solution Overview
Problem
Current wire testing methods, including ohmmeters and SSTDR systems, are inefficient in quickly locating discontinuities in vehicle electrical wires due to the need for expertise and time in using ohmmeters and the limited information provided by SSTDR systems regarding the structure and location of faults.
Innovation Solution
A method and system that combine SSTDR data with design database information to calculate a distance-to-fault and determine the type and location of failures within wire segments, using 3-point vehicle coordinates and 3-dimensional visualizations to pinpoint faults accurately.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ohmmeter testing is used for wire continuity testing, then connectivity can be verified, but extensive expertise and time are required to locate discontinuities
Solution Approach 1:
The patent combines SSTDR technology with vehicle-specific design data (wiring diagrams, 3D visualizations, coordinate systems) to merge fault detection capabilities with precise location information. This integration allows the system to not only detect discontinuities but also automatically locate them within the vehicle structure, eliminating the time-consuming manual tracing required by traditional ohmmeter methods.
Solution Approach 2:
The patent introduces an intermediary processing system that acts as a bridge between the SSTDR fault detection and the vehicle's design data. This intermediary correlates the electrical fault signals with physical vehicle structures using wiring diagrams and 3D visualizations, automatically translating electrical measurements into meaningful physical location information without requiring technician expertise.
2Ease of operation
If SSTDR system is used for wire testing, then one-sided testing is enabled, but limited information regarding fault location relative to the vehicle is provided
Solution Approach 1:
The patent merges SSTDR measurement data with vehicle design data including wiring diagrams, 3D visualizations, and coordinate systems. This combination transforms the limited distance-to-fault information from SSTDR into comprehensive location data that shows exactly where a fault occurs within the vehicle structure, providing both ease of operation and complete location information.
Solution Approach 2:
The patent adds spatial dimensions to the SSTDR fault detection by integrating 3D vehicle visualizations and coordinate systems. Instead of providing only a one-dimensional distance measurement, the system maps faults onto the three-dimensional vehicle structure, enabling technicians to locate faults in the context of the actual vehicle geometry and wiring paths.
3Reliability
If extensive testing is performed to ensure wire continuity, then connection reliability is verified, but the process requires great technician expertise
Solution Approach 1:
The patent enables the testing system to perform self-interpretation by automatically correlating fault detections with vehicle design data. The system self-determines fault locations by comparing SSTDR measurements against stored wiring diagrams and 3D models, eliminating the need for technicians to manually interpret results or trace wiring paths, thus maintaining reliability while greatly easing operation.
Solution Approach 2:
The patent implements a feedback mechanism where the system continuously compares actual SSTDR measurements with expected values from design data. This feedback loop automatically identifies deviations indicating faults and provides corrective location information, enabling reliable verification without requiring technician expertise in interpreting complex wiring configurations.
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
This approach enables faster and more accurate identification of wire faults by integrating SSTDR data with wiring and vehicle data, reducing the need for extensive expertise and time, and providing precise fault location within the vehicle.
Implementation Method 1
spread-spectrum time-domain reflectometry (SSTDR) and more particularly to using SSTDR data and design data in wire testing
Data Source
AI summary
A method for wire connectivity testing includes receiving wiring data indicating at least a length of a wire segment of a vehicle from a design database. The method further includes receiving spread-spectrum time-domain reflectometry (SSTDR) data associated with the wire segment from an SSTDR device coupled to an endpoint of the wire segment. The method also includes calculating a distance-to-fault based on the SSTDR data. The method includes comparing the distance-to-fault to the length of the wire segment. The method further includes, in response to the distance-to-fault being less than the length of the wire segment, generating fault data indicating a failure within the wire segment. The method also includes sending the fault data to a user output device.