Universal Mate-In Interface for Wiring Harness Testing
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Solution Overview
Problem
Current methods for testing electrical wiring harnesses in vehicles are inefficient, requiring multiple operators, specific mating connectors that are often unavailable, and prone to errors, leading to incomplete and inaccurate testing.
Innovation Solution
A universal mate-in interface system that includes a generic mate-in interface, intermediate mate-in interface, and specific mate-in interface, allowing for automated and flexible connection of test equipment to various connectors, with a method for reconfigurable assignment of test contacts and use of a universal mate-in interface kit for efficient and accurate testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual test equipment is used to ring nodes of the harness, then continuity testing can be performed, but multiple operators are required and testing is time-consuming and incomplete
Solution Approach 1:
The patent introduces an intermediate mate-in interface as a mediator between the specific harness connector and the generic test equipment interface. This intermediate connector enables automated testing by providing a standardized adaptation layer that translates between different connector types, allowing a single operator to perform comprehensive testing efficiently without manual node-by-node ringing
Solution Approach 2:
The generic mate-in interface is designed with universal characteristics that allow it to work with multiple specific harness connector types. By creating a universal interface standard, the system can test various harness configurations using the same test equipment, improving both completeness and efficiency of testing across different vehicle models and harness designs
2Reliability
If specific mating connectors are ordered in advance for test equipment interface, then proper connection can be achieved, but testing is delayed by days or weeks
Solution Approach 1:
The patent establishes a standardized generic mate-in interface specification in advance, allowing test equipment to be prepared with universal connectivity capabilities before arrival at the testing location. This preliminary standardization eliminates the need to order custom mating connectors for each specific harness type, enabling immediate testing while maintaining connection accuracy through predefined interface standards
Solution Approach 2:
The system allows dynamic configuration where the generic mate-in interface can adapt to different specific harness connectors through standardized adaptation mechanisms. This dynamic capability enables the test equipment to handle various connector types without requiring pre-ordering of specific mating connectors, reducing testing delays while maintaining reliable connections
3Productivity
If temporary cable interface is used when mate-in interface is unavailable, then testing can proceed, but errors and omissions occur and data recording is unreliable
Solution Approach 1:
The standardized intermediate mate-in interface serves as a reliable mediator that ensures accurate signal transmission and data recording. Unlike temporary cable interfaces, the standardized connector includes proper contact alignment, shielding, and identification features that prevent errors and omissions, ensuring data accuracy while maintaining testing availability
Solution Approach 2:
The mate-in interface system incorporates feedback mechanisms through standardized identification contacts that allow the test equipment to automatically detect and verify the connected harness type. This feedback ensures proper configuration and prevents errors, making the interface as reliable as permanent installations while maintaining the flexibility of temporary testing setups
4Reliability
If multiple specific connectors are required for different harness types, then proper testing can be performed, but device complexity and inventory requirements increase
Solution Approach 1:
The generic mate-in interface is designed with universal characteristics that enable a single test equipment unit to work with multiple specific harness connector types. The standardized interface provides consistent electrical and mechanical properties across different applications, eliminating the need for multiple specialized connectors while maintaining testing accuracy through proper signal routing and identification
Solution Approach 2:
The system segments the connector functionality into two distinct layers: a universal generic mate-in interface that handles standardization and a specific harness connector layer that handles application-specific variations. This segmentation allows the test equipment to maintain a simple universal interface while still supporting diverse harness types through the standardized adaptation layer
Data Source
AI summary
The present document describes an assembly for connecting a test unit to a wiring harness or equipment to be tested, and a method for testing using the assembly. The assembly may comprise a test box unit, a generic mate-in interface, an intermediate mate-in interface and at least one specific mate-in interface. The intermediate mate-in interface comprises an input/output connector connected between the generic-to-intermediate connector and the intermediate-to-specific connector, for enabling at least one of inputting a signal into the intermediate mate-in interface and outputting a signal from the intermediate mate-in interface. The assembly is used for performing tests on the equipment using at least one of a device adapted for generating a signal and a device adapted for measuring at least one attribute of a signal or circuit which is/are connected to the input/output connector of the intermediate mate-in interface.