Wireless Harness Automated Measurement System for Wiring Harness Testing

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Solution Overview

Problem

Traditional electrical wiring harness testing systems are inefficient due to their bulky, immobile nature, reliance on hard-wired adaptors, and inability to scale effectively, making it difficult to access and test wiring harnesses in various environments.

Innovation Solution

The implementation of a wireless harness automated measurement system (WHAMS) using wireless test modules that physically couple to electrical wiring harnesses and wirelessly transmit test results to a central computer, allowing for flexible, scalable, and efficient testing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If traditional hard-wired testing systems are used, then testing reliability is maintained, but mobility and flexibility are severely limited

Engineering Contradiction:

ImprovemobilityVSAvoidsystem complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The testing system is divided into separate functional modules: a portable wireless test module that couples to the wiring harness and a separate control system. This segmentation allows the test module to be mobile while maintaining reliable testing through wireless communication with the control system, resolving the contradiction between mobility and system complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent replaces traditional mechanical hard-wired connections with wireless communication technology. The wireless test module uses wireless transceivers to communicate test data with the control system, eliminating the need for physical cable connections and enabling mobility while maintaining testing reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If traditional hard-wired testing systems are used, then connection stability is ensured, but adaptability to different environments is reduced

Engineering Contradiction:

Improveenvironmental adaptabilityVSAvoidconnection reliability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent substitutes mechanical connections with wireless communication, allowing the testing system to adapt to various environments (mobile vehicles, fixed facilities, remote locations) while maintaining reliable data transmission through protocols that ensure connection stability across different settings.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The wireless test module is designed with universal functionality to test various types of wiring harnesses in different environments. The module can operate in mobile vehicles, fixed testing facilities, and remote locations, providing environmental adaptability while maintaining reliable testing through its wireless communication capabilities.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If traditional testing systems are used, then testing thoroughness is maintained, but productivity is reduced due to inefficiency

Engineering Contradiction:

Improvetesting efficiencyVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The testing system is segmented into a portable wireless test module and a separate control system, allowing for more efficient testing operations. The modular design enables faster setup and teardown times while maintaining thorough testing capabilities, thereby improving productivity without excessive complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The replacement of hard-wired connections with wireless communication eliminates time-consuming cable connections and disconnections, significantly improving testing efficiency and productivity while keeping the overall system complexity manageable through standardized wireless protocols.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Ease of operation

If wireless test modules are used, then mobility is improved, but device complexity increases

Engineering Contradiction:

ImprovemobilityVSAvoidmodule complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The wireless test module is designed as a separate, self-contained unit with integrated wireless transceivers, power management, and testing functionality. This segmentation isolates the complexity within the module while maintaining mobility, as the module can be independently handled and deployed without requiring complex external infrastructure.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS20250093430A1Systems and Methods for Operating a Wireless Harness Automated Measurement System

Publication Date: 2025.03.20 LOCKHEED MARTIN CORP

AI summary

According to some embodiments, a computer-implemented method accesses, using a computer server, a plurality of electrical wiring harnesses, testing criteria, and a wireless harness automated measurement system (WHAMS). The computer-implemented method generates a test plan for the plurality of electrical wiring harnesses based on the testing criteria. The computer-implemented method selects a plurality of wireless test modules (WTMs) using the test plan and the WHAMS. The computer-implemented method generates a plurality of test instructions based on the test plan and the plurality of WTMs. The computer-implemented method performs, using the plurality of WTMs, one or more tests on the plurality of electrical wiring harnesses according to the plurality of test instructions. The computer-implemented method wirelessly communicates, using the plurality of WTMs, test results to the computer server for display.