Wire Bundle Fault Detection via Return Signal Analysis
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Solution Overview
Problem
Current methods for detecting faults in electrical wires, especially intermittent faults, are inefficient and require manual intervention, making it difficult to diagnose and locate faults in bundles of wires, particularly in critical sectors like aeronautics where reliability and speed are paramount.
Innovation Solution
A method utilizing a signal generator, electrical ground, switching matrix, acquisition unit, and control unit to automatically detect and locate faults in bundles of wires by analyzing return signals, allowing for rapid and reliable detection of both intermittent and permanent faults without manual manipulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If current reflectometry-based fault detection methods are used, then fault detection capability is provided, but the method can only diagnose one wire at a time requiring lengthy manual manipulation
Solution Approach 1:
The patent combines multiple wire testing channels into a single integrated system. The switching matrix merges N wire channels with a single signal generator and acquisition unit, allowing sequential automatic testing of multiple wires without manual reconfiguration. This merging approach increases productivity by eliminating the need to manually connect and test each wire separately while maintaining comprehensive fault detection capability across the entire wire bundle.
Solution Approach 2:
The system implements automatic wire selection and testing through the switching matrix controlled by a control unit. The system self-manages the testing sequence by automatically switching between different wire channels based on control signals, eliminating the need for manual intervention. The acquisition unit automatically acquires return signals for each wire in sequence, and the system autonomously completes the entire fault detection process for multiple wires without human manipulation.
2Reliability
If manual wire-by-wire testing is performed, then fault detection is possible, but the process becomes lengthy and tedious
Solution Approach 1:
The system employs periodic action by sequentially switching between different wire channels at controlled intervals. The switching matrix rapidly cycles through each wire in the bundle, injecting test signals and acquiring return signals in a systematic periodic sequence. This periodic switching enables comprehensive testing of all wires within a short time frame while maintaining the reliability of individual wire diagnosis through consistent testing methodology applied to each channel.
Solution Approach 2:
The system maintains continuous useful action by eliminating idle time between wire tests. As soon as one wire testing cycle completes, the switching matrix immediately transitions to the next wire channel without manual intervention delays. The control unit continuously generates switching signals, and the acquisition unit continuously acquires return signals, ensuring that the testing process flows continuously through all wire channels, maximizing productivity while maintaining testing reliability.
3Difficulty of detecting and measuring
If intermittent faults are detected using traditional methods, then some fault information is obtained, but detection is difficult due to short disruption period and time variation
Solution Approach 1:
The system applies preliminary action by continuously and repeatedly injecting test signals into each wire channel through the switching matrix. Rather than waiting for intermittent faults to manifest naturally, the system proactively and continuously monitors each wire by periodically sending test signals and capturing return signals. This continuous preliminary monitoring increases the probability of capturing intermittent fault events during their brief disruption periods, improving detection capability while maintaining accurate fault characterization through consistent signal injection and measurement.
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
Enables fast and effective detection of faults in large sets of wires, reducing manual intervention and improving maintenance efficiency by precisely locating faults in a short duration, suitable for high-reliability applications like aeronautics.
Implementation Method 1
when it encounters a mismatch, some of its energy is reflected back to the point of injection
Data Source
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AI summary
The invention relates to a method for detecting faults in a set of wires (25) to be tested comprising at least two wires each having an input end and an output end. The method comprises in succession a step (10) of connecting at least one wire undergoing analysis to a signal generator (26) and of grounding the other wires, a step (12) of generating a test signal on the channel undergoing analysis with the signal generator (26), a step (13) of acquiring and measuring the power of a first signal returned over at least one wire connected to the acquiring unit (29), and a step (14) of analysing the integrity of the wire undergoing analysis using the power of the return signal of the wire in question and the analysing unit(31). These steps repeat automatically, the wire to be tested being changed each time.