Wire Bundle Rating Device for Test Harness Segmentation
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Solution Overview
Problem
In complex wiring systems with numerous harnesses and terminal devices, it is difficult to determine which electrical wire bundles are necessary for a test, as the connection state of core wires cannot be discerned by appearance, leading to challenges in identifying which wires can be removed for sub-system testing.
Innovation Solution
A device that determines which electrical wire bundles include test electrical wires by using a storage unit to store connection information between wires and connectors, and a processing unit to assign ratings (A, B, C) based on this information, allowing for efficient identification of necessary wire routes for testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If actual harnesses are used as-is for sub-system testing, then the test closely simulates the actual machine, but the test scale becomes large due to inclusion of unnecessary harnesses
Solution Approach 1:
The patent extracts only the necessary electrical wire bundles from the complete harness system for sub-system testing. By identifying and removing unnecessary wire bundles through connection information analysis, the test harness size is reduced while maintaining test validity for the specific sub-system being tested.
Solution Approach 2:
The patent segments the complete wiring system into individual electrical wire bundles and further into core wires, allowing selective identification and extraction of only those bundles needed for the specific test, thereby reducing overall test harness complexity.
2Quantity of substance
If unnecessary electrical wires are removed from the harness, then the test scale is reduced, but the lightning protection current through each remaining wire becomes larger
Solution Approach 1:
The patent carefully extracts only the minimum necessary electrical wire bundles required for the sub-system test, preserving all other wires including those that would carry lightning protection currents. This selective extraction reduces harness size without concentrating excessive current on remaining wires.
3Measurement precision
If connection information is manually traced through multiple wiring diagram sheets, then the connection route can be confirmed, but the process becomes extremely difficult and time-consuming
Solution Approach 1:
The patent replaces manual mechanical tracing through wiring diagrams with automated information processing. The determination device automatically analyzes connection information data structures to identify necessary electrical wire bundles, eliminating the need for manual diagram tracing while maintaining accurate connection route identification.
Solution Approach 2:
The patent creates a digital representation (connection information) of the physical wiring system, allowing automated analysis and identification of necessary wire bundles without physically tracing through actual wiring or manual diagrams.
4Ease of operation
If the connection state of core wires is determined by appearance inspection, then the process is simple, but the connection state cannot be accurately discerned
Solution Approach 1:
The patent replaces visual appearance inspection with automated information processing based on connection information data. The determination device accurately identifies the connection state of core wires by analyzing their electrical connection relationships in the data structure, providing precise identification without manual visual inspection.
Data Source
AI summary
A device for determining an electrical wire bundle, in which, when the electrical wire bundle includes even one test electrical wire which conducts electricity to a terminal device, the electrical wire bundle is given an A-rating indicating an electrical wire bundle to be used for a test; when the electrical wire bundle includes at least one electrical wire which conducts electricity to the terminal device but is not the test electrical wire, the electrical wire bundle is given a B-rating indicating that the electrical wire bundle is not allowed to be disconnected; and when the electrical wire bundle includes only electrical wires that do not conduct electricity to the terminal device, the electrical wire bundle is given a C-rating indicating an electrical wire bundle not to be used for the test.