Wireless Harness Module Calibration for Reliable Resistance Testing
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Solution Overview
Problem
Existing electrical wiring harness testing systems, such as cabinet-style relay boxes with hard-wired adaptors, are inefficient, immobile, and difficult to scale, requiring extensive manual setup and troubleshooting, which hampers the testing process in various industries.
Innovation Solution
A wireless harness automated measurement system (WHAMS) utilizing portable, wireless test modules that physically couple to electrical wiring harnesses and wirelessly communicate test results to a central computer, enabling flexible and scalable testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cabinet-style relay boxes with hard-wired adaptors are used for testing, then testing can be performed with established hardware, but the system becomes immobile and difficult to scale
Solution Approach 1:
The patent replaces the mechanical hard-wired cabinet-style relay box system with a wireless test module that communicates via wireless signals. This substitution eliminates the need for physical cable connections and fixed cabinet structures, enabling the system to be moved to different testing locations while maintaining reliable communication and testing capabilities.
Solution Approach 2:
The patent divides the monolithic cabinet-style relay box into separate modular components: a wireless test module and a computer system. This segmentation allows the test module to be independently deployed and moved to different locations, while the computer system can remain stationary or be relocated as needed, thus improving system adaptability without compromising testing reliability.
2Reliability
If cabinet-style relay boxes with hard-wired adaptors are used, then comprehensive testing capability is achieved, but setup time and equipment requirements increase
Solution Approach 1:
The wireless test module eliminates the need for extensive hard-wired connections and physical setup of cable adaptors. By using wireless communication, the system reduces setup time significantly while maintaining comprehensive testing capability, as the test module can be quickly deployed without complex physical installations.
Solution Approach 2:
The wireless test module is designed as a universal device that can perform multiple testing functions without requiring different hardware configurations for each test type. This multi-functionality allows a single device to replace multiple specialized cabinets, reducing overall equipment requirements and setup complexity while maintaining comprehensive testing capability.
3Adaptability or versatility
If manual setup and troubleshooting is performed with traditional systems, then testing can be customized, but productivity and efficiency decrease
Solution Approach 1:
The wireless test module incorporates automated feedback mechanisms that communicate test results, status, and diagnostics wirelessly to the computer system. This automated feedback loop enables real-time monitoring and troubleshooting without manual intervention, maintaining test customization capabilities while significantly improving testing efficiency and productivity.
Solution Approach 2:
The system implements self-service capabilities where the wireless test module automatically configures itself, performs self-diagnostics, and communicates results without requiring manual setup or troubleshooting. This automation maintains the ability to customize tests through software while eliminating time-consuming manual operations, thereby improving productivity.
Data Source
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AI summary
According to some embodiments, a computer-implemented method is applied to calibrate a wireless test module (WTM) of a wireless harness automated measurement system (WHAMS) using a computer server and a calibration fixture (1500). The WTM includes a plurality of field effect transistors (FETs). The calibration fixture (1500) includes a plurality of resistors. The method measures, using the calibration fixture (1500), a first/second resistance value of the plurality of FETs from a first/second internal measurement test for the WTM. The method determines a resistance calibration value by subtracting the first resistance value from the second resistance value. The method measures a plurality of calibration factors to determine a measured resistor value for a target resistor value for a respective resistor of the calibration fixture (1500).