Wireless Harness Test Modules Without Relay Cabinets
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Solution Overview
Problem
Existing electrical wiring harness testing systems, particularly in industries like aerospace and automobiles, are inefficient, bulky, and difficult to scale, requiring extensive manual setup and troubleshooting, with hard-wired adaptors that limit mobility and adaptability.
Innovation Solution
The implementation of wireless test modules that physically couple to electrical wiring harnesses and wirelessly communicate test results to a central computer, allowing for portable, scalable, and flexible testing without the need for bulky relay cabinets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hard-wired adaptors and bulky relay cabinets are used for testing electrical wiring harnesses, then testing coverage and reliability are improved, but device complexity and mobility are worsened
Solution Approach 1:
The system divides the testing function into multiple wireless test modules that can be distributed throughout the testing environment. Each module handles specific testing tasks independently, eliminating the need for a single complex centralized relay cabinet while maintaining comprehensive testing coverage through coordinated operation of multiple modular units
Solution Approach 2:
The wireless test modules are designed with multi-functional capabilities to perform various testing operations (continuity, insulation resistance, ground resistance, megger tests) through a single integrated platform. This universal design replaces the need for multiple specialized hard-wired adaptors and relay cabinets, reducing overall system complexity while maintaining comprehensive testing reliability
2Measurement precision
If hard-wired adaptors and relay cabinets are used, then testing accuracy is improved, but ease of operation and mobility are worsened
Solution Approach 1:
The system replaces mechanical hard-wired connections with wireless communication technology. Wireless test modules communicate test data and instructions through wireless protocols, eliminating the need for physical cable connections to relay cabinets. This substitution maintains measurement precision through digital communication while dramatically improving ease of operation by allowing modules to be placed and configured without complex wiring setup
Solution Approach 2:
The wireless test modules are pre-configured with testing parameters and algorithms before deployment. Test plans and measurement criteria are predetermined and loaded into the modules, allowing them to automatically execute accurate measurements upon connection to the wiring harness. This preliminary configuration eliminates time-consuming on-site setup while ensuring consistent testing accuracy across different locations
3Ease of operation
If wireless test modules are used, then mobility and ease of operation are improved, but device complexity is worsened
Solution Approach 1:
The wireless test modules integrate multiple functions (sensing, processing, wireless communication, power management) into single compact units. By merging these previously separate system components into integrated modules, the patent reduces overall system complexity despite adding wireless capabilities. The modules communicate with a central control system through standardized wireless protocols, creating a simplified network architecture that enhances mobility without proportionally increasing complexity
Data Source
AI summary
According to some embodiments, a system includes a computer system and a plurality of wireless test modules. Each wireless test module includes a wireless transceiver and physically couples to an electrical wiring harness. The computer system sends test instructions to the plurality of wireless test modules according to an automated test plan. Each wireless test module wirelessly receives one or more of the plurality of test instructions from the computer system using the wireless transceiver and performs one or more tests on the electrical wiring harness according to received one or more test instructions from the computer system. Each wireless test module wirelessly communicates test results to the computer system using the wireless transceiver.