Wireless Test Modules for Scalable Wiring Harness Measurement
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Solution Overview
Problem
Existing electrical wiring harness testing systems, particularly in aerospace and automobile industries, are inefficient, bulky, and difficult to scale, requiring extensive manual setup and troubleshooting, with hard-wired adaptors that limit mobility and flexibility.
Innovation Solution
A wireless harness automated measurement system (WHAMS) utilizing wireless test modules (WTMs) that physically couple to electrical wiring harnesses and wirelessly transmit test results to a central computer, allowing for portable, scalable, and adaptable testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hard-wired adaptors are used for testing electrical wiring harnesses, then reliable electrical connection is achieved, but mobility and flexibility are reduced
Solution Approach 1:
The patent replaces the mechanical hard-wired connection system with a wireless communication system. The wireless test module communicates with the wiring harness under test through wireless signals, eliminating the need for physical hard-wired adaptors while maintaining testing functionality. This substitution resolves the contradiction by providing both mobility (wireless operation) and reliable data transmission.
2Adaptability or versatility
If traditional bulky testing equipment is used, then comprehensive testing capability is achieved, but portability and ease of deployment are reduced
Solution Approach 1:
The patent divides the traditional monolithic testing system into modular wireless test modules. Each module is a self-contained unit with specific testing functions, allowing comprehensive testing capability through multiple small modules rather than one large system. This segmentation enables portability while maintaining versatility.
Solution Approach 2:
The wireless test modules are designed with universal functionality to perform multiple types of tests on different wiring harness configurations. The modules can be deployed in various combinations to achieve comprehensive testing capability without requiring heavy specialized equipment for each test type.
3Adaptability or versatility
If manual setup and troubleshooting procedures are used, then flexibility in handling unique cases is achieved, but testing efficiency and productivity are reduced
Solution Approach 1:
The wireless test modules incorporate self-diagnosis and automated troubleshooting capabilities that allow the system to handle unique cases independently without requiring manual intervention. The modules automatically adapt to different wiring harness configurations and resolve common issues, maintaining flexibility while improving efficiency.
Solution Approach 2:
The system implements automated feedback mechanisms where test results are immediately analyzed and used to adjust testing parameters automatically. This closed-loop approach enables the system to handle unique cases adaptively while maintaining high productivity through automated decision-making.
4Measurement precision
If extensive manual intervention is required for setup and troubleshooting, then precise control over testing parameters is achieved, but time consumption and complexity are increased
Solution Approach 1:
The wireless test modules come pre-configured with default testing parameters and automated setup routines. Common testing scenarios are pre-programmed, allowing the system to begin testing quickly without extensive manual parameter configuration. This preliminary preparation maintains precision while reducing setup time.
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
The system enhances testing efficiency and flexibility by enabling wireless communication, reducing equipment barriers, and facilitating rapid setup and adaptation to various environments, thus improving productivity and reducing manual intervention.
Implementation Method 1
The wireless test module is operable to wirelessly receive one or more of the plurality of test instructions from the computer system using the wireless transceiver
Implementation Method 2
Each wireless test module is further operable to wirelessly communicate test results to the computer system using the wireless transceiver
Data Source
AI summary
According to some embodiments, a system includes a wireless transceiver, an electrical wiring harness, and a wireless test module (WTM) operable to physically couple to the electrical wiring harness. The WTM comprising a chassis and a variable front end connected to the chassis using hot-swap connectors. The WTM wirelessly receives, using the wireless transceiver, a plurality of test instructions according to an automated test plan from a computer system. The WTM performs, using the variable front end, one or more tests on the electrical wiring harness according to the plurality of test instructions. The WTM wirelessly communicates, using the wireless transceiver, test results to the computer system.