Wireless Test Modules for Flexible Wiring Harness Setup

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional test bench systems are inflexible and require significant logistical effort to set up and reconfigure for different wiring harnesses, especially when dealing with various connectors and cables, as they lack adaptability and user-friendly design.

Innovation Solution

A modular test table system with wireless test modules that utilize NFC or similar short-range wireless technologies for data transmission, allowing for easy identification, positioning, and programming of test modules using portable devices like smartphones, which enables flexible and efficient setup and maintenance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If test modules are arranged on a test table for testing wiring harnesses, then testing capability is provided, but setup time and logistical effort increase significantly

Engineering Contradiction:

Improvetesting capabilityVSAvoidsetup time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The test system is divided into individual, independently addressable test modules that can be separately positioned and configured on the test table. Each module handles specific testing functions, allowing selective arrangement rather than requiring complete system reconfiguration for different testing scenarios.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Test modules are designed with universal interfaces and standardized communication protocols that allow them to function across multiple testing scenarios. The modules can be reused for different wiring harness configurations through software configuration rather than physical reconfiguration, reducing setup time.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of operation

If test modules are positioned far apart to avoid interference, then plug insertion is facilitated, but device complexity and space requirements increase

Engineering Contradiction:

Improveplug insertionVSAvoidtest table space

Core Design Contradiction:

Ease of operationVSArea of stationary object

Solution Approach 1:

The system manages spatial constraints by utilizing vertical stacking and multi-layer positioning of test modules, effectively adding a vertical dimension to the layout. This allows modules to be positioned closer horizontally while maintaining operational independence through vertical separation and targeted addressing.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Reliability

If test modules require direct power supply and complex hardware connections, then functionality is ensured, but ease of maintenance and expandability decrease

Engineering Contradiction:

ImprovefunctionalityVSAvoidmaintenance

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

Physical hardware connections and direct power supply mechanisms are replaced with wireless communication technologies. Test modules communicate with the central controller and receive power wirelessly, eliminating complex cable connections and making modules easier to install, maintain, and replace without requiring electrical disassembly.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If conventional test bench systems are used, then basic testing is achieved, but flexibility and adaptability to different wiring harnesses are limited

Engineering Contradiction:

Improvetesting accuracyVSAvoidflexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The test system transitions from static, fixed configurations to dynamic, reconfigurable arrangements. Test modules can be dynamically added, removed, or repositioned on the test table, and their functions can be dynamically assigned through software configuration, allowing the system to adapt to different wiring harness types while maintaining testing accuracy.

Inventive Principle:

Principle #15Dynamics

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

This solution allows for a user-friendly, flexible, and efficient setup of test tables, reducing setup time and improving traceability of testing processes, while enabling easy maintenance and expandability of the test modules without the need for direct power supply or complex hardware.

Implementation Method 1

A wireless interface (12) is provided in the test module (6) for wireless data connection with the input device (15). The wireless interface (12) is designed for short-range data transmission, in particular as an NFC interface

Methodology Applied

Scientific EffectNFC (Near Field Communication):

Data Source

PatentEP3460495B9Test module for a test bench and method for forming a test bench

Publication Date: 2023.08.30 KOMAX TESTING GERMANY GMBH

Figure 1
Figure 2~3
Figure 4

AI summary

The invention relates to a test module (6) for a test bench, wherein the test module (6) comprises: a data connection port (8) for a test bench data system, a receiving device (14) for receiving a test part of the cable harness, a module control unit (7), and a module memory (9) for storing a unique identification number (IN-i) and position data of a bench position of the test module (6), module-specific data, and/or project-specific data. It also features a wireless interface (12) for a direct wireless data connection (17) with a portable input device (15), via which position data of a test bench position and a unique identification number for unambiguous identification within the test bench can be transmitted. This data connection can, in particular, be an NFC connection initiated via, for example, a mobile phone or tablet PC.