Wireless Remote Tester for Wiring Harness Verification
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Solution Overview
Problem
Existing test systems for wiring harnesses are cumbersome and inefficient, requiring extensive cabling and being unsuitable for in-situ testing, especially in complex electrical systems like aircraft, where hundreds or thousands of wires need effective and efficient connectivity verification.
Innovation Solution
A wireless test system comprising remote testers that directly couple with electrical connectors of the wiring harness, each equipped with a connector, integrated control housing, test circuitry, a wireless transceiver, and a battery, allowing for wireless communication with a central controller to perform tests and report results without additional cabling, enabling testing during fabrication or post-installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional test systems use extensive cabling to connect testing equipment to wiring harnesses, then electrical connections can be verified, but the testing process becomes cumbersome and inefficient
Solution Approach 1:
The patent extracts the control portion from the connector assembly, creating a separate wireless controller that communicates with the connector via wireless transceivers. This eliminates the need for extensive cabling between the controller and connector, while maintaining full testing functionality through wireless communication protocols.
Solution Approach 2:
The patent replaces the mechanical cabling system with an electromagnetic wireless communication system. The controller and connector exchange data and control signals through wireless transceivers, substituting physical cable connections with radio frequency or other wireless communication methods.
2Ease of operation
If remote testers are made self-contained with integrated control portions, then portability and ease of use improve, but device size and manufacturing complexity increase
Solution Approach 1:
The patent combines the control portion, wireless transceiver, and connector into a single integrated remote tester unit. This merging of previously separate components into one self-contained device improves portability and ease of operation, allowing the tester to be easily moved and deployed without complex assembly requirements.
3Adaptability or versatility
If traditional test systems require back-wired assemblies, then electrical testing can be performed, but the systems are unsuitable for in-situ testing after installation
Solution Approach 1:
The patent divides the testing system into modular segments: wireless controllers, connectors, and test circuitry that can be independently configured and deployed. This segmentation allows the system to be adapted to various testing scenarios, including in-situ testing after wiring harness installation, without requiring complete reconfiguration.
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 allows for efficient and portable testing of wiring harnesses, reducing the need for cumbersome back-wired assemblies and enabling in-situ verification of electrical connections, improving testing efficiency and flexibility.
Implementation Method 1
a wireless transceiver within the housing that is configured to communicate with a central controller of the wiring harness test system
Implementation Method 2
a battery within the housing that is configured to provide power to the test circuitry and the wireless transceiver
Data Source
AI summary
Test system and methods for testing a wiring harness. In one embodiment, a remote tester of the test system includes a connector member comprising a terminal end having one or more terminals configured to mate with terminals in an electrical connector of the wiring harness, and a tester control member integrated on a back end. The tester control member includes a housing that protrudes from the back end of the connector member, test circuitry electrically coupled to the terminals of the connector member, a wireless transceiver that communicates with a central controller to receive a test program, and a battery. The test circuitry performs a test on the wiring harness based on the test program, and reports test results to the central controller.