Wiring Harness Test System With Adapter Modules And Visual Guidance
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Solution Overview
Problem
The connection of complex electrical wiring harnesses to test machines is laborious and prone to errors due to the mismatch between general-purpose test machines and industry-specific connector typologies, particularly in the aeronautical industry.
Innovation Solution
A system comprising a workstation with extendable test terminals, adapter modules with electronic circuits, and projection devices to guide operators in connecting harnesses to test machines, using identification codes and cameras for error-free setup, allowing for flexible configuration to accommodate various harness types and sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If general purpose test machines are used for electrical wiring harnesses, then testing capability is provided, but connection complexity and error proneness increase due to mismatch with industry-specific connectors
Solution Approach 1:
The patent introduces adapter modules as intermediary components that connect general-purpose test terminals to industry-specific harness connectors. These adapter modules serve as mediators that bridge the interface mismatch between the test machine and the specific connector typology, enabling compatibility without requiring industry-specific test machines for each connector type.
Solution Approach 2:
The test terminals are designed with universal adaptability through the use of interchangeable adapter modules. A single test terminal can connect to multiple types of connectors by swapping adapters, making the test machine universally applicable across different industries and connector types while maintaining standardized test interfaces.
2Reliability
If complex electrical wiring harnesses with multiple connectors are tested, then comprehensive electrical testing is achieved, but connection time and operator effort increase significantly
Solution Approach 1:
The adapter modules are pre-configured with identification codes and connected to specific test terminals before the harness assembly process. This preliminary configuration allows the system to automatically recognize and guide the connection process, eliminating the need for operators to manually configure complex connections during testing.
Solution Approach 2:
The system uses identification codes on adapter modules and automated recognition to provide feedback to the control system. This feedback mechanism guides the operator through the connection process step-by-step, confirming correct connections and reducing the time required for comprehensive testing of multiple connectors.
3Adaptability or versatility
If manual connection of connectors to test machines is performed, then flexibility in handling different connector types is maintained, but error rate and labor intensity increase
Solution Approach 1:
The patent replaces manual mechanical connection processes with an automated identification and guidance system. Instead of relying on operators to manually match and connect connectors, the system uses electronic identification codes on adapter modules to automatically determine the correct connections and guide the operator, reducing manual effort while maintaining flexibility.
4Device complexity
If standardized test terminals are used for all connector types, then device simplicity is improved, but adaptability to specific connector typologies decreases
Solution Approach 1:
The connection interface is segmented into two independent parts: a standardized test terminal and a configurable adapter module. The terminal maintains simple standardized design, while the adapter module provides the specific adaptation to different connector types. This segmentation allows the terminal to remain simple while the system as a whole maintains high adaptability.
Data Source
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AI summary
The invention provides a system to perform tests quickly and accurately to wiring harness. The system comprises a workstation (15) equipped with an electrical test machine (12) with test terminals (19) disposed on the end of extendable hoses (17), a connection interface between harness connectors (13) and terminals tests (19), a working board (10) to perform on it the tests to a wiring harness (11), one or more projection devices (21, 21 21") arranged to project images onto the working board (10) and a computer system (31) to supply such projection devices (21, 21', 21") with images (40) to assist the operators performing the tests. Said connection interface is formed by adapter modules (41) connectable by one side to the wiring harness connectors (13) and by the other to the test terminals (19). Test terminals (19) and adapter modules (41) comprise electronic circuits and external identification labels holding identification information.