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Title:
WIRE HARNESS TEST SYSTEM AND METHOD OF OPERATION THEREOF
Document Type and Number:
WIPO Patent Application WO/2018/178847
Kind Code:
A1
Abstract:
A wire harness test system designed to facilitate and harmonize the integration of electrical test modules into the test table is disclosed, making it more versatile and multipurpose in terms of the diversity of wire harness families that can be tested on the same equipment. In order to achieve these objectives there is a need to change the traditional concept underlying a traditional testing system, decentralizing the processing associated with the test itself, except for the use of racks or interface and expansion cards. The test system developed is intended for use in the wiring industry and aims at facilitating and harmonizing the integration of electrical test modules in the test table, making said table more flexible and capable of adapting to the test of different types of wire harness.

Inventors:
MACHADO PINTO BRASIL MANUEL (PT)
Application Number:
PCT/IB2018/052047
Publication Date:
October 04, 2018
Filing Date:
March 26, 2018
Export Citation:
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Assignee:
DIVMAC PROJECTOS AUTOMATISMOS E PERIFERICOS IND S A (PT)
International Classes:
G01R31/02; G01R1/04; H01B13/012; G01R1/02
Domestic Patent References:
WO2001079871A12001-10-25
Foreign References:
JP2007085926A2007-04-05
US20120025044A12012-02-02
DE19500113A11995-08-03
EP2910430A12015-08-26
Other References:
ANONYMOUS: "PRÜFTISCH TS1700 - DIE LÖSUNG FÜR KOMPLEXE KABELSÄTZE", 19 August 2014 (2014-08-19), Germany, XP055487433, Retrieved from the Internet [retrieved on 20180625]
Attorney, Agent or Firm:
VIEIRA PEREIRA FERREIRA, Maria Silvina (PT)
Download PDF:
Claims:
CLAIMS

1. Wire harness test system characterized in that it comprises :

— a central processing unit configured to run test algorithms to be implemented on at least one test table ;

— at least one test table comprising at least one connection base mounted on the crossbars of said table; wherein

— the connection base comprises an interconnection mechanism which establishes the connection thereof to the test table and test module;

— at least one test module comprising an internal processing unit, an internal memory unit, a coupling structure for facilitating the physical connection to a connection base and a light indicator, wherein the central processing unit is adapted to establish bi-directional data communication with the internal processing unit of the test module via a connection base, via a data bus.

2. System according to claim 1, characterized in that the central processing unit comprises an interface terminal with the operator.

3. System according to claim 1, characterized in that the central processing unit is configured to map the test table according to a coordinate system.

4. System according to claim 3, characterized in that the central processing unit is configured to store the coordinates of all connection bases installed on the test table .

5. System according to claim 4, characterized in that the central processing unit is configured to map the connection bases installed on the test table according to a test zone and a storage zone.

6. System according to claim 1, characterized in that the interconnection mechanism of the connecting base comprises:

— a plug for connecting to the data bus of the central processing unit;

— a plug for electrical connection;

— a plug for pneumatic connection to the compressed air network of the test table.

7. System according to claim 1, characterized in that the coupling structure of the test module comprises:

— two screws for securing the module to the coupling base of the test table;

— an electrical connection plug, a pneumatic connection plug and a data interconnection plug;

— a guiding mechanism configured to ensure alignment on the connection between the module and the connection base ;

— a locking mechanism comprising two quarter-turn anchors ;

— a two-hole manipulation mechanism adapted to favor manipulation of the module in the replacement process.

8. System according to claim 1, characterized in that the light indicator of the test module is of the LED type.

9. Method of operating the wiring test system, characterized in that it is executed in the central processing unit of the system claimed in claims 1 and 8, comprising the following steps:

— receiving an input parameter entered by the operator;

— uploading of the algorithm of tests to run;

— identification of the test modules required to run the testing algorithm;

— indication of the assembly of the test module with a coordinate belonging to the storage zone, in a specific coordinate belonging to the test zone.

10. Method according to claim 9, characterized in that the step of identifying the test module comprises accessing and reading the internal memory of each module by the central processing unit.

11. Method according to claim 9, characterized in that in the step of identifying the test module the central processing unit actuates the test module so as to emit a light signal.

12. Method according to claim 9, characterized in that the assembly indication step sends the assembly coordinates of the test module to the interface terminal.

Description:
DESCRIPTION

"Wire harness test system and method of operation thereof"

Technical Domain

The present application relates to a wire harness test system and respective method of operation.

Background

The test tables are the equipment used to guarantee the quality of the wire harness produced, wherein different tests such as electrical continuity, electrical insulation between circuits, presence and value of several components, connectors leak test, component color or stress tests, among other more specific tests are carried out. Depending on the complexity and type of components installed in the wire harness, the test may take more or less time and be divided into several steps to test the wire harness under different conditions .

A common difficulty arises at the time of integration of the test module on the table. At that moment, besides the physical installation of the module, power supply and connection to the test system, there is also a need to integrate the module to be used at the software level, which involves setting it by indicating where it is connected in the test point matrix, which function each test point undertakes (whether it is a contact (connector position/cavity) , whether it is the detection of a function of the connector or the result of a specific test) , as well as assigning a name allusive to each test point so that it may be easily identifiable later. In addition, there is also a need to create visual aids for the operator. This step usually consists in uploading an image of the connector into the software and identifying in that image the different contacts and functionalities thereof so that in case of error the software shows the operator an illustrative image of the problem encountered. This initial work of configuring and integrating the test module, both at the physical level of assembly and at the software level, is a time-consuming manual process wherein a qualified operator for this task takes note of the position where each one is installed and using the manual of each module that informs on the function of each test point. Although the information is available, in this step errors frequently occur in the translation of the manual information on the various modules to the software, which later causes problems that are more difficult to diagnose. If the initial configuration is not correct at the time of the test of the wire harness, errors might arise as the result of wiring errors itself or improper module setting at the software level.

In a traditional test table, the test modules are connected to the interface cards by means of a cable and these are in turn connected to the expansion cards by means of a flat cable. Finally, there is at least one rack of the test system in which the expansion cards are installed. This rack is usually connected to a computer running a test software that allows interaction with the operators during the testing process .

Indeed, in a traditional system, each test module has a plug and a cable that allow establishing the connection between each module installed in the test table and the interface cards of the system. These interface cards provide electric power supply and the connection between the test points of the test system and the test points of the module. In turn, the test points of the test system arrive at the interface cards through a flat cable per each interface card. It establishes the connection between the interface cards and the expansion cards (test point cards) installed in the test system rack. The test systems associated with the wiring test are normally modular and their complexity is directly proportional to the number of test points required to test the wiring and types of test to be performed. A test system may consist of only one rack with a variable number of expansion cards or multiple racks to accommodate a larger number of expansion cards which translate into a larger number of test points. The number of expansion cards in a test system typically dictates the number of test points of the system. This means that if the test system rack(s) is (are) complete and there is a need to add another module because the wiring has evolved and has one more connector, the customer will have to purchase a new rack to add one or more expansion cards in order to connect the new module. This need is not only expensive, but also not always implementable since there may be no space available on the test table to accommodate one more rack or the test system itself may not be able to accommodate one more rack.

Wiring can often change with a view to reducing the cost of the final product, adding new features or simply because there are new technological trends and manufacturers tend to wish for a current product. When the need for these changes arises, there are often implications for the restructuring of the test table, which is why these equipment are usually very modular and versatile in order to meet new needs and of course to monetize the investment. However, a test table is often used to test a wire harness reference or a wire harness family wherein the various wire harness are not very different from each other. This is mainly due to difficulties in the wiring layout and consequently in the position of the modules on the test table which are arranged according to the wiring so that the operator can easily and intuitively connect the wiring connectors to the test table modules because otherwise there will be an impact on the time required for the operator to connect all connectors, which translates into a higher cycle time reflected in the cost of the test step and in the overall cost of wiring production.

Something that happens more regularly is that there are two distinct wire harness families that are similar with respect to the connectors used and their location in the wire harness. However, because some different connectors are present or because some wires in the wire harness have different dimensions, it is not possible to use the same test table for both situations and their conversion to test one or another wire harness family alternately is not usually even an option given the time, cost and risk entailed, whereupon in most cases it is necessary to duplicate the test equipment, one for each family with doubling the cost and room required, which is often limited.

Summary

The test system developed is intended for use in the wire harness industry and aims at facilitating and harmonizing the integration of electrical test modules in the test table, making said table more flexible and capable of adapting to the test of different types of wiring.

Therefore, the present application describes a wiring test system characterized in that it comprises: - a central processing unit configured to run test algorithms to be implemented on at least one test table; at least one test table comprising at least one connection base mounted on the crossbars of said table; wherein

the connection base comprises an interconnection mechanism which establishes the connection thereof to the test table and test module;

at least one test module comprising an internal processing unit, an internal memory unit, a coupling structure for facilitating the physical connection to a connection base and a light indicator,

Where in the central processing unit is adapted to establish bi-directional data communication with the internal processing unit of the test module via a connection base, via a data bus.

In one embodiment of the system, the central processing unit comprises an interface terminal with the operator.

In another embodiment of the system, the central processing unit is configured to map the test table according to a coordinate system.

In another embodiment of the system, the central processing unit is configured to store the coordinates of all connection bases installed on the test table.

In another embodiment of the system, the central processing unit is configured to map the connection bases installed on the test table according to a test zone and a storage zone. Yet in another embodiment of the system, the interconnection mechanism of the connecting base comprises:

- a plug for connecting to the data bus of the central processing unit;

- a plug for electrical connection;

- a plug for pneumatic connection to the compressed air network of the test table.

Yet in another embodiment of the system, the coupling structure of the test module comprises:

- two screws for securing the module to the coupling base of the test table;

- an electrical connection plug, a pneumatic connection plug and a data interconnection plug;

- a guiding mechanism configured to ensure alignment on the connection between the module and the connection base ;

a locking mechanism comprising two quarter-turn anchors ;

- a two-hole manipulation mechanism adapted to favor manipulation of the module in the replacement process.

Yet in another embodiment of the system, the light indicator of the test module is of the LED type.

The present application discloses also a method of operating the wiring test system, characterized in that it is executed in the central processing unit of the system above described, comprising the following steps:

- receiving an input parameter entered by the operator;

- uploading of the algorithm of tests to run;

- identification of the test modules required to run the testing algorithm. - indication of the assembly of the test module with a coordinate belonging to the storage zone, in a specific coordinate belonging to the test zone.

In one embodiment of the method, the step of identifying the test module comprises accessing and reading the internal memory of each module by the central processing unit.

Yet in another embodiment of the method, the step of identifying the test module the central processing unit actuates the test module so as to emit a light signal.

Yet in another embodiment of the method, the assembly indication step sends the assembly coordinates of the test module to the interface terminal.

General Description

A wiring test system designed to facilitate and harmonize the integration of electrical test modules into the test table is disclosed, making it more versatile and multipurpose in terms of the diversity of wire harness families that can be tested on the same equipment. In order to achieve these objectives there is a need to change the traditional concept underlying a traditional testing system, decentralizing the processing associated with the test itself, except for the use of racks or interface and expansion cards.

In fact, in order to face the current difficulties arising when adding a new module at the level of the test algorithm, a new architecture for the test module has been developed. It is now equipped with processing capacity and memory, where its initial settings are stored and run - setting of the necessary test points and function thereof, as well as visual aids, for example. This information is stored in the module memory after it has been manufactured during the internal testing and validation processes. At the time of integration of the module in the test table, this information becomes accessible to the test system that will download it from the memory integrated in the module adding it to the test algorithm automatically. In effect, for each wire harness or wire harness family to be tested, the test algorithms to be run and which modules implement them are already set in the central processing unit (stored in memory) . Depending on this specificity, the central processing unit determines which test modules need to be addressed, instructing the operator to carry out replacements between modules belonging to the test and storage zones. This configuration software abstraction allows the physical integration in the test table to be guaranteed quickly and easily, by means of a coupling structure present in the module and a connection base installed in the test table. This pair has cross characteristics that allow the installation of any module in any connection base present on the table, establishing both the electrical and pneumatic connection.

Following this concept, the test table represents only a structure supporting the test modules. The connection of each to the test table is made through connection bases, installed in the crossbars of the table. These bases have complementary connection characteristics to the coupling structure present in each module, thus complying with the connection requirements between module and test table. A central processing unit is responsible for managing all processing inherent to each test to be run, being connected to the test table and by extension to each connection base where the test module is installed, through a data bus. Depending on the specificities of each wire harness and the type of test to be run, the central processing unit will inform the operator on the test modules to be used.

In order to increase versatility, the test table is divided into two distinct zones, a zone used for wiring testing and another used as a modules storage. In practical terms, the central processing unit has both zones mapped into memory, storing the positions of the connection bases according to an n-dimensional coordinate system, which may be of the 2D or 3D type.

In the test zone are installed the necessary modules to test the wire harness or wire harness family that are currently in production. In turn, in the storage zone are stored the modules needed to test other wiring families that, however, will not be needed at the moment. The size of both zones varies depending on the requirements of the tests to be performed and the need to store the modules required for testing other wire harness families or wire harness versions that use different connectors. On the side of the central processing unit there is always information on which modules are in the test zone, which ones are in the storage zone and their position in both zones. To do this, the data bus connecting the central processing unit to each module installed on the test table, establishes a digital communication channel that allows accessing the information contained in the memory of each one and thus be able to identify a module. To determine the position and consequently the table zone (test zone or storage zone) where each module is installed the processing unit uses an opposite procedure. That is, at the time of integration of the bases connecting the modules to the test table, each one is connected to a communication channel of the central processing unit, via the data bus, which channel is stored within a non-volatile memory (for example: Communication channel No. 1 corresponds to the connection base in the position (x, y) of the test table) . This way it is possible to know the position of each connection base and the associated channel. After installing a module in one of these connection bases of the test table, the central processing unit will read the information from the memory contained in the module and in this way it is possible to know that module zzz is connected to the communication channel N°x which, in turn, corresponds to the connection base that is installed in the position (x, y) . At the software level there is a mapping between each position and the respective zone of the table to which it belongs.

On the other hand, in the central processing unit there is also information on which modules are required to test each wire harness, which allows the test algorithm to instruct the operator, at the beginning of the wiring test where other modules are required, to remove a module from the position (x, y) of the test zone and place it in the (x, y) position of the storage zone, as well as the reverse operation (remove from the storage zone to the test zone) in order to correctly set the table for that particular wire harness. This versatility allows the equipment to be much more versatile and to waive in many situations from the duplication of the test means.

In order to standardize the connection between the modules and the test system, it was necessary to change the concept underlying the state of the art systems, from a centralized system in a rack to a distributed one, wherein the test points are integrated into the module itself, being programmed in the initial stage of production thereof, thus creating an abstraction that limits the integration between module and test table to an electrical connection that is the same for all modules, regardless of the number of test points required by each module.

Indeed, at the assembly level of the modules, and having the traditional test tables as a point of comparison, where the replacement of each module implies the need to unscrew and remove it from the test zone, disconnect the wiring and storage the respective module in the storage zone, and then proceed to the reverse operation of installing a new module in the test zone, coming from the storage zone. In order to facilitate this process, the structure of a test module has been redesigned and a fastening mechanism has been developed that favors its integration into the test table - both in the test zone and in the storage zone - consisting of a coupling structure, which is the same for all modules, which allows them to be installed in the connection bases present on the crossbars of the test table. These connection bases are arranged on said crossbars, and have specific positions (x, y) , which allow identifying the relative position of the module installed therein, both in the context of the test zone and the storage zone. In this new concept of test table, a connection base is installed in each position of the table where it is necessary to install a new module to test the different wire harness families/variants.

Said module coupling structure establishes the connection interface with the test table bases. To this end, it is provided with a connection system comprising two screws for securing the module to the connection base, a plug for electrical connection with the test table and a plug for pneumatic connection to allow the movements of internal electro-pneumatic actuators of the module; a plug for robust interconnection for data transmission; a guiding mechanism that ensures perfect alignment between module and connection base during the replacement process in order to facilitate the process and prevent the electrical or pneumatic connection from being damaged during this process; a locking mechanism to facilitate the replacement process, which uses two quarter-turn anchors through which it is possible to lock/release the module in/from the position; a manipulation mechanism comprising two holes in which it is possible to introduce an appropriate tool which allows the manipulation of the module, in need of removing or installing it in a certain position. Alternatively, the locking system may be of the magnetic type, by placing magnets in the module coupling structure and in the connection base, facilitating the installation process.

During the reconfiguration process of the test table the operator is aided by the test algorithm to be run in the central processing unit and by light signals, for example LEDs, present either in front of the module or in the connection bases of the table, clearly indicating from where the module should be removed and where it should be placed.

The connection bases that support the modules have an interconnection mechanism that establishes the electrical, data and pneumatic connection to the module. This mechanism connects the base to the compressed air network of the test table through a pneumatic tube and to the data bus connecting the central processing unit installed inside the table. It is dimensioned to accommodate as many bases as needed. In fact, the data bus is modular and expandable depending on the needs, in particular on the number of test modules to be used. The connection between the data bus and central processing unit, which runs the test algorithm, is established through a USB cable, or through any other physical connection protocol between peripherals for data communication .

Brief Description of the Figures

For an easier understanding of the present application, figures representing preferred embodiments are herein attached which, however, are not intended to limit the technique disclosed herein.

Figures 1 and 2 illustrate the test modules developed.

Figure 3 illustrates the test table, in particular the connection base that receives the test module.

Figure 4 illustrates the assembly of a test module on the table .

Figure 5 illustrates the test table comprising a test zone and a storage zone.

The present description is of course in no way restricted to the embodiments presented herein and a person of ordinary skill in the art may provide many possibilities of modifying it without departing from the general idea as defined in the claims. The preferred embodiments described above are obviously combinable with each other. The following claims further define preferred embodiments.