APPARATUS AND PROCESS FOR TESTING AND IMPROVING ELECTRICAL AND/OR MECHANICAL CHARACTERISTICS OF AN ELECTRICAL CONNECTION

• US 20150168479A1
• Filed: 12/11/2014
• Published: 06/18/2015
• Est. Priority Date: 12/12/2013
• Status: Active Grant

• Current Assignee: Carlos Gutierrez Martinez
• Original Assignee: Carlos Gutierrez Martinez
• Inventors: Gutierrez Martinez, Carlos
• Granted Patent: US 9,863,996 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: G01R 31/69 of terminals at the end of a cable or a wire harness; of plugs; of sockets, e.g. wall sockets or power sockets in appliances

Abstract

An apparatus for testing a quality of an electrical connection of a test part is disclosed. The apparatus includes a first fixture holding the test part to one side of the electrical connection, a second fixture holding the test part to a second side of the electrical connection, wherein the first fixture and the second fixture apply a twist to the test part, and a electrical test module configured to test an electrical resistance of the electrical connection when the twist is applied.

Claims

1. An apparatus for testing a quality of an electrical connection of a test part, the apparatus comprising:

a first fixture holding the test part to one side of the electrical connection;

a second fixture holding the test part to a second side of the electrical connection, wherein the first fixture and the second fixture apply a twist to the test part; and

a electrical test module configured to test an electrical resistance of the electrical connection when the twist is applied.

2. The apparatus of claim 1, wherein the test part comprises a wire bundle and a terminal connector joined with a crimp connection.

3. The apparatus of claim 1, wherein the test part comprises a first wire bundle and a first terminal connector joined with a first crimp connection and a second wire bundle and a second terminal connector joined with a second crimp connection, wherein the terminal connectors are joined together with a male to female interference fit connection.

4. The apparatus of claim 1, wherein the test part comprises a electrical switch wherein two metallic terminals are configured to selectively join to connect the switch.

5. The apparatus of claim 1, wherein the first fixture and the second feature apply an axial load upon the test part.

6. The apparatus of claim 1, wherein the electrical test module is configured to test a change in electrical resistance of the test part at a time prior to the applied twist and at a time after the applied twist.

7. The apparatus of claim 1, wherein the electrical test module is configured to test a change in electrical resistance of the test part through a test period, the test period including a time prior to the applied twist and a time after the applied twist.

8. The apparatus of claim 1, wherein the electrical test module comprises a processing device configured to monitor the electrical resistance, compare the electrical resistance to a threshold electrical resistance, and provide a failure indication if the monitored electrical resistance exceeds the threshold resistance.

9. The apparatus of claim 8, wherein the processing device is further configured to monitor the electrical resistance through a test period wherein the twist applied to the test part comprises an increasing torque through the test period.

10. The apparatus of claim 9, wherein the processing device is further configured to compare a plurality of electrical resistance values monitored through the test to a threshold change in resistance and provide the failure indication if the plurality of resistance values change by more than the threshold change in resistance through the test period.

11. The apparatus of claim 8, wherein the processing device is further configured to monitor the electrical resistance through a first test period wherein the twist applied to the test part comprises an increasing torque in a first direction through the first test period and subsequently monitor the electrical resistance through a second test period wherein the twist applied to the test part comprises an increasing torque in a second direction through the second test period.

12. The apparatus of claim 1, further comprising a device providing a stream of hot air to blow on the electrical connection.

13. The apparatus of claim 1, further comprising a device providing increased humidity to air surrounding the electrical connection.

14. The apparatus of claim 1, further comprising a twist fixing mechanism to fix the twist in the electrical connection when a test result shows that the twist improves the electrical connection.

15. The apparatus of claim 14, wherein the twist fixing mechanism comprises one of a wedge device, glue, and a twisting retention clip connected to a plastic connector.

16. A process to test an electrical connection quality of a test part comprising a connected terminal crimped onto a wire bundle, the process comprising:

affixing the metal wire bundle to a first fixture;

affixing the connected terminal to a second fixture;

applying a twisting force to the test part;

testing an electrical resistance of the test part prior to the application of the twisting force and after the application of the twisting force;

comparing the electrical resistances to a threshold electrical resistance;

testing the electrical resistance of the test part during the application of the twisting force; and

marking the test part with a failed indication based upon the comparing.

17. The process of claim 16, further comprising iteratively cycling the test.

18. A computerized process to test an electrical connection quality of a test part comprising a connected terminal crimped onto a wire bundle, the process comprising:

affixing the metal wire bundle to a first fixture;

affixing the connected terminal to a second fixture;

attaching electrical test leads to the test part;

within a computerized processor,

controlling application of a twisting force to the test part;

testing an electrical resistance of the test part prior to the application of the twisting force and after the application of the twisting force;

comparing the electrical resistances to a threshold electrical resistance; and

marking the test part with a failed indication based upon the comparing.

19. The process of claim 18, wherein the computerized processor further tests the part during the application of the twisting force.

20. The process of claim 18, wherein the computerized processor further tests the part during application of a twisting force in a second, opposite direction.