Apparatus for testing a wire harness and method of use
First Claim
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1. Apparatus for testing a wire harness having at least one connector conductively connected by a terminal to a conductor of an insulated wire to form a conductive path, comprising:
- connector probe means for conductively engaging and connecting a terminal of a conductive path to be tested to a connector outlet;
test signal means for capacitively inducing an oscillatory test signal in the conductor of a wire of the conductive path to be tested; and
electrical continuity test means for measuring the amplitude of the oscillatory test signal at the connector outlet of each conductive path to be tested and comparing the measured amplitude to a pre-determined amplitude value and for providing a fault signal indicative of the condition of the conductive path to be tested when the measured amplitude is equal to the predetermined amplitude value;
wherein the electrical continuity test means includes a digital computer connected to the connector outlet, the digital computer is programmed to provide the comparison of the amplitude of the test signal and the provision of the fault signal, the test signal means includes an oscillator and an operational amplifier and the digital computer includes means for controlling the operational amplifier to increase the amplitude of the oscillatory test signal to a second signal amplitude.
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Abstract
An automatic harness testing apparatus test a multiconductor single connector wire harness for continuity faults in each conductive path of the wire harness by capacitively inducing an oscillatory test signal through the insulation of the conductors, probing each of the terminals of the connector and sequentially testing each probe for the presence of a test signal having a predetermined amplitude.
39 Citations
37 Claims
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1. Apparatus for testing a wire harness having at least one connector conductively connected by a terminal to a conductor of an insulated wire to form a conductive path, comprising:
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connector probe means for conductively engaging and connecting a terminal of a conductive path to be tested to a connector outlet; test signal means for capacitively inducing an oscillatory test signal in the conductor of a wire of the conductive path to be tested; and electrical continuity test means for measuring the amplitude of the oscillatory test signal at the connector outlet of each conductive path to be tested and comparing the measured amplitude to a pre-determined amplitude value and for providing a fault signal indicative of the condition of the conductive path to be tested when the measured amplitude is equal to the predetermined amplitude value; wherein the electrical continuity test means includes a digital computer connected to the connector outlet, the digital computer is programmed to provide the comparison of the amplitude of the test signal and the provision of the fault signal, the test signal means includes an oscillator and an operational amplifier and the digital computer includes means for controlling the operational amplifier to increase the amplitude of the oscillatory test signal to a second signal amplitude. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A method for testing a wire harness having at least one connector conductively connected by a terminal to an insulated wire to form a conductive path, comprising the steps of:
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conductively engaging and connecting a terminal of a conductive path to be tested to a connector outlet; capacitively inducing an oscillatory test signal in the wire of the conductive path to be tested; measuring the amplitude of the oscillatory test signal at the connector outlet of each conductive path to be tested; comparing the measured amplitude to a pre-determined amplitude value; providing a fault signal indicative of the condition of the conductive path to be tested when the measured amplitude is equal to the predetermined amplitude value; and
increasing the amplitude of the oscillatory test signal when the measured test signal amplitude is a predetermined lesser magnitude than the original oscillatory test signal and retesting the conductive path by comparing the increased amplitude of the test signal to a second predetermined amplitude value. - View Dependent Claims (11, 12)
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13. An apparatus for terminating a plurality of insulated wires to corresponding terminals of a connector to assembly a wire harness and for testing the assembled wire harness, comprising:
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press means for reciprocating a ram mounted on a press frame toward and away from a connector positioning means for termination of a connector disposed in the connector positioning means to a plurality of insulated wires to form a wire harness; probe means for individually conductively engaging each terminal of the connector after termination of the connector to the insulated wire by the ram; electrical continuity test means electrically connected to the probe means for testing the wire harness for electrical faults; and test signal means for emitting an oscillatory test signal generated by an oscillator, with the test signal means disposed at a position spaced from the connector in close proximity to the wires when the ram is in a testing position such that a test signal is capacitively induced in the wires by the test signal means, wherein the electrical continuity test means includes means for measuring the amplitude of the oscillatory test signal induced in each wire and comparing the measured amplitude to a pre-determined amplitude value and for providing a fault signal indicative of the condition of the wire when the measured amplitude is equal to the predetermined amplitude value; wherein the electrical continuity test means includes a digital computer connected to the probe means, the digital computer is programmed to provide the comparison of the amplitude of the test signal and the provision of the fault signal, the test signal means includes an operational amplifier and the digital computer includes means for controlling the operational amplifier to increase the amplitude of the oscillatory test signal to a second signal amplitude. - View Dependent Claims (14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25)
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26. An apparatus for terminating a plurality of insulated wires to corresponding terminals of a connector to assembly a wire harness and for testing the assembled wire harness, comprising:
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press means for reciprocating a ram mounted on a press frame toward and away from a connector positioning means for termination of a connector disposed in the connector positioning means to a plurality of insulated wires to form a wire harness; test signal means for emitting an oscillatory test signal generated by an oscillator, with the test signal means disposed at a position spaced from the connector in close proximity to the wires when the ram is in a testing position such that a test signal is capacitively induced in the wires by the test signal means; probe means carried on the ram of the press for individually conductively engaging each terminal of the connector after termination of the connector to the insulated wire by the ram the probe means including a plurality of resilient probe pins each disposed to enter individual apertures of the connector and engage contact portions of the terminals of the connector; and electrically continuity test means electrically connected to the probe means for testing the wire harness for electrical faults, wherein the electrical continuity test means includes means for measuring the amplitude of the oscillatory test signal induced in each wire and comparing the measured amplitude to a pre-determined amplitude value and for providing a fault signal indicative of the condition of the wire when the measured amplitude is equal to the predetermined amplitude value; wherein the electrical continuity test means includes a digital computer connected to the probe means, the digital computer is programmed to provide the comparison of the amplitude of the test signal and the provision of the fault signal, the test signal means includes an operational amplifier and the digital computer includes means for controlling the operational amplifier to increase the amplitude of the oscillatory test signal to a second signal amplitude. - View Dependent Claims (27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37)
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Specification