High voltage harness testing system

• US 7,696,760 B2
• Filed: 11/30/2007
• Issued: 04/13/2010
• Est. Priority Date: 11/30/2007
• Status: Active Grant

• Current Assignee: Caterpillar Incorporated
• Original Assignee: Caterpillar Incorporated
• Inventors: Lindsey, Robert W., Johnson, Curtis Brian, Glover, Rex Aaron
• Primary Examiner(s): NGUYEN, HOAI AN D
• Application Number:
  US11/987,543
• Publication Number:
  US 20090140748A1
• Time in Patent Office: 865 Days
• Field of Search: 324/538, 324/537, 324/500, 324/539, 324/541, 324/543, 324/544, 324/66, 324/67, 324/76.11, 702/58, 702/108, 702/117, 702/118
• US Class Current: 324/538
• CPC Class Codes: G01R 31/50 Testing of electric apparatus, lines, cables or components for short-circuits, continuity, leakage current or incorrect line connections testing of sparking plugs H01T13/58

Abstract

A wire harness testing system is disclosed. The wire harness testing system includes a voltage sensor configured to measure a voltage at a location associated with an electric load, wherein the electric load is connected with at least one wire harness. The wire harness testing system also includes a controller electrically coupled to the voltage sensor. The controller is configured to receive a wire harness test request. The controller is further configured to determine a voltage drop based on a voltage sensor measurement and a reference voltage and compare the voltage drop with a threshold. The controller is also configured to adaptively update the reference voltage with the voltage measurement responsive to a voltage drop below the threshold, and generate a fault notice responsive to a voltage drop above the threshold. The wire harness testing system further includes at least one indication device configured to provide a warning signal based on the fault notice generated by the controller.

Claims

1. A wire harness testing system, comprising:

a voltage sensor configured to measure a voltage at a location associated with an electric load, wherein the electric load is connected with at least one wire harness;

a controller electrically coupled to the voltage sensor, and being configured to;

receive a wire harness test request;

determine a voltage drop based on a voltage sensor measurement and a reference voltage;

compare the voltage drop with a threshold;

adaptively update the reference voltage with the voltage measurement responsive to the voltage drop being below the threshold; and

generate a fault notice responsive to the voltage drop being above the threshold; and

at least one indication device configured to provide a warning signal based on the fault notice generated by the controller.

2. The wire harness testing system of claim 1, further including a user input interface configured to receive user input to initiate a test request.

3. The wire harness testing system of claim 1, wherein the controller further includes a storage unit configured to store the reference voltage and characteristic data associated with the electric load.

4. The wire harness testing system of claim 1, wherein the at least one indication device is an operator panel configured to display results of the fault notice.

5. The wire harness testing system of claim 1, wherein the voltage sensor is integrated with the electric load.

6. A method of testing a wire harness, comprising:

receiving a wire harness test request;

measuring a voltage associated with an electric load, based on the test request;

determining a reference voltage based on characteristic data of the electric load;

determining a voltage drop as a difference between the voltage measurement and the reference voltage;

comparing the voltage drop with a threshold;

adaptively updating the reference voltage with the voltage measurement responsive to the voltage drop being below the threshold;

generating a fault notice responsive to the voltage drop being above the threshold; and

providing at least one warning signal based on the fault notice.

7. The method of claim 6, further including initiating a test request by a user via a user input interface.

8. The method of claim 6, further including adjusting the threshold by a user via a user input interface.

9. The method of claim 6, further including normalizing the voltage drop and the threshold of the voltage drop based on the reference voltage.

10. The method of claim 6, further including repetitively measuring the voltage and adaptively updating the reference voltage with an average value of a plurality of voltage measurements.

11. The method of claim 6, further including displaying faults based on the fault notice.

12. The method of claim 6, further including automatically disconnecting the wire harness from its power source responsive to detection of a fault.

13. The method of claim 6, further including testing a first wire harness associated with a first electric load, and testing at least a second wire harness associated with a second electric load.

14. The method of claim 6, further including correlating the reference voltage to usage power demand of the electric load being tested.

15. A machine, comprising:

a power source;

an electric load coupled to receive power from the power source, wherein the electric load is connected with at least one wire harness; and

a wire harness testing system operatively coupled to test the wire harness associated with the electric load, wherein the wire harness testing system includes;

a voltage sensor configured to measure a voltage at a point associated with the electric load;

a controller electrically coupled to the voltage sensor, and being configured to;

receive a wire harness test request;

determine a voltage drop based on a voltage sensor measurement and a reference voltage;

compare the voltage drop with a threshold;

adaptively update the reference voltage with the voltage measurement responsive to the voltage drop being below the threshold; and

generate a fault notice responsive to the voltage drop being above the threshold; and

at least one indication device configured to provide a warning signal based on the fault notice generated by the controller.

16. The machine of claim 15, wherein the at least one indication device is an operator panel configured to display results of the fault notice.

17. The machine of claim 15, wherein the voltage sensor is integrated with the electric load.

18. The machine of claim 15, wherein the power source is a high voltage power source higher than 50 volts.

19. The machine of claim 15, wherein the wire harness is an electrical connector.

20. The machine of claim 15, wherein the wire harness is an electrical conductor.