GB2607296A

GB2607296A - Test apparatus for wiring harness body clip

Info

Publication number: GB2607296A
Application number: GB2107772.2A
Authority: GB
Inventors: Barata Antonio; Filipe Nabais Figueira De Almeida Ricardo; Carrolo Nuno
Original assignee: Aptiv Technologies Ltd
Current assignee: Aptiv Technologies Ltd
Priority date: 2021-06-01
Filing date: 2021-06-01
Publication date: 2022-12-07
Also published as: GB202107772D0

Abstract

A test apparatus (30, figure 3) is provided for detecting the presence and at least one desired characteristic of a mechanical connector such as a wiring harness body clip (figure 1). The test apparatus comprises a housing (32) having a receiver 34 for receiving and retaining a connector, and a switch 62. A contact element 60 is arranged to move between an open position in which it is spaced from the switch and a closed position in which it operates the switch. First and second mechanical engagement elements 46, 56 are arranged to be engaged by first and second features of the connector respectively when the connector is inserted in the receiver. The contact element is arranged to move to the closed position (figure 8) when the connector is inserted in the receiver. The first and second mechanical engagement elements are arranged to prevent movement of the contact element to the closed position unless the first and second mechanical engagement elements are simultaneously contacted by the first and second features of a connector having a positional relationship corresponding to the correct connector.

Description

TEST APPARATUS FOR WIRING HARNESS BODY CLIP

FIELD OF INVENTION

[001] The present invention relates to a test apparatus for confirming the presence and at least one desired characteristic of a body clip during the assembly and testing procedure for an automotive wiring harness.

BACKGROUND

[2] A wiring harness or wiring loom is a bundle of electrical cables used in automotive applications to transmit electrical power supply or data signals around a vehicle. Wiring harnesses are pre-assembled with the cables arranged in the correct routing lengths and configurations and bound together for example using tape, clips, cable ties, or conduits. The terminal ends of the cables are provided with connector elements for electrical connection to the associated in-vehicle components. The wiring harness is also provided with connectors at various locations along its limbs for mechanically connecting the cable harness to various structures within the vehicle. These connectors are commonly referred to as body clips.

[3] A wiring harness comprises an extensive network of cables that extend around the entire vehicle. Each location within a vehicle presents a different mounting requirement due to its surface shape, orientation and the surrounding environment. The size and shape of the wiring harness itself also varies along its various limbs. Therefore, a variety of different clips are required depending on the mounting location within the vehicle and the specific location along the wiring to which the clip is secured.

[4] Many body clips typically comprise a t-shaped moulded plastic body having an elongate body section and a head section formed in a flange arrangement. In use the body section is inserted into a corresponding pre-formed aperture in the vehicle body and may include retaining elements such as barbs for retaining the clip within the aperture.

The head section limits insertion of the body section and provides a mounting structure for the cables.

[5] It is important when assembling a wiring harness that a body clip is provided at each required location along the harness. It is also essential that the correct body clip is provided at each location. This is complicated by the fact that many clips appear similar or have several common features. Failure to include a body clip at a given location, or the inclusion of an incorrect body clip prevents or hinders the installation process and requires the installation to be halted while a correct body clip is located, resulting in delay. This may also result in the harness being rejected and returned to the manufacturer.

[6] Wiring harnesses are assembled on an assembly board or workbench, which typically comprises a schematic of the wiring routes and includes labelling indicating the required components at each associated location along the harness. The electrical components are retained in mountings on the assembly board for connection to the cables, and cable laying guides and supports are arranged on the assembly board for guiding and angling the cables.

[007] It is known to provide body clip holders on a wiring harness assembly board that are configured to receive the body clips at each associated location and provide an electrical signal confirming the presence of the body clip at that location. During assembly, each body clip is connected to the wiring harness at its given location and at the same time inserted into the body clip holder. When assembly is complete, the body clip holders provide an indication of the body clips installed at each location and the absence of a signal enables the installers to identify a missing clip. However, commonly known body clip holders do not indicate whether the correct clips have been installed at each location. Therefore, an assembly with a confirmed full compliment of body clips may include one or more present but incorrect body clips. As a result, a wiring harness that has passed a body clip test may be rejected during installation due to the presence of incorrect body clips or may at least hinder assembly.

[8] It is therefore desirable to provide an improved test apparatus for a connector which addresses the above described problems and/or which offers improvements generally.

SUMMARY

[9] According to the present disclosure there is provided a test apparatus for a connector as described in the accompanying claims.

[0010] In one aspect of the disclosure there is provided a test apparatus for detecting the presence of a mechanical connector such as a wiring harness body clip and for confirming at least one desired characteristic of said connector, said connector having first and second features with a positional relationship that defines said at least one desired characteristic of the connector. The test apparatus comprises a housing having a receiver for receiving and retaining a connector and a switch. A contact element is arranged to move between an open position in which it is spaced from the switch and a closed position in which it operates the switch. A first mechanical engagement element is arranged to be engaged by a first feature of the connector when the connector is inserted in the receiver. A second mechanical engagement element is arranged to be engaged by a second feature of the connector when the connector is inserted in the receiver. The contact element is arranged to move to the closed position when the connector is inserted in the receiver and the first and second mechanical engagement elements are arranged to prevent movement of the contact element to the closed position unless the first and second mechanical engagement elements are simultaneously contacted by the first and second features of the connector respectively. The contact element is any element that is movable to operate the switch. The contact element may be an independent component or may be part of another component, for example an inner end of one of the first or second mechanical engagement elements. The switch may be configured to generate a signal when operated and may be any switch suitable to be operated by movement of the contact element.

[0011] The test apparatus thereby provides a receiver or holder for receiving a connector, which in use is located on a wiring harness test board at the location of a given body clip. The test apparatus includes an error proof mechanical means of verifying that the connector inserted in the holder is the correct connector required at the location along the wiring harness at which the test apparatus is located. It does this by verifying that the connector has a desired physical characteristic specific to that connector. Each test apparatus is provided with a unique identifier and is configured to validate a specific connector. Certain features of the test apparatus will prevent insertion of an incorrect connector altogether. Other features ensure that small deviations from the required characteristics of the connector will be detected and prevent the test apparatus providing a positive signal.

[0012] The connector preferably has a body section having a longitudinal axis and the first and second features of the connector are axially offset. The axial offset defines a desired characteristic of the connector, which may be the distance between the distal end of the body section a radial projection defining an engagement element that limits insertion of the connector. The defined characteristic may in one embodiment be the distance between the lower edge of a connector head and the distal end of the body section. In an operative state the first and second mechanical engagement elements are offset by a distance corresponding to the desired axial offset of the connector, such that they may only be simultaneously engaged in the operative state to move the contact element to the closed position by the first and second features of a connector having the desired axial offset. Consequently, the contact element may only be moved to the closed position when a connector having the required axial offset is inserted in the receiver. The operative state is a state in which the first and second mechanical engagement elements are operative to move the contact element to the closed position. The first and second mechanical engagement elements may be biased to the operative state or may transition to the operative state during use, for example on engagement with the connector.

S

[0013] The first and second mechanical engagement elements may comprise first and second push rods respectively that are arranged to be engaged by the first and second features of the connector and to move when simultaneously engaged to cause the contact element to move to the closed position. The push rods are preferably elongate pins having contact heads at their outer end. However, the term 'push rods' is used broadly herein to mean any element that moves axially when engaged or 'pushed' at one end.

[0014] The test apparatus may further comprise a rocker element pivotally mounted within the housing about a pivot axis. The push rods each have outer ends arranged to be engaged by the first and second features of the connector and inner ends arranged to engage and operate the rocker element on opposing sides of the pivot axis. The terms 'outer' end 'inner' are relative to the housing, with the outer end being the end facing outwardly from the housing, which is engaged by in the incoming connector. The rocker element is operatively connected to the contact element such that when the rocker element is actuated simultaneously by the first and second push rods it causes movement of the contact element to the closed position and when the rocker element is actuated by only one of the first and second push rods it rotates about the pivot axis without causing movement of the contact element. The push rods may be pivotally connected to the rocker element or may move axially into engagement with the rocker element when actuated by the connector.

[0015] A third push rod may be provided having an inner end and an outer end. The rocker element may be pivotally mounted to the outer end of the third push rod and the third push rod is axially depressed when the rocker element is simultaneously operated by the first and second push rods. The inner end of the third push rod defines the contact element and is arranged to engage the switch when the third push rod is move inwardly or depressed.

[0016] The inner ends of the push rods are preferably pivotally connected to the rocker element. The rocker element is preferably pivotally mounted to the third push rod such that in a neutral position it is arranged perpendicular to the longitudinal axis of the third push rod in a t-shaped configuration. The first and second rods are connected to the rocker element such that when they are simultaneously engaged by the first and second features of the connector they apply balanced moments to the rocker element resulting in a downward force on the rocker element with no rotation. Preferably the push rods are connected to the rocker element at equally spaced locations along the rocker element either side of the pivot axis.

[0017] The relative axial position of the first and second push rods may be variable. In a neutral configuration with no connector inserted the outer ends of the push rods are axially offset by a distance corresponding to the desired axial offset of the connector. In an engaged configuration in which the push rods are simultaneously engaged to move downwards to operate the contact element, the axial offset of the first and second push rods is maintained. In an imbalanced configuration where one but not both the of the push rods is engaged by one of the first and second features of the connector, the push rods move axially relative to each other and the axial offset no longer corresponds to the desired axial offset of the connector.

[0018] The receiver is any means suitable for receiving and holding the body section of the connector. The receiver preferably comprises an axially extending channel; the term axially being used relative to the longitudinal axis of the housing and the push rods. The housing may comprise an abutment or support surface surrounding the receiver channel, which is a surface that is engaged by the lower edge of the connector head when the body section is fully inserted into the receiver channel. The first push rod extends through an opening in the support surface and the second push rod is axially aligned with the opening of the receiver and is preferably located within or below the receiver channel. In the open position the contact element is spaced from the switch by an engagement distance and the first push rod extends outwardly above the support surface by a distance equal to the engagement such that the support surface in use limits axial travel of the second push rod to the engagement distance. That is to say, the lower end of the connector is able to push the second push rod downwardly by the engagement distance until it is flush with the support surface, and which point the head is not able to depress the second push rod any further. As such the head moves the second push rod the exact distance required to move the contact element into engagement with the switch.

[0019] The test apparatus is preferably configured for a connector comprising a body section and a head section and the peripheral shape of the head section defines a second desired characteristic. The receiver may be configured to receive the body section of the connector, and the housing further comprises a recess for receiving the head section of the connector when the body section is received within the receiver, the recess having a peripheral shape corresponding to at least part of the desired peripheral head shape of the connector to permit insertion of connectors having said desired peripheral head shape and to provide a mechanical obstruction that prevents insertion of connectors not having said desired peripheral head shape. The test apparatus thereby provides a two-stage verification of the connector, confirming both the head shape and length of the body section from the lower edge of the head.

[0020] A wireless transmitter may be provided that is configured to transmit a signal when the switch is operated. Because the switch may only be operated if the correct connector is received, the signal generated by operation of the switch is indicative of the presence of a connector in the test apparatus and that the connector has at least one desired characteristic.

[0021] The wireless transmitter may be further configured to transmit a unique identifier relating to the location and type of the test apparatus.

[0022] In another aspect of the disclosure there is provided a wiring harness test system comprising a support surface including a predefined wiring route along which the wiring harness to be tested is mounted. The support surface may be the assembly board of the wiring harness or may be a separate post-assembly test board. The support surface includes a plurality of test apparatus as described above arranged at locations along the wiring route corresponding to connector locations, each test apparatus having a unique identifier and being configured to confirm the presence of a specific connector in the test apparatus and that the connector has at least one desired characteristic specific to the connector required at that location. A processor is operative to receive a signal from each test apparatus and to confirm based on each of said signals whether each test apparatus is holding a connector and whether said connector has the desired characteristic corresponding to the correct connector for that location.

[0023] The signal from each test apparatus may be transmitted wirelessly to the processor. The processor may be operative to provide an indication that a connector is absent from one or more of the test apparatus or that one or more of the test apparatus contains the incorrect connector and/or that a full complement of correct connectors is present.

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The present disclosure will now be described by way of example only with reference to the following illustrative figures in which: Figure 1 is a conventional body clip for a wiring harness; Figure 2 is a plan view of the body clip of Figure 1; Figure 3 is a test apparatus according to an embodiment of the present disclosure; Figure 4 is a plan view of the test apparatus of Figure 3; Figure 5 is an illustrative representation of a test apparatus according to an embodiment of the present disclosures in the neutral condition; Figure 6 is an illustrative representation of a test apparatus according to an embodiment of the present disclosures in a first imbalanced condition; S Figure 7 is an illustrative representation of a test apparatus according to an embodiment of the present disclosures in a second imbalanced condition; Figure 8 is an illustrative representation of a test apparatus according to an embodiment of the present disclosures in an actuated condition; Figure 9 is an illustrative representation of a test apparatus according to another embodiment of the present disclosures in the neutral condition; and Figure 10 is an illustrative representation of the test apparatus of Figure 9 in an actuated condition.

DESCRIPTION OF EMBODIMENTS

[0025] The following description presents exemplary embodiments and, together with the drawings, serves to explain principles of the present disclosure. The scope of the present disclosure is not intended to be limited to the precise details of the embodiments or exact adherence with all method steps. Variations will be apparent to a skilled person and are deemed also to be covered by the description. Terms for features used herein should be given a broad interpretation that also encompasses equivalent functions and features. In some cases, several alternative terms (synonyms) for structural features have been provided but such terms are not intended to be exhaustive.

[0026] Descriptive terms should also be given the broadest possible interpretation; e.g. the term "comprising" as used in this specification means "consisting at least in part of" such that interpreting each statement in this specification that includes the term "comprising", features other than that or those prefaced by the term may also be present. Related terms such as "comprise" and "comprises" are to be interpreted in the same manner. Directional terms such as "vertical", "horizontal", "up", "down", "upper" and "lower" are relative terms that may be used for convenience of explanation usually with reference to the illustrations and are not intended to be ultimately limiting if an equivalent function can be achieved with an alternative dimension and/or direction.

[0027] The description herein refers to embodiments with particular combinations of configuration steps or features. However, it is envisaged that further combinations and cross-combinations of compatible steps or features between embodiments will be possible. The description of multiple features in relation to any specific embodiment is not an indication that such features are inextricably linked, and isolated features may function independently as an invention from other features and not necessarily require implementation as a complete combination.

[0028] Referring to Figure 1, a commonly known cable body clip 1 for securing a wiring harness comprises a body 2 and a head 4. The body 2 is an elongate shaft and the head 4 is arranged perpendicular to the longitudinal axis of the body 2. The body clip 1 of Figure 1 is a 'fir tree' clip having a series of barbs 6 arranged along the body 2.

[0029] The barbs 6 are angled upwardly in the axial direction of the head 4 and are arranged to deflect radially inwardly when the body 2 is inserted into a pre-drilled hole in a vehicle body panel. The barbs 6 return to their pre-flexed position when inserted fully through the hole and engage the inner side of the body panel to prevent retraction of the body 2 from the hole. The head 4 includes a mounting feature 8 for securing to and supporting a section of a wiring harness. The mounting feature 8 is located on the upper surface 10 of the head 4 on the opposing side of the head 4 to the body 2, and in use faces outwardly away from the body panel of the vehicle. The mounting feature 8 may be configured to be strapped, taped or otherwise secured to the cable harness in any other suitable way.

[0030] The body 2 has a cross sectional shape in the plane perpendicular to its longitudinal axis A-A. The cross-sectional shape of the body 2 may vary from clip to clip.

For example, the body 2 of certain body clips 1 may include longitudinally extending channels of varying radial depths. The number and position of the channels may vary from clip to clip. Other clips may have a non-circular cross-sectional form. The receiving channel may have a cross sectional shape corresponding to the cross-sectional shape of the body section to only permit insertion of a body section having the correct cross section. This feature may be provided independently or in combination with the other test features.

[0031] The head 4 has a peripheral edge 10. The head 4 includes an outer surface 12 and an inner surface 14 having a lower edge 16. The body 2 projects from the lower surface 14 of the head 4 in a direction away from the head 4. The body 2 has a longitudinal axis A-A that is arranged perpendicular to the lower edge 16 of the head 4. The body 2 has a proximal end 18 and a distal end 20.

[0032] The body 2 has an outer diameter dl defined by the unflexed diameter of the barbs 6, and an inner diameter d2 defined by the diameter of the shaft of the body section 2 from which the barbs 6 extend. The body 2 also has a length L defined by the distance from the lower edge 16 of the head 4 to the distal end 20.

[0033] The head 4 has a diameter d3. As shown in Figure 2, the peripheral edge 10 of the head 4 has a circular shape. The shape of the peripheral edge 10, the diameter d3 of the head 4, and the length L of the body 2, vary between body clips. Each body clip 1 has a specific combination of the shape of its peripheral edge 10, the diameter d3 of the head 4, and the length L of the body 2. For each body clip, the diameter d3 of the head 4 is greater than the inner diameter dZ of the body 2 and typically greater than the outer diameter dl of the body 2. It will be appreciated that for non-circular heads, the diameter of the head 4 will not be constant. The diameter d3 therefore represents a maximum distance across the head 4.

[0034] As the diameter c13 of the head 4 is greater than the inner and outer diameters dl,d2 of the body 2 the head 4 projects outwardly of the body in a direction perpendicular to the longitudinal axis A-A of the body 2. The pre-drilled holes of the vehicle body are formed to be substantially equal to the inner diameter d2 of the body 2 and less than the outer diameter dl of the body 2. As such, as the body 2 is inserted through the holes the barbs 6 are caused to flex inwardly and remain flexed until they have passed fully through the pre-drilled hole at which point they return to their unflexed state with the outer surface 24 of the barbs 6, that is to say the surface of the barbs which face in the direction of the head 4, engaging the inner surface of the body panel to prevent retraction. The lower edge 16 of the diametrically larger head d3 defines a flange that engages the region of the body panel immediately surrounding the pre-drilled hole to stop the body clip land prevent further insertion. Other known examples of body clips include different head configurations or may be provided without a head as described above. Such 'headless' body clips include alternative features which extend radially outwards of the body section and limit insertion of the body section. The term 'head' is therefore used broadly herein to encompass any radially expanded engagement feature of the connector that limits insertion of the body section into the aperture of the body panel. The body length L may be the distance from the lower edge of any such engagement features to the lower end of the body section.

[0035] The combination of the length L of the body 2, the diameter d3 of the head 4 and the peripheral shape 22 of the head 4 is unique to each clip. Therefore, the ability to confirm at least one of these characteristics, together with positive confirmation of the presence of a body clip at a required location along a wiring harness, enables a determination that the correct body clip has been selected. Accordingly, the present disclosure provides a test apparatus 30 as shown in Figure 3, that is configured to retain a body clip, such as but not limited to the body clip 1 described above, and confirm the presence of the retained body clip 1. The test apparatus 30 is also configured to confirm that the retained body clip 1 comprises the body length L and peripheral head shape 22 conforming to the body clip 1 required at the given location of the test apparatus 30 along the wiring harness, as will be described in further detail.

[0036] Referring to Figure 3, the test apparatus 30 comprises a body 32 which in use is connected to a wire harness assembly board at the location on a test board of a given body clip 1. The body 32 includes a channel 34 extending into the body that is configured to receive the section 2 of the body clip 1. The channel 34 has a diameter substantially equal to the inner diameter d2 of the body section 2 and less than the outer diameter dl to provide a positive engagement between the body section 2 and the side walls of the channel 34 to hold and retain the body section 2 within the channel 34. The body 32 of the test apparatus 30 defines a housing having side walls 36 and an upper surface 38. A recess 40 is formed in the upper surface 38. The recess 40 extends axially downwardly into the body 32. The recess 40 has a base surface 42 and side walls 44 defining a peripheral edge to the recess 40. The shape of the peripheral edge 44 is shaped to correspond to the peripheral edge 10 of the head 4 of the body clip 1. The recess 40 is arranged relative to the channel 34 to receive the head 4 when the body section 2 of the body clip 1 is inserted in the channel 34. Each test apparatus 30 is located at a unique location along the wiring harness route. The shape of the peripheral edge 44 of the recess 40 of each test apparatus 30 is shaped to correspond to the shape of the peripheral edge 10 of the body clip 1 intended for use at the specific location at which the test apparatus 30 is located. The shape of the peripheral edge 44 therefore provides a first check that the correct body clip has been selected. That is to say that a body clip 1 with a peripheral edge 10 shaped differently to the peripheral edge 44 of the recess 40 will not be capable of being inserted into the recess 40.

[0037] When a body clip 1 is inserted in the test apparatus 30 the body section 2 is firstly received within the channel 34 and, assuming the shape of the peripheral edge 10 conforms to the shape of the peripheral edge 44 of the recess 40, the head 4 is received within the recess 40. The body section 2 extends within the channel 34 until the lower edge 16 of the head 4 comes into engagement with the base of surface 42 of the recess 40, which defines an abutment surface preventing further axial insertion of the body clip 1.

[0038] The test apparatus 30 includes a first pin defining a first push rod 46. The first push rod 46 is received within an axially extending channel 48 arranged parallel to the channel 34. A head section 50 of the first push rod 46 extends axially above the base of surface 42 of the recess 40. The channel 48 is arranged such that it extends through the base section 42 with the head section 50 of the first push rod 46 extending through the base of surface 42. The head 50 of the first push rod 46 is arranged to be engaged by the lower surface 16 of the head 4 of the body pin 1 when the head 4 is inserted into the recess 40.

[0039] The test apparatus 30 includes a base section 52 located at the lower end of the housing 32 at the opposing end to the recess 40. Base section 52 contains a contact is switch and a wireless transmitter as described in further detail below. The side wall 36 of the housing 32 includes a longitudinally extending channel arranged to partially intersect the recess 40. As shown in Figure 4, the channel 54 has a curved profile forming a scalloped cutaway into the recess 40. The channel 54 enables a user to engage the lower surface 10 of the head 4 of the body clip 1 to grip the body clip land remove it from the test apparatus 30.

[0040] A second pin defining a second push rod 56 is located within the channel 34 and is slidingly received therein. The second push rod 56 includes a head 58 that in a neutral condition prior to insertion of the body clip 1 is axially spaced below the head 50 of the first push rod 46 and below the base surface of the recess 40. As can also be seen in Figure 4, the channel 48 of the first push rod 46 is located at the radial outer edge of the base surface 42 and partially intersects the peripheral edge 44 of the recess 40. This ensures that the head 50 of the first push rod 46 is engaged by the outer edge of the head 4 when the head 4 is inserted into the recess 40.

[0041] A diagrammatic representation of the internal structure of the test apparatus 30 is shown in Figure 5, which is a cross-sectional view through the housing 32. A third push rod 60 is provided within the housing 32. The third push rod 60 is slidingly received within a corresponding axially arranged channel formed within the housing or is otherwise supported within the housing 32 such that it is able to axially translate. A biasing means such as a compression spring may be provided to bias the third push rod 60 to a first raised position as shown in Figure 5. A contact switch 62 is located at the base of the housing 32 beneath the third push rod 60.

[0042] A rocker 64 is pivotally mounted to the upper end 66 of the third push rod 60.

The third push rod 60 has a longitudinal axis that is arranged parallel to the longitudinal axis of the first push rod 46 and second push rod 56. The rocker 64 is mounted to the third push rod 60 by a pivot pin 66 and in the neutral position as shown in Figure 5 extends substantially perpendicular to the longitudinal axis of the third push rod 64 in a substantially T-shaped arrangement. The lower end 68 of the first push rod 46 is pivotally connected to the rocker 64 by a pivot pin 70. The pivot pin 70 is laterally spaced from the pivot pin 66 along the length of the rocker 64. The second push rod 56 is connected at its lower end 72 to the rocker 64 by a pivot pin 74. The pivot pin 74 is spaced from the pivot pin 66 along the length of the rocker 64 on the opposing side of the third push rod 60 from the pivot pin 70 of the first push rod 46.

[0043] The lower end surface 76 of the third push rod 60 is spaced from the contact switch 62 by an axial distance H1. The length of the first push rod 46 is selected such that the upper surface 78 of the head 50 of the first push rod 46 is axially spaced above the base surface 42 of the recess 40 by a corresponding distance H2 in the neutral position.

The third push rod 60 is in the neutral position and the rocker 64 is un-tilted and arranged substantially perpendicular to the longitudinal axis of the third push rod 60. The distance H2 is selected to be equivalent to the distance H1. The distance between the upper surface 78 of the first push rod 46 and the upper surface 80 of the second push rod 56 is a distance H3 when the rocker 64 is in the neutral position substantially horizontal and perpendicular to the longitudinal axis of the third push rod 60. The distance H3 is selected to correspond to the required length L of the body section 2 of the body clip 1 associated with the test apparatus 34. In this way, when the body clip 1 is inserted into the channel 34 the lower surface 10 of the head 4 or other radially extended engagement feature will contact the upper surface 78 of the first push rod 46 at the same time that the distal end 20 of the body section 2 contacts the upper surface 80 of the second push rod 56 if the body clip 1 is correct.

[0044] Simultaneous contact of the head 4 with the first push rod 46 and the body 2 with the second push rod 56 enables the body clip 1 to push downwardly on the third push rod 60 via the push rods 46,56 without tilting the rocker. Applying a balanced force to the rocker 64 enables the third push rod 60 to be pushed downwardly against the biasing force of the compression spring to move the third push rod 60 into engagement with the contact switch 62. When the lower surface 10 of the head 4 has pushed the first push rod 46 downwardly a distance H2 the lower surface 10 comes into engagement with the lower base surface 42 of the recess 40 and is unable to push the first push rod 46 any further. As the distance H1 corresponds to the distance H2, the head 4 is therefore able to push the first push rod 46 a distance corresponding to the distance H1 required to make contact between the third push rod 60 and the contact switch 62. With the third push rod 60 in engagement with the contact switch 62 the body clip 1 is securely received within the channel 34 and the contact switch 62 provides an indication that the body clip 1 is present within the test apparatus 34. Furthermore, the fact that the contact switch 62 has been activated confirms that the body clip 1 has the correct length L and that the head 4 has the correct corresponding peripheral shape 22.

[0045] The arrangement of Figure 6 represents a situation in which an incorrect body clip 1 having a correctly shaped peripheral edge 10 but incorrect body length L has been inserted into the recess 40. The length L of the body section 2 is shorter than the desired length of the correct corresponding body clip 1. As such, the peripheral edge 10 of the head 4 engages the upper surface 78 of the first push rod 46 before the distal end 20 has engaged the upper surface 80 of the second push rod 56. The first push rod 46 therefore begins to move downwardly. Without the distal end 20 in engagement with the second push rod 56 the downward force on the rocker 64 is imbalanced causing the rocker to pivot downwardly about the pivot pin 66 on the head of the first push rod 46. At the same time, the opposing side of the rocker 64 pivots upwardly forcing the second push rod 56 to move upwardly. Therefore, because the length L of the body section 2 of the body clip 1 is too short, insertion of the body clip 1 into the test apparatus 34 only acts to pivot the rocker 64 and does not provide a downward force on the third push rod 60. As a result, the third push rod 60 remains spaced from the contact switch 62. The absence of contact between the push rod 60 and the contact switch 62 indicates that the incorrect body clip 1 has been inserted into the test apparatus 30 despite the shape of the peripheral edge 10 of the head 4 providing a visual indication that the correct clip has been selected.

[0046] Figure 7 illustrates a situation in which an incorrect body clip 1 has been selected having a body section 2 with a length [that is greater than the specified length L of the is correct body clip 1 corresponding to the test apparatus 30. As a result, when the body clip 1 is inserted into the test apparatus 34 the distal end 20 of the body section 2 contacts the upper surface 80 of the second push rod 56 before the lower edge 16 of the head 4 comes into engagement with the upper surface 78 of the first push rod 46. Consequently, the distal end 20 begins to push downwardly on the second push rod 56 and this force is not countered by the simultaneous engagement of the head 4 with the first push rod 46. As such, the second push rod 56 begins to push downwardly on the rocker 64 causing the rocker 64 to pivot about pivot pin 66 in a downward direction. At the same time, the opposing end of the rocker 64 pivots upwardly pushing the first push rod 46 in an upwards direction. The absence of simultaneous engagement of the head 4 and the body section 2 with the first push rod 46 and second push rod 56 respectively results in the downward force of the body clip 1 causing the rocker 64 to pivot rather than moving the third push rod 60 downwardly into contact with the contact switch 62. Again, the third push rod 60 remains spaced from the contact switch 62 providing an indication that the incorrect body clip 1 has been selected due to the absence of a signal from the contact switch 62.

[0047] In the arrangement of Figure 8 the correct body clip 1 has been selected having a head 4 with a peripheral edge 10 correctly shaped to correspond to the peripheral edge of the recess 40. The body section 2 has been inserted into the channel 34 until the distal end 20 contacts the upper surface 80 of the second push rod 56. The length L of the body section 2 corresponds to the height H3 between the upper surface 78 of the first push rod 46 and the upper surface 80 of the second push rod 56, and as such the lower surface 10 of the head 4 and the distal end 20 engage these corresponding surfaces simultaneously. The first push rod 46 and second push rod 56 apply balanced forces on opposing sides of the pivot pin 66 to the rocker 64 preventing the rocker 64 from pivoting. The downward force from the body clip 1 is transferred to the third push rod 60 via the pivot pin 66 causing the push rod 60 to move downwardly into engagement with the contact switch 62. As can be seen in Figure 8 the gap between the lower end of the third push rod 60 and the contact switch 62 has been closed and the third push rod 60 is in engagement with the contact switch 62. A signal is generated by the contact switch 62 to indicate the presence in the test apparatus 34 of the correct body clip 1. The signal from the contact switch 62 is transmitted to a processor by a wireless transmitter in the base 52 of the housing 32. Alternatively, the test apparatus 34 may be hard wired to the wiring harness assembly board.

[0048] In another embodiment of the present disclosure as shown in Figure 9, a test apparatus 130 has a body 132 defining a housing 134 within which a first push rod 146 and second push rod 156 are slidingly received. The housing 134 includes an upper surface 142. In the neutral position, as shown in Figure 9, prior to insertion of the body clip 1 the upper ends of the first push rod 146 and second push rod 156 extend above the upper surface 142 of the housing 134. The first push rod 146 and second push rod 156 are arranged parallel to each other and slide axially within the housing 134. A contact switch 162 is located below the lower end of the first push rod 146 and is axially aligned with the first push rod 146 such that downward axial movement of the first push rod 146 brings it into engagement with the contact switch 162.

[0049] A stop plate 157 is located between the lower end of the first push rod 146 and the contact switch 162. The stop plate 157 is horizontally arranged in a direction perpendicular to the longitudinal axis of the first push rod 146. The distal end of the stop plate 157 locates in the gap 153 between the first push rod 146 and the contact switch 162. The proximal end of the stop plate 157 includes a shoulder 159 that is upwardly extending in a direction perpendicular to the main body 161 of the stop plate 157. A compression spring or other biasing member 163 urges the stop plate 157 to the default position in which it is located between the first push rod 146 and the contact switch 162.

[0050] An L-shaped rocker element 164 is located at the proximal end of the stop plate 157. A first limb 165 of the rocker element 164 is vertically arranged in the default position such that it is parallel with and in abutment with the stop shoulder 159 of the stop plate 157. A pivot pin 166 is located at the upper end of the first limb. A second limb 167 extends horizontally from the upper end of the first limb 165 in a plane perpendicular to the longitudinal axis of the second push rod 156. The upper surface 169 of the second limb of the rocker 164 is arranged beneath the lower end of the second push rod 156. The second limb 169 extends away from the first limb 165 in a direction away from the stop shoulder 159. The application of a downward force to the second limb 169 by the second push rod 156 causes the rocker 164 to pivot about the pivot pin 166 with the second limb 167 rotating downwardly while the first limb 165 rotates in an upwards direction. As the first limb 165 rotates it provides a lateral force against the stop shoulder 159 pushing the stop shoulder 159 against the action of the biasing member 163 causing the stop plate 157 to slide away from the neutral position in a direction away from the first push rod 146, exposing the gap 153 between the first push rod 146 and the contact switch 162 enabling the push rod 146 to move axially into engagement with the contact switch 162 when a downward force is applied to the first push rod 146.

[0051] As shown in Figure 10, a stop member 171 is located on the opposing side of the stop shoulder 159 to the rocker 164. The stop element 171 limits movement of the stop plate 157 when the stop plate 157 has moved out of the gap 153 between the first push rod 146 and the contact switch 162. When the stop plate 157 is stopped by the stop element 171 further rotation of the rocker 164 is prevented. A further housing element (not shown) is located above the housing section 134, which includes a recess for receiving the head 4 of the body clip 1 and a channel for receiving the body of the body clip 1. The channel and recess of the upper housing section are arranged such that the body 2 of the clip 1 slides into engagement with the second push rod 156 and such that the head 4 of the body clip 1 is able to engage the first push rod 146.

[0052] In use, when a body clip 1 is inserted into the upper housing the distal end 20 of the body clip 1 engages the second push rod 156 forcing the second push rod 156 downwardly into engagement with the upper surface 169 of the rocker 164. The rocker 164 is caused to rotate causing the stop plate 157 to begin to slide in a direction away from the first push rod 146. If the length L of the body section 2 is shorter than the length L of the body clip 1 for which the test apparatus 134 is specified the head 4 will engage the first push rod 146 before the stop plate 157 has been fully removed from the gap 153 173 between the first push rod 146 and the contact switch 162. As such, the first push rod 146 is prevented from moving downwardly via the stop plate 157 and further downward movement of the body clip 1 is prevented. The body clip 1 is unable to further rotate the rocker 164 and the first push rod 146 is prevented from making contact with the contact switch 162. The contact switch 162 is therefore not engaged and no positive signal is created indicating that the incorrect body clip 1 has been inserted into the test apparatus 130. Conversely, if the body section 2 of the body clip 1 has a length L longer than the body clip 1 for which the test apparatus 130 has been specified, the downward movement of the second push rod 156 will cause the rocker 164 to rotate position to where the stop element 171 is engaged by the stop shoulder 159. At this point, the lower surface 16 of the head 4 of the body clip 1 has still not engaged the first push rod 146 or has not engaged the first push rod 146 to the extent that it has been pushed downwardly a sufficient distance to contact the contact switch 162. The distance of travel of the second push rod 156 is therefore selected such that only a body clip 1 having a body section 2 of the correct length L is able to engage the first push rod 146 once the stop plate 157 has been moved out of the gap 153 between the first push rod 146 and the contact switch 162 and still be able to move the first push rod 146 the correct distance into engagement with the contact switch 162 before the rocker 164 is pivoted to the extent that the stop shoulder 159 engages the stop element 171.

Claims

CLAIMS1. A test apparatus for detecting the presence of a mechanical connector such as a wiring harness body clip and for confirming at least one desired characteristic of said connector, said connector having first and second features with a positional relationship that defines said at least one desired characteristic of the connector; the test apparatus comprising: a housing having a receiver for receiving and retaining a connector; a switch; a contact element arranged to move between an open position in which it is spaced from the switch and a closed position in which it operates the switch; a first mechanical engagement element arranged to be engaged by a first feature of the connector when the connector is inserted in the receiver; and a second mechanical engagement element arranged to be engaged by a second feature of the connector when the connector is inserted in the receiver; wherein the contact element is arranged to move to the closed position when the connector is inserted in the receiver and the first and second mechanical engagement elements are arranged to prevent movement of the contact element to the closed position unless the first and second mechanical engagement elements are simultaneously contacted by the first and second features of the connector respectively.
2. A test apparatus according to claim 1, wherein the connector has a body section having a longitudinal axis and the first and second features of the connector are axially offset, said axial offset defining at least one desired characteristic of the connector, and wherein in an operative state the first and second mechanical engagement elements are offset by a distance corresponding to the desired axial offset of the connector, such that they may only be simultaneously engaged in the operative state to move the contact element to the closed position by the first and second features of a connector having the desired axial offset.
3. A test apparatus according to claim 2, wherein the first and second mechanical engagement elements comprise first and second push rods respectively that are arranged to be engaged by the first and second features of the connector and to move when simultaneously engaged to cause the contact element to move to the closed position.
4. A test apparatus according to claim 3, further comprising a rocker element pivotally mounted within the housing about a pivot axis, the push rods each having outer ends arranged to be engaged by the first and second features of the connector and inner ends arranged to engage and operate the rocker element on opposing sides of the pivot axis, wherein the rocker element is operatively connected to the contact element such that when the rocker element is operated simultaneously by the first and second push rods it causes movement of the contact element to the closed position and when the rocker element is operated by only one of the first and second push rods it rotates about the pivot axis without causing movement of the contact element.
5. A test apparatus according to claim 4, further comprising a third push rod having an inner end and an outer end, wherein the rocker element is pivotally mounted to the outer end of the third push rod and the third push rod is axially depressed when the rocker element is simultaneously operated by the first and second push rods, and the inner end of the third push rod defines the contact element and is arranged to engage the switch when the third push rod is depressed.
6. A test apparatus according to claim 4 or 5, wherein the inner ends of the push rods are pivotally connected to the rocker element.
7. A test apparatus according to any one of claims 4 to 6, wherein the outer ends of the push rods are axially offset by a distance corresponding to the desired axial offset of the connector.
8. A test apparatus according to claim 7, wherein the first and second rods are connected to the rocker element at equally spaced locations along the rocker element either side of the pivot axis.
9. A test apparatus according to any one of claims 3 to 8, wherein the receiver comprises an axially extending channel and the housing comprises a support surface surrounding the receiver channel and the first push rod extends through an aperture in the support surface and the second push rod is located within the receiver channel, and wherein in the open position the contact element is spaced from the switch by an engagement distance and the first push rod extends above the support surface by a distance equal to the engagement such that the support surface in use limits axial travel of the second push rod to the engagement distance.
10. A test apparatus according to any preceding claim, being configured for detecting the presence of a connector comprising a body section and a head section, a peripheral shape of the head section defining another of said at least one desired characteristics, wherein the receiver is configured to receive the body section of the connector, and the housing further comprises a recess for receiving the head section of the connector when the body section is received within the receiver, the recess having a peripheral shape corresponding to the desired peripheral head shape of the connector to permit insertion of connectors having said desired peripheral head shape and prevent insertion of connectors not having said desired peripheral head shape.
11. A test apparatus according to any preceding claim, further comprising a wireless transmitter configured to transmit a signal when the switch is operated that confirms the presence of a connector in the test apparatus and that the connector has at least one of said at least one desired characteristic.12. A test apparatus according to claim 11, wherein the wireless transmitter is further configured to transmit a unique identifier relating to the test apparatus.
12. A wiring harness test system comprising a support surface including a predefined wiring route along which the wiring harness is mounted, the support surface including a plurality of test apparatus according to any preceding claim arranged at locations along the wiring route corresponding to connector locations, each test apparatus having a unique identifier and being configured to confirm the presence of a connector in the test apparatus and that the connector has at least one desired characteristic specific to the connector required at that location, and a processor operative to receive a signal from each test apparatus and to confirm based on said signals whether each test apparatus is holding a connector and whether said connector has the desired characteristic corresponding to the correct connector for that location.
13. A wiring harness test system according to claim 12, wherein the signal from each test apparatus is transmitted wirelessly to the processor.
14. A wiring harness test system according to claim 12 or 13, wherein the processor is operative to provide an indication that a connector is absent from one or more of the test apparatus or that one or more of the test apparatus contains the incorrect connector.