KR100622695B1 - Inspection system of wire harness and method of inspecting the same - Google Patents

Abstract

The present invention relates to a wire harness test system and method, the wire harness test system and a connection connector is provided so that a plurality of wires of the wire can be connected to each terminal of both ends of the test target wire harness arrayed plurally; , The disconnection detecting unit installed to detect the conduction of each wire of the wire harness to be inspected through the connecting connector and the value of the first disconnection generated current causing the disconnection of the unit wire of the wire and corresponding to the normal An overcurrent applying device for forcibly applying an overcurrent determined within a range lower than the second disconnection generating current value to the inspection target wire harness, and a switching unit provided to selectively connect the connecting connector to either the disconnection detecting unit or the overcurrent applying device. And overvoltage by the overcurrent applying device by controlling the switching unit. After the flow is applied to the inspection target wire harness, and using the information output from the disconnection detection unit is provided with a non-payment determination execution unit for judging whether there is a connection failure of the inspection target wire harness. According to such a wire harness check system, current is conducted but only a part of the wires are forcibly disconnected by an applied over-current when the connection with the terminal is maintained, thereby providing the advantage of ensuring the classification of the check.

Description

Inspection system of wire harness and method of inspecting the same}

1 is a circuit diagram showing a wire harness test system according to a preferred embodiment of the present invention,

2 is a partial excerpt circuit diagram showing an example of the configuration of the disconnection detection unit of FIG.

Figure 3 is a flow diagram showing a wire harness check test process according to the present invention.

<Description of Symbols for Main Parts of Drawings>

The present invention relates to a wire harness test system and method, and more particularly, to a wire harness test system and method that can determine the amount of good for the case where only a small number of wires of a plurality of wires are connected. .

Wire harness refers to the binding of a plurality of wires in a bundle and coupling of contact terminals at both ends of each wire. Such wire harnesses are mainly used for electrical wiring of devices in which electrical devices are concentrated, for example, automobiles and refrigerators.

Wire harnesses are not easy to find and repair broken wires when one of the wires is broken, because many wires are in one module. In particular, if a part of the wire harness is molded after the bad wire harness is mounted on a product such as a car or a refrigerator, it may be difficult to find the cause of the failure, and even if the cause of the failure is found, the repair may be impossible. have.

Since such wire harnesses are virtually impossible to repair after shipment, pre-shipment inspections are difficult to detect for poor wire harnesses.

Pre-shipment inspection of the wire harness includes a method of inspecting the conduction of the wire harness by applying a voltage to the wire. However, even if only a part of the strands composed of a plurality of strands is connected to the contact terminal, the pass test may be passed. . If a wire harness in which some wires are disconnected passes the continuity test and is mounted on a product such as a car or a refrigerator, it may be damaged by a rated current or a momentary overload or cause a malfunction in another device. As a result, in severe cases, a fire may occur due to a short circuit. Therefore, a continuity test may not accurately detect some disconnection of the internal wire of the wire harness and uncompression of the terminal.

In order to improve this problem, Korean Laid-Open Patent Publication No. 2001-0018451 discloses a wire harness test method for applying a voltage to a wire harness that has passed a conduction test and determining that the detected voltage drop value is out of a set range. However, when some of the wires inside the wire are disconnected or only the contact terminal and some wires are coupled, the actual resistance fluctuation is very fine, so it is difficult to detect only the voltage drop fluctuations, which makes it difficult to detect the defects. have.

In addition, even if the voltage drop is measured by using a precision voltmeter that can detect the voltage drop amount up to several decimal places, it is precisely determined by the resistance value variation on the wiring from the contact terminal of the harness wire and the harness wire to the inspection target device. There is a problem that can be difficult.

In addition, if the defective part treated as defective due to high conduction but mixed with the untested product in the workplace is passed the conduction test during re-inspection, the voltage drop test must be performed again. Other than the other display method, there is a problem that cannot be distinguished by the inspection apparatus itself.

The present invention has been made to improve the above problems, and an object of the present invention is to provide a wire harness check system and method that can more easily determine whether the connection failure.

It is another object of the present invention to provide a wire harness test system and method that can determine the good quality of the wire harness that is poor connection only after the conduction test after inspection.

In order to achieve the above object, the wire harness test system according to the present invention

A wire harness inspection system for inspecting the quantity of wires of an inspection target wire harness in which a plurality of wires are arranged, comprising: a connection connector provided to be connected to correspond to each terminal of both ends of the inspection target wire harness; A disconnection detection unit installed to detect whether or not each wire of the inspection target wire harness is conductive through the connection connector; Forcibly applying an overcurrent determined within a range higher than a first disconnection generating current value that causes disconnection of unit wires of the wire and lower than a second disconnection generating current value corresponding to a normal sweep of the wire, to the inspection target wire harness. An overcurrent applying device; A switching unit provided to selectively connect the connection connector with any one of the disconnection detecting unit and the overcurrent applying device; A non-payment judgment machine for controlling the switching unit to determine whether there is a connection failure of the inspection target wire harness by using the information output from the disconnection detection unit after the overcurrent is applied to the inspection target wire harness by the overcurrent application device. It includes;

Preferably, the non-payment judgment performer controls the switching unit so that the connection connector is first connected to the disconnection detecting unit so that the overcurrent is applied to the inspection target wire harness when it is determined that the inspection target wire harness is normally conducted. Control the switch.

In addition, in order to achieve the above object, the wire harness test method according to the present invention. Applying a first voltage to the inspection target wire harness to determine the presence of conduction; I. If it is determined in step (a) that the inspection target wire harness is in normal conduction, applying an overcurrent set to the inspection target wire harness; All. And applying the first voltage to the wire harness that has passed the step B and determining whether the wire is disconnected to determine a good or bad.

Preferably, in the step b, the overcurrent is higher than a first disconnection generating current value that causes disconnection of unit wires of each wire of the inspected wire harness and is less than a second disconnection generating current value corresponding to a normal sweep of the wire. It is determined within the low range.

Hereinafter, with reference to the accompanying drawings will be described in more detail the wire harness test system and method according to a preferred embodiment of the present invention.

1 is a circuit diagram showing a wire harness test system according to a preferred embodiment of the present invention.

Referring to the drawings, the wire harness failure test system is provided with a connection connector (10a) (10b), disconnection detection unit 20, the overcurrent application device 30, the switching unit 40 (50) and the positive determination machine 60. do.

The connection connectors 10a and 10b may be applied to be electrically connected to each terminal of the inspection target wire harness 80. Here, the wire harness 80 means that a plurality of wires 81a, 81b, 81n of a plurality of small wires are arrayed, and terminals are coupled to both ends of each of the wires 81a, 81b, 81n. The wire harness 80 is generally used in a structure in which terminals at both ends of the wires 81a, 81b, 81n are respectively bound to the housings 83, 84.

The connecting connectors 10a and 10b are composed of the first connector 10a and the second connector 10b.

The first connector 10a and the second connector 10b can be electrically separated and connected to each terminal of the wire harness 80 by detaching and dismounting the housings 83 and 84 on both sides of the wire harness 80. have.

The first connector 10a is each relay switch 40a, 40b, 40n of the first switching unit 40 through first channel lines corresponding one to one to the number of wires of the wire harness 80. ) Is connected. In addition, the second connector 10b is each relay switch 50a of the second switching unit 40 through a second channel line corresponding one-to-one to each of the wires 81a, 81b, 81n of the wire harness 80. It is connected to 50b and 50n.

The switching units 40 and 50 are connected to the wire harnesses 80a and 81b and 81n through the connection connectors 10a and 10b of the disconnection detection unit 20 and the overcurrent applying device 30. In the illustrated example, the first and second switching units 40 and 50 are provided to control the power supply paths at both ends of the connection connectors 10a and 10b. .

The first switching portion 40 and the second switching portion 50 are each of the number of relay switches 40a, 40b, 40n (corresponding to the respective wires 81a, 81b, 81n of the wire harness 80) ( 50a) 50b) 50n have been applied per channel.

Each relay switch 40a, 40b, 40n of the first switching unit 40 connects each of the channel lines of the first connector 10a to each power line of the disconnection detecting unit 20 and each of the power supplies of the overcurrent applying device 30. It is installed to selectively connect any one of the wires.

Each of the relay switches 50a, 50b, and 50n of the second switching unit 50 connects each channel line of the second connector 10b to the ground line of the disconnection detecting unit 20 and the power line of the overcurrent applying device 30. It is installed so that any one of them can be selectively connected.

Unlike the illustrated example, when the overcurrent applying device 30 also uses a DC power source and uses a common ground line together with the disconnection detecting unit 20, the second switching unit 50 is omitted, and each of the second connectors 10b is omitted. Of course, the channel line can be directly connected to the ground line.

Each relay switch 40a, 40b, 40n, 50a, 50b, 50n is controlled by the inspection control unit 61.

Although relay switches 40a, 40b, 40n, 50a, 50b, 50n are applied in the example shown as the switch elements of the switching parts 40 and 50, a switch different from the illustrated example may be applied. Of course.

The disconnection detecting unit 20 is installed to detect whether the electric wires 81a, 81b, 81n of the inspection target wire harness 80 are conductive through the connection connectors 10a, 10b. As an example of the disconnection detecting unit 20, as shown in FIG. 2, each of the relay switches 40a and 40a of the first switching unit 40 from the DC voltage source Vcc, which is the first voltage source, through the pull-up resistor 21. ) And a voltage signal passing through pull-up resistors (21a) (21b) and (21n) for each channel are outputted to the inspection control unit (61). Preferably, the DC voltage source Vcc of the disconnection detecting unit 20 applies a low voltage, for example, 5 volts or less, capable of confirming only the conduction.

Therefore, each relay switch 40a, 40b, 40n of the first switching unit 40 is connected to the disconnection detecting unit 20, and each relay switch 50a, 50b of the second switching unit 50 is connected. When 50n is connected to the ground line, a voltage signal corresponding to disconnection of each wire of the wire harness 80 is output to the inspection control unit 61. As a result, when a 5-volt power supply is used for the power supply Vcc of the disconnection detecting unit 20, a current-carrying path is not formed for the disconnected wires 81a, 81b, and 81n, and a 5-volt signal is output. The current conduction path is formed for the wires 81a, 81b and 81n thus outputting a 0 volt signal. In addition, the inspection control unit 61, the first switching unit 40 and the second switching unit so as to check if the wiring position on the housing (10a) (10b) of each wire (81a) (81b) 81n is changed. It is preferable to control each relay switch 40a, 40b, 40n, 50a, 50b, 50n of 50 sequentially in all of the combinable modes.

The overcurrent applying device 30 is higher than the unit element wires constituting the wires 81a, 81b and 81n, that is, the first disconnection generated current value which may cause disconnection of one wire, and the wires 81a and 81b ( What is necessary is just to be comprised so that the overcurrent determined within the range lower than the 2nd break generation current value corresponding to the normal small bow of 81n) may be forcibly applied to the test object wire harness 80. FIG. Here, the strand refers to a stranded wire within a single wire.

For example, if one wire consists of 50 wires, and one wire melts and melts when a current of 0.5 amp or more flows, the first breakage generated current value is 0.5 ampere, and the second breakage generated current value is 50 strands. 25 amperes which is the maximum allowable current of the wire. Therefore, if the wire harness 80 in which more than 40 strands are connected to the terminal is in good condition, the overcurrent should be applied to 20 amps, and the wire harness 80 in which more than 45 strands are connected to the terminal is required. In case of good quality, 22.5 amp is applied to over current.

The overcurrent applying device 30 includes an AC power supply 31, a power switch 33, a load switch unit 35, and a load unit 37.

The AC power source 31 may be a conventional commercial AC voltage. The DC power source may be applied differently from the illustrated example.

The load switch unit 35 is provided for each channel between each relay switch 40a, 40b, 40n of the first switching unit 40 and each load 37a, 37b, 37n of the load unit 37. A plurality of load switches 35a, 35b, 35n are applied to interrupt the power supply from the AC power source 31 to the respective loads 37a, 37b, 37n, and may be omitted. Of course.

The load 37a, 37b, 37n is the second disconnection generating current higher than the first disconnection generating current value causing the disconnection of the unit element of the wires 81a, 81b, 81n and corresponding to the normal minority of the wire. It is applied to have a resistance value through which the determined overcurrent can flow within a lower range than the value. As an example of such loads 37a, 37b, 37n, a heater, a heating wire, or various other things can be applied, and it is preferable to apply a variable resistor capable of varying the resistance value to a desired value.

The non-payment judgment performer 60 controls the switching unit 40 (50), the load switch unit 35, and the power switch 33 so that the overcurrent is applied to the inspection target wire harness 80 by the overcurrent applying device 30. Thereafter, using the information output from the disconnection detecting unit 20, it is determined whether there is a connection failure related to whether or not the inspection target wire harness 80 is available.

The non-payment judgment executor 60 includes an inspection control unit 61, a key input unit 63, and a display unit 65.

The inspection control unit 61 determines the failure of the inspection target wire harness 80 by controlling the switching unit 40, 50, the load interrupting switch unit 35, and the power switch 33 according to the key input signal of the key input unit. The determination result is output via the display unit 65.

Preferably, the payoff judgment performer 60 is constructed by a computer.

In this case, the key input unit 61 is applied to a normal mouse or key, and the inspection control unit 61 provides an inspection execution menu through the display unit 65, controls each element according to the input key signal, and disconnects What is necessary is just to be constructed so that a good payment may be determined using the signal output from the detection part 20. FIG.

Although not shown, the good judgment apparatus 60 may be further provided with a printer capable of outputting the test result information on a paper and a speaker capable of outputting a voice message of the good judgment.

In addition, the power switch 33 can be constructed so that the operator can operate.

Hereinafter, a process of determining whether the wire harness system is good or bad will be described with reference to FIG. 3.

First, when the inspection start signal is input from the key input unit 63 while the inspection target wire harness 80 is mounted on the connection connectors 10a and 10b and the inspection preparation is completed, the wire harness 80 is initialized. Is applied to the first voltage for conduction determination (step 400).

Here, the first voltage refers to a DC voltage Vcc applied to the disconnection detecting unit 20 described above. That is, operation 400 corresponds to a process of controlling the first switching unit 40 to be connected to the disconnection detecting unit 20 and the second switching unit 50 to the ground line.

Preferably, in step 400, as described above, the relay switch of the first switching unit 40 and the relay switch of the second switching unit 50 may be combined in accordance with the connection method so as to check for disconnection and incorrect wiring. Control sequentially. That is, in a state in which the first release switch 40a of the first switching unit 40 is connected to the disconnection detecting unit 20, the relay switch of the second switching unit 50 is sequentially connected to the ground line, and then the first switching is performed. The second relay switch 40b of the unit 40 is connected to the disconnection detecting unit 20, and then the relay unit of the second switching unit 50 sequentially connects the relay switch to the ground line so that the switching unit ( 40) 50 to control.

Next, it is determined whether the normal call is output from the information output by the operation 400 (step 410). If it is determined in step 410 that there is a wire that is disconnected or incorrectly wired, a defect determination process is performed, and the good and poor inspection information for each wire is output together (step 420).

In contrast, when it is determined that the normal communication call is output in step 410, the switching units 40 and 50 are controlled so that the connection connectors 10a and 10b are connected to the overcurrent applying device 30, and the load switch unit 35 is connected. And controlling the power switch 33 to apply an overcurrent to the wire harness 80 (step 430).

At this time, if overcurrent is applied, some of the wires are disconnected, or if only the wires are connected to the terminal and only some of the wires are maintained, and if the main wire to which the connection is maintained is smaller than the number corresponding to the above-described overcurrent, even the wires maintained by the connection are also overcurrent. It is disconnected by.

After the overcurrent is applied, the switching units 40 and 50 are controlled and connected to the disconnection detecting unit 20 to apply a first voltage to the wire harness 80 (step 440).

After that, it is determined whether a normal call is output (step 450).

If it is determined in step 450 that all of the wires output a normal communication call, a good quality judgment process is performed (step 460).

On the contrary, if at least one signal corresponding to the disconnection is output in step 450, the defect determination process is performed (step 470).

According to the wire harness test system according to the present invention as described so far, when the current is conducted but only a part of the wires are kept connected to the terminal, the circuit is forcibly disconnected by an applied overcurrent, thereby reliably classifying the test. It offers the benefits of doing so.

Claims (4)

In the wire harness duplex inspection system for inspecting the duplex of the inspection target wire harness arrayed with a plurality of wires, A connection connector provided to be connected to correspond to each terminal of both ends of the inspection target wire harness; A disconnection detection unit installed to detect whether or not each wire of the inspection target wire harness is conductive through the connection connector; Forcibly applying an overcurrent determined within a range higher than a first disconnection generating current value that causes disconnection of unit wires of the wire and lower than a second disconnection generating current value corresponding to a normal sweep of the wire, to the inspection target wire harness. An overcurrent applying device; A switching unit provided to selectively connect the connection connector with any one of the disconnection detecting unit and the overcurrent applying device; A non-payment judgment machine for controlling the switching unit to determine whether there is a connection failure of the inspection target wire harness by using the information output from the disconnection detection unit after the overcurrent is applied to the inspection target wire harness by the overcurrent application device. Wire harness inspection system comprising a. The apparatus of claim 1, wherein And controlling the switching unit so that the connection connector is first connected to the disconnection detecting unit so that the overcurrent is applied to the inspection target wire harness when it is determined that the inspection target wire harness is normally conducted. Wire harness duplex inspection system. end. Applying a first voltage to the inspection target wire harness to determine the presence of conduction; I. If it is determined in step (a) that the inspection target wire harness is in normal conduction, applying an overcurrent set to the inspection target wire harness; All. And applying the first voltage to the wire harness that has passed the step B and detecting whether the wire is disconnected to determine whether the wire is in good condition. 4. The method of claim 3, wherein in step b, the overcurrent is higher than a first disconnection generating current value causing disconnection of unit wires of the respective wires of the inspected wire harness, and a second disconnection is generated corresponding to a normal sweep of the wire. A wire harness test method according to claim 1, characterized in that determined in the lower range than the current value.

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