“I believe that the small partners who usually pay attention to airborne cables must be very interested in the related content. Today, the editor of Aigtek will share with you a pure dry goods solution: distributed test system for wire harness testers for airborne cables. Without further ado, let’s continue reading with the editor!
I believe that the small partners who usually pay attention to airborne cables must be very interested in the related content. Today, the editor of Aigtek will share with you a pure dry goods solution: distributed test system for wire harness testers for airborne cables. Without further ado, let’s continue reading with the editor!
1. Application background
Aircraft are assembled from numerous finished components, and the electrical connections between these finished components are done by cables. During the general assembly and maintenance stage of the aircraft, due to the numerous cables, split-bundle switching, etc., problems such as wrong cable connection, short circuit, poor contact, and leakage are prone to occur, which in turn lead to system failures and even serious consequences of onboard equipment burning. . Therefore, the cable test must be carried out before the airborne equipment is installed and powered on to ensure the correct laying of the airborne cables.
2. System introduction
Cable testing using traditional manual methods such as multimeters and indicator lights has been replaced by automated cable testing equipment. The distributed test system uses the computer as the controller, the host as the test source, the switch array as the cable channel switching unit, and communicates through the communication bus, thereby realizing the continuity test of multiple cables. It can effectively improve the testing speed of the cable of the whole machine, realize the high-accuracy detection of cable resistance, and identify whether the multi-core cable is connected. The system adopts CAN serial communication bus to realize data exchange between sub-units, and has a self-defined function to define the cable name number, realize the Display of faulty cable information, and improve the efficiency of troubleshooting.
The distributed cable harness tester test system uses the host computer or an external computer as the test and data management center, uses the CAN bus as the serial communication, and uses the power supply cable and the CAN bus to connect the various test units to work to achieve distributed wiring. Cable test system, the test instrument used in the system is Aigtek harness tester, as shown in the figure.
Wiring Harness Tester ATX-3000S
Airborne Cable Harness Tester Test System
3. Principle of continuity test
1. Principle of cable continuity test
For each test unit, there is a reference current source inside, and the on-resistance of the cable can be obtained by the V-A method by testing the voltage at both ends of the cable.
2. Cable resistance test
The measurement object of this system is mainly the airborne cable. The cable resistance is measured by the four-wire method, which avoids the error caused by the resistance of the wire, and can accurately measure the resistance value of 0.001Ω-1MΩ.
Four-wire system for measuring resistance
The accuracy is shown in the figure:
3. Multi-core cable continuity test
Due to the high-speed flight of the aircraft, the vibration generated by its power can cause the cables to wear and break. When the multi-core wire is broken more than 50%, it should be regarded as a cable fault. For this reason, the multi-core wire is tested with a wire harness tester, and the on-resistance can be set to 50Ω~1kΩ (default 500Ω). If the resistance value is higher than the continuity setting, it will show no connection, and if it is lower than the resistance value, it will show continuity.
4. Line sequence display of faulty cables
When laying the airborne cables, it is necessary to pass through the cabin, divide the bundles, and combine the bundles, which makes it difficult to find the whereabouts of the cables. When a cable fault is detected by a common cable tester, the faulty cable information cannot be directly determined. For this reason, the cable name and number can be customized by using the wire harness customization function, and the faulty cable can be displayed on the display, so that the operator can easily find the location of the faulty cable, and help improve the efficiency of cable troubleshooting. .
The distributed cable testing system proposed in this paper can effectively improve the cable testing efficiency of the assembly line and improve the efficiency of troubleshooting; using the four-wire testing method, it can accurately and stably detect tiny resistances and identify cable breaks. Cable fault; the cable customization function can clearly point out the corresponding relationship of faulty cables, which is helpful for troubleshooting.
The experimental materials of this paper are organized and released by Xi’an Antai Electronics. Xi’an Antai Electronic Technology Co., Ltd. (Aigtek) is a high-tech enterprise specializing in the research and development, production and sales of measuring instruments in China. The company is committed to the research of related industry test solutions with power amplifiers, measurement calibration products, wire harness testers and other products as the core, and provides users with competitive test solutions. Aigtek has become a wide range of product lines in the industry, and has a considerable scale equipment suppliers. For more exciting industry information and application cases, please continue to pay attention to the official website of Aigtek.