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Application of Harness Tester on Aviation Case

发布:2021-01-19

Aviation airborne precision electronic equipment has a compact chassis structure, complex wiring, and the motherboard contains components. The wiring correctness test has considerable technical difficulties. This article introduces the application of wiring harness tester in the wiring test of aviation electronic equipment chassis.

The chassis wiring test of aviation electronic equipment involves wiring correctness test, including: basic component test, insulation performance test and withstand voltage test. The chassis has many models and complex structures, with up to 5000 test points. The test has considerable technical difficulty.

The wire harness tester is a comprehensive test instrument for large-scale dense cable testing. It integrates continuity, insulation, and withstand voltage tests. It can quantitatively test simple components and induction effects and set test technical conditions in a wide range. Flexible and diverse application of test signals, voltages, and currents is an ideal tool for large-scale testing. Using wire harness testing technology and computer technology, combined with the technical characteristics of the aeronautical box, building a test platform, researching adaptation technology and testing software technology, and establishing a chassis connector library are our main research content.

1) Analyze the testing principle and testing technology of the wiring harness tester, and study the testing application in the electrical box of aeronautics.

2) Analyze the characteristics of the output interface of the harness tester, study the adaption technology of the interface, and design a universal adapter tool.

3) Analyze the process, wiring, and structural characteristics of the aeromotor box, the distribution of basic components and the induction effect, and design the allocation and combination of chassis interfaces and slots.

Use the system software technology of the harness tester to establish the connector library of the tested chassis, self-learn the connection network of the chassis, and compile the test program.

Pictures and index parameters of the harness tester:

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① Continuity test (single point test, on-resistance R: 500Ω);

②Self-learning continuity test (multi-point test, on-resistance R: 500Ω);

③ Resistance test (< 20kΩ);

④Insulation resistance test (DC: 50V~750V, R: 10M~1000MΩ);

⑤ Withstand voltage test (AC: 50V~500V, I: 0.5mA~5 mA).

Note: When the resistance range is 20kΩ<R <10MΩ, the low-voltage resistance test result returns OL; the insulation resistance test result returns

The working principle of the wire harness tester ,The cable tester needs to be equipped with a computer, printer and system test software to build a test system. Its working principle is shown in the figure below. The two test terminals of the test unit inside the host are respectively connected to any two points of the tester through the relay matrix according to the test sequence, and the test unit completes the scan test through the relay matrix in permutation and combination.

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1) The wiring harness tester automatically recognizes the connection relationship of the collection points, and the same connection is defined as the connection network;

2) Test, judge and locate the correctness of all connected networks;

3) Give a test value to the correctness test of the connection relationship of the resistance between the connected networks;

4) Automatically recognize the induction effect in the wiring, and measure the magnitude of the induction value.

Through the actual measurement of multiple chassis of different models, the use of wire harness testing technology has shortened the detection time by more than 10 times, and the accuracy rate reached 100%, especially in the aspect of fault location, the accuracy rate reached 100%. The work that usually takes days or even weeks is compressed into a few hours to complete. This result shows that cable testing technology plays a huge role in shortening the inspection time, ensuring product quality, and shortening the troubleshooting cycle.

 

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