High voltage harness testing system
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.
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.