Apparatus and method for static testing a spark plug assembled in an internal combustion engine including cracked ceramic insulator detection

1. An apparatus for testing a spark plug after the spark plug is assembled in an internal combustion engine wherein the spark plug has a center electrode surrounded by an insulator and electrically connected to a terminal end, and a side electrode electrically connectable to an electrical ground and configured to form a spark plug gap between the center electrode and the side electrode, the apparatus comprising:

a high voltage test probe to mechanically probe the spark plug and having a non-electrically conductive part, an electrically conductive ring substantially shielded by the non-electrically conductive part, and a high voltage contactor for electrically connecting to the terminal end of the spark plug; and

a high voltage control box having a high voltage source and an electrical ground and including at least one of:

an insulator crack detection circuit for connecting the high voltage contactor to the electrical ground and the electrically conductive ring to the high voltage source to generate an insulator crack detection signal indicating if an insulator is cracked, and

a spark plug firing circuit for connecting the high voltage contactor to the high voltage source to fire the spark plug in a firing test and to generate a spark plug firing signal indicating if the spark plug gap is within specification.

2. The apparatus of claim 1 wherein the high voltage source is an ignition coil.

3. The apparatus of claim 1 wherein the spark plug has a base and wherein the electrically conductive ring extends substantially over the insulator while forming a first gap between the electrically conductive ring and the base sufficient to prevent arcing to the base and a second gap between the electrically conductive ring and the terminal end sufficient to prevent arcing to the terminal end.

4. The apparatus of claim 1 wherein the high voltage test probe non-electrically conductive part is formed of urethane.

5. A method for testing a spark plug after the spark plug is assembled in an internal combustion engine wherein the spark plug has a center electrode surrounded by an insulator and electrically connected to a terminal end, a side electrode electrically connectable to an electrical ground and configured to form a spark plug gap between the center electrode and the side electrode, the method comprising:

placing a high voltage test probe over substantially all of the spark plug extending from the internal combustion engine to mechanically probe the spark plug, wherein the high voltage test probe has a non-electrically conductive part, an electrically conductive ring substantially shielded by the non-electrically conductive part, and a high voltage contactor for electrically connecting to the terminal end of the spark plug; and

at least one of:

connecting the high voltage contactor and the electrically conductive ring to a high voltage control box so that an insulator crack detection circuit in the high voltage control box connects the high voltage contactor to an electrical ground and the electrically conductive ring to a high voltage source thereby generating an insulator crack detection signal indicating if an insulator is cracked; and

connecting the high voltage contactor to the high voltage control box so that a spark plug firing circuit in the high voltage control box connects the high voltage contactor to the high voltage source thereby generating a spark plug firing signal indicating if the spark plug gap is within specification.

6. The method of claim 5 further including the high voltage source is an ignition coil.

7. The method of claim 5 wherein the spark plug has a base and wherein the electrically conductive ring extends substantially over the insulator while forming a first gap between the electrically conductive ring and the base sufficient to prevent arcing to the base and a second gap between the electrically conductive ring and the terminal end sufficient to prevent arcing to the terminal end.

8. The method of claim 5 wherein the high voltage test probe non-electrically conductive part is formed of urethane.

9. An apparatus for testing a spark plug after the spark plug is assembled in an internal combustion engine, wherein the spark plug has a center electrode surrounded by an insulator and electrically connected to a terminal end, and a side electrode electrically connectable to an electrical ground and configured to form a spark plug gap between the center electrode and the side electrode, the apparatus comprising:

a high voltage test probe to mechanically probe the spark plug and having a non-electrically conductive part, an electrically conductive ring substantially shielded by the non-electrically conductive part, and a high voltage contactor electrically connected to the terminal end of the spark plug;

a high voltage control box having a high voltage source and an electrical ground;

an insulator crack detection circuit connecting the high voltage contactor to the electrical ground and the electrically conductive ring to the high voltage source when detecting if an insulator is cracked; and

a spark plug firing circuit connecting the high voltage contactor to the high voltage source to fire the spark plug in a firing test when detecting if the spark plug gap is within specification.

10. The apparatus of claim 9 wherein the high voltage test probe is placed over the spark plug when the spark plug extends from the internal combustion engine such that the electrically conductive ring surrounds a portion of the insulator without contacting the spark plug.

11. The apparatus of claim 9 wherein the electrically conductive ring overlaps the insulator except for a first gap and a second gap, with the first gap being between a first end of the electrically conductive ring and a base of the spark plug to sufficiently prevent arcing therebetween and the second gap being between a second end of the electrically conductive ring and the terminal end of the spark plug to sufficiently prevent arcing therebetween.

12. The apparatus of claim 9 wherein the high voltage test probe includes a probe locator to position the electrically conductive ring spaced from the insulator.

13. The apparatus of claim 9 wherein a drop in voltage across a resistor occurs when a potential of the high voltage source on the electrically conductive ring arcs through the insulator to the center electrode.

14. The apparatus of claim 9 further including a voltage divider including a first resistor and a second resistor, with the first resistor electrically connecting between a first contact of the high voltage source and a first contact of the second resistor, and a second contact of the second resistor is connected to the electrical ground.

15. The apparatus of claim 1 wherein the electrically conductive ring surrounds a portion of the insulator without contacting the spark plug.

16. The apparatus of claim 1 wherein the electrically conductive ring overlaps the insulator except for a first gap and a second gap, with the first gap being between a first end of the electrically conductive ring and a base of the spark plug and the second gap being between a second end of the electrically conductive ring and the terminal end of the spark plug.