This research introduces a new, modular, and digitally integrated method and system for testing and evaluation of wire harness systems and other electrical and automotive subassemblies. The testing system utilises a wireless, cloud-integrated platform. Each node is having test points, which allows the system to test complex wire harness / circuits in real-time. The solution reduces the requirement for complex manual setup changes and produces rapid results to make the test process more accurate, traceable and consistent.
The patented testing system works using a modular wireless architecture where many nodes are digitally connected to evaluate complex electrical devices. When a component, such as a wiring network or PCB, is connected to the board, the system automatically runs a predefined test sequence. These tests check for circuit account, signal integrity, insulation resistance and other important parameters. The system provides real-time results through cloud integration, while a log data scanner barcode for traceability and the generation of automatic reports.
The system has been tested in different production layouts and has been shown to improve productivity, reduce shutdown between tests and increase test coverage. The system removes the old, fixed layout with flexible, scalable and durable units for wiring.
The system is developed on the basis of principles of stability, where modular reuse, low physical fixtures and digital tests have been used to make production more environmentally friendly. The novelty of this invention is that it can consolidate several test scenarios into one agile platform without compromising compliance, data integrity, and high throughput, all without dependence on particular product configurations.
This research highlights the importance of smarter test automation for facilitating rapid, future-proof, environmentally friendly manufacturing practices and provides doors to exploring research in adaptive, software-based assessment systems across industries.