FORM 2
THE PATENTS ACT 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(See Section 10; rule 13)
TITLE OF THE INVENTION
An Integrated Test Rig For In Cab Mirror Controller
APPLICANTS
TATA MOTORS LIMITED, an Indian Company
having its registered office at,
Bombay House, 24 Homy Mody Street,
Hutatma Chowk, Mumbai 400 001
Maharashtra, India
INVENTORS
Ms. Shilpa Kale and Mr. Sudhir Sutar
Both are Indian Nationals
of TATA MOTORS LIMITED,
an Indian company having its registered office
at Bombay House, 24 Homi Mody Street, Hutatma Chowk,
Mumbai 400 001 Maharashtra, India
&
Mr. Bapu Khomane
Indian National
of JAYEM AUTOMOTIVES LTD,
an Indian company having its registered office
at No.2, Ondipudur Road, Singanallur,
Coimbatore, - 641005, Tamilnadu, India
PREAMBLE TO THE DESCRIPTION
The following Specification describes the invention and the manner in which it
is performed.

Field of Invention
The present invention relates to an integrated test rig used for testing in-cab mirror controller and more particularly it relates to testing the various functions in one cycle time. The object of this invention is to provide a tool for increasing product/component life under customer usage point of view.
Background of Invention:
'In cab mirror controller' performs the function of inclination/orientation of selected mirror, in different direction (i.e. up, down, left & right). This feature helps to view the movements of rear and adjacent vehicles on the road, during vehicle running condition. Mirror adjustment switch in the vehicle undergoes various modes of operation during customer usage. Conventional endurance test rigs provide testing of either mirror selection function or'mirror adjustment function. Such method of testing does not simulate the actual vehicle condition and find out failure under severity of functions, during targeted endurance test cycles. To address the above constraints, there is a need of test rig simulating vehicle conditions for doing endurance test of mirror selection function and mirror adjustment function simultaneously. This is to ensure the operation of mirror controller under severity of functions, only.
Summary of the invention
The main objective of the present invention is to provide the test rig capable of simulating vehicle conditions, which conducts endurance test of mirror selection function and mirror adjustment function in the mirror controller, simultaneously.
Another objective of the present invention is to validate the product for the targeted endurance cycles under criteria of customer usage and provide the method of failure simulation which improves the product life.

Statement of invention
Accordingly the present invention provides an integrated test rig for in cab mirror
controller comprising
at least one motor (2) configured to be mounted on a floor board (1) connected to
the frame of the rig;
at least one leader (3) coupled with said motor (1) through a primary shaft (5) to
rotate the assembly;
at least one secondary shaft (7) configured to be connected to metal plate (4) at one
end and to a cam arrangement (9) at other end, is guided through the guide (19)
mounted on the intermediate plate (18) fastened on the frame of the rig;
said leader (3) is further configured to accommodate said metal plate (4) such that
the rotation of said leader (3) caused said metal plate (4) to rotate along with it;
at least one secondary shaft (7) connected to a cam arrangement (9) is driven by
said plate (4);
plurality of pins (10) with resilient means (11) are slidably mounted in the holes
provided on a second floorboard (8) connected to said rig frame, are configured for
actuating the controller switches;
at least one flexible conductor (12) is mounted to the cam plate (9a) perpendicular
to the axis of rotation;
plurality of vertical conductive posts (13) located at a predetermined distance from
the axis of rotation for establishing contact between the flexible conductor (12) and
the post (13) to complete a circuit; and
at least one pneumatic actuator (14) configured for pushing or pulling the selector
switch from 'Left' to 'Right' position and vice versa through a knob holder (15) for
generating a drive when actuated.
The Method for testing an integrated test rig for cab mirror controller comprises of a mounting of mirror controller to be tested below the pin
b establishing contact between flexible conductor and first post to provide signal
to the rotary motor

c start motor to rotate the cam mechanism to press the heads of the pin/screws (nos. 10.1, 10.2, 10.3 and 10.4) one at a time to keep rest of the pins stress free thereby to press the corresponding controller switch located below for selection of different modes such as up, right, left and bottom in one rotation by pressing the controller switches in sequence
d establishing contact between flexible conductor and four posts one by one to give signal to the motor to stop for predetermined period
e establishing contact between flexible conductor and fifth post to stop the motor for predetermined period and to activate an actuator (14) to shift the selection switch of the mirror controller
f pushing or pulling the selector switch by pneumatic actuator (14) through a knob holder (15) for changing from 'Left' to 'Right' position or vice versa to complete one cycle by bringing flexible conductor to its original position
g to repeat above steps (b) to (f) to repeat the cycle.
Brief description of the drawings
Figure 1 shows the in-cab mirror controller
Figure 2 shows the font view of the in-cab mirror controller test rig.
Figure 3 shows the side view of the test rig.
Figure 4 shows the top view of the test rig.
Figure 5 shows the drive assembly of the test rig.
Figure 6 shows the details of rotational transfer arrangement.
Figure 7 shows the arrangement for activating switches in the mirror controller
Figure 8 shows the cam arrangement for driving spring loaded vertical members
Figure 9 shows the vertical members arranged for pressing mirror controller
switches and conductive posts for location identification.
Figure 10 shows the isometric view of cam and drive assembly.
Figure 11 shows the arrangement for driving selection switch of the controller.
Figure 12 shows the flowchart for method of testing the controller.

Detailed description of the Invention
Referring now to the drawings wherein the showings are for the purpose of illustrating a preferred embodiment of the invention only, and not for the purpose of limiting the same
Referring to the figure 1, a controller (C) for controlling Outer rear view mirrors will be located inside the cabin of vehicle. The controller has six different modes of operations, such as adjusting mirror to its right, left, top or bottom and selections modes for let or right rear view mirror. To validate the performance of the controller, a rig which is capable of activating these modes required. Here a test rig is devised to activate different modes of the controller. The test method followed is explained with help of a flowchart in figure 12. The modes are selected as given in the flowchart (figure 12).
Referring to figure 2 to 11, the test rig having a drive arrangement with a motor and drive transfer assemblies. The motor (2) is mounted on a floor board (1) connected to the frame of the rig. A leader (3) is coupled with rotating motor (2) through a primary shaft (5) and makes the assembly rotate along with it. A metal plate (4) keeps in contact with the leader (3) to rotate with it. The leader is formed in the shape of an open channel so that the plate (4) can freely move inside channel in vertical direction. A primary spring (6) located on primary shaft (5) inside the leader (3) and seated on the coaxial protrusion of the plate (4). This arrangement helps plate to stabilize the vertical movement. The plate (4) in turn drives a secondary shaft (7) connected to a cam arrangement (9). The secondary shaft is guided through the guide (19) mounted on the intermediate plate (18). The intermediate plate (18) is supported on the frame of the rig. The cam arrangement comprises two plates (9a, 9b), of which one is kept horizontal (9a) and connected to the secondary shaft (7) and the other plate (9b) kept at an angle and rigidly attached to the horizontal plate (9a). A spacer (9c) is placed between the plates and connected to it. The angled plate (9b) presses the vertical spring loaded pins in turn while rotating about its axis. The height of the spacer (9c) determines the vertical displacement of the pins/screws (10). The vertical pins/screws (10) arranged in a thorough hole on a second floorboard (8) connected to the frame of the rig. A

spring is located between the head of the pin and second floorboard (8) so that the pin retracts to initial position after it is pressed by the cam (9). A mirror controller which is to be tested is kept below the pin and while driving the cam (9) it pushes the pin to press the controller switch located below, Small rubber pads are tied with the screw end to provide the actual feeling of human finger during switch operation. During operation, the Cam Mechanism presses the heads of the screws (nos. 10.1, 10.2, 10.3 and 10.4) one by one, when assembly rotates it. For example, when head of screw no 10.1 is pressed by CAM, secondary spring (11) is compressed and allows the screw no. 10.1 to move down; other screws (no. 10.2, 10.3 and 10.4) will remain in its stress-free position. By pressing the controller switches different modes such as up, right, left and bottom are selected. One rotation of the cam selects these modes in sequence.
A first flexible conductor (12) is attached to the CAM plate perpendicular to the axis of rotation. Five vertical conductive posts (13) are located at a distance from the axis of rotation. The contact made between the flexible conductor (12) and the post (13) completes a circuit. When the contact between flexible conductor and post is made it gives signal to the rotary motor to stop rotation for predetermined period. Out of five post, the contact with four posts gives signal to the motor to stop for predetermined period and contact with fifth post it stop the motor for predetermined period and activates an actuator (14) to shift the selection switch of the mirror controller.
A shift arrangement is provided to shift the controller selection switch. Shift arrangement is placed on a table. A pneumatic actuator (14) is provided for generating a drive. When the actuator activated it pushes or pulls the selector switch through a knob holder (15).
A shift arrangement is provided to shift the controller selection switch. A pneumatic actuator (14) is provided for generating a drive. When the actuator activated it pushes or pulls the selector switch through a knob holder (15) from 'L' to 'R' position and vice versa. A metal cube (16) is provided to maintain the direction of the stroke in-line where the actuator connected to metal cube (16) and a

link connect metal cube to the knob holder. To provide the straight line movement of the cube, the cube disposed between two boxes (17, 17).
This test rig has multifunctional feature that performs 10 different operations in one cycle duration,
Mirror adjustment switch in the vehicle undergoes various modes of operation during customer usage. This bench test is carried out in order to validate the multifunctional mirror adjustment switch. This bench test can be classified as:
Performance test:
Under this test procedure, switch performance in terms of actual loads, voltage drop, efficiency at various forces can be determined.
Endurance test:
This test is conducted under multifunctional feature that are observed from customer practice during its entire life. This test gives the confidence on the life of multifunctional mirror adjustment switch.
During rig operation, following sequence is followed by CAM mechanism:
i) The flexible conductor-1 touches the four posts one by one and performs
the switch functions (left, up, right & down).
ii) The flexible conductor-1 then touches the fifth posts and pneumatic
actuator is activated.
iii) Pneumatic actuator moves the selector knob from left/right to right/left.
This completes the one cycle of endurance test.
iv) The flexible conductor-1 again comes to the first post and repeat the
cycle.
1 cycle = Right change over (X) and Left change over (Y)

The foregoing description is a specific embodiment of the present invention. It should be appreciated that this embodiment is described for purpose of illustration only, and that numerous alterations and modifications may be practiced by those skilled in the art without departing from the spirit and scope of the invention. It is intended that all such modifications and alterations be included insofar as they come within the scope of the invention as claimed or the equivalents thereof.

We claim:
1. An integrated test rig for in cab mirror controller comprising
at least one motor (2) configured to be mounted on a floor board (1) connected to the frame of the rig;
at least one leader (3) coupled with said motor (1) through a primary shaft (5) to rotate the assembly;
at least one secondary shaft (7) configured to be connected to metal plate (4) at one end and to a cam arrangement (9) at other end, is guided through the guide (19) mounted on the intermediate plate (18) fastened on the frame of the rig;
said leader (3) is further configured to accommodate said metal plate (4) such that the rotation of said leader (3) caused said metal plate (4) to rotate alongwith it;
at least one secondary shaft (7) connected to a cam arrangement (9) is driven by said plate (4);
plurality of pins (10) with resilient means (11) are slidably mounted in the holes provided on a second floorboard (8) connected to said rig frame, are configured for actuating the controller switches;
at least one flexible conductor (12) is mounted to the cam plate (9a) perpendicular to the axis of rotation;
plurality of vertical conductive posts (13) located at a predetermined distance from the axis of rotation for establishing contact between the flexible conductor (12) and the post (13) to complete a circuit; and
at least one pneumatic actuator (14) configured for pushing.or pulling the selector switch from 'Left' to 'Right' position and vice versa through a knob holder (15) for generating a drive when actuated.
2. The test rig as claimed in claim 1 wherein said leader (3) is an open channel adapted for free movement of said plate (4) inside said leader (3) channel in vertical direction.

3. The test rig as claimed in claim 1 wherein said cam arrangement comprises of two plates one horizontal plate (9a) connected to the secondary shaft (7) and the other plate (9b) is rigidly attached to the horizontal plate (9a) at an angle by providing spacer (9c) between said plates such that the height of said spacer (9c) determines the vertical displacement of the pins/screws (10).
4. The test rig as claimed in claim 1 wherein one metal cube (16) is guided between two guides (17, 17') connected to said actuator (14) at one end and to the knob holder (15) at the other end is adapted to maintain the straight line movement of the stroke in-line and at least one shift arrangement is provided to shift the controller selection switch.
5. The test rig as claimed in claim 1 wherein resilient means (6) are mounted on primary shaft (5) inside the leader (3) and rested on the coaxial protrusion of plate (4).
6. The test rig as claimed in claim 1 wherein said resilient means (11) the spring is located between the head of the pin and second floorboard (8) so that the pin (10) retracts to initial position after it is pressed by the cam arrangement (9).
7. The test rig as claimed in claim 1 wherein said vertical conductive posts (13) are configured for providing signal to the motor to stop for predetermined period whenever the contact of flexible conductor (12) is established with each of four posts and further to stop the motor for predetermined period and actuate an actuator (14) to shift the selection switch of the mirror controller on establishment of contact of flexible conductor (12) with fifth post.
8. The test rig as claimed in claim 1 wherein small rubber pads are provided on bottom end of said pin/screw (10) to get the actual feel of human finger during switch operation.

9. The Method for testing an integrated test rig for cab mirror controller comprises
of
a mounting of mirror controller to be tested below the pin
b establishing contact between flexible conductor and first post to provide
signal to the rotary motor
c start motor to rotate the cam mechanism to press the heads of the pin/screws
(nos. 10.1, 10.2, 10.3 and 10.4) one at a time to keep rest of the pins stress free
thereby to press the corresponding controller switch located below for selection of
different modes such as up, right, left and bottom in one rotation by pressing the
controller switches in sequence
d establishing contact between flexible conductor and four posts one by one
to give signal to the motor to stop for predetermined period
e establishing contact between flexible conductor and fifth post to stop the
motor for predetermined period and to activate an actuator (14) to shift the selection switch of the mirror controller
f pushing or pulling the selector switch by pneumatic actuator (14) through a
knob holder (15) for changing from 'Left' to 'Right' position or vice versa to
complete one cycle by bringing flexible conductor to its original position
g to repeat above steps (b) to (f) to repeat the cycle.
10. The integrated test rig for in cab mirror controller and the method for testing an
integrated test rig substantially as herein described with reference to accompanying
drawings.