DESC:FIELD OF INVENTION

The present invention relates to cable discontinuity testing tool. In particular, the invention relates to universal cable discontinuity testing tool. More particularly, the invention relates to a method for quick and simplified universal cable discontinuity testing tool.

BACKGROUND OF THE INVENTION

The automation was adopted to eliminate manufacturing defects originating from inadvertent human errors. These errors are usually caused by operator’s fatigue while performing repetitive tasks, which are quite often boring. Any automation process releases work force from onerous tasks and for achieving better performance in terms of quality and management in the manufacturing activities. The computer can take care of almost all tasks that a human can undertake by utilizing intelligence and five basic senses.

In any manufacturing process, e.g. automobile manufacture, often different machines are equipped with cables for communication with various units. Frequently, these cables are long elements which connect two sub-units for transferring communication signals to operate the concerned system/s.

The maintenance of these cables is an ongoing job. This also involves a continuity testing of moving cables, which is also a repetitive task often bringing boredom to the testing personnel. This is a particularly difficult task, especially for long cables connected via complex pin configurations.

For example, during vehicle manufacturing process, one of the important processes is the ‘Key learning or vehicle immobilizer process.’ It is an important process, without which a new vehicle cannot be started and moved further. Generally, this process is done after the complete vehicle is rolled down. In this immobilizer process, typically a computer is stationed along the assembly-line and electrically connected to a data server either via intranet or internet.
This computer is loaded with software for transferring certain predetermined files to every vehicle via a communication cable and by means of a device called as python. Python is an intermediate device communicating with this computer via a USB cable and connected to the vehicle via OBD (On Board Diagnostic) cable.

A typical process for Key learning is described below –

1. Vehicle arrives at the Key Learning stage.

2. Operator Connects the OBD cable Socket to the vehicle and switches on the ignition key, thereby a 12V power supply is fed to Python device.

3. Thereafter, the operator establishes the communication between the vehicle and the computer with the help of python device and a basic driver setup.

4. Generally, there are two keys from cranking the vehicle. The operator issues a Start command for file transfer to the vehicle for both the keys. Therefore, the transfer command is given to both the keys.

5. After successful completion of the file transfer, the computer issues a confirmation signal and then operator removes OBD cable socket from the vehicle.

6. The process is repeated for every subsequent vehicle on the assembly-line of the production plant.

DISADVANTAGES WITH THE PRIOR ART

On-Board Diagnostic (OBD) cable plays an important role for communication and data transfer between various sub-units in a diagnostics and testing system. Normally, OBD cable length is about 10 meter due to the typical work station layout, e.g. the distance between the vehicle moving on the conveyor and the computer placed by the side of the assembly-line is quite high. This long cable is placed along the length of the conveyor for vehicle movement and an overhead looping is provided to deal with this conveyor movement.
However, a recurrent problem is that the OBD cable often gets punctured at any position during handling of the cable, e.g. along the 10m long cable. Generally, the OBD cable has six cores of 0.5 mm2 cross-section and is widely connected randomly via 16 pin x 9 pin connectors. Normally, much time is required to identify the location of cable puncture or the disconnection point in such a multicore cable and to fix the same.

Once, OBD cable is punctured, the complete process of Key Learning process stops. This in turn leads to stoppage of the production conveyor and finally causes huge production loss and thus financial losses for the manufacturer.

On receiving information about the OBD cable puncture from the production operator, two other operators from maintenance section check the cable continuity by using a multi meter. Normally, this activity requires 25 to 30 min for diagnosis and another 05 minutes are required for repairing it. However, during this checking and repair process, the production is to be stopped. Unfortunately, this production loss not recoverable and thus not acceptable.

DESCRIPTION OF THE PRESENT INVENTION

This cable testing is not considered as a productive activity, but seen merely as a non-value-adding activity (NVA). Quite often, it is considered as an ‘expense’ and the operator is always under pressure to reduce this testing.

Different conventional proactive solutions have been tried to prevent the cable from getting punctured during cable handling. Although, the interval between the occurrences of cable puncture appears to increase, the results are not as per desired expectations. It was also attempted to minimize the time required to correct this abnormality of cable puncture and to quickly resolve this problem.

A circuit is developed for this purpose, which indicates the punctured cable immediately. This is accomplished simply by connecting both the cable ends to the testing unit configured in accordance with the present invention and by pressing a switch. If any of the cores of the multicore OBD cable is found to be disconnected or open circuited, the LED of this unit does not glow. This is a dedicated special testing equipment, which allows the testing of cables, e.g. OBD cables and sockets of a complex pin configuration within a shortest possible time.

The main advantages of this testing equipment are as under:

? The new innovative tool can be used by Maintenance technician or installation, commissioning engineer.

? Simply connect the both end of cable in to female sockets available on Fixture.

? Press one by one switch to ensure the proper continuity of cable.

? If Led light gets on means the proper continuity is there in cable & sockets.

? If Led light does not glow that means either cable is open circuit at either of end or socket is damaged. The damaged socket can be viewed physically but the faulty cable with the continuity of each core is difficult to view/identify over the length of the cable.

On receiving information from the production shop operator, maintenance personnel carrying this testing kit visits the site and checks the cable continuity by using this testing kit. This activity takes only about a minute to diagnose the problem, i.e. the location/core of the cable which got punctured and/or the faulty socket creating this discontinuity. This diagnosis is then followed by a regular cable / fault-repair process. Thus, the production of vehicles does not stop for long.

The cable discontinuity testing tool in accordance with the present invention is different from the existing systems in that:

• A cable tester is used to verify that all the intended connections exist and that there are no unintended connections (short circuits, open circuits etc. in the cable being tested.
• When an intended connection is missing, it is said to be ‘open’.

• It is more difficult in situations, where complex pin-to-pin connections are present.

• This requires disassembly up to the component level and to carry out further analysis for checking the cable and socket and requires substantial time and efforts.

• With this system, there is no need to open or disassemble the component, so it can be used even if there are complex pin connections involved therein. Only a suitable configuration is to be done before using the system.

This system can be adopted in the following ways:

• As a part of standard original equipment provided by OEMs.

• It can be provided by the OEMs as an add-on unit (spare).

• It is useful to users as a diagnosis tool, to quickly detect the problem eliminating the search time.

• OEMs can also adopt this solution for in-line testing. System can be installed at the most probable point of failure in a cable. Then system works as a junction between two cables. Thus, it continuously monitors the continuity of multicore cables.

• If any cable opens or shows inconsistence response, it is immediately indicated on the display. Further, it helps to reduce/optimize cost of rejection for multicore cables.

OBJECTS OF THE INVENTION

Some of the objects of the present invention - satisfied by at least one embodiment of the present invention - are as follows:
An object of the present invention is to provide a quick process for detecting the cable discontinuity in a long multicore cable.

Another object of the present invention is to provide a simple tool for testing cable discontinuity in a long multicore cable.

Still another object of the present invention is to provide an online cable discontinuity testing arrangement for detecting cable puncture in a long multicore cable.

Yet another object of the present invention is to provide a cost-effective cable discontinuity testing arrangement for detecting cable puncture in a long multicore cable.

A further object of the present invention is to provide a simple cable discontinuity testing arrangement for detecting cable puncture in a long multicore cable.

These and other objects and advantages of the present invention will become more apparent from the following description when read with the accompanying figures of drawing, which are, however, not intended to limit the scope of the present invention in any way.

SUMMARY OF THE INVENTION

In accordance with the present invention, there is provided an automobile immobilizer cable testing tool for testing the multi-core on-board diagnostic (OBD) cable, the tool comprises:

• a battery connected to the testing tool;

• a first multi-pin female connector with each socket thereof detachably connectable to the first end of a respective core of the multi-core OBD cable;

• a second multi-pin connector detachably connectable to the second end of a core of the multi-core OBD cable;

• one terminal of each switch connected at back end to a respective pin of the multi-pin connector and the other terminal thereof connected to a 9V battery via a light emitting diode (LED) indicator;

wherein pressing each switch corresponds to supplying power to the corresponding core of the multi-core OBD cable and an unlit Led indicate an open circuit or disconnected core and a glowing LED indicates the continuity of the corresponding core of the multi-core OBD cable.

According to an embodiment of the present invention, the OBD cable is an n-core cable.

According to another embodiment of the present invention, the first multi-pin female connector is a 9-pin connector and the second multi-pin connector is a 16-pin connector.

According to still another embodiment of the present invention, the OBD cable is a two-core cable.

According to yet another embodiment of the present invention, the OBD cable is a three-core cable.

According to a further embodiment of the present invention, the OBD cable is a five-core cable.

According to still further embodiment of the present invention, the connections are made between the pin 1 and 2 of the 9-pin and 16-pin connectors respectively.

According to yet further embodiment of the present invention, the connections are made between the pin 1, 2 and 3 of the 9-pin and 16-pin connectors respectively.
In another embodiment of the present invention, the connections are made between the pins 1, 2, 5, 7 and 8 of the 9-pin and with the pins 7, 14, 5, 6 and 16 of the16-pin connectors respectively.

In accordance with the present invention, there is also provided a method of testing an on-board diagnostic (OBD) cable by means of the automobile immobilizer cable testing tool as claimed in claims 1 to 9, wherein the method comprises the steps of:

• connecting the first end of the multi-core OBD cable to the first multi-pin connector of the testing tool;

• connecting the second end of the multi-core OBD cable to the second multi-pin connector of the testing tool;

• pressing the nth switch of the testing tool for testing the continuity of the respective nth core of the multi-core OBD cable testing tool;

wherein an unlit LED of the testing tool indicates an open circuit or the respective disconnected core and/or the respective defective cable socket of the multi-core OBD cable and a glowing LED of the testing tool indicates the continuity of the respective disconnected core and/or the respective defective cable socket of the multi-core OBD cable; and the same process is repeated for testing the multi-core OBD cable by testing all ‘n’ number of cores thereof one by one.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

The present invention will be briefly described with reference to the accompanying drawings, which include:

Figure 1 shows a schematic diagram of a vehicle Key-learning process at one of the automobile manufacturing plant of a model produced by the applicants.

Figure 2 shows the complex pin-wiring connection diagram for the OBD cable 20 shown in Figure 1.
Figure 3 shows cable testing tool made in accordance with the present invention for indicating the faulty or punctured core of the multicore cable connection by means of an LED indicator.

Figure 4 shows a schematic view of the circuit in the cable testing tool made in accordance with the present invention.

Figure 5 shows a typical circuit of the cable testing tool for testing any cable fault in a two-core cable and made in accordance with the present invention.

Figure 6 shows a typical circuit of the cable testing tool for testing any cable fault in a three-core cable and made in accordance with the present invention.

Figure 7 shows a typical circuit of the cable testing tool made in accordance with the present invention for testing any cable fault in a multi-core cable.

DETAILED DESCRIPTION OF THE ACCOMPANYING DRAWINGS

In the following, different embodiments of the present invention will be described in more details with reference to the accompanying drawings without limiting the scope and ambit of the present invention in any way.

Figure 1 shows a schematic diagram of a conventional vehicle Key-learning process at one of the manufacturing plant (TCF) of one of the models, e.g. Bolero produced by the applicants. The new vehicle 10 moving on a conveyor C of the assembly line is connected to the computer 40 via an On-Board Diagnostic (OBD) cable 20 looped via an overhead moveable cable suspending arrangement 30. The computer 40 is normally stationed beside the assembly line and connected to data server via Intranet or Internet.

The software necessary for transferring certain predetermined files via a communication cable and a Python device to the vehicle to be tested is pre-loaded/installed in this computer 40.
The operator connects the socket of this OBD cable 20 to the vehicle as well as Python device (not shown) by turning on the ignition key. Now, the power supply (e.g. 12 V) to the intermediate Python device is switched on, which communicates with the computer 40 via USB cable and the vehicle 10 via OBD cable 20. Once the communication is established between the vehicle 10 and the computer 40 via Python device and the basic driver set-up; the operator issues a ‘Start’ command for file transfer to the vehicle 10 for both the keys. Once the file is successfully transferred, the computer 40 issues a confirmation signal and the operator removes socket of the OBD cable 20 from the vehicle 10. Normally, OBD cable 20 is a multicore, preferably 6 core cable of 0.5 mm2 and about 10 m long, which is widely connected randomly to 16 pin x 9 pin connectors. Due to large number of cores (here, 6 cores) and 10m length, a lot of time is needed to identify the exact disconnection point, in case of the occurrence of a cable puncture. This is easily identified by non-receipt/issue of the confirmation signal by the computer, as discussed above. The time to identify and fix the cable fault is of the order of about 25 to 30 minutes and the cable puncture fixing also needs about 5 minutes and can be done by at least two operators. This is a non-productive activity, which stops the Key-learning process completely, until the cable fault is located and suitably corrected. This occurs frequently and often leads to stoppages of production conveyor movement and which causes huge production losses and also hampers a cost-effective production of the vehicles.

Figure 2 shows the complex pin-wiring connection diagram for the OBD cable 20 shown in Figure 1 and as discussed above. The different interconnections between the various numbered pins of 9-pin and 16-pin connectors are shown in this figure separately for easy identification.

Figure 3 shows a cable testing tool made in accordance with the present invention for indicating the faulty or punctured core of a multicore cable connection by means of an LED indicator. This cable testing tool includes a 9-pin connector and a 16-pin connector interconnected by a unique circuit (Figure 4). In this circuit, by simply connecting the two ends of the OBD cable to the cable testing tool and by pressing the switch thereof, the defect-free multicore OBD cable is deduced immediately from an unlit LED indicator. However, in case of a defective cable, including any open circuited or disconnected core thereof, the LED indicator glows immediately to indicate the presence of a defective cable connection and/or a defective cable socket.

Figure 4 shows a schematic view of the circuit diagram of the wiring of the cable testing tool made in accordance with the present invention, indicating the actual interconnections of the various numbered pins of 9-pin and 16-pin connectors for exactly showing which core out of multiple cores of the multi-core OBD cable is defective, if any core thereof is defective. When LED glows, it symbolizes that multi-core OBD cable is free from any defect, otherwise by unlit LED, the presence of punctured or discontinuous cable core is detected, which requires fixing to continue performing the Key-learning process on the vehicle assembly line.

Figure 5 shows a typical circuit of the cable testing tool for testing any cable fault in a two-core cable and made in accordance with the present invention. The circuit has the option of connecting pins 1 and 2 of a 9-pin connector to pins 1 and 2 respectively of a 16-pin connector. A glowing LED indicates a faultless 2-core cable and a non-glowing LED indicates the presence of a disconnection/open circuit in one of the two cores of this 2-core cable. The cores are checked one by one. Initially, the first core of the cable is checked, then the second core is checked. So, both the cores are not checked simultaneously. This testing is particularly useful in 2-core cable applications, such as DC power supply for powering equipment, e.g. transfer cars / trolleys, robots, fixtures, emergency controls etc.

Figure 6 shows a typical circuit of the cable testing tool for testing any cable fault in a three-core cable and made in accordance with the present invention. The circuit has the option of connecting pins 1, 2 and 3 of a 9-pin connector to pins 1, 2 and 3 respectively of a 16-pin connector. A glowing LED indicates a faultless 3-core cable and a non-glowing LED indicates the presence of a disconnection/open circuit in one of the three cores of this 3-core cable. The method of checking is similar to the one described for 2-core cables discussed above. This testing is specifically useful in 3-core cable applications such as AC power supply for powering equipment, e.g. hot air blowers as well as domestic wiring applications.

Figure 7 shows a typical circuit of the cable testing tool for testing any cable fault in a multi-core cable and made in accordance with the present invention. The circuit has the option of connecting pin numbers 1, 2, …. n numbers of a multi-pin connector to the respective pins of a similar multi--pin connector. A glowing LED indicates a faultless multi-core cable and a non-glowing LED indicates the presence of a disconnection/open circuit in one of the cores of this multi-core cable. The method of checking is similar to the one described for 2-core cables discussed above. This testing is specifically useful in multi-core cable applications such as cables used in cable applications for vehicles, complex robots, networks, telephony as well as in applications for elevators and any closed loop system.

Although, the present invention is described with reference to 2, 3 and multi-core OBD cables, the idea underlying the present invention is not merely restricted to the exemplary embodiments shown and discussed herein, but can easily be extended to cover any other such cable application, particularly by customization and specific adaptation to many more cable testing applications.

WORKING OF THE INVENTION

The cable testing tool is provided with two pins (as shown in Fig. 3). These pins accommodate the male or female ends of the multi-core cable. After the connections are made, the cable testing tool checks the continuity of each core of the cable. If there is continuity in any core of a cable, the relevant LED provided for the indication to the operator, glows to confirm that the core is continuous throughout. Once it is done for one core, the same procedure is followed for rest of the cores of the cable. Here, the operator must make contact with individual pins manually. There is no specific arrangement to automatically check the continuity of each individual core in the 2-core, 3-core or a multi-core cable.

TECHNICAL ADVANTAGES AND ECONOMIC SIGNIFICANCE

The automobile immobilizer cable testing tool configured in accordance with the present invention has the following advantages:

? Developed, installed and proven in-house for the first time for complex pin configurations.

? Universal design, which can be easily adopted/installed, at any industrial application for testing the multi-core cable continuity along the whole length thereof.

? Eco-friendly and energy-efficient sustainable solution for multi-core cable testing.

? Compact design with multiple configuration options, such as serial, parallel, OBD, Multi-point connectors.

? Completely safe due to working on a 9V (Replaceable or Rechargeable) battery provided with LED indicator.

? Easy to Test after installation.

? Effectively installed in remote areas, with high handling activities requiring sustained cable continuity to prevent any breakdown.

? Inventive concept can be easily deployed to any Telecommunications and networking cable testing and measurement equipment.

? Diagnostic time reduced from an average 25-30 minutes to 1 minute by eliminating the non-value-adding activities.

? Requires a single operator for the diagnosis of problem.

? Deskills the cable testing process due to the circuitry configured therein.

? Low-cost solution useful in remote working areas.

? Eliminates the ambiguity of damage cable or damage sockets.

? Reduces the operator fatigue due quick cable fault-finding.

? Simple solution with tremendous scope of horizontal deployment across
the industry to optimize cable-fault diagnosis time.

Throughout this specification, the word “comprise”, or variations such as “comprises” or “comprising”, shall be understood to implies including a described element, integer or method step, or group of elements, integers or method steps, however, does not imply excluding any other element, integer or step, or group of elements, integers or method steps.

The use of the expression “a”, “at least” or “at least one” shall imply using one or more elements or ingredients or quantities, as used in the embodiment of the disclosure in order to achieve one or more of the intended objects or results of the present invention.

The exemplary embodiments described in this specification are intended merely to provide an understanding of various manners in which this embodiment may be used and to further enable the skilled person in the relevant art to practice this invention. Although, only the preferred embodiments have been described herein, the skilled person in the art would readily recognize to apply these embodiments with any modification possible within the spirit and scope of the present invention as described in this specification.

Therefore, innumerable changes, variations, modifications, alterations may be made and/or integrations in terms of materials and method used may be devised to configure, manufacture and assemble various constituents, components, subassemblies and assemblies according to their size, shapes, orientations and interrelationships. The description provided herein is purely by way of example and illustration. The various features and advantageous details are explained with reference to this non-limiting embodiment in the above description in accordance with the present invention.
The descriptions of well-known components and manufacturing and processing techniques are consciously omitted in this specification, so as not to unnecessarily obscure the specification. In the previously detailed description, different features have been summarized for improving the conclusiveness of the representation in one or more examples.

However, it should be understood that the above description is merely illustrative, but not limiting under any circumstances. It helps in covering all alternatives, modifications and equivalents of the different features and exemplary embodiments. Many other examples are directly and immediately clear to the skilled person because of his/her professional knowledge in view of the above description.

The exemplary embodiments were selected and described in order to be able to best represent the principles and their possible practical application underlying the invention. Thereby, the experts can optimally modify and use the invention and its different exemplary embodiments with reference to the intended use. In the claims and the description, the terms “containing” and “having” are used as linguistically neutral terminologies for the corresponding terms “comprising”. Furthermore, the use of the term “one” shall not exclude the plurality of such features and components described. ,CLAIMS:We claim:

1. An automobile immobilizer cable testing tool for testing the multi-core on-board diagnostic (OBD) cable, the tool comprises:

• a battery connected to the testing tool;

• a first multi-pin female connector with each socket thereof detachably connectable to the first end of a respective core of the multi-core OBD cable;

• a second multi-pin connector detachably connectable to the second end of a core of the multi-core OBD cable;

• one terminal of each switch connected at back end to a respective pin of the multi-pin connector and the other terminal thereof connected to a 9V battery via a light emitting diode (LED) indicator;

wherein pressing each switch corresponds to supplying power to the corresponding core of the multi-core OBD cable and an unlit Led indicate an open circuit or disconnected core and a glowing LED indicates the continuity of the corresponding core of the multi-core OBD cable.

2. Automobile immobilizer cable testing tool as claimed in claim 1, wherein the OBD cable is an n-core cable.

3. Automobile immobilizer cable testing tool as claimed in claim 1, wherein the first multi-pin female connector is a 9-pin connector and the second multi-pin connector is a 16-pin connector.

4. Automobile immobilizer cable testing tool as claimed in claim 3, wherein the OBD cable is a two-core cable.

5. Automobile immobilizer cable testing tool as claimed in claim 3, wherein the OBD cable is a three-core cable.

6. Automobile immobilizer cable testing tool as claimed in claim 3, wherein the OBD cable is a five-core cable.

7. Automobile immobilizer cable testing tool as claimed in claim 4, wherein the connections are made between the pin 1 and 2 of the 9-pin and 16-pin connectors respectively.

8. Automobile immobilizer cable testing tool as claimed in claim 5, wherein the connections are made between the pin 1, 2 and 3 of the 9-pin and 16-pin connectors respectively.

9. Automobile immobilizer cable testing tool as claimed in claim 6, wherein the connections are made between the pins 1, 2, 5, 7 and 8 of the 9-pin and with the pins 7, 14, 5, 6 and 16 of the16-pin connectors respectively.

10. A method of testing an on-board diagnostic (OBD) cable by means of the automobile immobilizer cable testing tool as claimed in claims 1 to 9, wherein the method comprises the steps of:

• connecting the first end of the multi-core OBD cable to the first multi-pin connector of the testing tool;

• connecting the second end of the multi-core OBD cable to the second multi-pin connector of the testing tool;

• pressing the nth switch of the testing tool for testing the continuity of the respective nth core of the multi-core OBD cable testing tool;

wherein an unlit LED of the testing tool indicates an open circuit or the respective disconnected core and/or the respective defective cable socket of the multi-core OBD cable and a glowing LED of the testing tool indicates the continuity of the respective disconnected core and/or the respective defective cable socket of the multi-core OBD cable; and the same process is repeated for testing the multi-core OBD cable by testing all ‘n’ number of cores thereof one by one.

Dated: this day of 29th December, 2015. SANJAY KESHARWANI
APPLICANT’S PATENT AGENT