Detection System Design Of Electric Vehicle Wiring Harness

With the increasingly serious environmental problems in today’s world, the traditional car has brought a series of problems because of energy consumption and environmental pollution.And this time the electric car technology has been more and more attention and also has a fast development. The traditional car will use a large number of wire harness in the production process, and the traditional car wiring harness testing equipment also has a certain development,but there are not a lot equipment specifically for electric vehicle wiring harness testing. Because the number of the electrical appliances in the electric car are much more than the traditional car,so it is destined that the electric car wiring harness are much more and are more complex. If the amount of wire harness is small we can choose manual method, but in face of complex electric vehicle wiring harness manual testing is not able to solve the needs of daily production, so the market urgently need a kind of electric vehicle wiring harness testing instrument. Because there are a lot number and types wiring harness in the electric vehicle, so it is required that the electric vehicle wiring harness testing equipment must be able to achieve more points, multiple types of wiring harness testing, and must be sure that it is convenient to operate and easy to carry.In view of the electric vehicle wiring harness detection, this paper first describes and analyzes the current research results and the main functions and characteristics of the wire harness testing system at home and abroad, and we find out some deficiencies of these production on the basis of these results, and put forward a new overall design scheme of the electric vehicle wiring harness testing which is based on Visual Basic and has a network structure. In this program, the general computer is used as the main control unit and the master server, and the computer is equipped with monitoring software which is based on Visual Basic.And the computer is also as a master server to achieve the dynamic network sharing and network control technology exploration. In addition to the hardware, the CAN bus network technology is used to realize the distribution and expansion of the unit in the network,and the reference to this technique is an excellent solution to the problem that the number of points of the wiring harness is not enough and the category of the wiring harness is not complete.In the VB software development technology, focused on the real-time serial communication and the database reading and storage technology. In the interface design,we try to use graphical and text to display the detection results and there is an algorithm which can quickly and accurately detect the result of the wire harness is adopted in the analysis of the test results.The main control unit of the wiring harness detection module in hardware is Atmega128, and the scanning unit is composed of CD4067 group. In addition, the touch screen monitoring technology is also used inthe intelligent node. This article will introduce the theoretical basis of the topic, and the main contents include the failure mode of wiring harness, MCU control and communication technology, VB database development and serial communication technology, CAN bus technology, touch screen technology and dynamic web technology, etc. In this paper, the overall structure, hardware design and software design of the system are described in detail.This Wire harness detection system is powerful, in theory, it can detect 20 thousand wire harness points after expansion, can achieve the detection of the electric vehicle wiring harness in the circuit, short circuit, wrong connection, etc. In addition, the system provides database functions to achieve real-time data query from different client web pages.