DESIGN OF LOW COST IOT ENABLED UNIVERSAL WIRING HARNESS TESTER

A cable harness consists of number of wires connected in proper sequence. If there is any misconnection in the wiring, then it is very difficult to find out this manually. So, an instrument is required to detect these faults and display connection faults automatically. Such an instrument is needed where mass production of harness takes place. The developed system, first memorize the master harness connections and compares the same with the mass produced harnesses. If any mismatch occurs in the harness under test and the master, then it is declared as ‘FAIL’ and is sent for rework. The system reduces the checking time of the harness as well as it reduces the efforts of the user. This increases the production rate. The system uses a microcontroller ATmega8535. The system is capable of testing a harness with maximum 128 terminals. These 128 I/O connections are made available by using port expanders. The system also has a 20X4 LCD and a keyboard for man machine interface. In the conventional system, it is difficult to monitor the testing rate. The novel IoT feature enables the user to take the master data of the harness from remote place. This also gives additional feature of monitoring the testing report remotely for analysis. The system is designed using very low cost components as compared to the existing systems. So the designed system gives a low cost IoT enabled solution to small-scale industries for harness testing.