AUTOMATED HARNESS TESTER BY

M.SANTHOSH KUMAR (09951A0493) SANTOSH KUMAR (09951A0494) SATYENDRA KUMAR (09951A0498) SABBANI TEJA (09951A04B3)

Department of electronics and communication engineering Institute of aeronautical engineering (Affiliated to Jawaharlal Nehru Technological University) Hyderabad (2009-2013)

AUTOMATED HARNESS TESTER

Mini Project report submitted in partial fulfillment of the requirement for the award of the Degree of B.Tech.

By

M.SANTHOSH KUMAR (09951A0493) SANTOSH KUMAR (09951A0494) SATYENDRA KUMAR (09951A0498) SABBANI TEJA (09951A04B3)

Department of electronics and communication engineering Institute of aeronautical engineering (Affiliated to Jawaharlal Nehru Technological University) Hyderabad

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INSTITUTE OF AERONAUTICAL ENGINEERING

DUNDIGAL, HYDERABAD

CERTIFICATE
This is to certify that the project work entitled AUTOMATED HARNESS TESTER done by Sri/Kum M.SANTHOSH KUMAR (09951A0493) , SANTOSH KUMAR (09951A0494) SATYENDRA KUMAR (09951A0498) , SABBANI TEJA (09951A04B3) a students of Final year of course Bachelor of Technology in
ELECTRONIC

& COMMUNICATION ENGINEERING as a part of mini project work as described

by the Jawaharlal Nehru technological University, is a record of bonafide work carried out by them under my guidance and supervision. The matter embodied in this project report has not been submitted to any other university for the award of any other degree.

(Head of the Department)

Guide Name :MR.SAMPATH Designation:Senior Engineer At ACL

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ACKNOWLEDGEMENT

We owe our profound acknowledgement to all those people who made this project successful. We would like to express our most sincere thanks to all those people who are involved in our project work. We express our deep sense of gratitude to APOLLO COMPUTING LABORATORIES (P) LTD. Tarnaka , Hyderabad for permitting us to work in their organization. We express our special gratitude and thanks to Mr.SAMPATH Senior Engineer at ACL, Tarnaka, Hyderabad for his kind co-operation with out whom the project training would not have been completed. We take the opportunity to thank our Head of Department Mr.V.R.SHESHAGIRI RAO for his timely advice and guidance while pursuing this project as well as throughout the B.Tech course. Our sincere thanks to our beloved professor and internal guide Mr.B. NARESH for his guidance and contribution in developing the project.

With gratitude

M. SANTHOSH KUMAR (09951A0493) SANTOSH KUMAR (09951A0494) SATYENNDRA KUMAR (09951A0498) SABBANI TEJA (09951A04B3)

ABSTRACT

Automated Harness Testers are used in military ,navy and aerospace having electronic sub-systems to find the defective or miswired cables instantly before they damage equipment or waste valuable technician time. The existing system involves the manual checking of each and every pin of a connector. In this method the person directly uses the multimeter to check the connections of continuity and short. This method has several disadvantages as it consumes a lot of time and also much possibility of occurrence of errors again and again. As it is very much difficult to check out the connectivity of all pins manually we go for the Automated Harness Testing which executes the testing process in fraction of seconds.It performs high speed electrical interconnect testing for wiring connection and insulation quality. In this project the automated harness tester is a 128 pin test point device used to know the connectivity of a connector having maximum of 128 pins. Automated harness tester consists of a switching block, control block, multimeter and a test computer.The control block is microcontroller based system.We also use a RS232 communication port to communicate between the microcontroller and the test computer.

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TABLE OF CONTENTS

CHAPTER - 1

INTRODUCTION

1
1 3

1.1 Introduction to Automated Harness Tester 1.2 Need for the system

CHAPTER - 2

REQUIRMENTS

4
4 4 4 4 4 4 4 4 5 5

2.1 Hardware Requirements 2.1.1 Relays 2.1.2 Relay drivers 2.1.3 Microcontroller 2.1.4 CPLD 2.1.5 Diodes 2.1.6 Multimeter 2.1.7 RS-232 2.1.8 Test Computer 2.1.9 Chassis mounts

2.2 Software Requirements

CHAPTER - 3

LITERATURE SURVEY8
6 6

3.1 Existing method/System 3.2 Proposed Method/System

CHAPTER - 4

BLOCK DIAGRAM ORGANISATION

8
8 9 9 13 14

4.1 Block diagram of automated harness tester 4.2 Main components of block diagram 4.2.1 Switching Block 4.2.2 Control Block 4.2.2.1 Micro Controller Based System
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4.2.2.2 Control Bus 4.2.3 Two-wired Multimeter 4.2. 4 RS-232 Communication port 4.2.5 A Test Computer

20 21 24 30

CHAPTER - 5

PROJECT EXPLANATION

31
31 32 33

5.1 Working principle 5.2. Input to the test monitor 5.3 Output of the system

CHATER - 6

FUTURE SCOPE

37

REFERENCES

38

APPENDICES

39

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List of figures
FIGURE NO. TITLE page no.

1.1 4.1

THE AUTOMATED HARNESS TESTER Block diagram of Automated Harness Tester An example describing relays The inside of a SPST RELAY Working of Relay Omron relays used in the project PHILIPS 8051 MICROCONTROLLER Architecture of 8051 Pin diagram of 8051 Digital Multimeter RS-232 Example of RS232 Working of RS232 Various pinouts of rs232 Dataflow in rs232 standard A Test Computer Input to the test computer Ouptut of the system Snapshots

8 10 11 11 12 16 18 19 21 24 25 26 27 29 30 33 34 39-42

4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 5.1 5.2 8

List fo Tables
4.1 5.1 Data & Contorl Signals Connectivity of pins in a conncector 27 36

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