CableEye Barcodes

CableEye Barcodes

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CableEye Application – Barcodes

A while ago an existing CableEye® customer asked us to add barcoding to their CableEye HVX tester, so we looked at what they were doing and how we could help.

When we assessed the existing process, we found that each cable was given a 7-character label that contained the year/month/sequence-in-batch when it was tested and was only fitted to cables that PASSED the cable test. This meant that all cables that were shipped could be identified by the month/year and where in the batch it was tested. Better than nothing, but not great.

We learned that all Works Order numbers (WO numbers) were unique to a customer order but that several Part numbers (cable types) could be contained within one Works Order.

After some discussion we came up with an alternative 14-digit code containing:

Part number / WO number / Assembly Serial Number.

barcodes

A fixed-length field for each element was agreed upon with the customer and a single numerical string was designed. Each Part number became a numerical lookup (1-100,000) for a given cable name in a CSV file. The lookup is a cross-reference from the numerical value in the barcode field to an ASCII text, human-readable name of ‘unlimited’ length.

barcode lookup table

We then recommended that ALL cables received their unique ident label during assembly to improve the reporting from each assembly bench so that operator retraining needs could be identified, or their crimp tools recalibrated etc.

In operation:

As the cable is taken from one of our Protean Cable Stands and put on the test bench its barcode gets scanned by the test operator (identifiable by their unique log-in).

Our script then reads the WO-specific log file (on the customer’s network) to check if the assembly has been seen before. If it has been previously tested it asks the operator if this is a retest, or not. Retests could be due to the cable having previously FAILED on the tester and been reworked, or the operator having been distracted and trying to test the same cable twice.

The script then advises the test operator which connector adaptors are needed for this assembly and to which bank each must be connected. The correct test program is automatically loaded and ready for the ‘TEST’ button to be pressed.

Once ‘TEST’ has been pressed, the WO-specific log file is opened again, this time for writing, the test is run and the test results, along with the Date/Time and the tester operator’s ID stored in the log file. If the cable PASSES the test, a tamperproof sealing label is printed and placed over the end of the connector.

Outcome:

Using the CableEye Standalone Software option and built-in log tools, production management has an immediate view of the production throughput and statistics from their own desk.

This relatively simple change means that every assembly has a unique identity from the point at which it is assembled, identifying the workstation and the operator.

The configuration of the CableEye test station is semi-automated, speeding up the test process and reducing error time.

ALL cables that are delivered to ALL customers have full traceability, down to the individual conductor test results. Consequently, warranty claims are dealt with quicker with fewer ‘valid’ claims, and pre-emptive training or tool servicing is easier to manage.

All of the script work was done by Cimbian UK for the customer using standard, built-in tools included with EVERY CAMI Research CableEye, as standard!

FAQ:

Why use Barcodes?

Barcodes are reliable, fast and eliminate operator input errors. In this case, 14 characters are entered, without error in under a second!

How are Barcodes read?

A simple USB scanner is all that is needed to read a barcode in the CableEye software.

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New CableEye M2Z

New CableEye M2Z

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Announcing the new CableEye M2Z

The all-new CableEye M2Z entry-level tester from CAMI Research provides essential continuity measurement in cables and small wire harnesses.

It is ideal for cables carrying digital signals or any electronic signalling where small amounts of resistance in the cable or connections will not affect the function of the equipment to which the cables are connected. The CableEye M2Z cable tester includes a 128-point fixture, a probe port, and electronics permitting it to test cables with up to 64 conductors.

Measurement for a typical cable completes in less than a second, with results displayed by LEDs on the tester as well as on the PC monitor.

We use industry-standard 64-pin dual-row latch headers as an interface to our plug-in connector boards and external test fixtures. Presently we have over 60 Connector Boards (CB) and most of them are directly compatible with the new CableEye M2Z

A standard Windows (7 and up) PC with one free USB port is all that is needed to use the powerful software supplied with the CableEye M2Z… exactly the same software used by the top-of-the-range CableEye testers.

cableeye m2z

The price includes a board set (CB15c), probe, operating software, power module, USB cable, Getting Started Guide, Software Introduction Booklet, User’s Manual (PDF), and Product Support Subscription.

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CableEye Needs Analysis

CableEye Needs Analysis

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adpator cables needs analysis
customer specific interface
harness test
motorsport harnesses - hvx printed test report

Needs Analysis

When considering investing in a Cable Tester some initial groundwork identifying your specific requirements using a Needs Analysis can make the process a lot easier. This page will get you started on collating the information you will need to narrow down the wide range of CableEye products and options to suit your application.

Ask yourself

  1. Are you testing cables or harnesses, or both?
    Some of our customers produce straight-forward cables, such as Ethernet cables. Others produce very complex harnesses/looms. From a cable testing perspective, this can affect the number of connections required.
  2. The number of connector types
  3. Products and variants:
    • How many different cable/harness types need testing
    • How many variants of a given product need testing
  1. What will be the method of connection to the CableEye?The three main options are connecting to CB boards, Connecting via adaptor cables, and connecting via a fixture/connector panel
  2. Will interface cables be used between the CableEye and the cable/harness under test?
    • If yes, what is the longest interface cable expected?
  3. The number of cables/harnesses to be tested per month?
  4. Existing test method?
  5. Average time to test a cable/harness?
  6. Which sector is the cable/harness destined for?
  7. Working voltage of end product (cable/harness)
  8. Are you looking for a tester to configure yourself or a turnkey solution?
  9. The timescale for implementation?
  10. Budget?

We are happy to help in this process. Please just drop us a line and we’ll get back to you.

needs analysis thumbnail

Needs Analysis

When considering investing in a Cable Tester some initial groundwork identifying your specific requirements using a Needs Analysis can make the process a lot easier. This page will get you started on collating the information you will need to narrow down the wide range of CableEye products and options to suit your application.

Ask yourself

  1. Are you testing cables or harnesses, or both?
    Some of our customers produce straight-forward cables, such as Ethernet cables. Others produce very complex harnesses/looms. From a cable testing perspective, this can affect the number of connections required.
  2. The number of connector types
  3. Products and variants:
    • How many different cable/harness types need testing
    • How many variants of a given product need testing
  1. What will be the method of connection to the CableEye?The three main options are connecting to CB boards, Connecting via adaptor cables, and connecting via a fixture/connector panel
  2. Will interface cables be used between the CableEye and the cable/harness under test?
    • If yes, what is the longest interface cable expected?
  3. The number of cables/harnesses to be tested per month?
  4. Existing test method?
  5. Average time to test a cable/harness?
  6. Which sector is the cable/harness destined for?
  7. Working voltage of end product (cable/harness)
  8. Are you looking for a tester to configure yourself or a turnkey solution?
  9. The timescale for implementation?
  10. Budget?

We are happy to help in this process. Please just drop us a line and we’ll get back to you.

needs analysis thumbnail

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CableEye Twisted Pair Testing – NEW FEATURE

CableEye Twisted Pair Testing – NEW FEATURE

You asked for Twisted Pair Testing, and CAMI Research delivered!

Now available on the ever-popular CableEye range of cable testers are two new features:

  • Capacitance measurement
  • Twisted pair testing and verification
  • Twisted pair ethernet cables

Combining these two features also gives a distance-to-fault testing capability, which means that incoming inspection can test new reels of cable prior to accepting for production.

Available immediately, the new CableEye M4 tester is the same, compact and rugged format as the M2 and M3 systems and utilises the same software, though extended for the new twisted pair testing and capacitance testing capabilities.

The initial application is to detect the infamous ‘Ethernet’ cable issue of incorrectly paired cores (eg CAT5/CAT6 cables).

During a single test phase the CableEye M4 will:

  • check continuity for shorts and opens
  • check resistance (the 4-wire option will increase precision when needed)
  • check for diodes (presence, polarity, and forward voltage drop)
  • check capacitance
  • check for miswired pairs using a new technique across multiple pairs
  • report Pass/Fail
  • display results in wiring diagram or table format
  • log the result – even to a network drive
  • print a detailed report on any windows printer – even networked
  • print a label on local or network label printers

And all of this happens within a matter of seconds, using a single button-press from a low-skilled operator!

For more details on all of the CableEye products from CAMI Research take a look at our dedicated section here

Cimbian UK will be demonstrating a brand new M4 on Stand A52 at the WNIE show (NEC 25th and 26th September), and will also be available for technical discussions, and to help you get the best from your Cable and Cable Harness Testing.

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Motorsport harnesses

Motorsport harnesses

Motorsport harnesses live in a hostile world… CableEye makes sure they are ready.

If you stop to think for a moment of the environment that motorsport harnesses have to operate in, it’s a pretty mean place.

  • Chemical contamination
  • Extremes of temperature
  • Vibration
  • Electrical noise

Cimbian UK, working as exclusive distributor for CableEye from CAMI Research, has many years of helping people to both improve their processes and, up-rate their testing to ensure that cable-harnesses leave the assembly department ready for reliable, long-life operation.

CableEye provides two real options for testing motorsport cable-harnesses:

  1. A low-voltage system (M3U) for testing continuity between programmable thresholds as well as measuring resistance and testing diodes.
  2. A high-voltage (HiPot) system (HVX) which does everything the M3U does but also provides a parametric test at high-voltage to test for insulation breakdown and/or whiskers.

The unique measurement algorithms used in CableEye ensure that every point is tested against every other point at high speed, and is tested using a bi-polar method to ensure that the continuity is good in both directions.

After a cable-harness has passed its low-voltage test it will then switch, automatically, into the HiPot mode. Here the assembly undergoes several different stages of test including dcV and acV, both with a programmable ramp-up and ramp-down rates to prevent damage to the insulation that may lead to early life failures (vehicle breakdown).

 

motorsport harnesses - programmable ramp-up

Both the CableEye M3U and the CableEye HVX use the same software, which includes serial number entry by barcode (a single barcode can contain Serial number, batch, operator ID, part-code and more), data logging, and reporting.


Testing motorsport harnesses in the real-world:

Colin Harmer, owner of Creative Motorsport Solutions and user of a 256 pin HVX HiPot tester, seen below, said:

In this test, the customer had an issue that pointed at the corner looms being “suspect”. These were not looms we built but because the CableEye tester is so flexible we could quickly reverse engineer the loom, check it against the supplied drawings, and perform a Hi-Pot test in very little time. In general, motorsport-type builds are typically low volume which puts a premium on flexibility with fixtures and ease of use, which is a true delineator of the CAMI testers. We are now able to easily Hi-Pot test every product we produce which ensures that the client receives a goods that are exactly to specification. By keeping records of all the tests, we can easily retest at a future point to ensure that there’s been no change in the loom.

motorsport harnesses - test result

There are no “off the shelf” (interface fixture) solutions for motorsport connectors, so these have to be made.” “Each board is a breakout of 64 test points. Boards are modular so you can mix and match to fit the loom you’re testing.

motorsport harnesses - test station and report

Image (Courtesy Of Creative Motorsport Solutions) Of  A 256 Test Point Continuity &Amp; Hipot Harness Tester With Interface Fixtures Comprising A 128 Test Point Base Unit ,With One Expansion Module. The Tester Is Further Expandable To 1024 Test Points.

For more information on how a CableEye cable test system can help you in testing your motorsport harnesses simply fill in the form below and drop us a line.

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