Scantillon Design for Sponges Detection in Harnesses

Gerardo Duran Medrano ¹*

Luis Raúl Robles Ramos ²
Manuel Baro Tijerina ³
1,2,3
Profesor of the Instituto Tecnológico Superior de Nuevo Casas Grandes, City, Nuevo Casas
Grandes, Chihuahua, C.P 31700, Mexico.

* Corresponding Author
gduran@itsncg.edu.mx;

1
 Scantillon Design for Sponges Detection in Harnesses
Abstract
The paper deals with the problem that has been
arising in the omission of the placement of
protective sponges for automotive electrical
harnesses. The objective was to design a scanner
with fiber optic sensors that detect the protection of
the harnesses, as well as the gray industrial belt and
the sponge, using optical sensors. As a result, we
obtained the design of a scantillon with illumination
sensors using in the circuit an accommodation of
logic gates with relays giving a favorable result, two
illumination sensors are used and an arrangement
in the circuit avoids the manipulation that can be
done with a single sensor.
KEYWORDS: Automotive, Harness, Design,
Scantling, Sensor, Optic Fiber, Solidworks.
Introduction
In the eighties decade and given the increased
competitive pressure many western companies
discovered the quality. After decades of indifference
to what was happening in Japan, a few organizations
came to convince that quality products and services
were the key for the future. For many of them it
meant total commitment to this philosophy, for
others it still occupied a secondary level. Anyway,
we can affirm that all organizations are aware of
their importance y we see how they are recognizing
the strategic role as much as the product quality and
the direction of the quality or total quality
management (TQM) [1] .
Manufacturing, in the full sense, is the process of
converting prime materials into products, it also
includes the activities in which the manufactured
product itself is used to make other products. [2] The
manufacturing properties of the materials determine
whether it can be melted, formed, machined, bonded
and thermally treated with relative ease. The method
or methods used to process materials into the desired
final forms may affect the performance, service life
and cost of the product [3].
Creativity is one of the main axes of this whole
process; Although the steps listed can systematically
organize all the process, it should not be forgotten
2
that a particular case may demand a modification to
the outlined and then the person or the group in
charge must innovate to adapt the generic process to
the specificity of the case [4].
The two fundamental theories that support all
branches of electrical engineering are those of
electrical circuits and electromagnetic. Many
branches of electrical engineering, such as power,
electrical machines, control, electronics,
communications and instrumentation are based on
the theory of electrical circuits.
An electrical circuit is an interconnection of
electronic elements, consisting of three basic
elements: a battery, a lamp and connecting wires. It
has several applications, such as flashlights,
reflector, and so on. Electrical circuits are used in
numerous electrical systems to perform different
tasks. This study begins with the definition of some
basic concepts. These concepts are load, current,
voltage elements of the circuit [5].
The relay can be defined as an electromagnetic
device used to open or close a switch controlling
another circuit. The circuit of a coil is an RL circuit,
where R and L are the resistance and the inductance
of the coil, when the switch is closed, the coil’s
circuit is activated. The coil current increases
gradually and produces a magnetic field. In the long
run the magnetic field is enough to attract the
moving contact of the other circuit and close the
switch [6].
The term sensor refers to an element that produces a
signal related to the amount being measured. For
example, in the case of an element for measuring
temperature by means of electrical resistance, the
quantity measured is the temperature and the sensor
transforms a temperature input into a change in
resistance. The term transducer is often used instead
of sensor. Transducers are defined as elements that
subjecting them to a physical change experiments a
related change. That is to say, the sensors are
transducers. However, in a measurement system,
transducers, in addition to sensors, can be used in
other parts of the system to convert signals from one
given form to another [7].
The choice of a sensor cannot be made without
considering the type of output that the system must
produce after conditioning the signal; For this
reason, a suitable integration between sensor and
signal conditioner is necessary [8].
Demand for power and power in automotive power
grids has increased on a large scale in recent
decades. New methods are needed for the
development and dimensioning of automotive
energy networks, as well as intelligent energy and
energy management systems [9].
Effective product design involves a wide range of
tasks requiring flexibility in software. Solid 3D
modeling offers many more benefits than traditional
2D design, but it needs 3D CAD tools that you can
use every day while being powerful enough to
handle aspects of the design process.
With SolidWorks, you'll have an intuitive 3D CAD
system that combines ease of use with powerful
modeling capabilities that can handle the most
complex design projects. SolidWorks accelerates
design, saving development time and costs, and
increasing productivity [10].
Material and Methods
For the manufacture of this product that is the
harness is carried a series of procedures in the
production lines, which are workstations where each
product passes through these stations and is
performed a procedure and also a test to verify that
each step Was made with regard to quality
standards.
The first workstations are the ones that carry out the
wiring to the connectors that the harness carries, as
mentioned before, it is done a pull test to each
connector that has been wired to make sure that no
terminal was badly inserted, from here the
connectors pass to the area of the boards where the
operators are forming the harness by means of more
connections with the wiring. In addition, by placing
certain protections that you carry in different
product areas, which are plastic tubes that cover the
wiring that are tied with black tape, as well as the
placement of protections to the harness, there will be
placed an endless number of protections and
processes that must be done to finish that process,
passing to the following workstations that are the
electrical tests each one has a different process to the
other, one of them is the electrical test of
3
connections where conductivity of the harnesses is
reviewed, in another one the trimming of the clips
that are placed in the process of the boards and also
take care of the placement of a protection that takes
in several parts of the product, mainly in the tubes.
In the manufacturing process a test is performed for
the detection of certain protections carried by the
harness which are sponges, this is one of the final
sessions for the packaging of the product and this is
where a problem arose that was that the harness was
packed and was sent without the protections already
mentioned (sponges).
Fiber Optics Sensors
It was necessary the use of sensors to solve the
problem of the proposed project where several
options were analyzed trying to find the best,
discarding all the sensors that were not optical since
what is intended is to detect that the harnesses have
the protective sponge and the most Relevant is the
optical comparison.
The decision was made that two light sensors would
be used, since one would not be the most efficient
for the detection, with two sensors so one would
detect the low luminosity and the other the high one
making a band pass, these sensors being activated
they let out a negative signal (-). Another of the
conditions is the activation of a micro that is placed
in the scantillon to fulfill the condition that the
operator places the part of the harness where goes
the protection.
The circuit would let the signal sent through the
computer's memory to confirm detection of the
sponge, but only if the three conditions mentioned
above were met, another characteristic of the circuit
had to be that if the case were reached only two
conditions it will not let the signal pass.
AND Logic with Relays
Applying the logic of the digital electronics, creating
logical gates of type AND, these perform a
multiplication doing that if we have one by one we
have as output one but if you multiply one by zero
we will have a zero to the exit, these variables will
be given by the Sensors that if they are activated
they give us a one and when they are not, a zero, the
example of the circuit is that if the two sensors are
activated they will send a one making a one out and distance or diameter thereof and to hold the sensors.
the condition of the micro if it is active, . Figure 2 shows the test scantillon:
Following this we have the following logic:

Figure 1. AND type logic with relays.

The connection of the circuit was as follows, two Figure 2. Test scantillon.
relays of 24 VCD were used, a positive terminal of
a source of 24 VCD was connected in both, the next The materials used in this scatillon were merely hard
terminal was connected the signal sent by the plastics scraps glued with adhesive tape and had
memory for when the relay activates it passes perforations that were not centered that were only
through the normally open (NO). The other terminal for the sensor to embone.
of the relay that is of the coil will be connected to
the output of one of the sensors that is (-), when Sponge Detection Testing
activated the sensor let pass the signal (-) thus Tests were carried out to detect the sponge, imitating
activating the relay and letting the signal pass, the the work performed by the operator. The following
NO terminal of the first relay is connected to the table shows the test number, the attempts made and
middle terminal of the second relay. the activation of the sensors, using harnesses that did
In the same way, the second (-) output of the second not have the sponge, being as follows:
sensor is connected to the other relay at the other end
Table 1. Sensors test without sponge in harness.
of the coil to activate the second relay, letting the
memory signal to the NO, this terminal will be Test Number Harness Sensors
connected to the micro that will not let that signal Placement Activation
pass until it is activated, the output of this micro will Attempts
be connected to the return cable of the memory so
that the memory confirms the detection. 1 5 0
Being activated the micro and complying with the 2 5 0
previous conditions that is the activation of the 3 5 0
sensors letting the signal pass through the relays and 4 5 0
the last to the micro thus reaching the memory. 5 5 0
Making the function of an AND gate with relays and 6 5 0
fulfilling the conditions for the detection. 7 5 0
8 5 0
It was decided to make a rustic model where the
9 5 0
sensors could be placed and a section of pipe could
10 5 0
be supported with the protective sponge to be 11 5 0
detected. 12 5 0
13 5 0
Test Scantillon 14 5 0
This test scantillon was only limited to insert the 15 5 0
pipe length with the sponge without considering 16 5 0

4
 17 5 0
18 5 0

As seen in the table sponge was not detected in the

harness, since it was counted without protection,
which gives us a correct operation.

A second test was performed that is similar to the

first one only this time we will use the harness with
the protection to verify if the sponge would be
detected in the harness. The following table shows
the results obtained:
Tabla 2. Sensors test with sponge in harness. Figure 3. Scantillon Design.

Test Number Harness Sensors An improvement was made to the design by adding
Placement Activation a cover for the protection of the sensors because the
Attempts
sensors in the part of the optical fiber are very
fragile.
1 1 1
2 1 1
3 3 1
4 1 1
5 1 1
6 1 1
7 2 1
8 2 1
9 1 1
10 3 1
11 4 1
Figure 4. Fiber optic sensor’s protection.
12 1 1
13 1 1 Being finally a finished design as following:
14 3 1
15 1 1
16 5 1
17 1 1
18 1 1

Once the two tests have been carried out, the

configuration of the sensors, the layout of the
scanners and the circuit can be checked correctly
functioning.

Results
The result of the design of the scantillons was the
following:
Figure 5. Scantillon final design.

5
Conclusions Vehicle Power and Propulsion
The design of the scantillon where the light sensors Conference (VPPC), 2016.
will be placed to detect the sponge was based on the
[10 D. Systemes, «Solidworks,» Solidworks,
detection conditions of the protections, which would
be the placement of two sensors as well as a micro, ] [En línea]. Available:
thus designing the two-color scantillon, since the http://www.solidworks.es/sw/products/3d
configuration of the sensors is the detection of the -cad/part-assemly-modeling.htm. [Último
high and low luminosity, as the white color reflects acceso: 01 Febrero 2017].
the light this would give a high luminosity reading
and the blue color absorbs a certain amount of light
making a low reading of luminosity, having all the
terms for the detection, it was designed in the
solidworks program where this allows us to design
pieces in 3D.

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[9] M. Winter, S. Schoenewolf y H.-G.
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