The car seat electrical inspection system accurately identifies the location of heater wire disconnect faults by combining physical testing, circuit analysis, and intelligent diagnostic technology, using multi-dimensional data cross-validation to pinpoint the fault. The system first confirms the fault's location through basic physical testing. Using an infrared thermal imager, it scans the seat surface temperature distribution. If the temperature in a specific area is significantly lower than other areas, it can be preliminarily determined to have a heater wire disconnect in that area. Tactile feedback provides further verification. If no heat is transferred to a specific area when the seat is pressed, the fault can be narrowed down to the heater wire circuit in that area.
Circuit analysis is the core step in locating disconnects. The car seat electrical inspection system connects the seat heating circuit to a dedicated diagnostic instrument to read real-time voltage and current data. Under normal circumstances, the heater wire circuit should form a complete closed loop. A sudden voltage drop or zero current in a specific section of the circuit indicates a disconnect. The system compares the standard circuit diagram with the measured data to pinpoint the disconnect branch. The system also measures the resistance across the heater wire. If the resistance value is infinite, the disconnect is confirmed.
Intelligent diagnostic technology improves fault location efficiency through algorithm optimization. The car seat electrical inspection system's built-in expert diagnostic system intelligently analyzes inspection data based on a vehicle model database and historical fault cases. For example, if the system detects frequent disconnections in a certain vehicle model's seat heater wire within a specific temperature range, it automatically correlates the material characteristics of the heater wire with process defects, prompting the inspector to focus on checking the bond strength between the heater wire and the fabric layer. This big data-based intelligent diagnosis significantly reduces manual troubleshooting time.
For complex fault scenarios, the system uses a segmented detection method, setting multiple test points in the heater wire circuit to gradually narrow down the scope of the disconnection. For example, it first tests the heater wire inlet voltage at the bottom of the seat. If normal, it then tests the center test point. If the center voltage is abnormal, it indicates the disconnection is located between the inlet and the center. This "binary" detection method allows the system to quickly narrow down the fault location to the centimeter level.
The car seat electrical inspection system also integrates a visual diagnostic tool that uses a high-definition endoscope to observe the heater wire surface condition. If signs of insulation damage, oxidation, or melting are detected, the disconnection point can be directly identified. The system also supports 3D modeling, overlaying inspection data with a seat structure model to generate a heater wire fault heat map, visually demonstrating the specific location of the fault within the seat.
During the diagnostic process, the system monitors and eliminates interfering factors in real time. For example, if it detects parasitic resistance or poor contact in the seat heating circuit, it automatically prompts the inspector to clean the connector or replace the wiring harness to avoid misdiagnosis. The system also verifies power supply stability to ensure that test results are not affected by voltage fluctuations.
The car seat electrical inspection system utilizes a multi-technology fusion to precisely locate faults. Combining physical testing, circuit analysis, intelligent diagnostics, and visualization tools, the system can complete a full-chain diagnosis, from fault symptoms to fault location, within minutes. This efficient and accurate inspection approach not only improves repair efficiency but also reduces the risk of secondary disassembly and reassembly due to misdiagnosis, providing reliable technical support for repairing automotive seat electrical faults.
