High-voltage wire harness part assembly detection system and control method

Abstract

The invention relates to the technical field of new energy automobile high-voltage wiring harness production detection, in particular to a high-voltage wiring harness part assembly detection system and a control method, and the system comprises a sensing layer, a control layer and an execution layer, the sensing layer comprises a visual recognition module, a laser ranging module and a pressure feedback module; the visual identification module comprises an industrial camera and an annular light source, the laser ranging module comprises a laser ranging sensor, the pressure feedback module comprises a pressure sensor, the control layer comprises an industrial controller and a feature database, the industrial controller is in signal connection with the feature database, and the execution layer comprises an indicator lamp, a buzzer, a pneumatic clamp lock and a conveying belt. And the indicating lamp, the buzzer, the pneumatic clamp lock and the conveyor belt are all in signal connection with the industrial controller. The problems of neglected loading and disqualification of the high-voltage wire harness in the assembling process at the present stage, low manual visual inspection efficiency and limitation of a single detection means at present are solved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of new energy vehicle high-voltage wiring harness production detection, and particularly relates to a high-voltage wiring harness part assembly detection system and a control method. BACKGROUND

[0002] New energy high-voltage wiring harness is a key component of the electrical system of a new energy vehicle, mainly composed of wires, connectors, tubular materials, straps and tapes. The high-voltage wiring harness is very important in an electric vehicle, responsible for transmitting high-voltage power. Missing parts may cause serious safety hazards, such as short circuits, system failures or vehicle failure to start. The common reasons for missing parts need to be considered: negligence in the production process, insufficient worker training, and insufficient quality inspection. The existing technology has the following problems:

[0003] Low efficiency of manual visual inspection: manual inspection of wiring harness terminals, sheaths and other parts is inefficient, and missing parts are very high;

[0004] Single detection method is limited: existing patents only use visual or pressure sensor detection, which cannot distinguish between similar parts or hidden missing parts;

[0005] Lack of process traceability: traditional solutions cannot locate the process where the error occurs, resulting in low rework efficiency.

[0006] In view of the above, a high-voltage wiring harness part assembly detection system and a control method are proposed to solve the problems raised in the background. SUMMARY

[0007] The purpose of the present application is to provide a high-voltage wiring harness part assembly detection system and a control method, which ensures the accuracy and integrity of the wiring harness assembly process through phased logical judgment and feature matching.

[0008] A high-voltage wiring harness part assembly detection system includes a perception layer, a control layer and an execution layer. The perception layer includes a visual recognition module, a laser ranging module and a pressure feedback module. The visual recognition module includes an industrial camera and a ring light source. The industrial camera captures part color and shape, performs HSV color analysis and two-dimensional code recognition. The laser ranging module includes a laser ranging sensor to detect part installation depth and in-place condition. The pressure feedback module includes a pressure sensor embedded in a tool clamp to monitor assembly pressure curve. The control layer includes an industrial controller and a feature database. The industrial controller is signal connected to the feature database. The execution layer includes an indicator light, a buzzer, a pneumatic clamp lock and a conveyor belt, all of which are signal connected to the industrial controller.

[0009] Further limited, the pixel of the industrial camera is 200W pixel, the indicator light is red, yellow and green indicator light, the execution layer further comprises a data board, and the data board uploads error records through Wi-Fi.

[0010] Further limited, a control method of a high-voltage wire harness component assembly detection system, the perception layer collects data through a visual recognition module, a laser ranging module and a pressure feedback module, the perception layer sends the collected data to an industrial controller, the industrial controller performs real-time analysis, database comparison and logical judgment, and sends the results to the execution layer, and the execution layer performs sound and light alarm, mechanical interlocking and data uploading through the data results.

[0011] Further limited, comprising a pre-checking and grabbing stage, an assembly monitoring stage and a final inspection and confirmation stage, and the specific steps are as follows:

[0012] Step S10, the industrial camera scans the components, extracts the color HSV value of the components, compares the color HSV value with the feature database, allows a deviation of ±5%, reads the two-dimensional code, analyzes the model, verifies whether it matches the work order requirement, if yes, executes step S11, and if not, executes step S12;

[0013] Step S11, the green indicator light of the red, yellow and green indicator light is lit, the pneumatic clamp lock is unlocked, and the conveying belt is released;

[0014] Step S12, the red indicator light of the red, yellow and green indicator light is lit, the buzzer alarm is sounded, and the pneumatic clamp lock is locked, which needs manual intervention;

[0015] Step S20, the laser ranging sensor detects the installation depth and the in-place condition of the components, judges whether the actual depth is the standard depth ±0.03mm, if yes, it indicates that it is qualified, and if not, it indicates that it is missing or not installed in place;

[0016] Step S21, the pressure sensor samples and monitors the assembly pressure curve, generates a real-time curve and analyzes the slope and peak value, if the depth or pressure is normal, the assembly continues, and if it is abnormal, step S21.1 is executed for judgment;

[0017] Step S21.1, when the slope is insufficient, the yellow indicator light of the red, yellow and green indicator light is lit, prompting to replace the component, if the size is wrong, the red indicator light of the red, yellow and green indicator light is lit, and the assembly line is forcibly paused and locked;

[0018] Step S21.1, when the slope is insufficient, the yellow indicator light of the red, yellow and green indicator light is lit, prompting to replace the component, if the size is wrong, the red indicator light of the red, yellow and green indicator light is lit, and the assembly line is forcibly paused and locked;

[0019] Step S30, panoramic scanning is carried out through the visual recognition module, comparison is made with the standard template, OpenCV edge detection is carried out, the contour coincidence degree needs to be greater than or equal to 95%, and the number of terminals, sheaths and the like is counted, when all are qualified, the green indicating lamp of the red, yellow and green three-color indicating lamps is lighted, the next process is transferred, when any item is abnormal, error code and station ID are recorded, a buzzer is triggered to give an alarm and the assembly line is paused, and a data board uploads error records and displays specific error types through Wi-Fi.

[0020] The present application has the following beneficial effects compared with the prior art:

[0021] 1. Multiple sensor cooperative verification: combined with vision, laser and pressure data cross verification, the misjudgment rate is low.

[0022] 2. Interception design in stages: errors are intercepted in three stages of grabbing, assembling and final inspection, thereby reducing the rework cost. BRIEF DESCRIPTION OF DRAWINGS

[0023] Figure 1 System control schematic diagram of the present application

[0024] Figure 2 Process schematic diagram of pre-inspection grabbing of the present application

[0025] Figure 3 Process schematic diagram of assembly monitoring of the present application

[0026] Figure 4 Final inspection confirmation flowchart of the present application. DETAILED DESCRIPTION

[0027] In order for those skilled in the art to better understand the technical solutions of the present application, the technical solutions of the present application are further described below in combination with the drawings and examples. Example:

[0028] As Figures 1-4As shown, a high-voltage wire harness component assembly detection system includes a perception layer, a control layer and an execution layer. The perception layer includes a visual recognition module, a laser ranging module and a pressure feedback module. The visual recognition module includes a 200W pixel industrial camera and a ring light source. The industrial camera captures the color and shape of the parts and performs HSV color analysis and QR code recognition. The laser ranging module includes a laser ranging sensor to detect the installation depth and position of the parts. The pressure feedback module includes a pressure sensor, which is embedded in the tooling fixture to monitor the assembly pressure curve. The control layer includes an industrial controller and a feature database, which are signal-connected to the industrial controller and the feature database. The execution layer includes red, yellow and green indicator lights, a buzzer, a pneumatic fixture lock and a conveyor belt. The red, yellow and green indicator lights, the buzzer, the pneumatic fixture lock and the conveyor belt are all signal-connected to the industrial controller. The system also includes a data dashboard, which uploads error records via Wi-Fi.

[0029] A control method for a high-voltage wire harness component assembly detection system includes a pre-inspection grabbing stage, an assembly monitoring stage, and a final inspection confirmation stage. The specific steps are as follows:

[0030] Step S10: The industrial camera scans the parts to extract the HSV color value of the parts and compares it with the feature database.

[0031] The data in the table is allowed to have a deviation of ±5%. At the same time, the QR code is read, the model is parsed, and it is verified whether it matches the work order requirements. If so, step S11 is executed, otherwise step S12 is executed;

[0032] Step S11: The green indicator light of the red, yellow and green indicator lights is on, the pneumatic clamp lock is unlocked, and the conveyor belt is released;

[0033] Step S12: The red indicator light of the red, yellow and green indicator lights is on, the buzzer sounds an alarm, and the pneumatic clamp lock is locked, requiring manual intervention;

[0034] Step S20: The laser distance measuring sensor detects the installation depth and position of the parts (such as the depth of the terminal inserted into the sheath) and determines whether the actual depth is within the standard depth ±0.03mm. If so, it is qualified; if not, it indicates that the parts are missing or not installed properly.

[0035] Step S21: The pressure sensor samples and monitors the assembly pressure curve, generates a real-time curve, and analyzes the slope and peak value. The normal slope is 0.3N / ms and the peak value is ≤40N. If the depth or pressure is normal, assembly continues. If it is abnormal, execute step S21.1 for judgment.

[0036] Step S21.1, when the slope is insufficient, the yellow indicator light of the red, yellow and green three-color indicator light is lit, prompting to replace the parts, if it is a size error, the red indicator light of the red, yellow and green three-color indicator light is lit, and the flow line is forced to pause and lock;

[0037] Step S30, panoramic scanning is performed through a visual recognition module, comparison with a standard template is performed, OpenCV edge detection is performed, the contour coincidence degree needs to be ≥95%, and the number of terminals, sheaths and the like is counted, when all are qualified, the green indicator light of the red, yellow and green three-color indicator light is lit, and the next process is transferred, when any item is abnormal, an error code and a station ID are recorded, a buzzer is triggered to issue an alarm and the flow line is paused, and a data board uploads error records and displays specific error types through Wi-Fi.

[0038] Repeated verification is performed, 3 times of repeated detection are performed on suspected error parts, the false alarm rate is reduced, after 2 times of continuous detection failure, a manual reinspection button is unlocked by the system, an operator is confirmed, a feature database is updated every month, and color tolerance and pressure curve parameters are optimized

[0039] The high-voltage wire harness part assembly detection system and the control method provided by the application are described in detail, and the description of the specific embodiments is only used to help understand the method and the core idea of the application. It should be pointed out that for ordinary skilled persons in the technical field, without departing from the application, the application can be improved and modified, and these improvements and modifications also fall within the protection scope of the claims of the application.

Claims

1. A high-voltage wire harness component assembly detection system, characterized by: It includes a perception layer, a control layer and an execution layer. The perception layer includes a visual recognition module, a laser ranging module and a pressure feedback module. The visual recognition module includes an industrial camera and a ring light source. The industrial camera captures the color and shape of parts and performs HSV color analysis and QR code recognition. The laser ranging module includes a laser ranging sensor to detect the installation depth and position of parts. The pressure feedback module includes a pressure sensor, which is embedded in the tooling fixture to monitor the assembly pressure curve. The control layer includes an industrial controller and a feature database, and the industrial controller and the feature database are signal-connected. The execution layer includes an indicator light, a buzzer, a pneumatic fixture lock and a conveyor belt, and the indicator light, buzzer, pneumatic fixture lock and conveyor belt are all signal-connected to the industrial controller.

2. A high-voltage wire harness component assembly detection system according to claim 1, characterized in that: The pixel of the industrial camera is 200W pixels, the indicator light is a red, yellow and green indicator light, and the execution layer also includes a data dashboard, which uploads error records via Wi-Fi.

3. The control method of a high-voltage wire harness component assembly detection system according to claim 2, characterized in that: The perception layer collects data from multiple sensors through a visual recognition module, a laser ranging module, and a pressure feedback module. The perception layer sends the collected data to the industrial controller, which performs real-time analysis, database comparison, and logical judgment, and sends the results to the execution layer. The execution layer uses the data results to perform operations such as sound and light alarms, mechanical interlocking, and data uploading.

4. The control method of a high-voltage wire harness component assembly detection system according to claim 3, characterized in that: It includes the pre-inspection grabbing stage, assembly monitoring stage and final inspection confirmation stage. The specific steps are as follows: Step S10: The industrial camera scans the parts, extracts the HSV value of the parts, and compares the HSV value of the parts. The feature database is described above, with a deviation of ±5% allowed. At the same time, the QR code is read, the model is parsed, and it is verified whether it matches the work order requirements. If so, step S11 is executed, otherwise step S12 is executed; Step S11: The green indicator light of the red, yellow and green indicator lights is on, the pneumatic clamp lock is unlocked, and the conveyor belt is released; Step S12: The red indicator light of the red, yellow and green indicator lights is on, the buzzer sounds an alarm, and the pneumatic clamp lock is locked, requiring manual intervention; Step S20: The laser ranging sensor detects the installation depth and position of the parts, and determines whether the actual depth is within the standard depth ±0.03mm. If so, it is qualified; if not, it indicates that the parts are missing or not installed in place; Step S21: The pressure sensor samples and monitors the assembly pressure curve, generates a real-time curve, and analyzes the slope and peak value. If the depth or pressure is normal, assembly continues; if it is abnormal, step S21.1 is executed for judgment; Step S21.1: If the slope is insufficient, the yellow indicator light of the red, yellow, and green three-color indicator lights will light up, prompting the user to replace the parts. If the size is incorrect, the red indicator light of the red, yellow, and green three-color indicator lights will light up, forcing the assembly line to be paused and locked. In step S30, a panoramic scan is performed through the visual recognition module, compared with the standard template, and OpenCV edge detection is performed. The contour overlap must be ≥95%, and the number of terminals, sheaths, etc. is counted. When all are qualified, the green indicator light of the red, yellow, and green three-color indicator lights lights up, and the process is transferred to the next process. If any abnormality occurs, the error code and station ID are recorded, the buzzer is triggered to sound an alarm, and the assembly line is paused. The data dashboard uploads the error record via Wi-Fi and displays the specific error type.

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