A method for calculating the current carrying value of bundled wires based on digital simulation of three-dimensional wire harnesses

Abstract

The present invention discloses a method for calculating the current carrying value of bundled wires based on a digital simulation three-dimensional wire harness, and relates to the field of electrical design technology. The method includes the establishment of a digital electrical three-dimensional model component library, the drawing of a parameterized electrical plane schematic diagram, the simulation laying of a three-dimensional wire harness, and the calculation and statistics of the current carrying value of the wires. The present invention avoids the problem of "a big horse pulling a small cart" during the use of cables, effectively improves the utilization rate of cables, adopts digital simulation technology in the process of equipment development, standardizes the cable laying process, accurately calculates, reasonably selects, saves unnecessary cable waste, and reduces production costs.

Description

Technical Field

[0001] The invention belongs to the technical field of cable computational electrical design, and in particular relates to a method for calculating the current carrying value of bundled wires based on digital simulation of three-dimensional wire harnesses. Background Art

[0002] As we all know, when the current carrying value of the wire is greater than the rated current, the wire will generate heat and heat. When multiple wires are bundled into a wire harness, the heat dissipation is poor when powered on for a long time, resulting in cumulative temperature rise, causing premature aging and shedding of the wire insulation layer, which seriously endangers the safety of equipment and personnel. It is difficult to determine the wire current carrying value correction factor K in the early stage of design with existing technical means. sh In order to reduce the impact of current higher than the rated current on the wire, usually only an excessively high safety assessment can be adopted.

[0003] On the other hand, with the vigorous development of testing simulation equipment and intelligent equipment, the upgrading of industrial structure has been promoted. The annual output value of the department has gradually increased from tens of millions to hundreds of millions, the production scale has steadily increased, and the demand for cables has increased year by year. The cable data consumed in the long-term electrical production of the electronic control modules of this department was collected. It was concluded that the actual effective utilization rate of cables is less than 60%, and the waste in the design and production processes is very common. In order to save production costs, improve product benefits, and enhance market competitiveness, digital simulation electrical process technology is used. It can simulate the cable laying situation in advance and obtain complete process data. It can not only optimize cable selection, but also standardize cable laying paths, and eliminate the "all roads lead to Rome" phenomenon caused by differences in the technical level of front-line workers, inconsistent wiring paths, and various styles. Fundamentally solve the problem of electromagnetic compatibility that is prone to irregularities.

[0004] The existing technical process method has thousands or tens of thousands of wires for a device. It is obviously unrealistic to analyze which wire group each wire belongs to, formulate its routing path, and calculate the huge amount of data when the number of wires is continuously added or reduced to the wire harness. The large workload is very unfavorable to achieve industrialization and large-scale production. According to the cable manual standard, excluding the influence of other factors, the effective current carrying value of the bundled cable decreases by 0.017% for each additional wire. For a group of 30 wires in a wire harness group, the effective current carrying value is calculated to decrease by 0.51%, which is half the decrease, reflecting the great influence of the wire harness group on the current carrying value.

[0005] For a single piece of customized equipment, it is impossible to make standardized design specifications for the routing paths of hundreds or thousands of cables in the entire machine, and it is impossible to accurately grasp the length and model of the cables. The use of evaluation and calculation methods is of no help in saving cable costs and is the root cause of cable waste. Cable specifications are too large, cable length data is missing, and safety factor assessment is too high, which are all root causes of cable waste. Summary of the invention

[0006] The technical problem solved by the present invention is: to overcome the shortcomings of the prior art and provide a method for calculating the current-carrying value of bundled wires based on digital simulation of three-dimensional wire harnesses. Through digital simulation technology, the cable laying form in the whole machine is simulated, key data is analyzed and calculated, and the actual cable consumption of the whole machine equipment is obtained, thereby reducing the electrical equipment cost of the whole machine.

[0007] The object of the present invention is achieved through the following technical scheme: a method for calculating the current carrying value of bundled wires based on digital simulation of three-dimensional wire harnesses, the method comprising the following steps: step one: creating a digital three-dimensional model library and a parameterized database; wherein the digital three-dimensional model library comprises a mechanical structure model, an electrical component model and a connector model; step two: based on the mechanical structure model, assembling the electrical component model and the connector model in the mechanical structure model according to the actual assembly relationship; step three: according to the logical parameter data provided by the parameterized database, automatically determining the position of the device port at both ends of the wire, following the specified planning path to realize the automatic interconnection of hundreds of wires, and generating a three-dimensional wire harness group; step four: obtaining the current carrying value correction coefficient K of a single wire in the three-dimensional wire harness group sh , calculate the wire current carrying value I, complete the wire selection according to the wire current carrying value I, and obtain the wire length data, and obtain the actual offline length according to the wire length data.

[0008] In the above method for calculating the current carrying value of bundled wires based on digital simulation of three-dimensional wire harnesses, in step one, the parameterized database includes parameterized 2D electrical schematics, initial parameters, operation rules, and identification of extracted parameters.

[0009] In the above method for calculating the current carrying value of bundled wires based on digital simulation of three-dimensional wire harnesses, in step three, the wiring harness laying path is planned, multiple wiring harness groups are set, and signal types of different strengths, frequencies, and functions are classified into groups.

[0010] In the above method for calculating the current carrying value of bundled wires based on digital simulation of three-dimensional wire harnesses, in step three, the logical parameter data includes: wire connection device port information, color, line type, bending radius, wire diameter, and manufacturer.

[0011] In the above method for calculating the current-carrying value of bundled wires based on digital simulation of three-dimensional wire harnesses, in step three, the three-dimensional wire harness group is a wire harness composed of n wire groups arranged in a circumferential direction, and then the digital prototype cable network is laid by n wire harness groups.

[0012] In the above method for calculating the current carrying value of bundled wires based on digital simulation of three-dimensional wire harnesses, in step 4, the current carrying value I of the wires is obtained by the following formula:

[0013] I=(((P / U*cosφ)*K sh )*K g )*β;

[0014] Among them, I is the current carrying value of the wire; P is the power of the equipment; U is the voltage; cosφ is the power factor; β is the peak current safety factor; K sh K is the current correction factor; g is the altitude correction factor.

[0015] In the above method for calculating the current carrying value of bundled wires based on digital simulation of three-dimensional wire harnesses, in step 4, the actual length of the wires is obtained by the following formula:

[0016] L0=L+L2;

[0017] Among them, L0 represents the actual down-line length; L is the wire length data; L2 is the stress release length.

[0018] Compared with the prior art, the present invention has the following beneficial effects:

[0019] (1) The present invention realizes a complete digital machine and successfully solves the technical difficulty that the existing technical means cannot calculate and analyze the current carrying value of bundled cables in the design stage. The effect achieved is to make up for the shortcomings of traditional 2D electrical design drawings and cause production, and improve the long-standing phenomenon of digital three-dimensional design focusing on machinery and neglecting electricity. Digital three-dimensional cable design is an important component to make up for the electrical part of the digital machine. It can pull the traditional structure and electrical serial design method onto a unified digital design platform, enhance the coordination of structure and electronic control design, and correct product design defects at the beginning of drawing design through complete digital prototype review.

[0020] (2) The present invention realizes the uniqueness of reading and calling data sources through the transmission of logical parameters of 2D electrical schematics. Both design data and production data are derived from the basic database, which fundamentally guarantees the uniformity of data sources, so as to achieve the purpose of generating data tables without verification, eliminate human statistical errors in product research and development, and realize real-time data exchange. When the top-level data needs to be changed, it is only necessary to modify the underlying data source, and the data chains related to it at the back end are automatically associated and changed, thereby improving design accuracy.

[0021] (3) The present invention achieves the acquisition of each wire length L and wire current correction coefficient K through digital simulation by aggregating parameters into statistics and calculations. sh The current carrying value I of the wire is calculated, and the selected wire specification model is obtained by looking up the table. Compared with the existing technical solutions, the cable utilization rate can be increased by 99%. At the same time, the actual cable consumption of the whole machine electrical equipment can be obtained in the early stage of design, which is conducive to cost accounting. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Various other advantages and benefits will become apparent to those of ordinary skill in the art by reading the detailed description of the preferred embodiments below. The accompanying drawings are only for the purpose of illustrating the preferred embodiments and are not to be considered as limiting the present invention. Moreover, the same reference symbols are used throughout the accompanying drawings to represent the same components. In the accompanying drawings:

[0023] Figure 1 It is a flow chart of a method for calculating the current carrying value of bundled wires based on digital simulation of three-dimensional wire harnesses provided by an embodiment of the present invention;

[0024] Figure 2 is a schematic diagram of a digital three-dimensional wiring harness spatial laying state provided by an embodiment of the present invention;

[0025] Figure 3 It is a cross-sectional view of a branch of a digitized three-dimensional wire harness provided by an embodiment of the present invention, and a schematic diagram listing the number of wires thereof. DETAILED DESCRIPTION

[0026] Exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings. Although exemplary embodiments of the present disclosure are shown in the accompanying drawings, it should be understood that the present disclosure can be implemented in various forms and should not be limited by the embodiments set forth herein. On the contrary, these embodiments are provided in order to enable a more thorough understanding of the present disclosure and to be able to fully convey the scope of the present disclosure to those skilled in the art. It should be noted that, in the absence of conflict, the embodiments of the present invention and the features described in the embodiments can be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0027] Figure 1 1 is a flow chart of a method for calculating the current carrying value of bundled wires based on digital simulation of three-dimensional wire harnesses provided by an embodiment of the present invention. Figure 1 As shown, the method comprises the following steps:

[0028] Step 1: Create a digital 3D model library (including: mechanical structure model, electrical component model, connector model, etc.), a parametric database (including: parametric 2D electrical schematics, setting initial parameters, operation rules, and extraction parameter identification).

[0029] Step 2: Use a digital 3D virtual environment to simulate the assembly of the entire machine. Based on the mechanical structure model and the actual assembly relationship, assemble the electrical component model and connector model into the mechanical structure. According to the electromagnetic compatibility technical requirements, separate the high-voltage and high-frequency devices and the low-voltage and low-frequency devices to determine the relative positions of the devices.

[0030] Step 3: Plan the wiring harness routing, set up multiple wiring harness groups, and classify signal types of different strengths, frequencies, functions, etc. into groups.

[0031] Step 4: Import the logical parameter data of the parametric 2D electrical schematic (including: wire connection device port information, color, line type, bending radius, wire diameter, manufacturer, etc.). The digital 3D environment provides logical parameter data based on the 2D electrical schematic, automatically determines the position of the device port at both ends of the wire, and follows the specified planning path to automatically interconnect hundreds of wires to generate a 3D wire harness group.

[0032] Step 5: By analyzing the wiring harness information on the laying path, insert the detection point to extract the wire number, number of wires and other data passing through the point, which is used to analyze and calculate the wire current correction coefficient K sh , calculate the corrected current-carrying value, independently complete the wire selection, obtain the wire length data, and generate a data statistics table.

[0033] The information collection of digital 3D model library, parametric database, etc. can be counted and sorted by third-party software and transmitted through data channels, or it can be created by this software; the grouping of 3D harness groups and the transmission of connection data are controlled by 2D electrical schematics.

[0034] The main cable path, branch routing paths and sub-harness groups are created in a three-dimensional environment by attaching to the outer surface or internal cavity of the mechanical structure model; the harness cross-sectional shape is composed of n wires arranged in a circular direction, and the digital prototype cable network is laid out by n harness groups.

[0035] The shield grounding of the shielded cable is controlled by the 2D electrical schematic, and the grounding port connected to the electrical model is automatically generated.

[0036] After the whole machine is virtually assembled, hundreds or thousands of wires are accurately connected to the logical parameter information in the device port, which is obtained by transferring the parameterized 2D electrical schematic diagram. The number of wires generated ranges from n to n×10 n All wires can be automatically generated and connected to the ports on the electrical component model.

[0037] Generate a virtual three-dimensional wire harness, obtain the number of wires distributed in each wire harness group, and query the attenuation table to obtain the current correction coefficient K sh , calculate the precise wire current carrying value I, the expression is as follows:

[0038] I=(((P / U*cosφ)*K sh )*K g )*β;

[0039] Among them, I is the current carrying value of the wire; P is the power of the equipment; U is the voltage; cosφ is the power factor; β is the peak current safety factor; Ksh K is the current correction factor; g is the altitude correction factor.

[0040] The virtual wire harness can be simulated to obtain the precise length L. The actual offline length needs to be added with the stress release length L2. The expression is as follows;

[0041] L0=L+L2

[0042] Among them, L0 represents the actual length of the downline;

[0043] Through calculation and analysis, data such as the length of the wire and the current carrying value of the wire are obtained, and charts are automatically generated from the BOM table statistics without manual intervention.

[0044] Specifically, 1. Creation of 3D digital mechanical structure model: Modeling based on the design 1:1, the whole machine actuator module, and the skeleton that carries the digital 3D electrical model and 3D wiring harness, providing protection and fixed position for it;

[0045] 2. Creation of a 3D digital electrical component model library: Create models at a 1:1 ratio based on the physical device appearance. The models have parameters such as external color, model, manufacturer, weight, and wiring port location. The device layout is distributed in the mechanical structure model according to the rule of shortest input and output distance between the two related components and optimal electromagnetic compatibility.

[0046] 3. Digital parameter library: It is the basic database for implementing the algorithm. It forms a data group according to the type grouping and algorithm rules, provides a data source for reading and calling, and can connect with the external software data channel to transfer data. It is the data support for the data harness to generate a three-dimensional harness, and provides a data source for reading analysis, calculation, and statistics;

[0047] 4. Parametric 2D electrical schematic plan: It is mainly divided into two parts. One part is the logical relationship diagram of electrical interconnection, and the other part is the underlying parametric equipment, device, and cable data set. It can communicate with the 3D digital virtual parameter library for data exchange, provide electrical logic parameter information for the 3D environment, and drive the key steps of automatic wiring.

[0048] 5. Three-dimensional digital virtual environment: It combines structural parts, model library, parameter library, electrical principle and logic parameters for assembly, and automatically generates and completes the laying according to the preset path and wire harness grouping. By analyzing and calculating the number of wires in the bundled wire harness, the current correction coefficient K is obtained. sh , calculate the accurate wire current carrying value (such as Figure 2 and Figure 3 shown);

[0049] (1) In this embodiment, the creation of the three-dimensional digital virtual structural parts described in step 1 is completed by the structural engineer and then passed to the electrical engineer. After the electrical engineer completes the design of the electrical and cable protection and fixing measures, the structural changes are fed back to the structural engineer for further improvement.

[0050] (2) In this embodiment, the creation of the three-dimensional digital virtual electrical model library described in step 2 is completed by electrical engineers. Each electrical model requires a name set according to fixed regulations as a material code for convenient searching, function differentiation, parameter reading and filtering.

[0051] (3) In this embodiment, the three-dimensional digital virtual parameter library described in steps 3 to 5 has a huge amount of underlying data, which is filled in using software that can be connected to the data channel and batch imported. The parameters are all variables that are transmitted in a directional manner. If the top-level data needs to be changed, only the bottom-level data needs to be modified, and the parameters in this data chain will be changed.

[0052] (4) In this embodiment, the above-mentioned modeling steps are completed to obtain a complete digital prototype, which can be used for review, cost accounting, improving the coordination of various functional modules, digital assembly of multiple individually designed functional modules, analysis of interference inspection, internal space, heat dissipation conditions to correct design defects in drawings, and improve the coordination of the interconnection of various functional modules.

[0053] (5) The preferred cable laying path is as follows;

[0054] The reasonable layout of devices is used to drive the cable laying path. Based on the principle of shortest routing and shortest distance, the axis of the cable laying path and the reference plane of the side wall are kept horizontal and vertical. At the turning corner, the arc radius is greater than the cable bending radius and is on the same reference plane; the planning path avoids sharp angles, heating components, electrical components with strong magnetic fields, and moving structure positions. Customized preset routing paths for different harness groups, the vertical spacing of strong and weak signals L1 ≥ 500mm, and vertical cross crossing is adopted when it is unavoidable to reduce harness signal coupling interference and improve the electromagnetic compatibility of the whole machine.

[0055] (6) Optimal calculation and selection scheme

[0056] Calculated current correction factor K sh , the expression for the accurate wire current carrying value is as follows;

[0057] I=(((P / U*cosφ)*β)*K sh )*K g

[0058] Among them, cosφ is taken as 0.8, and β is taken as 0.7;

[0059] The actual offline length needs to be added with the stress release length L2, the expression is as follows;

[0060] L0=L+L2

[0061] Among them, L0 takes the value of 35mm. When the cross-sectional area of ​​the wire is greater than 10mm 2 The value is 0;

[0062] (7) In this embodiment, the above steps are completed: the data calculation and statistics of each conductor are all added by using the above expression to add the operation rules, automatically fill in the simulation parameters, and the operation results are tabulated and counted. The cable selection is based on the cable manual to establish a database, and the judgment statement is used to quickly generate the cable specification table.

[0063] The present invention realizes a complete digital whole machine, and successfully solves the technical difficulty that the existing technical means cannot calculate and analyze the current carrying value of the bundled cable in the design stage. The effect achieved is to make up for the shortcomings of traditional 2D electrical design drawings that cause production, and improve the long-term phenomenon of digital three-dimensional design focusing on machinery and neglecting electricity. Digital three-dimensional cable design is an important component to make up for the electrical part of the digital whole machine. The traditional structure and electrical serial design method can be pulled onto a unified digital design platform to enhance the coordination of structure and electric control design. Through the complete digital prototype review, the product design defects can be corrected at the beginning of the drawing design; the present invention realizes the uniqueness of reading and calling data sources through the 2D electrical schematic logical parameter transmission. The design data and production data are all derived from the basic database, which fundamentally guarantees the uniformity of the data source, so as to achieve the purpose of generating data tables without verification, eliminate artificial statistical errors in the product development link, and realize real-time data exchange. When the top-level data needs to be changed, it is only necessary to modify the bottom-level data source, and the data links related to it at the back end are automatically associated and changed, thereby improving the design accuracy; the present invention realizes the acquisition of each wire length L and wire current carrying value correction coefficient K through digital simulation by aggregating parameters in statistics and calculations. sh The current carrying value I of the wire is calculated, and the selected wire specification model is obtained by looking up the table. Compared with the existing technical solutions, the cable utilization rate can be increased by 99%. At the same time, the actual cable consumption of the whole machine electrical equipment can be obtained in the early stage of design, which is conducive to cost accounting.

[0064] Although the present invention has been disclosed as above in the form of a preferred embodiment, it is not intended to limit the present invention. Any person skilled in the art may make possible changes and modifications to the technical solution of the present invention by using the methods and technical contents disclosed above without departing from the spirit and scope of the present invention. Therefore, any simple modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solution of the present invention shall fall within the protection scope of the technical solution of the present invention.

Claims

1. A method for calculating the current carrying value of bundled wires based on digital simulation of three-dimensional wire harnesses, characterized in that: The method comprises the following steps: Step 1: Create a digital 3D model library and a parametric database; wherein the digital 3D model library includes mechanical structure models, electrical component models and connector models; Step 2: Based on the mechanical structure model and the actual assembly relationship, assemble the electrical component model and the connector model into the mechanical structure model; Step 3: According to the logical parameter data provided by the parameterized database, the positions of the device ports at both ends of the wires are automatically determined, and hundreds of wires are automatically interconnected according to the specified planning path to generate a three-dimensional wire harness group; Step 4: Obtain the current-carrying value correction coefficient of a single wire in the three-dimensional wire harness group, calculate the wire current-carrying value, complete the wire selection based on the wire current-carrying value, and obtain the wire length data, and obtain the actual offline length based on the wire length data.

2. The method for calculating the current carrying value of bundled wires based on digital simulation of three-dimensional wire harness according to claim 1, characterized in that: In step one, the parameterized database includes a parameterized 2D electrical schematic diagram, initial parameters, operation rules, and identification of extracted parameters.

3. The method for calculating the current carrying value of bundled wires based on digital simulation of three-dimensional wire harness according to claim 1, characterized in that: In step three, the wiring harness routing is planned, multiple wiring harness groups are set, and signal types of different strengths, frequencies, and functions are classified into groups.

4. The method for calculating the current carrying value of bundled wires based on digital simulation of three-dimensional wire harness according to claim 1, characterized in that: In step three, the logical parameter data includes: wire connection device port information, color, line type, bending radius, wire diameter, and manufacturer.

5. The method for calculating the current carrying value of bundled wires based on digital simulation of three-dimensional wire harness according to claim 1, characterized in that: In step three, the three-dimensional wire harness group is a wire harness composed of n wire groups arranged in a circumferential direction, and then the digital prototype cable network is laid out by the n wire harness groups.

6. The method for calculating the current carrying value of bundled wires based on digital simulation of three-dimensional wire harness according to claim 1, characterized in that: In step 4, the wire current carrying value I is obtained by the following formula: I=(((P / U*cosφ)*K sh )*K g )*β; Among them, I is the current carrying value of the wire; P is the power of the equipment; U is the voltage; cosφ is the power factor; β is the peak current safety factor; K sh K is the current correction factor; g is the altitude correction factor.

7. The method for calculating the current carrying value of bundled wires based on digital simulation of three-dimensional wire harness according to claim 1, characterized in that: In step 4, the actual offline length is obtained by the following formula: L0=L+L2; Among them, L0 represents the actual down-line length; L is the wire length data; L2 is the stress release length.

Images