Intelligent automobile wire harness detection system and detection method thereof

Abstract

The invention discloses an intelligent automobile wire harness detection system which comprises a mechanical positioning module, and the mechanical positioning module comprises an XYZ three-axis motion platform driven by a servo motor, an adjustable clamp system, a high-precision position sensor and a manipulator. The electrical detection module comprises a multi-channel conduction test unit, an insulation resistance test unit, a withstand voltage test unit, a short circuit detection unit and a signal integrity test unit; the visual detection module comprises a high-resolution industrial camera, a multi-angle light source system, an optical amplification system and a bar code / RFID reader; a control and data processing module; a man-machine interaction module; and a communication interface module. Through cooperation of multiple modules, comprehensive detection of key indexes such as continuity, insulativity, conductivity and assembly correctness of the wire harness is realized, the production quality and detection efficiency of the automobile wire harness can be effectively improved, and the labor cost and the quality risk are reduced.

Description

Technical Field

[0001] The present invention belongs to the technical field of automotive wire harness detection. Specifically, it relates to an intelligent automotive wire harness detection system and its detection method. Background Art

[0002] An automotive wire harness refers to a component formed by crimping contact terminals (connectors) made of copper with wires and cables, then plastically molding an insulator outside or adding a metal housing, etc., bundling the wire harness and connecting plug connectors to form a connecting circuit. It is the network main body of the automotive circuit. With the improvement of people's requirements for automotive safety, comfort, economy, and emissions, the electrical configurations and functions on automobiles are increasing, and the reliability requirements for automotive wire harnesses are getting higher and higher. This requires strict detection and a large number of tests during the production process of automotive wire harnesses to ensure the overall quality of the vehicle. The traditional means of on-site detecting the continuity of wire harnesses is to use a multimeter, buzzer, or indicator light, manually connecting point by point, and judging the continuity of each connecting wire by observing whether there is an electrical, sound, or light signal. The troubleshooting and inspection of errors can only be carried out for each wire one by one, which is not only slow and inefficient but also prone to misdetection and missed detection of wire harnesses.

[0003] The article "Design of an Automatic Wire Harness Detector" published in Chinese Journal of Scientific Instrument 2005, No.2, P99 - 103 introduced an automotive wire harness detection method. A certain voltage is applied to a selected terminal in sequence, and the levels of the remaining terminals are read. After scanning each terminal, it is immediately compared with the standard circuit table, and error information is recorded. After scanning all terminals, wire harness fault location is carried out. This method requires point-by-point scanning of all terminals, resulting in a large amount of detection data, a long time for the fault location algorithm, and low detection efficiency; moreover, since each terminal has to serve as both an input terminal and an output terminal, it increases the complexity of the hardware design.

[0004] Therefore, it is necessary to design an efficient, intelligent, and accurate automotive wire harness detection system at present. Summary of the Invention

[0005] In view of this, the technical problem to be solved by the present invention is to provide an intelligent automotive wire harness detection system to avoid the trouble of low efficiency, easy misdetection and missed detection in the previous manual detection of automotive wire harnesses.

[0006] To solve the above technical problem, the present invention discloses an intelligent automotive wire harness detection system, which includes: A mechanical positioning module, which includes an XYZ three-axis motion platform driven by a servo motor, an adjustable fixture system, a high-precision position sensor, and a manipulator for automatic replacement of wire harness trays; Electrical detection module, which includes a multi-channel conduction test unit, an insulation resistance test unit, a withstand voltage test unit, a short-circuit detection unit, and a signal integrity test unit; Vision detection module, which includes a high-resolution industrial camera, a multi-angle light source system, an optical magnification system, and a barcode / RFID reader; Control and data processing module, which includes an industrial PC, a PLC controller, a data acquisition card, and a database server; Human-machine interaction module, which includes an operator interface and an alarm system; Communication interface module, which is used for system integration and data exchange.

[0007] The present invention also discloses a detection method for an intelligent automotive wiring harness detection system, including: Step a. Preparation stage: The operator scans the wiring harness ID, the system retrieves the corresponding detection program, the manipulator automatically loads the wiring harness onto the detection tooling, and the system performs self-check to confirm that the status of each module is normal; Step b. Electrical detection stage: Conduction test: Detect the connectivity of all terminals point by point; Insulation test: Detect the insulation resistance between adjacent terminals; Withstand voltage test: Apply high voltage to detect the insulation strength; Signal test: Perform impedance and crosstalk tests on high-speed signal lines; Step c. Vision detection stage: Detect the terminal position and insertion depth; Check the wiring harness routing and fixing points; Identify labels and markings; Detect appearance defects; Step d. Result processing stage: Comprehensively evaluate all test results; Generate a detection report; Upload data to the MES system; Automatically sort out non-conforming products; Step e. End stage: The manipulator unloads the detected wiring harness; The system resets and prepares for the next detection cycle.

[0008] According to an embodiment of the present invention, the above-mentioned human-machine interaction module includes a 15-inch touch screen, an audible and visual alarm system, a barcode scanner, and a report printer; The audible and visual alarm system has a three-color light and a buzzer.

[0009] According to an embodiment of the present invention, the above-mentioned communication interface module includes an Ethernet / IP interface, an RS232 / 485 interface, a CAN bus interface; An OPC UA server.

[0010] According to an embodiment of the present invention, in the above-mentioned step c, for the detection of the terminal position and insertion depth, the actual insertion depth is calculated by combining the captured terminal images and using the PnP algorithm.

[0011] Compared with the prior art, the present invention can achieve the following technical effects: Through multi-module collaboration, comprehensive detection of key indicators such as the continuity, insulation, conductivity, and assembly correctness of the wire harness is realized, which can effectively improve the production quality and detection efficiency of automotive wire harnesses, and reduce labor costs and quality risks.

[0012] Of course, it is not necessary for any product implementing the present invention to achieve all the above-mentioned technical effects simultaneously. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The drawings described herein are used to provide a further understanding of the present invention and constitute a part of the present invention. The illustrative embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation to the present invention. In the drawings: Figure 1 is a block diagram of an intelligent automotive wire harness detection system according to an embodiment of the present invention; Figure 2 is a flowchart of a detection method for an intelligent automotive wire harness detection system according to an embodiment of the present invention. REFERENCE SIGNS

[0014] Lamp socket housing 10, low beam lamp group 11, high beam lamp socket 12, dynamic adjustment assembly 20, ball head base 30, ball head rod 40, ball head portion 41, internal thread sleeve portion 42, screw rod portion 50, first right-angle transmission seat 61, second right-angle transmission seat 62, secondary transmission rod 71, main transmission rod 72, limit card 80, limit groove 81, limit ring 90. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0015] The following will describe in detail the embodiments of the present invention in conjunction with the drawings and embodiments, so as to fully understand how the present invention uses technical means to solve technical problems and achieve the realization process of technical effects and implement accordingly.

[0016] Please refer to Figure 1 and Figure 2 , Figure 1 is a block diagram of an intelligent automotive wire harness detection system according to an embodiment of the present invention; Figure 2 is a flowchart of a detection method for an intelligent automotive wire harness detection system according to an embodiment of the present invention.

[0017] As shown in the figure, an intelligent automotive wire harness detection system includes: A mechanical positioning module, which includes an XYZ three-axis motion platform driven by a servo motor, an adjustable fixture system, a high-precision position sensor, and a manipulator for automatic replacement of the wire harness tray; wherein, the manipulator completes the replacement of the wire harness tray, and the adjustable fixture system performs clamping and fixing, and a pneumatic crimping pliers can be selected. The high-precision position sensor monitors the position on the XYZ three-axis motion platform in real time.

[0018] An electrical detection module, which includes a multi-channel conduction test unit, an insulation resistance test unit, a withstand voltage test unit, a short-circuit detection unit, and a signal integrity test unit; among them, the multi-channel conduction test unit supports a maximum of 512 channels, the test voltage of the insulation resistance test unit is adjustable from 50V to 1000V, the AC / DC of the withstand voltage test unit is 0 - 5kV, and the signal integrity test unit is used for high-speed signals such as CAN bus.

[0019] A vision detection module, which includes a high-resolution industrial camera, a multi-angle light source system with more than 5 million pixels, and it has a ring light, a coaxial light, and a backlight; an optical magnification system is used for detecting micro terminals; a barcode / RFID reader is used for product traceability; A control and data processing module, which includes an industrial PC, an i7 processor can be selected, 16GB RAM, a PLC controller for mechanical control, a data acquisition card, a 24-bit ADC, a sampling rate of 1MS / s, and a database server for storing detection results and statistical information; A human-machine interaction module, which includes an operator interface and an alarm system; it includes a 15-inch touch screen, an audible and visual alarm system, a barcode scanner, and a report printer; among them, the audible and visual alarm system has a three-color light and a buzzer.

[0020] A communication interface module, which is used for system integration and data exchange, and includes an Ethernet / IP interface, an RS232 / 485 interface, a CAN bus interface; an OPC UA server.

[0021] The present invention also discloses a detection method for an intelligent automotive wire harness detection system, including: Step a. Preparation stage: The operator scans the wire harness ID, the system retrieves the corresponding detection program, the manipulator automatically loads the wire harness into the detection tooling, and the system performs a self-check to confirm that the status of each module is normal; Step b. Electrical detection stage: Conduction test: Detect the connectivity of all terminals point by point; Insulation test: Detect the insulation resistance between adjacent terminals; Withstand voltage test: Apply a high voltage to detect the insulation strength; Signal test: Perform impedance and crosstalk tests on high-speed signal lines; Step c. Vision detection stage: Detect the terminal position and insertion depth; Check the wire harness routing and fixing points; Identify labels and markings; Detect appearance defects; Step d. Result processing stage: Comprehensively evaluate all test results; Generate a detection report; Upload data to the MES system; Automatically sort out non-conforming products; Step e. End stage: The manipulator unloads the detected wire harness; the system resets and prepares for the next detection cycle.

[0022] Preferably, in step c, during the detection of the terminal position and insertion depth, the captured terminal images are combined and the actual insertion depth is calculated using the PnP algorithm. Embodiment 1

[0023] Four common defects that need to be detected in the wire harness terminals: Bending deformation (physical deformation occurs in the metal part of the terminal) Surface oxidation (discoloration or corrosion appears on the terminal surface) Insufficient insertion (the terminal is not fully inserted into the connector) Contamination by foreign objects (oil stains or particles on the terminal surface) Taking the detection of a terminal connector as an example: Input: Terminal images taken from three different angles (top view, 45° side view, 90° side view) Preprocessing: Perform HDR fusion on the three images; Apply CLAHE to enhance the contrast; Extract the ROI region; Detection and classification: YOLOv5 detects the terminal position (confidence 0.98); The classification branch outputs: [0.02, 0.85, 0.10, 0.03] → Determined as "surface oxidation"; The regression branch outputs a depth value of 0.73 (normalized value); 3D verification: Match feature points from multi-view images; The PnP algorithm calculates the actual insertion depth as 3.21 mm (the standard should be 3.5 - 4.0 mm); Combining the 2D classification results and 3D measurements, the final determination is "insufficient insertion + surface oxidation".

[0024] In summary, through the cooperation of multiple modules, the present invention realizes the comprehensive detection of key indicators such as the continuity, insulation, conductivity, and assembly correctness of the wire harness, can effectively improve the production quality and detection efficiency of automotive wire harnesses, and reduce labor costs and quality risks.

[0025] The foregoing description has shown and described several preferred embodiments of the present invention. However, as previously mentioned, it should be understood that the present invention is not limited to the forms disclosed herein, should not be regarded as excluding other embodiments, but can be used in various other combinations, modifications, and environments, and can be altered within the scope of the inventive concept described herein through the above teachings or the skills or knowledge in related fields. Any alterations and changes made by those skilled in the art that do not depart from the spirit and scope of the present invention shall fall within the protection scope of the appended claims of the present invention.

Claims

1. An intelligent vehicle wiring harness detection system, characterized in that, Including: A mechanical positioning module, which includes an XYZ three-axis motion platform driven by a servo motor, an adjustable fixture system, a high-precision position sensor, and a manipulator for automatic replacement of the wire harness tray; An electrical detection module, which includes a multi-channel continuity test unit, an insulation resistance test unit, a withstand voltage test unit, a short-circuit detection unit, and a signal integrity test unit; A vision detection module, which includes a high-resolution industrial camera, a multi-angle light source system, an optical magnification system, and a barcode / RFID reader; A control and data processing module, which includes an industrial PC, a PLC controller, a data acquisition card, and a database server; A human-machine interaction module, which includes an operator interface and an alarm system; A communication interface module, which is used for system integration and data exchange.

2. The detection method of an intelligent vehicle wiring harness detection system as described in claim 1, characterized in that, Including: Step a. Preparation stage: The operator scans the wire harness ID, the system retrieves the corresponding detection program, the manipulator automatically loads the wire harness onto the detection tooling, and the system performs a self-check to confirm that the status of each module is normal; Step b. Electrical detection stage: Continuity test: Detect the connectivity of all terminals point by point; Insulation test: Detect the insulation resistance between adjacent terminals; Withstand voltage test: Apply a high voltage to detect the insulation strength; Signal test: Perform impedance and crosstalk tests on high-speed signal lines; Step c. Vision detection stage: Detect the terminal position and insertion depth; Check the wire harness routing and fixing points; Identify labels and markings; Detect appearance defects; Step d. Result processing stage: Comprehensively evaluate all test results; Generate a detection report; Upload data to the MES system; Automatically sort out unqualified products; Step e. End stage: The manipulator unloads the detected wire harness; The system resets and prepares for the next detection cycle.

3. The detection method of the intelligent vehicle wiring harness detection system according to claim 2, characterized in that Wherein the human-machine interaction module includes a 15-inch touch screen, an audible and visual alarm system, a barcode scanner, and a report printer; Wherein the audible and visual alarm system has a three-color light and a buzzer.

4. The detection method of the intelligent vehicle wiring harness detection system according to claim 2, characterized in that Wherein the communication interface module includes an Ethernet / IP interface, an RS232 / 485 interface, a CAN bus interface; An OPC UA server.

5. The detection method of the intelligent vehicle wiring harness detection system according to claim 2, wherein, Wherein in the detection of the terminal position and insertion depth in step c, the actual insertion depth is calculated by combining the captured terminal images and using the PnP algorithm.

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