Intelligent wire harness based on sensor monitoring

Abstract

The invention discloses an intelligent wire harness based on sensor monitoring, which comprises a plurality of wires, the outer sides of the plurality of wires are wrapped with an insulating layer, a temperature sensor array and a humidity sensor array are integrated in the insulating layer, one end of each wire is connected with a connecting male head, and the other end of each wire is connected with a connecting female head; a current sensing module is integrated in the connecting male head, and a voltage sensing module is integrated in the connecting female head; the outer side of the insulating layer is provided with a sheath, and the sheath is connected with the connecting female head, the connecting male head and the insulating layer in a live transmission mode through a communication line. A vibration sensor group and a microprocessor are integrated in the sheath, and the sheath is connected with a monitoring terminal in a wireless connection mode. The temperature sensor array and the humidity sensor array are arranged in the insulating layer, so that the temperature and humidity changes around the wire can be monitored in real time, and the problems of aging, short circuit and the like of the insulating layer of the wire caused by over-high temperature or over-high humidity can be found in time.

Description

Technical Field

[0001] The present invention relates to the technical field of wire harnesses, and particularly to an intelligent wire harness based on sensor monitoring. Background Art

[0002] In modern industries, transportation, electronic devices and other fields, the wire harness, as a key component connecting various electrical components, its stable operation is crucial. With the continuous development of technology, the degree of intelligence of equipment is getting higher and higher, and higher requirements are also put forward for the reliability, safety and functionality of wire harnesses. Traditional wire harnesses are mainly composed of wires, insulation layers, sheaths, etc. Their functions are relatively single, only playing the role of transmitting electrical energy and signals, lacking the ability to monitor and protect their own states. Therefore, some intelligent wire harnesses have emerged on the market.

[0003] For example, the utility model patent with the publication number CN211252481U discloses a trailer intelligent wire harness, including sensors, collectors, controllers, gateways and display modules; the collectors analyze the data obtained from the sensors; the controllers supply power to the collectors, and the controllers process, store and feedback the data obtained from the collectors. The controllers and gateways are powered by a tractor. The gateways send, store and feedback the data obtained from the controllers; the gateways communicate with the display modules wirelessly or wiredly, and the display modules display and feedback the data obtained from the gateways. The gateways store the information in a network server wirelessly, and the network server stores and feedbacks the data obtained from the gateways.

[0004] The intelligent wire harness provided by the above patent helps the driver obtain the trailer state data and the cargo state data, but this intelligent wire harness cannot monitor its own usage environment. In practical applications, the wire harness may face various complex environmental factors, such as too high or too low temperature, high humidity, vibration, electromagnetic interference, etc. These factors may cause faults in the wire harness, such as aging of the wire insulation layer, short circuit, open circuit, etc., which may affect the normal operation of the equipment and even cause safety accidents. For example, in the automotive field, the wire harness is distributed in the engine compartment, chassis and other parts. The temperature in the engine compartment is relatively high. The wire harness in the high-temperature environment for a long time is prone to aging of the insulation layer, resulting in a short circuit, which may cause the vehicle to catch fire; in industrial equipment, the wire harness joints are prone to looseness in a vibrating environment, resulting in poor contact and affecting the stable operation of the equipment.

[0005] In addition, after a fault occurs in a traditional wire harness, manual troubleshooting and maintenance are required. This not only has low efficiency but also makes it difficult to detect potential problems in a timely manner before the fault occurs, and it is impossible to take preventive measures in advance. With the popularization of the Internet of Things and intelligent devices, intelligent monitoring and management of wire harnesses have become an urgent need. Therefore, this application proposes an intelligent wire harness that integrates sensors on the wire harness, can monitor various parameters of the wire harness in real time, such as temperature, humidity, current, voltage, vibration, etc., can detect abnormal states of the wire harness in a timely manner, give early warnings of faults, improve the reliability and safety of equipment, and reduce maintenance costs. Summary of the Invention

[0006] The purpose of the present invention is to provide an intelligent wire harness based on sensor monitoring to solve the problems in the above-mentioned background technology, such as the traditional wire harness lacking the ability to monitor and protect its own state, low efficiency in troubleshooting and maintenance, and deficiencies in existing intelligent wire harnesses.

[0007] The present invention is implemented as follows:

[0008] An intelligent wire harness based on sensor monitoring includes multiple wires. An insulating layer is wrapped outside the multiple wires. A temperature sensor array and a humidity sensor array are integrated in the insulating layer. One end of each of the multiple wires is connected to a male connector, and the other end is connected to a female connector. A current induction module is integrated in the male connector, and a voltage induction module is integrated in the female connector. A sheath is provided outside the insulating layer. The sheath is connected to the female connector, the male connector, and the insulating layer in a charged transmission manner through a connecting wire. A vibration sensor group and a microprocessor are integrated inside the sheath. The sheath is connected to a monitoring terminal in a wireless connection manner.

[0009] Preferably, the temperature sensor array includes multiple NTC thermistors. The multiple NTC thermistors are evenly distributed along the axial direction of the wire at an interval of 5-15 cm. The humidity sensor array includes multiple polymer film capacitive humidity sensors. The multiple polymer film capacitive humidity sensors and the multiple NTC thermistors are arranged alternately.

[0010] Preferably, the current induction module is a manganin shunt integrated on the conductive pin of the male connector, and the voltage induction module is a resistor voltage division circuit integrated in the conductive jack of the female connector.

[0011] Preferably, the vibration sensor group includes multiple three-axis acceleration sensors. The multiple three-axis acceleration sensors are evenly distributed along the length direction of the sheath, and the interval between adjacent three-axis acceleration sensors is 20-50 cm.

[0012] Preferably, the microprocessor inside the sheath is connected to a signal receiving module, a signal processing module, a wireless communication module, a signal conditioning module, a data encoding module, and a fault alarm module; the signal receiving module is used to receive signals fed back by various sensors, the signal processing module is used to process the received sensor signals, the wireless communication module is used for wireless connection between the sheath and the monitoring terminal, the signal conditioning module is used for signal amplification and gain control, the data encoding module is used for standardizing the data format and protocol adaptation of the data, and the fault alarm module is used to issue an alarm when an abnormality is detected in the wire harness; the wireless communication module supports multi-mode communication and at least includes a Bluetooth 5.0 module and a 4G LTE module, and can automatically switch the communication protocol according to the type of the monitoring terminal; the amplification circuit gain G of the signal conditioning module can be dynamically adjusted by a digital potentiometer to meet where R f is the feedback resistor, and R g is the gain setting resistor.

[0013] Preferably, the insulating layer is made of a heat-conductive silicone rubber material and is internally provided with a grid-shaped support structure for fixing the sensors. The sheath is a fiber-reinforced thermoplastic composite material, and its inner wall is provided with a spiral groove for the routing of the sensor cables. The groove pitch P and the wire harness bending radius R satisfy P ≤ 2πR × 0.8.

[0014] Preferably, the conductive pins of the male connector and the conductive jacks of the female connector are coated with a nano-silver coating with a thickness of 5 - 10 μm. The signal output ends of the current induction module and the voltage induction module are provided with electromagnetic shielding sleeves, and the shielding effectiveness SE satisfies where E inc is the incident electric field strength, and E out is the electric field strength after shielding.

[0015] Preferably, the monitoring terminal includes a cloud server and a user interaction interface. The cloud server has a built-in fault prediction model, and the calculation of the fault probability P based on the sensor data uses a weighted support vector machine algorithm, and the expression is: where x1 - x n are characteristic parameters such as temperature, humidity, vibration amplitude, etc., w1 - w n are characteristic weights, and b is the bias term.

[0016] Preferably, the microprocessor is also connected to an energy management module and a local storage module. The energy management module includes a lithium battery pack and a wireless charging receiving coil, and the local storage module is used for caching sensor data.

[0017] Preferably, a strain sensor is further disposed inside the sheath. The strain sensor is arranged along the bending stress concentration area of the wire harness body and is used to monitor the deformation amount when the wire harness is in tension or compression. The strain value ε and the change rate of the sensor resistance ΔR / R satisfy ΔR / R = K·ε, where K is the strain gauge sensitivity coefficient.

[0018] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0019] 1. By arranging a temperature sensor array and a humidity sensor array inside the insulating layer, the present invention can monitor the temperature and humidity changes around the wire in real time, and timely detect problems such as aging and short - circuit of the wire insulating layer caused by too high temperature or too high humidity. By arranging a vibration sensor group on the sheath, the vibration condition of the wire harness can be monitored in real time, and problems such as loosening and wear of the wire harness caused by excessive vibration can be detected in time. By arranging a current induction module and a voltage induction module inside the connector, the current and voltage changes at the connector can be monitored in real time, and connector failures caused by poor contact, overload, etc. can be detected in time. At the same time, after the signal processing module processes the signals collected by the sensors, they are transmitted to an external monitoring terminal through the wireless communication module, realizing remote real - time monitoring of the wire harness state and improving the reliability and safety of the equipment.

[0020] 2. By setting a local storage module, the present invention stores the data of the wire harness through the local storage module, which is convenient for users to view the past data of the wire harness, so as to determine whether there is a trend of damage to the wire harness.

[0021] 3. By arranging a strain sensor inside the sheath, and the strain sensor is arranged along the bending stress concentration area of the wire harness body, it is used to monitor the deformation amount when the wire harness is in tension or compression, which is convenient to give a warning when there is a risk of damage to the wire bundle. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 is the overall structural schematic diagram of the present invention;

[0023] Figure 2 is the structural block diagram of the male connector of the present invention;

[0024] Figure 3 is the structural block diagram of the female connector of the present invention;

[0025] Figure 4 is the structural block diagram of the insulating layer of the present invention;

[0026] Figure 5 is the structural block diagram of the sheath cooperating with the monitoring terminal of the present invention.

[0027] In the figure: 1. Wire; 2. Male connector; 3. Female connector; 4. Insulating layer; 5. Sheath; 51. Connecting wire. DETAILED DESCRIPTION OF THE INVENTION

[0028] In the present invention, unless otherwise clearly defined and limited, terms such as "installation", "connection", "linkage", "fixation" shall be understood in a broad sense. For example, it may be a fixed connection, a detachable connection, or integrated as a whole; it may be a mechanical connection or an electrical connection; it may be directly connected or indirectly connected through an intermediate medium, and it may be the communication inside two components or the interaction relationship between two components. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0029] The following will be further described in conjunction with the accompanying drawings and specific embodiments:

[0030] Embodiment 1

[0031] As Figure 1 shown, an intelligent wire harness based on sensor monitoring includes multiple wires 1. An insulating layer 4 is wrapped outside the multiple wires 1. A temperature sensor array and a humidity sensor array are integrated inside the insulating layer 4. The insulating layer 4 is used for insulating protection of the wire harness and also facilitates the monitoring of the temperature and humidity of the wire harness. One end of the multiple wires 1 is connected with a male connector 2, and the other end is connected with a female connector 3; the male connector 2 and the female connector 3 facilitate the connection of the wire harness with corresponding components or other wire harnesses. A current sensing module is integrated inside the male connector 2, and a voltage sensing module is integrated inside the female connector 3; the current sensing module and the voltage sensing module are used for monitoring the current and voltage changes of the male connector 2 and the female connector 3, so as to facilitate timely handling in case of poor contact. A sheath 5 is provided outside the insulating layer 4. The sheath 5 is connected with the female connector 3, the male connector 2 and the insulating layer 4 in a charged transmission manner through a communication wire 51; it facilitates the transmission of the data detected by the temperature sensor array, the humidity sensor array, the current sensing module and the voltage sensing module to the sheath 5. A vibration sensor group and a microprocessor are integrated inside the sheath 5. The vibration sensor group is used for monitoring the vibration condition of the wire harness. The sheath 5 is connected with a monitoring terminal in a wireless connection manner, which facilitates the feedback of the monitored data to the terminal for the terminal to view.

[0032] As Figure 4 shown, the temperature sensor array includes multiple NTC thermistors. The multiple NTC thermistors are evenly distributed at equal intervals along the axial direction of the wire 1. The distance between the NTC thermistors is 5 - 15 cm, which facilitates the effective monitoring of the temperature at each position of the wire harness. The humidity sensor array includes multiple polymer film capacitive humidity sensors. The multiple polymer film capacitive humidity sensors and the multiple NTC thermistors are arranged alternately, which facilitates the effective humidity monitoring of each position of the wire harness.

[0033] As Figure 2 and Figure 3As shown, the current induction module is a manganin shunt integrated on the conductive pins of the male connector 2, and its induced voltage V I and the measured current I satisfy: V I = I·R s , where R s is the internal resistance of the shunt. The voltage induction module is a resistive voltage division circuit integrated in the conductive socket of the female connector 3. The calculation formula for the shunt output voltage V U is: where V in is the input voltage, and R1 and R2 are the resistance values of the voltage division resistors.

[0034] As Figure 5 shown, the vibration sensor group includes multiple three-axis acceleration sensors. The multiple three-axis acceleration sensors are evenly distributed along the length direction of the sheath 5, and the distance between adjacent three-axis acceleration sensors is 20 - 50 cm. The calculation formula for the combined vibration amplitude A of a single three-axis acceleration sensor is: where a x , a y , a z are the acceleration components of the x, y, and z axes respectively.

[0035] As Figure 5 shown, the microprocessor in the sheath 5 is connected with a signal receiving module, a signal processing module, a wireless communication module, a signal conditioning module, a data encoding module, and a fault alarm module. The signal receiving module is used to receive the signals fed back by various sensors. The signal processing module is used to process the received sensor signals. The wireless communication module is used for wireless connection between the sheath 5 and the monitoring terminal. The signal conditioning module is used for signal amplification and gain control. The data encoding module is used for data format standardization and protocol adaptation of the data. The fault alarm module is used to give an alarm when an abnormality in the wire harness is detected. The wireless communication module supports multi-mode communication and at least includes a Bluetooth 5.0 module and a 4G LTE module, and can automatically switch the communication protocol according to the type of the monitoring terminal. The bit error rate BER of data transmission satisfies where N e is the number of error bits, and N t is the total number of transmitted bits. The gain G of the amplification circuit of the signal conditioning module can be dynamically adjusted by a digital potentiometer and satisfies where R f is the feedback resistor, and R g is the gain setting resistor.

[0036] As Figure 4As shown, the insulating layer 4 is made of a thermally conductive silicone rubber material and is internally provided with a grid-shaped support structure for fixing the sensor. The silicone rubber material has good insulation properties. The sheath 5 is a fiber-reinforced thermoplastic composite material, which can effectively improve the protection effect of the sheath 5. Its inner wall is provided with a spiral groove for the routing of the sensor cable, and the groove pitch P and the bending radius R of the wire harness satisfy P ≤ 2πR × 0.8.

[0037] As Figure 2 and Figure 3 shown, the conductive pins of the male connector 2 and the conductive jacks of the female connector 3 are coated with a nano-silver coating on the surface, and the coating thickness is 5 - 10 μm. The surface effect of the nano-silver particles in the nano-silver coating is used to reduce the contact resistance. The signal output ends of the current sensing module and the voltage sensing module are provided with electromagnetic shielding sleeves, and the shielding effectiveness SE satisfies where E inc is the incident electric field strength, and E out is the electric field strength after shielding.

[0038] As Figure 5 shown, the monitoring terminal includes a cloud server and a user interface. The cloud server is built-in with a fault prediction model. The calculation of the fault probability P based on the sensor data adopts a weighted support vector machine algorithm, and the expression is: where x1 - x n are characteristic parameters such as temperature, humidity, vibration amplitude, etc., w1 - w n are characteristic weights, and b is a bias term. The cloud server serves as a data transfer station between the sheath 5 and the monitoring terminal. It can store data and also facilitate the feedback of data to the monitoring terminal.

[0039] Example 2

[0040] As Figure 1As shown in the figure, an intelligent wire harness based on sensor monitoring includes multiple wires 1. An insulating layer 4 is wrapped around the outside of the multiple wires 1. A temperature sensor array and a humidity sensor array are integrated inside the insulating layer 4. The insulating layer 4 is used to insulate and protect the wire harness, and at the same time, it is convenient to monitor the temperature and humidity of the wire harness. One end of the multiple wires 1 is connected with a male connector 2, and the other end is connected with a female connector 3. The male connector 2 and the female connector 3 are convenient for the wire harness to be connected with corresponding components or other wire harnesses. A current sensing module is integrated inside the male connector 2, and a voltage sensing module is integrated inside the female connector 3. The current sensing module and the voltage sensing module are used to monitor the current and voltage changes of the male connector 2 and the female connector 3, which is convenient for timely handling when there is poor contact. A sheath 5 is provided outside the insulating layer 4. The sheath 5 is connected to the female connector 3, the male connector 2, and the insulating layer 4 in a charged transmission manner through a connecting wire 51. It is convenient for the data detected by the temperature sensor array, the humidity sensor array, the current sensing module, and the voltage sensing module to be transmitted to the sheath 5. A vibration sensor group and a microprocessor are integrated inside the sheath 5. The vibration sensor group is used to monitor the vibration condition of the wire harness. The sheath 5 is connected to a monitoring terminal in a wireless connection manner, which is convenient for feeding back the monitored data to the terminal for the terminal to view.

[0041] As Figure 4 shown, the temperature sensor array includes multiple NTC thermistors. The multiple NTC thermistors are evenly distributed at equal intervals along the axial direction of the wire 1. The distance between the NTC thermistors is 5 - 15 cm, which is convenient for effectively monitoring the temperature at each position of the wire harness. The humidity sensor array includes multiple polymer film capacitive humidity sensors. The multiple polymer film capacitive humidity sensors and the multiple NTC thermistors are arranged alternately, which is convenient for effectively monitoring the humidity at each position of the wire harness.

[0042] As Figure 2 and Figure 3 shown, the current sensing module is a manganin shunt integrated on the conductive pin of the male connector 2. Its induced voltage V I and the measured current I satisfy: V I = I·R s , where R s is the internal resistance of the shunt. The voltage sensing module is a resistive voltage division circuit integrated inside the conductive jack of the female connector 3. The calculation formula for the shunt output voltage V U is: where V in is the input voltage, and R1 and R2 are the resistance values of the voltage division resistors.

[0043] As Figure 5As shown, the vibration sensor group includes multiple triaxial acceleration sensors, which are evenly distributed along the length direction of the sheath 5, and the distance between adjacent triaxial acceleration sensors is 20 - 50 cm; the calculation formula for the combined vibration amplitude A of a single triaxial acceleration sensor is: where a x , a y , and a z are the acceleration components of the x, y, and z axes respectively.

[0044] As Figure 5 shown, the microprocessor inside the sheath 5 is connected to a signal receiving module, a signal processing module, a wireless communication module, a signal conditioning module, a data encoding module, and a fault alarm module; the signal receiving module is used to receive signals fed back by various sensors, the signal processing module is used to process the received sensor signals, the wireless communication module is used to wirelessly connect the sheath 5 to the monitoring terminal, the signal conditioning module is used for signal amplification and gain control, the data encoding module is used for data format standardization and protocol adaptation of the data, and the fault alarm module is used to issue an alarm when an abnormality in the wire harness is detected; the wireless communication module supports multi-mode communication and at least includes a Bluetooth 5.0 module and a 4G LTE module, and can automatically switch the communication protocol according to the type of the monitoring terminal; the bit error rate BER of data transmission satisfies where N e is the number of error bits, and N t is the total number of transmitted bits. The gain G of the amplification circuit of the signal conditioning module can be dynamically adjusted by a digital potentiometer to satisfy where R f is the feedback resistor, and R g is the gain setting resistor.

[0045] As Figure 4 shown, the insulating layer 4 is made of a thermally conductive silicone rubber material and is internally provided with a grid-shaped support structure for fixing the sensors, and the silicone rubber material has good insulation. The sheath 5 is a fiber-reinforced thermoplastic composite material, which can effectively improve the protection effect of the sheath 5. Its inner wall is provided with a spiral groove for the routing of the sensor cables, and the groove pitch P and the wire harness bending radius R satisfy P ≤ 2πR × 0.8.

[0046] As Figure 2 and Figure 3 shown, the conductive pins of the male connector 2 and the conductive jacks of the female connector 3 are coated with a nano-silver coating, and the coating thickness is 5 - 10 μm. The surface effect of the nano-silver particles of the nano-silver coating is used to reduce the contact resistance. The signal output ends of the current induction module and the voltage induction module are provided with electromagnetic shielding sleeves, and the shielding effectiveness SE satisfies where E inc is the incident electric field strength, and E out is the electric field strength after shielding.

[0047] As shown Figure 5 in the figure, the monitoring terminal includes a cloud server and a user interface. The cloud server has a built-in fault prediction model. The calculation of the fault probability P based on sensor data uses the weighted support vector machine algorithm, and the expression is: where x1 - x n are characteristic parameters such as temperature, humidity, vibration amplitude, etc., w1 - w n are characteristic weights, and b is the bias term. The cloud server serves as a data transfer station between the sheath 5 and the monitoring terminal. It can store data and also facilitate the feedback of data to the monitoring terminal.

[0048] As shown Figure 5 in the figure, the microprocessor is also connected to an energy management module and a local storage module. The energy management module includes a lithium battery pack and a wireless charging receiving coil. The calculation formula for the charging efficiency η is:

[0049]

[0050] where V in / I in is the input voltage / current, V o ut / I out is the output voltage / current; the local storage module is used to cache sensor data. The data storage capacity S satisfies S ≥ N × D × T, where N is the number of sensors, D is the data accuracy (bit) of a single sensor, and T is the cache time (s).

[0051] Embodiment 3

[0052] As shown Figure 1As shown in the figure, an intelligent wire harness based on sensor monitoring includes multiple wires 1. An insulating layer 4 is wrapped around the outside of the multiple wires 1. A temperature sensor array and a humidity sensor array are integrated inside the insulating layer 4. The insulating layer 4 is used to insulate and protect the wire harness, and at the same time, it is convenient to monitor the temperature and humidity of the wire harness. One end of the multiple wires 1 is connected with a male connector 2, and the other end is connected with a female connector 3. The male connector 2 and the female connector 3 are convenient for the wire harness to be connected to corresponding components or other wire harnesses. A current induction module is integrated inside the male connector 2, and a voltage induction module is integrated inside the female connector 3. The current induction module and the voltage induction module are used to monitor the current and voltage changes of the male connector 2 and the female connector 3, which is convenient for timely handling when there is poor contact. A sheath 5 is provided outside the insulating layer 4. The sheath 5 is connected to the female connector 3, the male connector 2, and the insulating layer 4 in a charged transmission manner through a connecting wire 51. It is convenient for the data detected by the temperature sensor array, the humidity sensor array, the current induction module, and the voltage induction module to be transmitted to the sheath 5. A vibration sensor group and a microprocessor are integrated inside the sheath 5. The vibration sensor group is used to monitor the vibration condition of the wire harness. The sheath 5 is connected to a monitoring terminal in a wireless connection manner, which is convenient for feeding back the monitored data to the terminal for easy viewing by the terminal.

[0053] As Figure 4 shown, the temperature sensor array includes multiple NTC thermistors. The multiple NTC thermistors are evenly distributed at equal intervals along the axial direction of the wire 1. The distance between the NTC thermistors is 5 - 15 cm, which is convenient for effectively monitoring the temperature at each position of the wire harness. The humidity sensor array includes multiple polymer film capacitive humidity sensors. The multiple polymer film capacitive humidity sensors and the multiple NTC thermistors are arranged alternately, which is convenient for effectively monitoring the humidity at each position of the wire harness.

[0054] As Figure 2 and Figure 3 shown, the current induction module is a manganin shunt integrated on the conductive pin of the male connector 2. Its induced voltage V I and the measured current I satisfy: V I = I·R s , where R s is the internal resistance of the shunt. The voltage induction module is a resistive voltage division circuit integrated inside the conductive jack of the female connector 3. The calculation formula for the shunt output voltage V U is: where V in is the input voltage, and R1 and R2 are the resistance values of the voltage division resistors.

[0055] As Figure 5As shown, the vibration sensor group includes multiple triaxial acceleration sensors, which are evenly distributed along the length direction of the sheath 5, and the distance between adjacent triaxial acceleration sensors is 20 - 50 cm; the calculation formula for the synthetic vibration amplitude A of a single triaxial acceleration sensor is: where a x , a y , a z are the acceleration components of the x, y, and z axes respectively.

[0056] As Figure 5 shown, the microprocessor in the sheath 5 is connected to a signal receiving module, a signal processing module, a wireless communication module, a signal conditioning module, a data encoding module, and a fault alarm module; the signal receiving module is used to receive the signals fed back by various sensors, the signal processing module is used to process the received sensor signals, the wireless communication module is used for wireless connection between the sheath 5 and the monitoring terminal, the signal conditioning module is used for signal amplification and gain control, the data encoding module is used for standardizing the data format and protocol adaptation of the data, and the fault alarm module is used to issue an alarm when an abnormality in the wire harness is detected; the wireless communication module supports multi-mode communication, at least including a Bluetooth 5.0 module and a 4G LTE module, and can automatically switch the communication protocol according to the type of the monitoring terminal; the bit error rate BER of data transmission satisfies where N e is the number of error bits, and N t is the total number of transmitted bits. The gain G of the amplification circuit of the signal conditioning module can be dynamically adjusted by a digital potentiometer to satisfy where R f is the feedback resistor, and R g is the gain setting resistor.

[0057] As Figure 4 shown, the insulating layer 4 is made of a thermally conductive silicone rubber material and is internally provided with a grid-shaped support structure for fixing the sensors. The silicone rubber material has good insulation. The sheath 5 is a fiber-reinforced thermoplastic composite material, which can effectively improve the protection effect of the sheath 5. Its inner wall is provided with a spiral groove for the routing of the sensor cables, and the groove pitch P and the wire harness bending radius R satisfy P ≤ 2πR × 0.8.

[0058] As Figure 2 and Figure 3 shown, the conductive pins of the male connector 2 and the conductive jacks of the female connector 3 are coated with a nano-silver coating, and the coating thickness is 5 - 10 μm. The surface effect of the nano-silver particles of the nano-silver coating is used to reduce the contact resistance. The signal output ends of the current induction module and the voltage induction module are provided with electromagnetic shielding sleeves, and the shielding effectiveness SE satisfies where E inc is the incident electric field strength, and E out is the electric field strength after shielding.

[0059] As shown Figure 5 in the figure, the monitoring terminal includes a cloud server and a user interface. The cloud server has a built-in fault prediction model. The weighted support vector machine algorithm is used to calculate the fault probability P based on the sensor data. The expression is: where, x1 - x n are characteristic parameters such as temperature, humidity, vibration amplitude, etc., w1 - w n are characteristic weights, and b is the bias term. The cloud server serves as a data transfer station between the sheath 5 and the monitoring terminal. It can store data and also conveniently feedback the data to the monitoring terminal.

[0060] As shown Figure 5 in the figure, the microprocessor is also connected to an energy management module and a local storage module. The energy management module includes a lithium battery pack and a wireless charging receiving coil. The calculation formula for the charging efficiency η is:

[0061]

[0062] where, V in / I in is the input voltage / current, V o ut / I out is the output voltage / current; the local storage module is used to cache sensor data. The data storage capacity S satisfies S≥N×D×T, where N is the number of sensors, D is the data accuracy (bit) of a single sensor, and T is the caching time (s).

[0063] As shown Figure 5 in the figure, a strain sensor is also provided inside the sheath 5. The strain sensor is arranged along the bending stress concentration area of the wire harness body and is used to monitor the deformation amount when the wire harness is in tension or compression. The strain value ε and the sensor resistance change rate ΔR / R satisfy ΔR / R = K·ε, where K is the strain gauge sensitivity coefficient, which is convenient for giving a warning when there is a risk of wire harness damage.

[0064] Working principle: During use, the wire harness is installed at the usage position of the corresponding device. The temperature sensor array and the humidity sensor array will monitor the temperature and humidity of the wire harness in real time. At the same time, the vibration sensor group will monitor the vibration condition of the wire harness in real time; the current induction module and the voltage induction module will monitor the current and voltage at the connection point of the wire harness in real time; the monitored data, after being processed by the signal acquisition module, the signal processing module, the signal adjustment module, and the data encoding module, is fed back to the monitoring terminal through the wireless communication module. The data will enter the cloud server, and the cloud server will predict the faults of the wire harness through the fault prediction model and at the same time feedback the predicted data to the monitoring terminal. When the data is abnormal, the microprocessor will feedback the alarm information to the monitoring terminal through the fault alarm module to remind the user to handle the abnormal situation in time.

[0065] In summary, compared with the prior art, by providing a temperature sensor array and a humidity sensor array in the insulating layer 4 in the present application, the changes in temperature and humidity around the wire 1 can be monitored in real time, and problems such as aging and short - circuit of the insulating layer 4 of the wire 1 caused by excessive temperature or humidity can be detected in time; by providing a vibration sensor group on the sheath 5, the vibration condition of the wire harness can be monitored in real time, and problems such as loosening and abrasion of the wire harness caused by excessive vibration can be detected in time; by providing a current sensing module and a voltage sensing module in the connector, the changes in current and voltage at the connector can be monitored in real time, and connector failures caused by poor contact, overload, etc. can be detected in time. At the same time, after the signal processing module processes the signals collected by the sensors, they are transmitted to an external monitoring terminal through the wireless communication module, realizing remote real - time monitoring of the wire harness state and improving the reliability and safety of the equipment.

[0066] The above is only the preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention can have various changes and modifications. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. An intelligent wire harness based on sensor monitoring, comprising a plurality of wires (1), characterized in that, An insulating layer (4) is wrapped around the outside of multiple wires (1). A temperature sensor array and a humidity sensor array are integrated in the insulating layer (4). One end of multiple wires (1) is connected to a male connector (2), and the other end is connected to a female connector (3). An electric current sensing module is integrated in the male connector (2), and a voltage sensing module is integrated in the female connector (3). A sheath (5) is provided on the outside of the insulating layer (4). The sheath (5) is connected to the female connector (3), the male connector (2), and the insulating layer (4) in a charged transmission manner through a connecting wire (51). A vibration sensor group and a microprocessor are integrated inside the sheath (5). The sheath (5) is connected to a monitoring terminal in a wireless connection manner.

2. The intelligent wire harness based on sensor monitoring according to claim 1, characterized in that, The temperature sensor array includes multiple NTC thermistors. The multiple NTC thermistors are evenly distributed at equal intervals along the axial direction of the wire (1). The interval between the NTC thermistors is 5 - 15 cm. The humidity sensor array includes multiple polymer film capacitive humidity sensors. The multiple polymer film capacitive humidity sensors and the multiple NTC thermistors are arranged alternately.

3. The intelligent wire harness based on sensor monitoring according to claim 1, wherein The electric current sensing module is a manganin shunt integrated on the conductive pin of the male connector (2), and the voltage sensing module is a resistive voltage division circuit integrated in the conductive socket of the female connector (3).

4. The intelligent wire harness based on sensor monitoring according to claim 1, characterized in that, The vibration sensor group includes multiple three-axis acceleration sensors. The multiple three-axis acceleration sensors are evenly distributed along the length direction of the sheath (5). The interval between adjacent three-axis acceleration sensors is 20 - 50 cm.

5. The intelligent wire harness based on sensor monitoring according to claim 1, characterized in that, A microprocessor within the sheath (5) is connected to a signal receiving module, a signal processing module, a wireless communication module, a signal conditioning module, a data encoding module, and a fault alarm module; the signal receiving module is used to receive signals fed back by various sensors, the signal processing module is used to process the received sensor signals, the wireless communication module is used for wireless connection between the sheath (5) and a monitoring terminal, the signal conditioning module is used for signal amplification and gain control, the data encoding module is used for standardizing the data format and protocol adaptation of the data, and the fault alarm module is used to issue an alarm when an abnormality in the wire harness is detected; the wireless communication module supports multi-mode communication and includes at least a Bluetooth 5.0 module and a 4G LTE module, and can automatically switch the communication protocol according to the type of the monitoring terminal; the gain G of the amplification circuit of the signal conditioning module can be dynamically adjusted by a digital potentiometer to meet where R f is the feedback resistor, and R g is the gain setting resistor.

6. The intelligent wire harness based on sensor monitoring according to claim 1, characterized in that, The insulating layer (4) is made of a heat-conductive silicone rubber material and is internally provided with a grid-shaped support structure for fixing sensors. The sheath (5) is a fiber-reinforced thermoplastic composite material, and its inner wall is provided with a spiral groove for the routing of sensor cables. The groove pitch P and the bending radius R of the wire harness satisfy P ≤ 2πR × 0.

8.

7. An intelligent wire harness based on sensor monitoring according to claim 1, characterized in that, The conductive pins connecting the male connector (2) and the conductive jacks connecting the female connector (3) are coated with a nano-silver coating on the surface, and the coating thickness is 5-10 μm. An electromagnetic shielding sleeve is provided at the signal output ends of the current induction module and the voltage induction module, and the shielding effectiveness SE satisfies ≥60 dB, where E inc is the incident electric field strength, and E out is the electric field strength after shielding.

8. An intelligent wire harness based on sensor monitoring according to claim 1, characterized in that, The monitoring terminal includes a cloud server and a user interaction interface. The cloud server has a built-in fault prediction model. The calculation of the fault probability P based on sensor data uses the weighted support vector machine algorithm, and the expression is: where x1 - x n are characteristic parameters such as temperature, humidity, vibration amplitude, etc., w1 - w n are characteristic weights, and b is the bias term.

9. An intelligent wiring harness based on sensor monitoring according to any one of claims 1-8, characterized in that, The microprocessor is also connected to an energy management module and a local storage module. The energy management module includes a lithium battery pack and a wireless charging receiving coil. The local storage module is used for caching sensor data.

10. A smart wire harness based on sensor monitoring according to any one of claims 1-8, characterized in that, A strain sensor is further provided inside the sheath (5). The strain sensor is arranged along the bending stress concentration area of the wire harness body and is used for monitoring the deformation amount when the wire harness is in tension or compression. The strain value ε and the change rate of the sensor resistance ΔR / R satisfy ΔR / R = K·ε, where K is the sensitivity coefficient of the strain gauge.

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