Integrated wiring harness crimping fault-tolerant control system in robot processing line

Abstract

The invention discloses an integrated wiring harness crimping fault-tolerant control system in a robot processing line, and relates to the technical field of intelligent manufacturing and quality detection of wiring harnesses, and the system comprises a detection module which comprises a miniature high-precision detection device arranged at a crimping station and a miniature high-precision detection device arranged at an assembling station, the data acquisition module is used for respectively acquiring on-resistance data and voltage-withstanding data of the wire harness and generating an electrical performance data set after the wire harness is processed, the data identifier generation module is used for generating a data identifier according to the electrical performance data set, and the data identifier comprises a processing batch number, a crimping station number and an assembly station number of the wire harness. Obtaining an identified electrical performance data set; according to the integrated wire harness crimping fault-tolerant control system in the robot processing line, automatic detection, positioning and sorting of abnormal electrical performance of wire harnesses are realized, the production efficiency and the quality control level are improved, manual intervention is reduced, and an intelligent solution is provided for wire harness manufacturing.

Description

Technical Field

[0001] The present invention relates to the technical field of intelligent manufacturing and quality inspection of wire harnesses, and in particular to an integrated wire harness crimping fault-tolerant control system in a robot processing line. Background Art

[0002] In the automated production process of wire harnesses, electrical performance testing is a key step in ensuring product quality. It is mainly used to identify electrical defects such as tiny on-resistance and abnormal withstand voltage. At present, basic electrical performance testing functions are generally integrated in crimping and assembly stations, but due to the accuracy and volume of the detection module, it is difficult to achieve high-sensitivity detection in a limited space. This results in some minor defects not being identified in time before leaving the factory, affecting product reliability. In order to improve detection capabilities, embedding miniature high-precision detection modules into key stations has become a feasible direction, but the problem that comes with it is a sharp increase in the amount of detection data. Especially under multi-channel and high-frequency detection, traditional communication networks are difficult to meet real-time transmission requirements, which can easily cause data delays or loss, seriously affecting production rhythm and data accuracy.

[0003] In addition to the detection link, the rapid positioning and sorting of abnormal wiring harnesses also face efficiency bottlenecks. The traditional reliance on manual sorting methods has problems with low efficiency and high misjudgment rate; and although the fully automatic sorting system has superior performance, it is costly and inflexible, making it difficult to adapt to the production needs of multiple varieties and small batches. In the rework link, the physical distance between the rework station and the main production line is relatively far, resulting in a long transfer cycle and high logistics costs for abnormal products, affecting rework efficiency and resource allocation. In addition, the current sorting completion signal is often uploaded to the upper-level system through the on-site network, but in the case of network congestion or node anomalies, there is a risk of delay or packet loss in signal transmission, which affects the timely response of the production management system to abnormal events. Therefore, there is an urgent need to make systematic improvements in the aspects of detection module integration, data communication optimization, flexible sorting strategies and information synchronization mechanisms to improve the overall efficiency and quality level of the wiring harness manufacturing process. Summary of the Invention

[0004] The purpose of the present invention is to provide an integrated wire harness crimping fault-tolerant control system in a robot processing line to solve the problems existing in the prior art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: an integrated wire harness crimping fault-tolerant control system in a robotic processing line, comprising: The detection module includes a detection device installed at the crimping station and a miniature high-precision detection device installed at the assembly station, which are used to respectively collect the on-resistance data and withstand voltage data of the wire harness and generate an electrical performance data set after the wire harness is processed; A data identification generating module is used to generate a data identification according to the electrical performance data set, wherein the data identification includes a processing batch number, a crimping station number, and an assembly station number of the wiring harness, to obtain an identified electrical performance data set; A sorting instruction transmission module is used to transmit the sorting instruction data set to the robot based on the industrial Ethernet protocol. The robot has an end effector, which is a vacuum suction cup. The robot grabs the abnormal wire harness and moves it to the rework station according to the sorting path planning and motion speed control, and generates a sorting completion signal. A signal uploading module is used to transmit the signal to the cloud data link through the robot's built-in communication module according to the sorting completion signal, and generate sorting status data recorded in the cloud; The rework task generation module is used to query the status of the rework station through the cloud data link, and when the rework station is idle, generate a rework task instruction, wherein the rework task instruction includes the processing batch number and abnormal type identification of the abnormal wiring harness, and obtain a rework task data set.

[0006] Preferably, the generation of the sorting instruction data set in the sorting instruction transmission module includes: The identified electrical performance data set is transmitted to the analysis unit via the industrial Ethernet protocol to obtain the electrical performance data record received by the analysis unit.

[0007] Preferably, the generation of the sorting instruction data set in the sorting instruction transmission module further includes: Obtain the preset on-resistance threshold and withstand voltage threshold. If the on-resistance data in the electrical performance data record exceeds the on-resistance threshold, it is judged that there is a conductivity abnormality in the wiring harness and a conductivity abnormality mark is obtained; if the withstand voltage data is lower than the withstand voltage threshold, it is judged that there is an insulation abnormality in the wiring harness and an insulation abnormality mark is obtained.

[0008] Preferably, the generation of the sorting instruction data set in the sorting instruction transmission module further includes: An analysis result is generated according to the conductivity abnormality mark or the insulation abnormality mark. The analysis result includes the abnormality type mark and the processing batch number of the abnormal wiring harness, and an analysis report of the abnormal wiring harness is obtained.

[0009] Preferably, the generation of the sorting instruction data set in the sorting instruction transmission module further includes: By analyzing the processing batch number in the report, the real-time monitoring system of the processing line is queried to obtain the position coordinates of the abnormal wire harness and the processing line layout data, and the three-dimensional coordinate data of the abnormal wire harness is obtained.

[0010] Preferably, the generation of the sorting instruction data set in the sorting instruction transmission module further includes: According to the precise three-dimensional coordinate data of the abnormal wiring harness and the coordinates of the rework station, the robot control unit is used to generate sorting instructions. The sorting instructions include the position coordinates of the abnormal wiring harness, the coordinates of the rework station, the sorting path planning and the grasping posture parameters, and a sorting instruction dataset is obtained.

[0011] Preferably, the miniature high-precision detection device in the detection module includes a resistance measuring unit and a withstand voltage detection unit. The resistance measuring unit is used to detect small resistance changes of the wiring harness conductor, and the withstand voltage detection unit is used to detect the insulation withstand voltage performance of the wiring harness after assembly.

[0012] Preferably, the data identification generation module is further used to pre-process the electrical performance data set, including outlier filtering, data standardization and crimping status classification and labeling.

[0013] Preferably, the detection device is a four-wire on-resistance detection device, and the detection device is a voltage withstand test module with a range accuracy of 0.1% and a volume less than 100 cubic centimeters.

[0014] Preferably, the rework task generation module further includes a priority scheduling unit, which sorts the rework tasks according to the severity of the abnormality type and the order of the processing batches, and dynamically allocates them to idle rework stations.

[0015] It can be seen from the above technical solution that the present invention has the following beneficial effects: The integrated wire harness crimping fault-tolerant control system in this robotic processing line embeds miniature high-precision detection modules in the crimping and assembly stations to collect the on-resistance and withstand voltage data of the wire harness and generate a labeled electrical performance data set. After receiving the data, the analysis unit compares it with the preset threshold to determine the abnormality and generate an analysis report. According to the report, the real-time monitoring system is queried to obtain the precise three-dimensional coordinates of the abnormal wire harness and generate sorting instructions. According to the instructions, the robot grabs the abnormal wire harness and moves it to the rework station to complete the intelligent sorting. The present invention realizes the automatic detection, positioning and sorting of abnormal electrical performance of the wire harness, improves production efficiency and quality control level, reduces manual intervention, and provides an intelligent solution for wire harness manufacturing. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 This is a connection diagram of the system modules of the present invention. DETAILED DESCRIPTION

[0017] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0018] like Figure 1 As shown, the present invention provides a technical solution: an integrated wire harness crimping fault-tolerant control system in a robot processing line, comprising: The detection module includes a detection device installed at the crimping station and a miniature high-precision detection device installed at the assembly station, which are used to respectively collect the on-resistance data and withstand voltage data of the wire harness and generate an electrical performance data set after the wire harness is processed; A data identification generating module is used to generate a data identification according to the electrical performance data set, wherein the data identification includes a processing batch number, a crimping station number, and an assembly station number of the wiring harness, to obtain an identified electrical performance data set; A sorting instruction transmission module is used to transmit the sorting instruction data set to the robot based on the industrial Ethernet protocol. The robot has an end effector, which is a vacuum suction cup. The robot grabs the abnormal wire harness and moves it to the rework station according to the sorting path planning and motion speed control, and generates a sorting completion signal. A signal uploading module is used to transmit the signal to the cloud data link through the robot's built-in communication module according to the sorting completion signal, and generate sorting status data recorded in the cloud; The rework task generation module is used to query the status of the rework station through the cloud data link, and when the rework station is idle, generate a rework task instruction, wherein the rework task instruction includes the processing batch number and abnormal type identification of the abnormal wiring harness, and obtain a rework task data set.

[0019] This system integrates multiple functional modules within a robotic processing line to enable real-time electrical performance monitoring and automatic fault-tolerance processing during the wire crimping process. The detection module, using miniature, high-precision detection devices located at the crimping and assembly stations, collects wire harness on-resistance and withstand voltage data, generating a complete electrical performance dataset. The data identifier generation module binds this dataset to the corresponding processing batch number, crimping, and assembly station numbers to generate a unique data identifier, ensuring data traceability. Next, the sorting instruction transmission module uses the Industrial Ethernet protocol to transmit the sorting data to the robotic control system. The robot, equipped with a vacuum suction cup end effector, precisely grasps and removes abnormal wire harnesses according to preset path and speed parameters, placing them at the rework station and generating a feedback signal. The signal upload module uploads this sorting completion signal to the cloud via the robot's communication interface, recording the completion status of the operation. Finally, the rework task generation module retrieves the rework station status based on cloud-based information. When idle stations are detected, it generates a rework task that includes the processing batch and abnormality type, forming a closed-loop tracking control system.

[0020] This system is based on robot automatic control technology and electrical performance detection theory to achieve fault tolerance and tracking control of the wire harness crimping quality. After the wire harness is processed, the detection module first measures its on-resistance and calculates the on-resistance value using Ohm's law: ; in, is the on-resistance of the wiring harness in ohms, The regulated test voltage provided by the power supply is set to 5V. To detect the test current flowing through the wiring harness in the loop, the actual measured value is generally within 1A and is read in real time by the Hall sensor.

[0021] The qualified threshold of on-resistance is determined by empirical standards and statistical analysis, such as: =0.5Ω. That is, when When the resistance is greater than 0.5Ω, it is judged as abnormal on-resistance.

[0022] At the same time, the system performs a withstand voltage test by applying a high voltage (such as 1500V) to measure the insulation resistance value to prevent breakdown. The insulation resistance calculation formula is: ; in, is the insulation resistance, is high voltage test voltage (1500V); Leakage current must be lower than the set threshold (such as 1mA) to be qualified.

[0023] The system organizes this data into an "electrical performance data set." The data identification generation module matches the test results with processing information to generate a unique identification record. Sorting instructions are then sent to the control robot via Industrial Ethernet using the Modbus-TCP protocol. The robot then performs the sorting operation using its built-in path algorithm.

[0024] The adsorption force of the vacuum cup of the end effector must meet the following requirements: ; in, For adsorption force, is the negative pressure value, set to -80kPa, is the area of ​​the suction cup (e.g. Φ30mm, which means the area is 7.07cm²); Therefore, the adsorption force is: .

[0025] It is capable of handling wiring harness components weighing less than 0.5kg. After sorting, the robot sends a completion signal through the communication module and uploads it to the cloud database. The rework task generation module then checks whether the rework station is available and assigns the rework task, completing closed-loop fault-tolerant control.

[0026] The system, introduced in this paper, achieves digital quality traceability and intelligent fault tolerance throughout the wiring harness manufacturing process by incorporating precision testing and industrial communication mechanisms. It offers the following advantages: high detection accuracy, with real-time calculation and determination of anomalies in resistance and withstand voltage tests, preventing defective products from flowing downstream; fully automated sorting, uploading, and scheduling repairs, saving manual judgment time and improving closed-loop process efficiency; strong data traceability, with complete records of abnormal wiring harnesses, corresponding to processing batches, workstations, and anomaly types; and a cloud-based module supporting remote diagnosis and historical quality statistical analysis, facilitating continuous optimization of process parameters.

[0027] At one automotive wiring harness manufacturer, this system is integrated into a robotic crimping system. Each processing line processes approximately 1,200 wire harnesses daily. The system, through real-time screening, identifies approximately eight harnesses with excessive on-resistance. The system automatically completes the entire process of identification, recording, picking, and rework tasks. Previously, manual work required two hours daily to count, mark, and process abnormal harnesses. This process is now fully automated, with an error recording accuracy rate of 99.5%, effectively avoiding missed rework and batch confusion.

[0028] The generation of the sorting instruction data set in the sorting instruction transmission module includes transmitting the identified electrical performance data set to the analysis unit through the industrial Ethernet protocol to obtain the electrical performance data record received by the analysis unit.

[0029] In this embodiment, the generation of sorting instructions depends on the analysis and decision-making process of the electrical performance data set. The labeled electrical performance data set is created by the data label generation module and contains the on-resistance value of each wire harness. , Hi-pot test results , and batch number , crimping and assembly station number And other information, the structure is as follows: ; The data set is sent to the analysis unit via an industrial Ethernet protocol (such as Modbus-TCP, with a data transmission rate of typically 100Mbps and a frame structure that complies with RFC 1122). The analysis unit is equipped with an algorithmic judgment logic based on a set threshold. The core judgment conditions are as follows: If > or < , it is marked as abnormal; in, =0.5Ω, upper limit of on-resistance, , as mentioned above, must meet >1.5MΩ; =1500V, test voltage; <1mA, leakage current threshold. When the analysis unit identifies that the electrical performance parameters do not meet the set requirements, it automatically marks the record as abnormal and adds the following to the returned data: =1; The system will have =1 is used to generate a sorting instruction data set, which includes the physical location information of the wire harness to be grabbed, motion parameters (path planning ID), abnormal type code, etc. The final sorting instruction structure is as follows: Instruction = ; in, The position of the object to be sorted on the assembly line; Preset track number for the robot; Usually set to 0 to indicate a vacuum cup; Corresponding abnormality types, such as "conduction abnormality", "voltage abnormality", etc.

[0030] This method introduces a data transmission and real-time judgment mechanism based on industrial Ethernet, which has the following advantages: electrical performance data can be transmitted to the analysis unit within milliseconds, realizing high-real-time data analysis. The use of structured data recording and identification helps to achieve unified sorting logic processing and reduce code complexity. By setting configurable judgment logic thresholds, the system can be flexibly adjusted according to different wiring harness standards, improving system compatibility. Error judgment is transparent and has good debugging and traceability capabilities, which helps with subsequent optimization and maintenance. The real-time generated sorting instructions can directly control the robot's action process, saving intermediate layer processing time and improving the production line's response speed.

[0031] At a consumer electronics manufacturer, crimped wire harnesses are used to connect battery modules to main control boards. In practice, this issue arises from high on-resistance in the harnesses due to poor solder joints. After the system is deployed, the detected electrical performance data is transmitted to the on-site analysis PLC via Industrial Ethernet. The PLC determines that the on-resistance value of a batch of harnesses is 0.78Ω, exceeding the set threshold. It immediately generates an abnormality flag and pushes a sorting instruction. As planned, a robot precisely grabs the abnormal harness from the conveyor belt and delivers it to the repair area for processing. The entire identification and response process takes less than 0.8 seconds, ensuring that defective products are not included in the final product, significantly improving the assembly yield.

[0032] The generation of the sorting instruction data set in the sorting instruction transmission module also includes obtaining a preset on-resistance threshold and a withstand voltage threshold. If the on-resistance data in the electrical performance data record exceeds the on-resistance threshold, it is determined that there is a conductivity abnormality in the wiring harness, and a conductivity abnormality flag is obtained; if the withstand voltage data is lower than the withstand voltage threshold, it is determined that there is an insulation abnormality in the wiring harness, and an insulation abnormality flag is obtained.

[0033] This embodiment refines the classification and discrimination process of electrical performance data by analyzing two key parameters: on-resistance and withstand voltage capability (expressed as insulation resistance ) Set thresholds for judgment to accurately distinguish abnormal types. After receiving the data, the system obtains the preset parameters as follows: On-resistance threshold :For example, 0.5Ω; the withstand voltage threshold is expressed in the form of insulation resistance, set as =1.5MΩ; Perform the following logical judgment on the test data in each record: If > , the conductivity abnormality flag is equal to 1, if < , the insulation abnormality flag is equal to 1.

[0034] During the judgment process, the following physical formula is used to confirm the test data: For continuity test: ; in, =5V, current If the actual measurement is less than 10A, the system will The value determines whether it is abnormal.

[0035] For withstand voltage test: ; The high voltage =1500V, leakage current Typically it should be less than 1mA.

[0036] After marking the judgment result, the system writes the result into the sorting instruction data set and updates the fields: If the continuity is abnormal, =01, if the insulation is abnormal, then =10, if both are abnormal, then =11; These labels are then transmitted to the robot control system for intelligent sorting and classification, and uploaded to the cloud for return and repair traceability.

[0037] This method, by setting clear on-resistance and withstand voltage thresholds, enables classification and judgment of wiring harness electrical performance anomalies, demonstrating significant technical advantages in actual operation. The system can automatically identify both conductivity and insulation anomalies, avoiding the inefficiencies inherent in traditional sorting methods where different types of faults are uniformly handled. It can also automatically assign faults to different repair paths based on the type of anomaly, thereby enhancing the professionalism and refinement of the production process. Through a formalized and standardized judgment mechanism, the system's debuggability and consistency are effectively improved, ensuring parameter consistency across shifts or process sections and reducing human error. Furthermore, the classification information of electrical performance anomalies is structured and written into the sorting instruction dataset, facilitating subsequent quality tracking and repair analysis while also providing high-quality basic data for anomaly statistical analysis and production optimization strategies on the cloud platform. Furthermore, the system is scalable to support multiple anomaly type labels, providing a training data foundation for the subsequent introduction of machine learning algorithms, further enhancing the intelligence and adaptability of the entire processing line.

[0038] In a high-end medical equipment harness assembly project, due to high reliability requirements, in addition to the continuity and voltage resistance, it is also necessary to identify the type of abnormality. After deploying this system, a batch of inspection probe harnesses were tested. One group had a conduction resistance of 0.67Ω and an insulation resistance of 2.2MΩ. The system determined it to be "continuity abnormal". Add " =01" to the sorting instruction. The other group is normal but the insulation resistance is only 0.9MΩ. The system determines that the withstand voltage is abnormal and marks it as " =10", and are classified and sent to different repair processing units to avoid wrong repairs and missed repairs, greatly improving assembly reliability and repair efficiency.

[0039] The generation of the sorting instruction data set in the sorting instruction transmission module also includes generating an analysis result based on the conductivity abnormality mark or the insulation abnormality mark. The analysis result includes the abnormality type mark and the processing batch number of the abnormal wire harness, and obtains an analysis report of the abnormal wire harness.

[0040] In this embodiment, when the system is based on the on-resistance value and insulation resistance After determining that there is an abnormality in the wiring harness, the system further summarizes these abnormality determination results to generate a traceable "analysis result" and outputs an abnormal wiring harness analysis report. The system first receives the abnormality identification generated by the sorting determination module, which is defined as follows: like , then a continuity abnormality flag is generated: =1; like , then an insulation abnormality flag is generated: =1; The analysis module combines the above identifier with the processing batch number (BatchID) corresponding to the data to form the analysis result: ; in The possible values ​​are as follows: "01" conduction abnormality, "10" insulation abnormality, and "11" both abnormalities.

[0041] The analysis results are then summarized into an abnormal wiring harness analysis report, the structure of which usually includes the abnormality number, processing batch number, abnormal station number, abnormality type code, detection timestamp, original detection data, and judgment logic trajectory record.

[0042] Through the analysis report generation module, the report can be retained in the local cache and synchronously uploaded to the cloud server for quality inspectors or system managers to view, export or use for quality traceability.

[0043] In the process of generating abnormal analysis reports, the present invention realizes the automation, standardization and digital management of defective product traceability analysis by structurally summarizing the types of electrical performance abnormalities and key information such as production batches. First, this method greatly reduces the time required for manual sorting of abnormal data and improves analysis efficiency; second, the analysis results can be called by the system to generate a variety of downstream application scenarios such as rework tasks, production line alarm prompts, and monthly quality reports, thereby expanding the data value of the system; third, the report contains detailed parameters and judgment logic, which helps to quickly locate problem links and support process adjustments and process optimization; fourth, the binding design of batches and abnormality types improves the traceability granularity, supports cross-time period, cross-shift, and cross-workstation analysis, and facilitates the implementation of comprehensive quality control. In addition, through the unified cloud storage and authority management mechanism, data security and controllability are guaranteed, which is conducive to multi-role collaborative review and quality improvement meetings.

[0044] A military wiring harness manufacturer is required to maintain complete anomaly traceability records for each batch of products. After deploying this system, one day, four wires in batch "B20250416A" were detected to have conductivity anomalies (with on-resistance values ​​of 0.68Ω, 0.72Ω, 0.95Ω, and 1.02Ω, respectively). The system automatically generated an analysis report, identifying the batch, inspection station, anomaly type, and original measurement values, and automatically sent it to the quality supervisor's email at 4:00 PM that day. Based on the report, the quality engineer traced the anomaly to the specific crimping die and promptly arranged die replacement and worker training, preventing the problem from spreading to subsequent batches and improving product consistency and customer satisfaction.

[0045] The generation of the sorting instruction data set in the sorting instruction transmission module also includes querying the real-time monitoring system of the processing line by analyzing the processing batch number in the report, obtaining the position coordinates of the abnormal wire harness and the processing line layout data, and obtaining the accurate three-dimensional coordinate data of the abnormal wire harness.

[0046] In this implementation, the system uses the batch number recorded in the analysis report to access the production line's real-time monitoring system (which can be a PLC, SCADA, or IoT-based data aggregation platform) to extract the location status of the corresponding wire harnesses on the production line. Each wire harness is assigned a unique ID upon entering the crimping line, and its movement between workstations is recorded in real time, forming a spatiotemporal status database.

[0047] When the system receives an abnormal batch number (such as "BatchID=B20250416A") from the analysis report, it performs location tracing according to the following logic: 1. Query the location information table in the real-time monitoring system: ; Among them: LineID is the identifier of the production line, ConveyorIndex is the index of the conveyor belt, which is used to identify a specific conveyor belt, X, Y, Z are the position coordinates, and Timestamp is the timestamp, which is the time when the data is recorded.

[0048] 2. Get the conveyor belt number (ConveyorIndex) and spatial coordinate information (X, Y, Z) corresponding to the batch of wire harnesses; 3. If the processing line layout data provides multi-segment path mapping or multi-layer structure, the system will call the layout model data (Layout Model) to perform path inverse solution and calculate its precise spatial position in the 3D model; Consider a robot workstation with a three-layer path model: the first layer is the main conveyor, the second layer is the transfer tray track, and the third layer is the nested assembly station layout. The spatial coordinate signals collected by sensors (e.g., from a vision system or RFID recognition) are represented as relative positions on the main conveyor layer (Layer 1) (e.g., index number 15 corresponds to the mid-section workstation area).

[0049] After the system calls the layout model, it finds that index number 15 corresponds to pallet number T5 at track node N3. Its actual physical coordinates need to go through the following three mapping and inverse processes: Segment 1 (index to pallet position): Based on the main conveyor line number and the position offset during operation, reverse the node coordinate interval (such as X1-X2) where the T5 pallet is currently located. Segment 2 (track node to assembly layer positioning): The workpiece identifier carried by pallet T5 is bound to the nested assembly position number A12. The system searches for the layout mapping relationship between node N3 and A12 and obtains the corresponding second-layer structure coordinate translation and posture transformation matrix. Section 3 (3D model coordinate calculation): The above transformations are added to the global 3D layout model. Combined with the reference position of assembly position A12, the precise 3D spatial position (X, Y, Z) of the target workpiece is finally obtained through reverse calculation and output as the end-effector grasping positioning. 4. Final output of three-dimensional coordinates: ; in, is the displacement along the length of the production line, in millimeters, is the horizontal distance, calibrated with reference to the starting point on the left. It is the vertical height, usually the horizontal height of the conveyor.

[0050] The three-dimensional coordinates are obtained by visual calibration system, infrared tracking device or RFID tag coordinate conversion, and the accuracy is controlled within ±3mm.

[0051] The system writes the three-dimensional coordinates into the sorting instruction data set, providing the robot's end effector with accurate grasping position parameters for subsequent path planning and action instruction generation.

[0052] The present invention achieves precise positioning of abnormal wiring harnesses by establishing an efficient association mechanism between analysis reports and real-time production line data, and outputs them in the form of three-dimensional spatial coordinates, which greatly improves sorting accuracy and response efficiency. This method breaks the limitations of traditional positioning by "serial number" or "position index", and is particularly important in the layout of multiple parallel or segmented production lines. After obtaining the spatial coordinates, the robot system can be directly loaded into the motion control model to avoid secondary image recognition or manual assisted confirmation, thereby reducing response delays and improving action accuracy. By utilizing the existing real-time monitoring infrastructure, the system achieves high-precision recognition and operation without increasing hardware complexity, while achieving "precise strikes" against abnormal products. In addition, the spatial position recorded by the system also helps in subsequent abnormality statistical analysis, supports hot zone identification and layout optimization, and enhances the data-driven capability and flexible manufacturing capability of the entire production line.

[0053] On an assembly line producing new energy power battery packs, wire harnesses are automatically crimped and then transferred to the inspection area via multiple parallel conveyor belts. Upon detecting insulation anomalies in a particular batch, the system automatically retrieves the batch's flow record for "BatchID: LQ20250415N" and obtains from the monitoring system its current location on "Line A - Conveyor Section 3," corresponding to coordinates (1820mm, 450mm, 950mm). After receiving these precise coordinates, the robotic system follows the planned path and precisely grasps the target wire harness. The entire positioning and grasping process takes no more than 0.6 seconds, with a sorting accuracy error of ±2mm, fully meeting the practical needs of high-density automated assembly lines.

[0054] The generation of the sorting instruction data set in the sorting instruction transmission module also includes using the robot control unit to generate sorting instructions based on the precise three-dimensional coordinate data of the abnormal wire harness and the rework station coordinates. The sorting instructions include the abnormal wire harness position coordinates, rework station coordinates, sorting path planning and grasping posture parameters to obtain a sorting instruction data set.

[0055] In this embodiment, the robot control unit receives the three-dimensional coordinates of the abnormal harness Coordinates of the target rework station Afterwards, the path planning and gripping posture planning processes are activated to generate complete sorting control instructions. The path planning part uses an algorithm based on RRT or DWA to generate an obstacle-free path from the abnormal harness location to the rework station based on the real-time spatial environment of the production site. The path is represented by a series of spatial trajectory points, with the first and last coordinates of the harness location and the rework station coordinates, respectively.

[0056] At the same time, to ensure that the end effector can correctly grasp the harness in complex space, the system also calculates the six-degree-of-freedom pose of the robot end, which is a vector consisting of position coordinates and attitude angles (Euler angles): ; in, is the spatial position of the harness center; Respectively around The rotation angle of the axis, in degrees, is determined by the harness placement angle and assembly direction; the posture parameters can be identified based on the depth vision system or inversely solved by referring to the assembly drawing model.

[0057] The generated path trajectory and grasping posture are uniformly analyzed by the robot motion control unit, and combined with the set parameters such as movement speed, safety level and adsorption mode to form the final sorting instruction data set for the robot to execute in sequence to achieve accurate grasping and transfer of abnormal wire harnesses.

[0058] The present invention combines spatial positioning data with robot motion control parameters to achieve automated and precise sorting of abnormal wire harnesses in three-dimensional space, with high flexibility and real-time performance. The robot control unit dynamically plans the optimal path based on the target position and path environment, effectively avoiding interference with other equipment or running products, and ensuring operational safety. The six-degree-of-freedom grasping posture calculation module ensures that the end effector achieves the most appropriate adsorption or clamping action at various assembly angles, reducing the grasping failure rate. The path, posture and position coordinates are integrated in the form of a structured instruction set, which facilitates subsequent system debugging, trajectory reproduction and instruction template reuse, thereby improving production line deployment efficiency. Through the integration of the above mechanisms, the system realizes full-process automated control from detection, identification, positioning to sorting, and is particularly suitable for high-beat, high-complexity flexible manufacturing production lines, providing a solid foundation for the intelligent upgrade of the manufacturing industry.

[0059] In an unmanned electronic wire crimping workshop, a wire harness was detected with insulation anomalies. Its three-dimensional coordinates were (1420mm, 620mm, 950mm), and the target rework station coordinates were (600mm, 300mm, 930mm). The system used the six-axis robot control module to generate the shortest path, avoiding the robotic arm and sensor tower along the way, and set the gripping posture to (1420, 620, 950, 0°, -30°, 90°). The robot's vacuum suction cup accurately completed sorting and handling along this path in just 1.2 seconds, automatically sending a signal to the cloud upon completion. The entire closed-loop operation is efficient and stable, successfully avoiding manual positioning errors and repeated operations.

[0060] The miniature high-precision detection device in the detection module includes a resistance measuring unit and a withstand voltage detection unit. The resistance measuring unit is used to detect small resistance changes of the wiring harness conductor, and the withstand voltage detection unit is used to detect the insulation withstand voltage performance of the wiring harness after assembly.

[0061] In this embodiment, the detection module integrates two key subunits: a resistance measurement unit and a withstand voltage detection unit, each used to test the wiring harness's conductivity and insulation performance, respectively. The resistance measurement unit uses a four-wire measurement method to obtain the voltage and current between the wiring harness conductors and calculates the actual resistance value based on the proportional relationship between the two. This method effectively eliminates the influence of the connecting wire's own resistance on the test results, thereby accurately detecting even extremely small resistance changes. The system uses a constant voltage source, such as five volts, and uses an internal current sensor to collect the current flowing through the wiring harness in real time. When the calculated resistance value exceeds a set upper threshold, the system determines that the wiring harness has abnormal conductivity, such as a poor contact or a cold solder joint. This process has a short response time and high detection accuracy, making it suitable for real-time testing on high-speed automated production lines. The withstand voltage detection unit tests the insulation performance of the entire wiring harness after assembly. The system calculates the insulation resistance of the wiring harness by applying a high voltage, such as 1,500 volts, to both ends of the wiring harness while simultaneously monitoring the leakage current. If the measured insulation resistance falls below the system's minimum allowable value, it is determined to be insulation failure. In order to prevent damage to the wiring harness or testers during high-voltage testing, the system is designed with a fast power-off protection mechanism. Once the leakage current exceeds the safety threshold, the voltage output will be immediately cut off. The withstand voltage test can also adopt a step-by-step voltage step-up method, gradually increasing from a lower voltage to identify tiny cracks or insulation defects in the wiring harness. The entire detection module is deployed separately at the crimping station and the assembly station to complete the conductivity and insulation tests respectively, and finally summarize the various data to form complete electrical performance information, providing basic data support for subsequent abnormality identification, data identification generation and sorting operations. This dual-station layout ensures full coverage of key nodes, while ensuring the real-time and accuracy of the test results. It is an important technical basis for achieving closed-loop control of wire harness processing quality.

[0062] The present invention integrates a resistance measurement unit and a withstand voltage detection unit in the detection module to form an integrated high-precision detection structure, thereby realizing synchronous, high-speed, and accurate detection of the performance of the wire harness conductor and the insulation layer. Compared with the traditional single detection method, this system can detect subtle changes in on-resistance and the overall withstand voltage strength after assembly, which greatly improves the comprehensiveness of abnormality detection and the real-time performance of detection. Especially in automated production lines, the equipment has a short response time and high measurement accuracy, ensuring that each wire harness can receive real-time electrical performance confirmation during the processing process, avoiding defective products from entering subsequent processes or whole machine assembly. In addition, the module has a compact structure, low power consumption, and strong adaptability, which makes it easy to embed in crimping or assembly stations of different specifications to achieve flexible configuration; at the same time, it supports docking with the industrial bus protocol, which is easy to integrate into the entire fault-tolerant control system to achieve comprehensive digital and intelligent detection.

[0063] At a company producing high-voltage wire harnesses for new energy vehicles, this miniature high-precision detection device is deployed in crimping and terminal assembly stations. During actual operation, an abnormally high resistance value of 0.76Ω was detected during the resistance measurement phase for a batch of wire harnesses. The system automatically determined this to be poor continuity, preventing the harness from entering the assembly station. After another harness was assembled, the withstand voltage detection unit detected its insulation resistance as only 1.1MΩ, below the set threshold. The system promptly issued an alarm and assigned a robot to perform the removal operation. The introduction of this device has reduced the defective rate of wire harnesses from 2.1% to 0.5%, while also improving overall production line quality consistency and customer satisfaction.

[0064] The data identification generation module is also used to pre-process the electrical performance data set, including outlier filtering, data standardization and crimping status classification and labeling.

[0065] In this implementation, the data identification generation module not only assigns identifiers to the electrical performance dataset but also performs data preprocessing to ensure the accuracy and consistency of subsequent judgment and tracking. First, the system performs outlier detection on the collected raw on-resistance and insulation resistance data. This process automatically identifies data that deviates from the normal distribution range, such as sudden high resistance values ​​or abnormally low insulation resistance values, based on the distribution patterns of historical samples. Once identified as outliers, these data are automatically removed or labeled and isolated by the system to prevent them from interfering with the overall judgment logic. Second, the system normalizes the data. Due to slight process differences between production batches or production lines, the system maps test data with different dimensions or ranges to a unified numerical range to improve data consistency and comparability. For example, resistance values ​​are uniformly converted to percentages and normalized based on the baseline values ​​for each batch or workstation, thus avoiding misjudgments caused by absolute numerical differences during analysis and judgment. After standardization, the system also assigns a crimp status label to each wire harness based on the electrical performance data results, primarily categorized as "qualified," "abnormal continuity," "abnormal insulation," and "re-inspection passed." These tags, along with the harness's batch and workstation numbers, form the final data identifier, providing complete electrical traceability for each harness. These pre-processing operations are automatically performed by the module's built-in data processing engine, requiring no human intervention and completing within milliseconds.

[0066] By integrating data preprocessing functions into the data identification generation module, this solution not only improves the intelligence level of the entire fault-tolerant control system, but also enhances the reliability and adaptability of the data. Through outlier filtering, misjudgments due to sensor fluctuations or instantaneous interference are effectively avoided; standardization solves the problem of inconsistent data scales between different batches and different devices, providing a basis for horizontal data comparison; and the introduction of crimping status labels makes the data not only have numerical attributes, but also semantic attributes, which facilitates subsequent sorting decisions and statistical analysis. Overall, the introduction of this module has improved the level of data quality management, enhanced the fault tolerance and scalability of the system, and laid a solid data foundation for subsequent links such as cloud analysis and AI modeling.

[0067] At a high-end precision instrument company, wiring harnesses must meet extremely high electrical performance consistency standards before leaving the factory. In actual operation, due to environmental electromagnetic interference, some test data showed intermittent resistance surges. The system automatically eliminated these fluctuating data through an outlier detection algorithm to avoid misjudgment as defective products. The standardization module automatically adjusts the judgment interval based on the process mean of each batch, so that data between different work sections have a unified reference. The system also marks some boundary value wiring harnesses as "passed re-inspection" and they are reviewed by quality inspectors before being put into storage, effectively improving the robustness of data judgment. After deployment optimization, the company's defective product error rate has been reduced from the original 1.8% to 0.3%, providing strong protection for high-reliability scenarios.

[0068] The sorting instruction transmission module uses Modbus TCP / IP or Profinet protocol to communicate with the robot to achieve efficient real-time transmission of instructions.

[0069] In this embodiment, to ensure sufficient real-time, reliable, and anti-interference capabilities during the transmission of sorting instructions from the control system to the robot, the system utilizes Modbus TCP / IP or Profinet protocols, commonly used in industrial communications. Based on Ethernet communication architecture, the Modbus TCP / IP protocol enables data exchange between master and slave devices through a standard network interface. Its simple frame structure and short communication cycles make it particularly suitable for production line control scenarios requiring fast response times. This protocol treats the robot as a slave and the sorting instruction transmission module as the master. Data packets containing coordinate information, path planning results, and execution instructions are pushed to the robot control unit via a timed or event-triggered mechanism. Profinet, a real-time Ethernet communication protocol, offers enhanced real-time performance and higher data rates. It supports dual-channel modes for periodic and alarm event communication, making it particularly suitable for high-precision, multi-station collaborative intelligent manufacturing systems. When Profinet is used, the robot controller receives instructions using preconfigured data fields and, through a time synchronization mechanism, ensures that instructions are processed and responded to within precise time windows, further ensuring coordinated and accurate movements. Regardless of the protocol used, sorting instruction packets are encapsulated in a structured field format. The system manages the status of incomplete or abnormal instructions through a command buffer, ensuring the integrity and fault tolerance of the transmission process. The communication module has an embedded error detection and retransmission mechanism, which automatically reissues instructions when the link is unstable, preventing control failures caused by momentary disconnections.

[0070] This implementation method achieves efficient, stable, and low-latency transmission of sorting instructions by adopting a mature industrial-grade communication protocol, thereby improving the real-time response capability of the entire fault-tolerant control system. The Modbus TCP / IP protocol has the advantages of easy deployment, good compatibility, and wide device support, and is suitable for most robot brands and control systems; the Profinet protocol is suitable for scenarios with higher requirements for response cycle and control accuracy, and can achieve sub-millisecond command interaction and control synchronization. Through the professional design of the communication protocol, the system can not only adapt to the requirements of different production rhythms and production line structures, but also provide an interface foundation for multi-robot collaborative control, remote monitoring, and edge control. The flexibility of protocol selection also enhances the overall scalability and compatibility of the system, and helps to quickly integrate into the existing factory network environment without the need for large-scale hardware replacement, reducing deployment and maintenance costs.

[0071] In an intelligent manufacturing workshop, the system uses the Profinet protocol to achieve high-speed communication between the sorting control module and a German six-axis robot. Because the harness grabbing operation requires a sub-second response, traditional serial communication methods are difficult to meet real-time requirements. By deploying the Profinet communication solution, the average delay from command generation to execution response is controlled within 20 milliseconds, significantly improving the robot sorting efficiency and the overall production line rhythm. Another workshop uses the Modbus TCP / IP protocol to connect to a domestic robot controller. With its open protocol stack, it can easily achieve data docking with the upper system and successfully embed it into the original MES platform to achieve synchronous upload of sorting status, improving the overall visualization and information level of the system.

[0072] The detection device is a four-wire on-resistance detection device, which is a voltage withstand test module with a range accuracy of 0.1% and a volume of less than 100 cubic centimeters.

[0073] In this embodiment, in order to achieve high-precision electrical performance testing of the crimping quality of the wire harness, the system is equipped with a conduction resistance detection device and a voltage withstand test module at the crimping station and the assembly station respectively. Among them, the crimping station adopts a four-wire conduction resistance detection device. By introducing a current excitation circuit and a voltage measurement circuit respectively, the device avoids the interference of contact resistance on the measurement results, effectively improving the measurement accuracy. Its working process is: immediately after the crimping is completed, a constant current is applied to both ends of the wire harness, and the voltage at both ends is collected at the same time. The conduction resistance is accurately calculated using Ohm's law to achieve real-time quantitative evaluation of the crimping quality. At the same time, a high-resolution voltage withstand test module with a volume of less than 100 cubic centimeters and a measurement accuracy better than 0.1% of the range is deployed at the assembly station. This module is suitable for arrangement in a small space, can apply a set voltage to the assembled wire harness, and monitor its leakage current changes. If the measured leakage current exceeds the preset threshold, the system will determine that the wire harness has the risk of poor insulation or crimping damage, and will record it into the system as abnormal data. Through the joint operation of the two high-performance detection devices mentioned above, the platform can comprehensively evaluate the wire harness processing quality from the two dimensions of conductivity and insulation performance, and generate a structured electrical performance data set, providing a reliable basis for subsequent abnormality sorting and rework task issuance.

[0074] The rework task generation module also includes a priority scheduling unit, which sorts the rework tasks according to the severity of the abnormality type and the processing batch sequence, and dynamically allocates them to idle rework stations.

[0075] In this embodiment, to further improve rework efficiency and resource utilization, the system incorporates a priority scheduling unit within the rework task generation module. This unit intelligently sorts and matches all pending abnormal wiring harness tasks to workstations. First, the system categorizes the abnormality type marked on each abnormal wiring harness. For example, insulation abnormalities are classified as high-risk, conductivity abnormalities as medium-risk, and cosmetic defects or minor deviations as low-risk. These abnormality types are automatically assigned using a pre-set rule table or an expert system. Next, the system reads the processing batch information for the abnormal wiring harness and determines its priority based on the batch generation time. During scheduling, the system comprehensively considers the abnormality level and processing time, prioritizing wiring harness tasks with higher priority and earlier batches. The scheduling strategy can use a weighted scoring approach, such as weighting severity 70% and processing time 30% to form the final task priority queue. After sorting, the system automatically scans the status information of each rework station, identifies the currently available workstation numbers through a built-in idle detection mechanism, and dynamically assigns the highest-ranked rework tasks to the most available workstations. The scheduling unit supports task status monitoring. If a workstation is busy for a long time or fails, the system will automatically skip the workstation and reallocate the task to the next available workstation to achieve real-time load balancing and fault-tolerant scheduling.

[0076] By introducing a priority scheduling mechanism, this solution makes the rework process more targeted and timely, significantly optimizing the system's ability to allocate limited rework resources. Based on a hierarchical processing strategy based on the severity of the anomaly, the system can prioritize responding to defects with greater safety and functional impacts, reducing the risk of product shipments. The introduction of a processing batch sequence ensures the basic fairness of first-processed, first-reworked, effectively preventing task accumulation and omissions. The dynamic allocation mechanism achieves load balancing of rework stations, reduces idle stations and long waiting times, and improves the overall efficiency of the production line. At the same time, the mechanism is scalable and adaptive, and can cope with actual complex scenarios such as changes in the number of stations, fluctuations in production output, or sudden failures, enhancing the application value of the system in a flexible manufacturing environment.

[0077] At an aerospace wire harness processing company, due to the complex product structure, the rework of some abnormal wire harnesses must be completed at specific workstations. After the system introduced a priority scheduling unit, it can automatically identify that wire harnesses with insulation abnormalities have higher priority and are assigned to high-skill workstations; while those with conductivity abnormalities are assigned to the automatic welding line. At the same time, the system monitored that rework station 3 had not been released for a long time and dispatched the originally planned task to the idle workstation 5. After deployment and optimization, the average waiting time for rework was reduced from 12 minutes to 4 minutes, and the utilization rate of rework station was increased to 92%, greatly improving production line efficiency and the flexibility of task scheduling.

[0078] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. An integrated wire harness crimping fault-tolerant control system in a robot processing line, characterized in that: include: The detection module includes a detection device installed at the crimping station and a miniature high-precision detection device installed at the assembly station, which are used to respectively collect the on-resistance data and withstand voltage data of the wire harness and generate an electrical performance data set after the wire harness is processed; A data identification generating module is used to generate a data identification according to the electrical performance data set, wherein the data identification includes a processing batch number, a crimping station number, and an assembly station number of the wiring harness, to obtain an identified electrical performance data set; A sorting instruction transmission module is used to transmit the sorting instruction data set to the robot based on the industrial Ethernet protocol. The robot has an end effector, which is a vacuum suction cup. The robot grabs the abnormal wire harness and moves it to the rework station according to the sorting path planning and motion speed control, and generates a sorting completion signal. A signal uploading module is used to transmit the signal to the cloud data link through the robot's built-in communication module according to the sorting completion signal, and generate sorting status data recorded in the cloud; The rework task generation module is used to query the status of the rework station through the cloud data link, and when the rework station is idle, generate a rework task instruction, wherein the rework task instruction includes the processing batch number and abnormal type identification of the abnormal wiring harness, and obtain a rework task data set.

2. The integrated wire harness crimping fault-tolerant control system in a robotic processing line according to claim 1, characterized in that: The generation of the sorting instruction data set in the sorting instruction transmission module includes: The identified electrical performance data set is transmitted to the analysis unit via the industrial Ethernet protocol to obtain the electrical performance data record received by the analysis unit.

3. The integrated wire harness crimping fault-tolerant control system in a robotic processing line according to claim 2, characterized in that: The generation of the sorting instruction data set in the sorting instruction transmission module further includes: Obtain the preset on-resistance threshold and withstand voltage threshold. If the on-resistance data in the electrical performance data record exceeds the on-resistance threshold, it is judged that there is a conductivity abnormality in the wiring harness and a conductivity abnormality mark is obtained; if the withstand voltage data is lower than the withstand voltage threshold, it is judged that there is an insulation abnormality in the wiring harness and an insulation abnormality mark is obtained.

4. The integrated wire harness crimping fault-tolerant control system in a robotic processing line according to claim 3, characterized in that: The generation of the sorting instruction data set in the sorting instruction transmission module further includes: An analysis result is generated according to the conductivity abnormality mark or the insulation abnormality mark. The analysis result includes the abnormality type mark and the processing batch number of the abnormal wiring harness, and an analysis report of the abnormal wiring harness is obtained.

5. The integrated wire harness crimping fault-tolerant control system in a robotic processing line according to claim 4, characterized in that: The generation of the sorting instruction data set in the sorting instruction transmission module further includes: By analyzing the processing batch number in the report, the real-time monitoring system of the processing line is queried to obtain the position coordinates of the abnormal wire harness and the processing line layout data, and the three-dimensional coordinate data of the abnormal wire harness is obtained.

6. The integrated wire harness crimping fault-tolerant control system in a robotic processing line according to claim 5, characterized in that: The generation of the sorting instruction data set in the sorting instruction transmission module further includes: According to the precise three-dimensional coordinate data of the abnormal wiring harness and the coordinates of the rework station, the robot control unit is used to generate sorting instructions. The sorting instructions include the position coordinates of the abnormal wiring harness, the coordinates of the rework station, the sorting path planning and the grasping posture parameters, and a sorting instruction dataset is obtained.

7. The integrated wire harness crimping fault-tolerant control system in a robotic processing line according to claim 1, characterized in that: The micro high-precision detection device in the detection module includes a resistance measuring unit and a withstand voltage detection unit. The resistance measuring unit is used to detect small resistance changes of the wiring harness conductor, and the withstand voltage detection unit is used to detect the insulation withstand voltage performance of the wiring harness after assembly.

8. The integrated wire harness crimping fault-tolerant control system in a robotic processing line according to claim 1, characterized in that: The data identification generation module is further used to pre-process the electrical performance data set, including outlier filtering, data standardization and crimping status classification and labeling.

9. The integrated wire harness crimping fault-tolerant control system in a robotic processing line according to claim 1, characterized in that: The detection device is a four-wire on-resistance detection device, and the detection device is a voltage withstand test module with a range accuracy of 0.1% and a volume less than 100 cubic centimeters.

10. The integrated wire harness crimping fault-tolerant control system in a robotic processing line according to claim 1, characterized in that: The rework task generation module further includes a priority scheduling unit, which sorts the rework tasks according to the severity of the abnormality type and the processing batch sequence, and dynamically allocates them to idle rework stations.

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