Wire harness swing testing device and method

Abstract

The invention discloses a wire harness swing testing device which comprises a mechanical swing unit, an electrical detection unit and a control analysis unit. The mechanical swinging unit comprises a fixing support, the fixing support comprises a bottom plate and a vertical frame, and the vertical frame is vertically arranged on the upper end face of the bottom plate and detachably connected with the bottom plate; the swing arm is rotationally connected with the vertical frame through a rotating shaft; the wiring block is fixedly connected with the lower end of the swing arm; a port is formed in the wiring block; the driving motor directly drives the swing arm to swing through the coupler; the angle sensor monitors the swing amplitude of the swing arm in real time; the electrical detection unit comprises a current acquisition module for monitoring current fluctuation in a swinging process in real time; the contact resistance measuring module is used for acquiring the resistance change of the connector by adopting a four-wire system detection method; according to the invention, the structure is reasonable, various parameters of the wire harness during shaking can be tested through simple equipment and a test instrument, and the performance of the wire harness is ensured.

Description

Technical Field

[0001] The present invention relates to the field of wire harness detection devices, and in particular to a wire harness swing testing device and method. Background Art

[0002] The automotive wiring harness is the network backbone of the vehicle's electrical circuits. Without it, there would be no automotive circuits. A wiring harness is a component that connects electrical circuits by crimping copper contact terminals with wires and cables, then wrapping them with plastic-molded insulation or a metal casing.

[0003] After a wiring harness is installed in a vehicle, it will vibrate due to driving. To ensure that the components connected by the wiring harness can transmit data more efficiently, it is particularly important to test the changes in parameters such as resistance and current during vibration. Testing the vibration characteristics of wiring harnesses is an ongoing research and development issue. The following proposes a solution to this problem. Summary of the Invention

[0004] The object of the present invention is to provide a wire harness swing test device and method, which have the advantages of being able to simulate the vibration of a vehicle when it is running and to detect the properties of the wire harness.

[0005] The above technical objectives of the present invention are achieved through the following technical solutions: A wire harness swing test device includes a mechanical swing unit, an electrical detection unit, and a control and analysis unit; The mechanical swing unit includes Fixed bracket; the fixed bracket includes a base plate and a stand, the stand is vertically arranged on the upper end surface of the base plate and is detachably connected to the base plate; The swing arm is rotatably connected to the stand via a rotating shaft; A junction block, the junction block being fixedly connected to the lower end of the swing arm and having a port provided on the junction block; The driving motor directly drives the swing arm to swing at a set angle θ through the coupling; and angle sensors to monitor the swing amplitude of the swing arm in real time; The electrical detection unit includes The current acquisition module is connected in series with the harness to be tested to monitor the current fluctuations during the swing process in real time; The contact resistance measurement module uses a four-wire detection method to obtain the resistance change of the connector; The control and analysis unit includes Controlling the drive motor to operate according to preset parameters, wherein the parameters include a swing frequency of 0.15 Hz and a swing amplitude of 25°±1°; Synchronously collect data from the angle sensor, current acquisition module, and contact resistance measurement module; When a current interruption exceeding a threshold or a sudden change in contact resistance is detected, a fault alarm is generated.

[0006] Preferably, the wiring block is provided with a quick clamping device, which includes a V-shaped groove with adjustable wire diameter and a non-slip rubber pad. The V-shaped groove is suitable for wiring harnesses of Φ3-Φ25mm, and the surface friction coefficient of the non-slip rubber pad is ≥0.6; the drive motor is a stepper motor, and the angle control accuracy is ±0.5°.

[0007] Preferably, the current acquisition module includes: a Hall effect sensor with an adjustable sampling frequency of 1kHz-10kHz; and a noise filter with a cutoff frequency set to 10 times the swing frequency; the contact resistance measurement module applies a constant detection current of 10mA-1A during the test.

[0008] As a preferred embodiment, a testing method of a harness swing testing device is characterized by comprising the following steps: S1: Mechanical excitation stage S11: Fix one end of the wiring harness to the fixed bracket and clamp the other end to the swing arm; S12: Drive the swing arm to swing back and forth at an amplitude of 25°±1°, and the swing frequency is set to 0.52Hz; S2: Synchronous detection phase S21: The following parameters are continuously collected during the swinging process: The actual swing angle of the swing arm is obtained through the angle sensor; The harness current value is obtained through the current acquisition module; Connector contact resistance, obtained through the contact resistance measurement module; S22: Create a 3D dataset with aligned timestamps, with a time synchronization error of ≤1ms; S3: Fault diagnosis stage: S31: Failure is determined when any of the following conditions are detected: ① The cumulative current interruption within a single swing cycle is ≥10ms; ②The contact resistance fluctuation exceeds 50% of the initial value; ③ The current glitch amplitude appears for 3 consecutive cycles > 30% of the rated value; S32: Generate a correlation report including the swing number, resistance change and current anomaly.

[0009] As a preference, in step S31 Current interruption detection uses a sliding window algorithm with a window width of 10 sampling points; The contact resistance fluctuation was calculated using the moving standard deviation method, and the standard deviation threshold was set to 0.5 mΩ.

[0010] The beneficial effects of the present invention are: 1. The basic mechanical structure of "fixed bracket + single swing arm" is adopted, which reduces the manufacturing cost of the equipment compared with traditional multi-axis test benches. 2. By replacing the fixture adapter, it can be compatible with the wiring harness testing needs of different fields such as automobiles, aviation, and industrial equipment. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 Schematic diagram of the structure of the embodiment.

[0012] Figure numerals: 1, base plate; 2, stand; 3, swing arm; 4, junction block; 5, drive motor; 6, V-shaped slot. DETAILED DESCRIPTION

[0013] The following is only a preferred embodiment of the present invention, and the scope of protection is not limited to this embodiment. All technical solutions under the concept of the present invention should fall within the scope of protection of the present invention. The same parts are represented by the same figure marks. It should be noted that the words "front", "rear", "left", "right", "up" and "down" used in the following description refer to the directions in the accompanying drawings, and the words "bottom" and "top", "inside" and "outside" refer to the directions toward or away from the geometric center of a specific component, respectively.

[0014] like Figure 1 As shown, a wire harness swing test device includes a mechanical swing unit, an electrical detection unit and a control and analysis unit; The mechanical swing unit consists of a fixed bracket, a swing arm, a wiring block, a drive motor, and an angle sensor. The fixed bracket consists of a base plate and a vertical frame, which is positioned perpendicular to the base plate. Several fixing holes are provided at different locations on the base plate, allowing the vertical frame to be secured to different locations on the base plate using screws and other fasteners.

[0015] The rotating shaft is rotatably connected to the vertical frame, and a terminal block is fixed horizontally at the lower end of the rotating shaft. The terminal block has several ports that simulate the connectors of electronic components in the car. The wiring harness connectors are plugged into the ports to simulate the stability of the wiring harness connector during vibration.

[0016] The drive motor is fixed on the vertical frame and connected to the upper end of the swing arm through a coupling, driving the swing arm to swing at a set angle θ; the angle sensor monitors the actual swing amplitude of the swing arm in real time.

[0017] The terminal block is equipped with a quick-clamping device consisting of a V-shaped slot for adjustable wire diameter and a non-slip rubber pad. The V-shaped slot accommodates wires Ø3-Ø25 mm and prevents them from detaching from the terminal block. The non-slip rubber pad in this design has a surface friction coefficient of ≥0.6. The drive motor is a stepper motor with an angle control accuracy of ±0.5°.

[0018] The electrical detection unit in this design includes a current acquisition module and a contact resistance measurement module. The current acquisition module is connected in series with the wiring harness to monitor the current flowing through the harness during the swinging process. The current acquisition module includes a Hall effect sensor and a noise filter. The sampling frequency of the Hall effect sensor used in this design is adjustable from 1kHz to 10kHz; the cutoff frequency of the noise filter is set to 10 times the swinging frequency; and the contact resistance measurement module uses an ohmmeter to detect changes in the resistance of the connector. The control and analysis unit controls the drive motor to operate according to preset parameters, including a swing frequency of 0.15 Hz and a swing amplitude of 25°±1°; and synchronously collects data from the angle sensor, current acquisition module, and contact resistance measurement module.

[0019] A testing method for a harness swing testing device generates a fault alarm when it is detected that a current interruption exceeds a threshold or a contact resistance mutation occurs.

[0020] Mainly includes the following steps S1: Mechanical excitation stage S11: Fix one end of the wiring harness to the fixed bracket and clamp the other end to the swing arm; S12: Drive the swing arm to swing back and forth at an amplitude of 25°±1°, and the swing frequency is set to 0.52Hz; S2: Synchronous detection phase S21: The following parameters are continuously collected during the swinging process: Get the actual swing angle of the swing arm through the angle sensor; Obtain the harness current value through the current acquisition module; Obtain the connector contact resistance through the contact resistance measurement module; S22: Create a 3D dataset with aligned timestamps, with a time synchronization error of ≤1ms; S3: Fault diagnosis stage: S31: Failure is determined when any of the following conditions are detected: ① The cumulative current interruption within a single swing cycle is ≥10ms; ②The contact resistance fluctuation exceeds 50% of the initial value; ③ The current glitch amplitude appears for 3 consecutive cycles > 30% of the rated value; S32: Generate a correlation report including the swing number, resistance change and current anomaly.

[0021] In step S31 Current interruption detection uses a sliding window algorithm with a window width of 10 sampling points; The contact resistance fluctuation was calculated using the moving standard deviation method, and the standard deviation threshold was set to 0.5 mΩ.

[0022] The specific embodiments described above further illustrate the technical problems, technical solutions and beneficial effects solved by the present invention. It should be understood that the above are only specific embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A harness swing test device, characterized in that: It includes a mechanical swing unit, an electrical detection unit and a control and analysis unit; The mechanical swing unit includes Fixed bracket; the fixed bracket includes a base plate and a stand, the stand is vertically arranged on the upper end surface of the base plate and is detachably connected to the base plate; The swing arm is rotatably connected to the stand via a rotating shaft; A junction block, the junction block being fixedly connected to the lower end of the swing arm and having a port provided on the junction block; The driving motor directly drives the swing arm to swing at a set angle θ through the coupling; and angle sensors to monitor the swing amplitude of the swing arm in real time; The electrical detection unit includes The current acquisition module is connected in series with the harness to be tested to monitor the current fluctuations during the swing process in real time; Contact resistance measurement module, using an ohmmeter to detect resistance changes of connectors; The control and analysis unit includes Controlling the drive motor to operate according to preset parameters, wherein the parameters include a swing frequency of 0.15 Hz and a swing amplitude of 25°±1°; Synchronously collect data from the angle sensor, current acquisition module, and contact resistance measurement module; When a current interruption exceeding a threshold or a sudden change in contact resistance is detected, a fault alarm is generated.

2. A harness sway test device according to claim 1, characterized in that: The junction block is provided with a quick clamping device, which includes a V-shaped groove with adjustable wire diameter and a non-slip rubber pad. The V-shaped groove is suitable for wiring harnesses of Φ3-Φ25mm, and the surface friction coefficient of the non-slip rubber pad is ≥0.6; the drive motor is a stepper motor with an angle control accuracy of ±0.5°.

3. The harness sway test device according to claim 1, characterized in that: The current acquisition module includes: a Hall effect sensor with an adjustable sampling frequency of 1kHz-10kHz; and a noise filter with a cutoff frequency set to 10 times the swing frequency; the contact resistance measurement module applies a constant detection current of 10mA-1A during the test.

4. The testing method of a harness sway testing device according to claim 3, characterized in that: The following steps are included S1: Mechanical excitation stage S11: Fix one end of the wiring harness to the fixed bracket and clamp the other end to the swing arm; S12: Drive the swing arm to swing back and forth at an amplitude of 25°±1°, and the swing frequency is set to 0.52Hz; S2: Synchronous detection phase S21: The following parameters are continuously collected during the swinging process: The actual swing angle of the swing arm is obtained through the angle sensor; Obtain the harness current value through the current acquisition module; Obtain the connector contact resistance through the contact resistance measurement module; S22: Create a 3D dataset with aligned timestamps, with a time synchronization error of ≤1ms; S3: Fault diagnosis stage: S31: Failure is determined when any of the following conditions are detected: ① The cumulative current interruption within a single swing cycle is ≥10ms; ②The contact resistance fluctuation exceeds 50% of the initial value; ③ The current glitch amplitude appears for 3 consecutive cycles > 30% of the rated value; S32: Generate a correlation report including the swing number, resistance change and current anomaly.

5. The testing method of a harness sway testing device according to claim 4, characterized in that: In step S31 Current interruption detection uses a sliding window algorithm with a window width of 10 sampling points; The contact resistance fluctuation was calculated using the moving standard deviation method, and the standard deviation threshold was set to 0.5 mΩ.

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