Device for detecting insulating layer of pressure sensor wire harness

Abstract

The invention discloses a pressure sensor wire harness insulation layer detection device, and relates to the technical field of wire harness insulation layer detection, the pressure sensor wire harness insulation layer detection device comprises a detection bench, the upper part of the detection bench is fixedly connected with a spacing adjusting mechanism, the upper part of the spacing adjusting mechanism is provided with a rotating mechanism, and the upper part of the detection bench is provided with a detection assembly used for carrying out quality detection on a wire harness. According to the wire harness clamping device, a first servo motor and a first lead screw are used for driving a first mounting frame to slide along a first guide assembly, flexible adjustment of the distance between two sets of wire harness clamping mechanisms is achieved, the clamp assembly can adapt to wire harnesses with different overall lengths and complete preliminary clamping, and forced stretching of a traditional fixed-distance device on the long wire harnesses is avoided; a third servo motor and a third lead screw drive a third screw block to slide along a sliding rail, independent position adjustment of each clamp assembly is achieved, branch lines with different lengths in the wire harness can be accurately fixed and independently straightened, and the problem of deformation of a branch structure caused by uneven tension is solved.

Description

Technical Field

[0001] The present invention relates to the technical field of wire harness insulation layer detection, in particular to a pressure sensor wire harness insulation layer detection device. Background Art

[0002] The pressure sensor wiring harness is a special wiring harness assembly that connects the pressure sensor with external equipment (such as controllers, display terminals, etc.). It is mainly used to transmit the signal and power supply of the pressure sensor. It is widely used in automobile manufacturing, industrial automation and other fields. Although the pressure sensor wiring harness seems small, it is crucial to the stability and accuracy of the system. Its design and selection need to comprehensively consider electrical performance, mechanical strength and environmental adaptability. Therefore, the quality of its insulation layer needs to be tested during the production and processing of the pressure sensor wiring harness.

[0003] For example, announcement number CN116753853B discloses an apparatus and method for detecting the surface insulation layer of an electric wire, comprising two conveyors and a detection device through which the electric wire passes. The detection device is located between the two conveyors, and the two conveyors flatten the electric wire passing through the detection device and pull it forward. The detection device comprises an outer shell, a through hole of the outer shell is provided in the inner shell, a spring is provided in the through hole of the outer shell, one end of the spring is connected to a laser detector fixed on the outer shell, and the other end contacts a detection rod, which is also connected to a scale rod. When the electric wire passes through the detection device, the surface of the electric wire pushes the scale rod and the detection rod to move along the compression direction of the spring, and the laser detector records the displacement of the detection rod.

[0004] However, in the prior art, when targeting the automotive manufacturing field, automotive pressure sensor wiring harnesses usually contain multiple wires, connectors, sensor elements, etc., with complex structures such as bends, branches, and terminal crimping. The loading method in the prior art relies on the rollers of two conveyors to "flatten" the wires and pull them in a straight line. It is only suitable for long wire harnesses of a single specification and a straight line. For pressure sensor wiring harnesses with bends or branches, forced flattening can easily lead to deformation of the wiring harness, damage to components, and even failure to pass through the center hole of the inner ring bearing sleeve of the detection device, resulting in detection interruption. Summary of the Invention

[0005] The object of the present invention is to provide a pressure sensor harness insulation layer detection device to solve the problems raised by the above background technology.

[0006] To achieve the above-mentioned purpose, the present invention provides the following technical solutions: a pressure sensor harness insulation layer detection device, comprising a detection platform, a spacing adjustment mechanism fixedly connected to the upper portion of the detection platform, a rotating mechanism installed on the upper portion of the spacing adjustment mechanism, and a detection assembly for performing quality detection on the wiring harness installed on the upper portion of the detection platform, the rotating mechanism comprising two No. 1 mounting brackets, one No. 1 mounting bracket being fixedly connected to the spacing adjustment mechanism, and the other No. 1 mounting bracket being slidably connected to the spacing adjustment mechanism, the spacing adjustment mechanism being used to adjust the position of the slidingly connected No. 1 mounting bracket, both No. 1 mounting brackets being rotatably connected to a No. 1 fixing bracket on their sides, a wiring harness clamping mechanism being fixedly connected to the surface of the No. 1 fixing bracket, the rotating mechanism being used to drive the wiring harness clamping mechanism to rotate, the wiring harness clamping mechanism comprising a wiring harness angle adjustment assembly, a wiring harness distance adjustment assembly and a clamp assembly, the clamp assembly being used to clamp and fix the wiring harness, the wiring harness distance adjustment assembly being used to adjust the distance between the clamp assembly and the wiring harness, and the wiring harness angle adjustment assembly being used to adjust the angle between the wiring harnesses fixed by the clamp assembly;

[0007] The rotating end of the No. 1 fixing frame is fixedly connected with a linkage mechanism, and a moving mechanism is installed on the upper part of the detection component. The linkage mechanism is used to drive the moving mechanism to drive the detection component to move. The detection component is located above the wire harness clamping mechanism.

[0008] Preferably, the linkage mechanism includes pulley No. 1, a connecting belt and pulley No. 2, pulley No. 1 is fixedly connected to the rotating end of the No. 1 fixed frame, pulley No. 1 is movably connected to the connecting belt, the connecting belt is movably connected to pulley No. 2, the upper part of the detection platform is fixedly connected to the No. 2 mounting frame, the moving mechanism includes guide assembly No. 4 and lead screw No. 4, the bottom of the guide assembly No. 4 is slidingly connected to the No. 4 wire block, the No. 4 lead screw is rotatably connected to the No. 2 mounting frame, and the No. 4 lead screw is threadedly connected to the No. 4 wire block, and the bottom of the No. 4 wire block is fixedly connected to the detection assembly.

[0009] Preferably, the spacing adjustment mechanism includes a No. 1 servo motor and a No. 1 guide assembly, the output end of the No. 1 servo motor is fixedly connected to the No. 1 lead screw, the surface of the No. 1 lead screw is threadedly connected to the No. 1 wire block, a No. 1 mounting bracket is fixedly connected to the No. 1 guide assembly, another No. 1 mounting bracket is slidingly connected to the No. 1 guide assembly and is fixedly connected to the side of the No. 1 wire block, a reduction motor is installed on the side of a No. 1 mounting bracket, and the output end of the reduction motor is fixedly connected to the No. 1 fixing bracket.

[0010] Preferably, a connecting mechanism is fixedly connected between the two No. 1 fixing frames, and the connecting mechanism includes a sleeve, an insertion rod and a fixed block. The bottom of one No. 1 fixing frame is fixedly connected to the sleeve, and the bottom of the other No. 1 fixing frame is fixedly connected to the fixed block. The fixed block is fixedly connected to the insertion rod, one end of the insertion rod is inserted into the inside of the sleeve, and the insertion rod is engaged with the sleeve.

[0011] Preferably, the detection component consists of a laser thickness gauge and an industrial camera, both of which are connected to an industrial computer. The laser thickness gauge is used to detect the thickness of the insulation layer of the wire harness, and the industrial camera is used to detect the apparent quality of the insulation layer of the wire harness.

[0012] Preferably, the harness angle adjustment assembly includes a fixed plate and a No. 2 servo motor, the upper portion of the fixed plate is fixedly connected to the No. 3 guide assembly, three No. 2 fixing frames are installed on the upper portion of the No. 3 guide assembly, and the three No. 2 fixing frames are arranged in sequence, the middle No. 2 fixing frame is fixedly connected to the No. 3 guide assembly, the No. 2 fixing frames on both sides are slidably connected to the No. 3 guide assembly, and the upper portions of the No. 2 fixing frames on both sides are rotatably connected to guide columns, the No. 2 servo motor is fixedly connected to the fixed plate, and the output end of the No. 2 servo motor is fixedly connected to the No. 2 lead screw, the surface of the No. 2 lead screw is threadedly connected to the No. 2 wire block, the upper portion of the fixed plate is fixedly connected to the No. 2 guide assembly, the No. 2 guide assembly is located at the end of the No. 3 guide assembly, and the upper portion of the No. 2 guide assembly is slidably connected to the adjusting plate, one side of the adjusting plate is fixedly connected to the No. 2 wire block, and the upper portion of the adjusting plate has two guide grooves arranged in an eight-shaped shape, and the guide columns are located inside the guide grooves.

[0013] Preferably, the harness distance adjustment assembly includes a slide rail, which is fixedly connected to the upper part of the No. 2 fixed frame, and the end of the slide rail is fixedly connected to the No. 3 servo motor, the output end of the No. 3 servo motor is fixedly connected to the No. 3 lead screw, the surface of the No. 3 lead screw is threadedly connected to the No. 3 wire block, and the No. 3 wire block is slidably connected to the slide rail.

[0014] Preferably, the clamp assembly includes a No. 3 fixing frame, which is fixedly connected to the upper part of the No. 3 wire block, and a clamp body is installed on the side of the No. 3 fixing frame, and a tension sensor is installed between the No. 3 fixing frame and the clamp body.

[0015] Compared with the prior art, the present invention has the following beneficial effects:

[0016] 1. In the present invention, the No. 1 servo motor and the No. 1 lead screw are used to drive the No. 1 mounting frame to slide along the No. 1 guide assembly, thereby realizing flexible adjustment of the spacing between the two sets of wire harness clamping mechanisms, so that the clamp assembly can adapt to wire harnesses of different overall lengths and complete preliminary clamping, avoiding the forced stretching of long wire harnesses by traditional fixed spacing devices; the No. 3 servo motor and the No. 3 lead screw are used to drive the No. 3 wire block to slide along the slide rail, thereby realizing independent position adjustment of each clamp assembly, and can accurately fix and independently straighten branches of different lengths in the wire harness, thereby solving the deformation problem of the branch structure caused by uneven tension.

[0017] 2. In the present invention, the No. 2 servo motor and the No. 2 lead screw drive the No. 2 wire block, the adjustment plate and the guide column to slide, so that the main line and the branch line with the angle are fully unfolded, exposing the hidden detection position and avoiding the detection blind spot caused by the structure obstruction; the tension at each position is monitored in real time by the tension sensor between the No. 3 fixing frame and the fixture body, and combined with feedback control, the damage to components or interruption of detection caused by traditional rigid leveling is eliminated, and non-destructive detection and comprehensive detection coverage of complex structure wiring harnesses are realized, which significantly improves the detection efficiency and reliability.

[0018] 3. In the present invention, a reduction motor is used to drive the No. 1 fixed frame to drive the wire harness to rotate °, so that the detection component can scan the wire harness circumferentially without dead angles, solving the problem of detection blind spots in hidden positions in curved and branched structures, and ensuring the comprehensiveness of insulation layer thickness uniformity detection; through the transmission coupling of the No. 1 pulley and the No. 2 pulley, the rotational kinetic energy of the wire harness is converted into the rotational power of the No. 4 screw, driving the No. 4 wire block to drive the detection component to slide smoothly along the No. 4 guide component, realizing the horizontal movement of the detection component in the axial direction of the wire harness, and can perform segmented continuous scanning on longer wire harnesses, avoiding the splicing error of traditional single-station detection. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 This is a first three-dimensional structural schematic diagram of a pressure sensor harness insulation layer detection device according to the present invention;

[0020] Figure 2 This is a second three-dimensional structural schematic diagram of a pressure sensor harness insulation layer detection device according to the present invention;

[0021] Figure 3 This is a third three-dimensional structural schematic diagram of a pressure sensor harness insulation layer detection device according to the present invention;

[0022] Figure 4 This is a schematic diagram of the three-dimensional structure of a connection mechanism in a pressure sensor harness insulation layer detection device according to the present invention;

[0023] Figure 5 This is a schematic diagram of the three-dimensional structure of a wire harness clamping mechanism in a pressure sensor wire harness insulation layer detection device of the present invention;

[0024] Figure 6 This is a schematic diagram of the three-dimensional structure of a moving mechanism in a pressure sensor harness insulation layer detection device of the present invention;

[0025] Figure 7 The present invention is a schematic diagram of the three-dimensional structure of a clamp assembly in a pressure sensor harness insulation layer detection device.

[0026] In the figure: 1. Test table; 2. Spacing adjustment mechanism; 21. Servo motor No. 1; 22. Lead screw No. 1; 23. Screw block No. 1; 24. Guide assembly No. 1; 3. Rotation mechanism; 31. Mounting frame No. 1; 32. Reducer motor; 33. Fixing frame No. 1; 4. Wire harness clamping mechanism; 41. Fixing plate; 42. Servo motor No. 2; 43. Lead screw No. 2; 44. Screw block No. 2; 45. Guide assembly No. 2; 46. Adjustment plate; 47. Guide assembly No. 3; 48. Fixing frame No. 2; 49. Guide column; 410. Guide slot; 411. Wire harness spacing Distance adjustment assembly; 412, slide rail; 413, servo motor No. 3; 414, wire block No. 3; 415, lead screw No. 3; 416, fixture assembly; 417, fixed frame No. 3; 418, fixture body; 419, tension sensor; 5, mounting frame No. 2; 6, moving mechanism; 61, lead screw No. 4; 62, wire block No. 4; 63, guide assembly No. 4; 7, detection assembly; 8, linkage mechanism; 81, pulley No. 1; 82, connecting belt; 83, pulley No. 2; 9, connecting mechanism; 91, sleeve; 92, plug rod; 93, fixed block. DETAILED DESCRIPTION

[0027] 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 implementation regulations described are only part of the embodiments of the present invention, not all of the embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0028] Example 1: Reference Figure 1-Figure 7 As shown: A pressure sensor harness insulation layer detection device includes a detection platform 1, a spacing adjustment mechanism 2 is fixedly connected to the upper part of the detection platform 1, a rotating mechanism 3 is installed on the upper part of the spacing adjustment mechanism 2, and a detection component 7 for quality detection of the wiring harness is installed on the upper part of the detection platform 1, the rotating mechanism 3 includes two No. 1 mounting brackets 31, one No. 1 mounting bracket 31 is fixedly connected to the spacing adjustment mechanism 2, and the other No. 1 mounting bracket 31 is slidably connected to the spacing adjustment mechanism 2, and the spacing adjustment mechanism 2 is used to adjust the position of the sliding connection No. 1 mounting bracket 31, the two Each side of the No. 1 mounting frame 31 is rotatably connected to the No. 1 fixing frame 33, and the surface of the No. 1 fixing frame 33 is fixedly connected to the wire harness clamping mechanism 4. The rotating mechanism 3 is used to drive the wire harness clamping mechanism 4 to rotate. The wire harness clamping mechanism 4 includes a wire harness angle adjustment component, a wire harness distance adjustment component 411 and a clamp component 416. The clamp component 416 is used to clamp and fix the wire harness. The wire harness distance adjustment component 411 is used to adjust the distance between the clamp component 416 and the wire harness. The wire harness angle adjustment component is used to adjust the angle between the wire harnesses fixed by the clamp component 416;

[0029] The rotating end of the No. 1 fixing frame 33 is fixedly connected with a linkage mechanism 8, and a moving mechanism 6 is installed on the upper part of the detection component 7. The linkage mechanism 8 is used to drive the moving mechanism 6 to drive the detection component 7 to move. The detection component 7 is located above the harness clamping mechanism 4. The harness angle adjustment component includes a fixing plate 41 and a No. 2 servo motor 42. The upper part of the fixing plate 41 is fixedly connected with a No. 3 guide component 47. Three No. 2 fixing frames 48 are installed on the upper part of the No. 3 guide component 47. The three No. 2 fixing frames 48 are arranged in sequence. The middle No. 2 fixing frame 48 is fixedly connected to the No. 3 guide component 47, and the No. 2 fixing frames 48 on both sides are slidably connected to the No. 3 guide component 47, and The upper part of the No. 2 fixing frame 48 on both sides is rotatably connected to the guide column 49, the No. 2 servo motor 42 is fixedly connected to the fixing plate 41, and the output end of the No. 2 servo motor 42 is fixedly connected to the No. 2 lead screw 43, and the surface of the No. 2 lead screw 43 is threadedly connected to the No. 2 wire block 44. The upper part of the fixing plate 41 is fixedly connected to the No. 2 guide assembly 45, which is located at the end of the No. 3 guide assembly 47, and the upper part of the No. 2 guide assembly 45 is slidably connected to the adjustment plate 46, one side of the adjustment plate 46 is fixedly connected to the No. 2 wire block 44, and the upper part of the adjustment plate 46 has two guide grooves 410 arranged in an eight-shaped manner, and the guide column 49 is located inside the guide groove 410;

[0030] The harness distance adjustment assembly 411 includes a slide rail 412, which is fixedly connected to the upper part of the No. 2 fixing frame 48, and the end of the slide rail 412 is fixedly connected to the No. 3 servo motor 413, and the output end of the No. 3 servo motor 413 is fixedly connected to the No. 3 lead screw 415, and the surface of the No. 3 lead screw 415 is threadedly connected to the No. 3 wire block 414, and the No. 3 wire block 414 is slidably connected to the slide rail 412, and the clamp assembly 416 includes a No. 3 fixing frame 417, which is fixedly connected to the upper part of the No. 3 wire block 414, and a clamp body 418 is installed on the side of the No. 3 fixing frame 417, and a tension sensor 419 is installed between the No. 3 fixing frame 417 and the clamp body 418.

[0031] In this embodiment, according to the overall length of the pressure sensor harness to be tested, the first servo motor 21 drives the first lead screw 22 to rotate, causing the first lead block 23 to drive a first mounting bracket 31 to slide along the first guide assembly 24, thereby adjusting the distance between the two sets of harness clamping mechanisms 4, so that the clamp assemblies 416 in the two sets of harness clamping mechanisms 4 can facilitate the preliminary clamping and fixing of harnesses of different lengths;

[0032] After the distance between the two No. 1 mounting frames 31 is adjusted, the two ends of the wiring harness are clamped and fixed respectively by the clamp assembly 416. During the process of clamping and fixing the wiring harness, the No. 3 servo motor 413 drives the No. 3 lead screw 415 to rotate according to the length of the branch line in the wiring harness as a whole, so that the No. 3 wire block 414 slides along the slide rail 412, thereby independently adjusting the position of the clamp assembly 416, so that the clamp assembly 416 can independently fix the branch line in the wiring harness and independently straighten the branch line;

[0033] When there is a certain angle between the main line and the branch line in the wiring harness, the main line is fixed to the clamp assembly 416 at the middle position of the upper part of the fixing plate 41, and the No. 2 servo motor 42 drives the No. 2 lead screw 43 to rotate, thereby driving the No. 2 wire block 44 and the No. 2 guide assembly 45 to slide along the No. 2 guide assembly 45, and the guide groove 410 provided on the surface of the adjustment plate 46 drives the guide column 49 and the No. 2 fixing frame 48 to slide along the No. 3 guide assembly 47, so that the clamp assemblies 416 on both sides drive the branch line to unfold along the main line, so that the position between the branch line and the main line is completely exposed, which is convenient for the detection assembly 7 to fully detect each position of the wiring harness;

[0034] When the harness distance adjustment component 411 adjusts the position of the clamp component 416 and straightens the main line and branch line of the harness, the tension sensor 419 between the third fixing frame 417 and the clamp body 418 monitors the tension at each position of the harness to avoid excessive or insufficient tension on the harness.

[0035] The No. 1 servo motor 21 and the No. 1 lead screw 22 are used to drive the No. 1 mounting frame 31 to slide along the No. 1 guide assembly 24, so as to realize the flexible adjustment of the spacing between the two sets of harness clamping mechanisms 4, so that the clamp assembly 416 can adapt to harnesses of different overall lengths and complete the initial clamping, avoiding the forced stretching of long harnesses by traditional fixed spacing devices; the No. 3 servo motor 413 and the No. 3 lead screw 415 drive the No. 3 wire block 414 to slide along the slide rail 412, so as to realize the independent position adjustment of each clamp assembly 416, and can accurately fix and independently straighten branches of different lengths in the harness, solving the problem of branch structure. Deformation problems caused by uneven tension; with the help of the No. 2 servo motor 42 and the No. 2 lead screw 43, the No. 2 wire block 44, the adjustment plate 46 and the guide column 49 are driven to slide, so that the main line and the branch line with the angle are fully unfolded, exposing the hidden detection position, avoiding the detection blind area caused by structural obstruction; the tension at each position is monitored in real time by the tension sensor 419 between the No. 3 fixing frame 417 and the clamp body 418, combined with feedback control, to eliminate component damage or detection interruption caused by traditional rigid leveling, realize non-destructive detection and comprehensive detection coverage of complex structure wiring harnesses, and significantly improve detection efficiency and reliability.

[0036] Example 2: According to Figure 1-Figure 7As shown, the linkage mechanism 8 includes a No. 1 pulley 81, a connecting belt 82 and a No. 2 pulley 83. The No. 1 pulley 81 is fixedly connected to the rotating end of the No. 1 fixed frame 33, the No. 1 pulley 81 is movably connected to the connecting belt 82, and the connecting belt 82 is movably connected to the No. 2 pulley 83. The upper part of the detection platform 1 is fixedly connected to the No. 2 mounting frame 5, and the moving mechanism 6 includes a No. 4 guide assembly 63 and a No. 4 lead screw 61. The bottom of the No. 4 guide assembly 63 is slidably connected to the No. 4 wire block 62. The No. 4 lead screw 61 is rotatably connected to the No. 2 mounting frame 5, and the No. 4 lead screw 61 is threadedly connected to the No. 4 wire block 62. The bottom of the No. 1 wire block 62 is fixedly connected to the detection component 7, and the spacing adjustment mechanism 2 includes a No. 1 servo motor 21 and a No. 1 guide component 24. The output end of the No. 1 servo motor 21 is fixedly connected to the No. 1 screw 22, and the surface of the No. 1 screw 22 is threadedly connected to the No. 1 wire block 23. A No. 1 mounting bracket 31 is fixedly connected to the No. 1 guide component 24, and another No. 1 mounting bracket 31 is slidingly connected to the No. 1 guide component 24 and fixedly connected to the side of the No. 1 wire block 23. A reduction motor 32 is installed on the side of a No. 1 mounting bracket 31, and the output end of the reduction motor 32 is fixedly connected to the No. 1 fixing bracket 33.

[0037] A connecting mechanism 9 is fixedly connected between the two No. 1 fixing frames 33. The connecting mechanism 9 includes a sleeve 91, an insertion rod 92 and a fixed block 93. The bottom of one No. 1 fixing frame 33 is fixedly connected to the sleeve 91, and the bottom of the other No. 1 fixing frame 33 is fixedly connected to the fixed block 93. The fixed block 93 is fixedly connected to the insertion rod 92. One end of the insertion rod 92 is plugged into the inside of the sleeve 91, and the insertion rod 92 is engaged with the sleeve 91. The detection component 7 consists of a laser thickness gauge and an industrial camera. The laser thickness gauge and the industrial camera are both connected to an industrial computer. The laser thickness gauge is used to detect the thickness of the insulation layer of the wire harness, and the industrial camera is used to detect the apparent quality of the insulation layer of the wire harness.

[0038] In this embodiment, after the wiring harness is fixed, the thickness and surface quality of the insulation layer of the wiring harness are inspected by the inspection component 7 to ensure the uniformity of the thickness of the insulation layer and to check for obvious defects such as bubbles, scratches, and uneven color on the surface of the insulation layer;

[0039] When inspecting the insulation layer of the wire harness, the reduction motor 32 drives the No. 1 fixing frame 33 to rotate, thereby driving the wire harness to rotate. During the rotation of the wire harness, the detection component 7 performs a full-scale scanning inspection on the wire harness. At the same time, the No. 1 fixing frame 33 will also drive the No. 1 pulley 81 to rotate, and then drive the No. 2 pulley 83 to drive the No. 4 screw 61 to rotate, so that the No. 4 wire block 62 drives the detection component 7 to slide along the No. 4 guide component 63. At this time, the detection component 7 moves horizontally above the wire harness, and a comprehensive and stable inspection of the wire harness with a longer length can be performed.

[0040] The reduction motor 32 is used to drive the No. 1 fixed frame 33 to drive the wire harness to rotate 360°, so that the detection component 7 can scan the circumference of the wire harness without dead angles, solving the problem of blind spot detection in hidden positions in curved and branched structures, and ensuring the comprehensiveness of the insulation layer thickness uniformity detection; through the transmission coupling of the No. 1 pulley 81 and the No. 2 pulley 83, the rotational kinetic energy of the wire harness is converted into the rotational power of the No. 4 screw 61, driving the No. 4 wire block 62 to drive the detection component 7 to slide smoothly along the No. 4 guide component 63, realizing the horizontal movement of the detection component 7 in the axial direction of the wire harness, and can perform segmented continuous scanning of longer wire harnesses, avoiding the splicing error of traditional single-station detection; the mechanical linkage design ensures that the detection speed is accurately matched with the wire harness rotation rate, and cooperates with the high-frequency data acquisition of the detection component 7, such as the 10kHz scanning frequency of the linear array camera, to achieve stable identification of defects such as bubbles and scratches on the surface of the insulation layer, improve detection efficiency, and avoid detection position offset caused by human intervention.

[0041] Example 3: An automated control system is used in an industrial computer to control the detection component 7 to detect the insulation thickness and surface quality of the wiring harness. The core control architecture includes:

[0042] 1. Control platform: adopts "PLC (Programmable Logic Controller) + Industrial PC" dual-core architecture.

[0043] PLC: Choose Siemens S7-1200 or Omron NJ series, which is responsible for real-time motion control (such as motor start and stop, speed adjustment, and limit protection).

[0044] Industrial PC: Equipped with Advantech UNO series industrial computers, running Windows Embedded system, and integrated with host computer software to achieve parameter configuration, process monitoring and data management.

[0045] Communication protocol: Connect PLC and industrial computer via PROFINET or EtherCAT bus to ensure real-time multi-axis linkage control (response time < 10ms).

[0046] 2. Data processing and intelligent analysis technology, using machine vision algorithms, including:

[0047] Image preprocessing: Use median filtering to remove noise and segment the focused beam area through ROI (region of interest) to reduce the amount of calculation.

[0048] Defect identification uses deep learning algorithms: deploying YOLOv5 or FasterR-CNN models, with a training set containing more than 100,000 wire harness defect samples, to achieve automatic identification of tiny defects (≥0.1mm) with an accuracy rate of >95%.

[0049] Thickness detection: After a laser thickness gauge (such as the Keyence IL-600) collects data, it uses a polynomial fitting algorithm to remove noise, calculate the standard deviation (σ) and uniformity index (UI = 1-σ / μ) of the insulation layer thickness, and output a thickness distribution cloud map.

[0050] 3. Data management and traceability, including:

[0051] Database: Use MySQL or SQL Server to store information such as inspection number, harness model, inspection time, thickness data, image snapshots, etc., and support fast retrieval by batch / date.

[0052] Quality Assessment: Set dual thresholds: a primary threshold (e.g., thickness tolerance ±0.05mm) triggers an alert, while a secondary threshold (±0.1mm) determines failure. Automatically generate a test report (PDF format) containing test results, defect location annotations, and CPK process capability analysis.

[0053] The method of use and working principle of this device are as follows: Based on the overall length of the pressure sensor harness to be tested, the first servo motor 21 drives the first lead screw 22 to rotate, causing the first lead block 23 to drive a first mounting bracket 31 to slide along the first guide assembly 24, thereby adjusting the distance between the two sets of harness clamping mechanisms 4, so that the clamp assemblies 416 in the two sets of harness clamping mechanisms 4 can facilitate the preliminary clamping and fixing of harnesses of different lengths;

[0054] After the distance between the two No. 1 mounting frames 31 is adjusted, the two ends of the wiring harness are clamped and fixed respectively by the clamp assembly 416. During the process of clamping and fixing the wiring harness, the No. 3 servo motor 413 drives the No. 3 lead screw 415 to rotate according to the length of the branch line in the wiring harness as a whole, so that the No. 3 wire block 414 slides along the slide rail 412, thereby independently adjusting the position of the clamp assembly 416, so that the clamp assembly 416 can independently fix the branch line in the wiring harness and independently straighten the branch line;

[0055] When there is a certain angle between the main line and the branch line in the wiring harness, the main line is fixed to the clamp assembly 416 at the middle position of the upper part of the fixing plate 41, and the No. 2 servo motor 42 drives the No. 2 lead screw 43 to rotate, thereby driving the No. 2 wire block 44 and the No. 2 guide assembly 45 to slide along the No. 2 guide assembly 45, and the guide groove 410 provided on the surface of the adjustment plate 46 drives the guide column 49 and the No. 2 fixing frame 48 to slide along the No. 3 guide assembly 47, so that the clamp assemblies 416 on both sides drive the branch line to unfold along the main line, so that the position between the branch line and the main line is completely exposed, which is convenient for the detection assembly 7 to fully detect each position of the wiring harness;

[0056] When the harness distance adjustment component 411 adjusts the position of the clamp component 416 and straightens the main line and branch line of the harness, the tension sensor 419 between the third fixing frame 417 and the clamp body 418 monitors the tension at each position of the harness to avoid excessive or insufficient tension on the harness.

[0057] After the wiring harness is fixed, the insulation thickness and surface quality of the wiring harness are inspected by the inspection component 7 to ensure the uniformity of the insulation thickness and to check for obvious defects such as bubbles, scratches, and uneven color on the surface of the insulation layer.

[0058] When inspecting the insulation layer of the wire harness, the reduction motor 32 drives the No. 1 fixing frame 33 to rotate, thereby driving the wire harness to rotate. During the rotation of the wire harness, the detection component 7 performs a full-scale scanning inspection on the wire harness. At the same time, the No. 1 fixing frame 33 will also drive the No. 1 pulley 81 to rotate, and then drive the No. 2 pulley 83 to drive the No. 4 screw 61 to rotate, so that the No. 4 wire block 62 drives the detection component 7 to slide along the No. 4 guide component 63. At this time, the detection component 7 moves horizontally above the wire harness, and a comprehensive and stable inspection of the wire harness with a longer length can be performed.

[0059] Although the present invention has been described in detail with reference to the aforementioned embodiments, it is still possible for those skilled in the art to modify the technical solutions described in the aforementioned embodiments, or to make equivalent substitutions for some of the technical features therein. 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 pressure sensor harness insulation layer testing device, comprising a testing platform (1), a spacing adjustment mechanism (2) fixedly connected to the upper portion of the testing platform (1), a rotating mechanism (3) mounted on the upper portion of the spacing adjustment mechanism (2), and a testing component (7) for performing quality testing on the harness mounted on the upper portion of the testing platform (1), characterized in that: The rotating mechanism (3) comprises two No. 1 mounting frames (31), one No. 1 mounting frame (31) is fixedly connected to the spacing adjustment mechanism (2), and the other No. 1 mounting frame (31) is slidably connected to the spacing adjustment mechanism (2), the spacing adjustment mechanism (2) is used to adjust the position of the slidingly connected No. 1 mounting frame (31), the sides of the two No. 1 mounting frames (31) are both rotatably connected to the No. 1 fixing frame (33), and the surface of the No. 1 fixing frame (33) is fixedly connected to the wire harness clamping mechanism (4); The rotating mechanism (3) is used to drive the wire harness clamping mechanism (4) to rotate. The wire harness clamping mechanism (4) includes a wire harness angle adjustment component, a wire harness distance adjustment component (411), and a clamp component (416). The clamp component (416) is used to clamp and fix the wire harness. The wire harness distance adjustment component (411) is used to adjust the distance between the clamp component (416) and the wire harness. The wire harness angle adjustment component is used to adjust the angle between the wire harnesses fixed by the clamp component (416). The rotating end of the No. 1 fixing frame (33) is fixedly connected to a linkage mechanism (8), and a moving mechanism (6) is installed on the upper part of the detection component (7). The linkage mechanism (8) is used to drive the moving mechanism (6) to drive the detection component (7) to move, and the detection component (7) is located above the wire harness clamping mechanism (4).

2. The pressure sensor harness insulation layer detection device according to claim 1, characterized in that: The linkage mechanism (8) comprises a first pulley (81), a connecting belt (82) and a second pulley (83), wherein the first pulley (81) is fixedly connected to the rotating end of the first fixed frame (33), the first pulley (81) is movably connected to the connecting belt (82), and the connecting belt (82) is movably connected to the second pulley (83), the upper part of the detection platform (1) is fixedly connected to the second mounting frame (5), the moving mechanism (6) comprises a fourth guide assembly (63) and a fourth lead screw (61), the bottom of the fourth guide assembly (63) is slidably connected to the fourth wire block (62), the fourth lead screw (61) is rotatably connected to the second mounting frame (5), and the fourth lead screw (61) is threadedly connected to the fourth wire block (62), and the bottom of the fourth wire block (62) is fixedly connected to the detection assembly (7).

3. The pressure sensor harness insulation layer detection device according to claim 1, characterized in that: The linkage mechanism (8) comprises a first pulley (81), a connecting belt (82) and a second pulley (83), wherein the first pulley (81) is fixedly connected to the rotating end of the first fixed frame (33), the first pulley (81) is movably connected to the connecting belt (82), and the connecting belt (82) is movably connected to the second pulley (83), the upper part of the detection platform (1) is fixedly connected to the second mounting frame (5), the moving mechanism (6) comprises a fourth guide assembly (63) and a fourth lead screw (61), the bottom of the fourth guide assembly (63) is slidably connected to the fourth wire block (62), the fourth lead screw (61) is rotatably connected to the second mounting frame (5), and the fourth lead screw (61) is threadedly connected to the fourth wire block (62), and the bottom of the fourth wire block (62) is fixedly connected to the detection assembly (7).

4. The pressure sensor harness insulation layer detection device according to claim 1, characterized in that: The spacing adjustment mechanism (2) comprises a No. 1 servo motor (21) and a No. 1 guide assembly (24); the output end of the No. 1 servo motor (21) is fixedly connected to the No. 1 lead screw (22); the surface of the No. 1 lead screw (22) is threadedly connected to the No. 1 wire block (23); a No. 1 mounting frame (31) is fixedly connected to the No. 1 guide assembly (24); another No. 1 mounting frame (31) is slidably connected to the No. 1 guide assembly (24) and fixedly connected to the side of the No. 1 wire block (23); a reduction motor (32) is installed on the side of the No. 1 mounting frame (31); and the output end of the reduction motor (32) is fixedly connected to the No. 1 fixing frame (33).

5. The pressure sensor harness insulation layer detection device according to claim 1, characterized in that: A connecting mechanism (9) is fixedly connected between the two No. 1 fixing frames (33), and the connecting mechanism (9) includes a sleeve (91), an insertion rod (92) and a fixing block (93). The bottom of one No. 1 fixing frame (33) is fixedly connected to the sleeve (91), and the bottom of the other No. 1 fixing frame (33) is fixedly connected to the fixing block (93). The fixing block (93) is fixedly connected to the insertion rod (92). One end of the insertion rod (92) is plugged into the inside of the sleeve (91), and the insertion rod (92) is engaged with the sleeve (91).

6. The pressure sensor harness insulation layer detection device according to claim 1, characterized in that: The detection component (7) consists of a laser thickness gauge and an industrial camera. Both the laser thickness gauge and the industrial camera are externally connected to an industrial computer. The laser thickness gauge is used to detect the thickness of the insulation layer of the wire harness, and the industrial camera is used to detect the apparent quality of the insulation layer of the wire harness.

7. The pressure sensor harness insulation layer detection device according to claim 1, characterized in that: The harness angle adjustment assembly includes a fixed plate (41) and a No. 2 servo motor (42). The upper portion of the fixed plate (41) is fixedly connected to a No. 3 guide assembly (47). The upper portion of the No. 3 guide assembly (47) is equipped with three No. 2 fixed frames (48). The three No. 2 fixed frames (48) are arranged in sequence. The middle No. 2 fixed frame (48) is fixedly connected to the No. 3 guide assembly (47). The No. 2 fixed frames (48) on both sides are slidably connected to the No. 3 guide assembly (47). The upper portions of the No. 2 fixed frames (48) on both sides are rotatably connected to guide columns (49). The No. 2 servo motor (42) is fixedly connected to the fixed plate (41). , and the output end of the No. 2 servo motor (42) is fixedly connected to the No. 2 lead screw (43), the surface of the No. 2 lead screw (43) is threadedly connected to the No. 2 wire block (44), the upper part of the fixed plate (41) is fixedly connected to the No. 2 guide assembly (45), the No. 2 guide assembly (45) is located at the end of the No. 3 guide assembly (47), and the upper part of the No. 2 guide assembly (45) is slidably connected to the adjustment plate (46), one side of the adjustment plate (46) is fixedly connected to the No. 2 wire block (44), and the upper part of the adjustment plate (46) has two guide grooves (410) arranged in an eight-shaped shape, and the guide column (49) is located inside the guide groove (410).

8. The pressure sensor harness insulation layer detection device according to claim 1, characterized in that: The harness distance adjustment assembly (411) comprises a slide rail (412), the slide rail (412) being fixedly connected to the upper portion of the second fixing frame (48), and the end of the slide rail (412) being fixedly connected to a third servo motor (413), the output end of the third servo motor (413) being fixedly connected to a third lead screw (415), the surface of the third lead screw (415) being threadedly connected to a third wire block (414), and the third wire block (414) being slidably connected to the slide rail (412).

9. The pressure sensor harness insulation layer detection device according to claim 1, characterized in that: The clamp assembly (416) includes a No. 3 fixing frame (417), which is fixedly connected to the upper part of the No. 3 wire block (414), and a clamp body (418) is installed on the side of the No. 3 fixing frame (417), and a tension sensor (419) is installed between the No. 3 fixing frame (417) and the clamp body (418).

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