Wire harness production method based on high polymer material

Abstract

The invention relates to the technical field of wire harness production, in particular to a high polymer material-based wire harness production method, which can accurately analyze the management and control risk complexity of a single production chain link of wire harness production by acquiring sample data information of each production chain link of wire harness production in a target area, and can accurately analyze the management and control risk complexity of the single production chain link of wire harness production through the management and control risk complexity. According to the invention, the risk tendency of wire harness production can be accurately analyzed, misjudgment of wire harness production control is reduced, and the efficiency of wire harness production control is improved. The characteristic characterization value of the wire harness can be obtained by analyzing the sectional area of the high polymer material wire harness and the crimping rate of the terminal, so that the characteristic difference of the wire harness in the target area is synthesized, and whether the abnormal risk of the wire harness exists or not can be further analyzed; the adjustment amplitude of the control sampling period and the adjustment amplitude of the equipment operation tension can be accurately determined by analyzing the wire harness abnormity reason, and the precision of wire harness production control is improved.

Description

Technical Field

[0001] This invention relates to the field of wire harness manufacturing technology, and in particular to a method for manufacturing wire harnesses based on polymer materials. Background Technology

[0002] With the rapid development of industrial automation, new energy, and intelligent manufacturing industries, the demand for wire harnesses, as core components for power and signal transmission, has surged, and performance requirements have become increasingly stringent. Traditional wire harness production relies on manual operation, resulting in low precision in material processing, including stripping the polymer insulation layer, combing the shielding layer, and crimping terminals. This also leads to poor quality consistency due to fluctuations in the properties of polymer materials, such as elasticity and temperature resistance.

[0003] Meanwhile, the automotive, forklift, and smart device industries are demanding higher levels of weather resistance and insulation for wire harnesses. Traditional processes are struggling to meet the flexible production needs of diverse products in small batches, resulting in low efficiency, high costs, and difficulties in traceability. Therefore, intelligent manufacturing of wire harnesses based on polymer materials is becoming a trend. By using automated equipment and digital systems to optimize material handling, process control, and quality inspection, the high-precision and high-reliability production requirements can be met.

[0004] Chinese Patent Publication No. CN111724041A discloses an intelligent production control system for forklift wiring harnesses. The system includes a production control local area network (LAN) comprised of a central server and various devices on the production line. The central server is wirelessly connected to each device. It also includes identification codes for each worker and wireless barcode readers for each device on the production line, all wirelessly connected to the central server. The central server integrates a database, a device production parameter database, a personnel identification and matching program, and a production control program. Based on the identification code data and its own program, the central server matches personnel with devices and controls the equipment operation. This invention provides an intelligent control system for forklift wiring harness production, enabling automated control of equipment production after personnel and equipment matching, and intelligent monitoring of production efficiency, product qualification rate, and raw material consumption rate.

[0005] Chinese Patent Publication No. CN111489866A discloses a manufacturing process for a special wiring harness for new energy vehicles, including the following steps: S1, preparing materials; S2, cutting wires; S3, pre-threading the main wires into the holes of the sheath sealing cover, inserting sealing plugs, dividing each main wire into two ends, A and B, with the end closer to the sealing plug being the main conductor A end and the other end being the main conductor B end, performing shielding ring crimping treatment on the A ends of the two main wires, assembling the high-voltage sheath, performing shielding ring crimping treatment on the B ends of the two main wires, fixing the two auxiliary wires to the two main wires, twisting the wires, pre-installing black double-wall heat shrink tubing, ultrasonic welding, and heating the black double-wall heat shrink tubing; S4, assembling with adhesive wrapping; S5, performing pull-out tests, continuity tests, dimensional inspections, appearance inspections, and packaging the finished products, and warehousing the qualified finished products to complete the manufacturing process of the special wiring harness for new energy vehicles. The manufacturing process proposed in this invention has a high pass rate, produces wiring harnesses with excellent performance and a long service life.

[0006] However, the following problems still exist in the existing technology: In existing intelligent production control systems for wire harnesses, the data representation of different production chain links in wire harness production is not considered in terms of production control dimensions. In reality, wire harness production has relatively obvious characteristics in some production chain links, and some production chain links are quite similar. If the same control risk analysis method is used for each production chain link in wire harness production, there will be a defect of low production control monitoring efficiency. Summary of the Invention

[0007] To address this, the present invention provides a wire harness production method based on polymer materials, which overcomes the problem of low production control and monitoring efficiency caused by the prior art's failure to consider the differences in data characterization of different production chain links in wire harness production and the differences in control risks of each production chain link.

[0008] To achieve the above objectives, the present invention provides a method for producing wire harnesses based on polymer materials, comprising: Based on the predetermined control sampling interval, sample data information of each link in the production chain of wire harness production in the target area is obtained. Based on the sample data, analyze the control risk complexity of a single production chain link in wire harness production, and analyze the risk tendency of wire harness production based on the difference between the control risk complexity and the predetermined control risk complexity benchmark. Based on the aforementioned risk tendency in wire harness production, the cross-sectional area of ​​polymer material wire harnesses and the terminal crimping rate in wire harness production are extracted, and the characteristic values ​​of wire harnesses are analyzed based on the cross-sectional area of ​​polymer material wire harnesses and the terminal crimping rate in wire harness production. The ratio of the stated wire harness characteristic value to a predetermined wire harness characteristic value is used to determine whether there is a wire harness anomaly risk in the corresponding production chain link. If a wire harness anomaly risk exists, the reason for the wire harness anomaly risk in the corresponding production chain link is determined based on the difference between the stated wire harness characteristic value and the predetermined wire harness characteristic value. The adjustment range of the control sampling interval reference is determined based on the difference between the terminal crimping rate and the predetermined terminal crimping rate reference; or, the adjustment range of the equipment operating tension is determined based on the difference between the shielding effectiveness and the predetermined shielding effectiveness reference. The sample data includes shielding effectiveness and equipment operating tension.

[0009] Preferably, the process of analyzing the complexity of control risks in a single production chain link includes: Extract the shielding effectiveness and equipment operating tension of individual production chain links; The ratio of shielding effectiveness to a predetermined shielding effectiveness threshold is determined as the first complexity factor; The ratio of the equipment operating tension to the predetermined equipment operating tension threshold is determined as the second complexity factor; The sum of the first complexity factor and the second complexity factor is determined as the complexity of the risk management.

[0010] Preferably, the process of analyzing the risk tendency in wire harness production includes: Calculate the difference between the complexity of the managed risk and the predetermined baseline for the complexity of the managed risk; If the difference is less than or equal to the preset difference benchmark, it is determined to be a tendency to balance the risks in wire harness production; If the difference is greater than the preset difference benchmark, it is determined to be a significant tendency for wire harness production risk.

[0011] Preferably, the conditions for extracting the cross-sectional area of ​​the polymer material wire harness and the terminal crimping rate in wire harness production are based on the risk balance tendency cycle of wire harness production.

[0012] Preferably, the process of analyzing the characteristic values ​​of the wire harness includes: Extracting the cross-sectional area of ​​polymer material wire harnesses and terminal crimping rate in wire harness production; The ratio of the cross-sectional area of ​​the polymer material wire harness actually produced to the predetermined threshold of the cross-sectional area of ​​the polymer material wire harness is determined as the first characteristic factor. The ratio of the predetermined terminal crimping rate threshold to the actual terminal crimping rate is determined as the second characteristic factor; The sum of the first feature factor and the second feature factor is determined as the feature characterization value of the wire harness.

[0013] Preferably, the process of determining whether there is a risk of wire harness abnormality in the corresponding production chain link includes: Calculate the ratio of the characteristic value of the wire harness to the predetermined characteristic value of the wire harness; If the ratio is greater than or equal to a predetermined ratio threshold, then a risk of harness abnormality is determined.

[0014] Preferably, the reasons for determining the abnormal risk of the wiring harness in the corresponding production chain link include: Calculate the difference between the characteristic value of the wire harness and the predetermined characteristic value of the wire harness; If the difference is less than or equal to the predetermined characteristic difference threshold, the cause is determined to be that the terminal crimping rate of the corresponding production chain link does not match the control sampling interval benchmark, resulting in abnormal sampling and causing abnormal system operation. If the difference is greater than a predetermined threshold for characterization difference, the cause is determined to be a mismatch between the operating tension and shielding effectiveness of the equipment in the corresponding production chain link, leading to equipment malfunction.

[0015] Furthermore, the adjustment range of the control sampling interval benchmark is positively correlated with the difference in terminal crimping rate. The terminal crimping rate difference is the difference between the terminal crimping rate and the predetermined terminal crimping rate benchmark.

[0016] Furthermore, the adjustment range of the equipment's operating tension is positively correlated with the difference in shielding effectiveness. The shielding effectiveness difference is the difference between the shielding effectiveness and the predetermined shielding effectiveness benchmark.

[0017] Furthermore, an alarm system is activated when a significant risk to wire harness production is identified.

[0018] Compared with existing technologies, this invention, by acquiring sample data from each stage of the wire harness production chain in the target area, can accurately analyze the complexity of risk management in each stage of the wire harness production chain. This comprehensively considers the differences in data representation across production chain stages in terms of production management, and by analyzing the complexity of management risks, it can accurately analyze the risk tendencies in wire harness production, reducing misjudgments in wire harness production management and improving its efficiency. Simultaneously, by analyzing the cross-sectional area of ​​the polymer material wire harness and the terminal crimping rate, it can obtain characteristic representation values ​​of the wire harness. This integrates multi-dimensional differences in production management features and the differences in wire harness features in the target area, enabling further analysis of whether there are wire harness anomaly risks. By analyzing the causes of wire harness anomalies, it can accurately determine the adjustment range of the management sampling cycle and the adjustment range of the equipment operating tension, improving the accuracy of wire harness production management and further enhancing wire harness production efficiency.

[0019] In particular, this invention ensures the systematic and continuous nature of the samples by collecting data from each link in the production chain at fixed intervals, avoiding the randomness and bias of data collection. This provides a stable and reliable data source for subsequent analysis, making the assessment of production status more objective and reducing judgment errors caused by missing or disorganized data. By focusing on analyzing the risk complexity of individual production links, high-risk weak links, including terminal crimping and polymer material wire harness cutting, can be accurately identified. This avoids a vague assessment of the entire production chain, allowing management resources to be concentrated on high-risk links, improving control efficiency and reducing overall production risk.

[0020] In particular, this invention quantifies the degree of risk deviation by analyzing the difference between the complexity of the controlled risk and the benchmark value, enabling early detection of whether the risk is rising, falling, or fluctuating. This predictive analysis allows production managers to intervene before risks escalate, shifting from passive response to proactive prevention and reducing the probability of abnormal situations. By focusing on two key parameters—the cross-sectional area of ​​the polymer material wire harness and the terminal crimping rate—from the risk tendency, interference from irrelevant information can be eliminated, focusing the analysis on the core elements that have the greatest impact on product quality. This improves the targeting of risk assessment, making subsequent analysis more efficient and accurate. By transforming the two key parameters into unified characteristic values, standardized expression of wire harness quality characteristics across different production stages and batches is achieved. This makes quality assessment more comparable, facilitating cross-stage and cross-batch analysis of wire harness quality change patterns and providing a clear direction for quality improvement.

[0021] In particular, this invention quantifies the deviation of a feature characteristic value from a benchmark value by using the ratio of the feature characteristic value to a predetermined feature characteristic value, replacing subjective judgment and providing a unified and objective standard for determining abnormal risks. This reduces misjudgments caused by differences in human experience, improves the consistency and accuracy of anomaly identification, and ensures that risks are not overlooked or falsely reported. By associating risk causes, including excessive cross-sectional area of ​​polymer material wire harnesses and abnormal crimping rates, the root cause of the problem can be quickly identified in the production process, including wire cutting equipment malfunctions and abnormal crimping parameter settings. This reduces blind troubleshooting, shortens problem-solving time, and minimizes the impact of anomalies on production. Attached Figure Description

[0022] Figure 1 This is a flowchart illustrating the steps of a wire harness production method based on polymer materials according to an embodiment of the present invention. Figure 2 This is a flowchart illustrating the steps involved in analyzing the complexity of risk management in a single production chain link according to an embodiment of the present invention. Figure 3 This is a flowchart illustrating the determination of risk tendency in wire harness production according to an embodiment of the present invention; Figure 4This is a flowchart illustrating the steps of analyzing the characteristic values ​​of a wire harness based on the cross-sectional area of ​​the polymer material wire harness produced by wire harness manufacturing and the terminal crimping rate, according to an embodiment of the present invention. Detailed Implementation

[0023] In order to make the objects and advantages of the present invention more clearly understood, the present invention is further described below in conjunction with embodiments; it should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0024] The preferred embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood by those skilled in the art that these embodiments are only used to explain the technical principles of the present invention and are not intended to limit the scope of protection of the present invention.

[0025] It should be noted that, in the description of this invention, unless otherwise explicitly specified and limited, the term "connection" should be interpreted broadly. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0026] Please see Figure 1 The diagram shown is a flowchart illustrating the steps of a wire harness production method based on polymer materials according to an embodiment of the present invention. The present invention provides a wire harness production method based on polymer materials, comprising: Step S1: Obtain sample data information of each production chain link in the wire harness production in the target area based on the predetermined control sampling interval benchmark; Step S2: Analyze the control risk complexity of a single production chain link in wire harness production based on the sample data information, and analyze the risk tendency of wire harness production based on the difference between the control risk complexity and the predetermined control risk complexity benchmark. Step S3: Based on the risk tendency of the wire harness production, extract the cross-sectional area of ​​the polymer material wire harness and the terminal crimping rate of the wire harness production, and analyze the characteristic value of the wire harness based on the cross-sectional area of ​​the polymer material wire harness and the terminal crimping rate of the wire harness production. Step S4: Determine whether there is a wire harness anomaly risk in the corresponding production chain link based on the ratio of the wire harness characteristic value to the predetermined wire harness characteristic value. If there is a wire harness anomaly risk, determine the cause of the wire harness anomaly risk in the corresponding production chain link based on the difference between the wire harness characteristic value and the predetermined wire harness characteristic value. The adjustment range of the control sampling interval reference is determined based on the difference between the terminal crimping rate and the predetermined terminal crimping rate reference; or, the adjustment range of the equipment operating tension is determined based on the difference between the shielding effectiveness and the predetermined shielding effectiveness reference. The sample data includes shielding effectiveness and equipment operating tension.

[0027] Specifically, the monitoring period in the embodiment is [10min, 30min].

[0028] Specifically, the control sampling interval benchmark is obtained in advance. In this embodiment, the predetermined control sampling interval benchmark is 0.95 times the average value of the control sampling cycle in the two months before the system starts operating. Preferably, the control sampling interval benchmark in this embodiment is [3s, 5s].

[0029] Specifically, the production chain of wire harness production in the target area is divided into several wire harness workshops, such as the first wire harness workshop, the second wire harness workshop, the third wire harness workshop, and the fourth wire harness workshop. Other division methods can also be used, which will not be elaborated here.

[0030] Specifically, this invention, by acquiring sample data from each stage of the wire harness production chain in the target area, can accurately analyze the complexity of risk management in each stage of the wire harness production chain. This comprehensively considers the differences in data representation across production control dimensions for each stage, and by analyzing the complexity of risk management, it can accurately analyze the risk tendency in wire harness production, reducing misjudgments in wire harness production control and improving its efficiency. Simultaneously, by analyzing the cross-sectional area of ​​the polymer material wire harness and the terminal crimping rate, it can obtain characteristic values ​​of the wire harness. This integrates multi-dimensional differences in production control characteristics as well as differences in wire harness characteristics in the target area, enabling further analysis of potential wire harness anomaly risks. By analyzing the causes of wire harness anomalies, it can accurately determine the adjustment range of the control sampling cycle and the adjustment range of the equipment operating tension, improving the accuracy of wire harness production control and further enhancing wire harness production efficiency.

[0031] Please see Figure 2 The diagram shown is a flowchart illustrating the steps involved in analyzing the complexity of control risks in a single production chain link according to an embodiment of the present invention. The process of analyzing the complexity of control risks in a single production chain link according to the present invention includes: Extract the shielding effectiveness and equipment operating tension of individual production chain links; The ratio of shielding effectiveness to a predetermined shielding effectiveness threshold is determined as the first complexity factor; The ratio of the equipment operating tension to the predetermined equipment operating tension threshold is determined as the second complexity factor; The sum of the first complexity factor and the second complexity factor is determined as the complexity of the risk management.

[0032] In this embodiment, the predetermined shielding effectiveness threshold is obtained by pre-setting, wherein the average shielding effectiveness of each production chain link is predetermined, and the shielding effectiveness threshold is set as the product of the average shielding effectiveness and the accuracy coefficient. The accuracy coefficient is selected in the range [0.90, 0.95], and preferably the accuracy coefficient is 0.92.

[0033] In this embodiment, the predetermined equipment operating tension threshold is obtained by pre-setting, wherein the average value of the equipment operating tension of each production chain link is predetermined, and the equipment operating tension threshold is set as the product of the average value of the equipment operating tension and the tension offset coefficient, wherein the tension offset coefficient is in the range [1.1, 1.2], and preferably the tension offset coefficient is 1.15.

[0034] This invention collects data from each stage of the production chain at fixed intervals, ensuring the systematic and continuous nature of the samples and avoiding the randomness and bias of data collection. This provides a stable and reliable data source for subsequent analysis, making the assessment of production status more objective and reducing judgment errors caused by missing or disorganized data. By focusing on analyzing the risk complexity of individual production stages, high-risk weak points, including terminal crimping and polymer material wire harness cutting, can be accurately identified. This avoids vague assessments of the entire production chain, allowing management resources to be concentrated on high-risk stages, improving control efficiency and reducing overall production risk.

[0035] Please see Figure 3 The diagram shown is a flowchart illustrating the determination of risk tendency in wire harness production according to an embodiment of the present invention. The process of analyzing the risk tendency in wire harness production according to the present invention includes: Calculate the difference between the complexity of the managed risk and the predetermined baseline for the complexity of the managed risk; If the difference is less than or equal to the preset difference benchmark, it is determined to be a tendency to balance the risks in wire harness production; If the difference is greater than the preset difference benchmark, it is determined to be a significant tendency for wire harness production risk.

[0036] Specifically, the risk complexity benchmark and the risk complexity control benchmark are predetermined. The risk complexity control benchmark is the product of the average risk complexity control over the past three months of the system's history and the accuracy coefficient. The accuracy coefficient is between [0.90, 0.95], preferably 0.92. The risk complexity control benchmark is the product of the average risk complexity control over the past three months of the system's history and the deviation coefficient. The deviation coefficient is between [0.90, 0.95].

[0037] This invention quantifies the degree of risk deviation by analyzing the difference between the complexity of risk control and the benchmark value, enabling early detection of whether a risk is rising, falling, or fluctuating. This predictive analysis allows production managers to intervene before risks escalate, shifting from passive response to proactive prevention and reducing the probability of anomalies. By focusing on two key parameters—the cross-sectional area of ​​the polymer material wire harness and the terminal crimping rate—from risk propensity, interference from irrelevant information can be eliminated, focusing the analysis on the core elements that have the greatest impact on product quality. This improves the targeting of risk assessment, making subsequent analysis more efficient and accurate. By transforming the two key parameters into unified characteristic values, standardized expressions of wire harness quality characteristics across different production stages and batches are achieved. This makes quality assessment more comparable, facilitating cross-stage and cross-batch analysis of wire harness quality variation patterns and providing a clear direction for quality improvement.

[0038] Specifically, the conditions for extracting the cross-sectional area of ​​polymer material wire harnesses and the terminal crimping rate in wire harness production are the risk balance tendency cycle of wire harness production.

[0039] Please see Figure 4 The diagram shows a flowchart illustrating the steps of analyzing the characteristic values ​​of a wire harness based on the cross-sectional area of ​​the polymer material wire harness produced by the present invention and the terminal crimping rate. The process of analyzing the characteristic values ​​of the wire harness in this invention includes: Extracting the cross-sectional area of ​​polymer material wire harnesses and terminal crimping rate in wire harness production; The ratio of the cross-sectional area of ​​the polymer material wire harness actually produced to the predetermined threshold of the cross-sectional area of ​​the polymer material wire harness is determined as the first characteristic factor. The ratio of the predetermined terminal crimping rate threshold to the actual terminal crimping rate is determined as the second characteristic factor; The sum of the first feature factor and the second feature factor is determined as the feature characterization value of the wire harness.

[0040] This invention quantifies the deviation of characteristic features from benchmark values ​​by analyzing the ratio of characteristic features to predetermined characteristic features, replacing subjective judgment and providing a unified and objective standard for identifying anomalies and risks. This reduces misjudgments caused by differences in human experience, improves the consistency and accuracy of anomaly identification, and ensures that risks are not overlooked or falsely reported. By associating risk causes, including excessive cross-sectional area of ​​polymer material wire harnesses and abnormal crimping rates, the root cause of the problem can be quickly identified in the production process, including wire cutting equipment malfunctions and abnormal crimping parameter settings. This reduces blind troubleshooting, shortens problem-solving time, and minimizes the impact of anomalies on production.

[0041] Specifically, the process of determining whether there is a risk of wire harness abnormalities in the corresponding production chain includes, Calculate the ratio of the characteristic value of the wire harness to the predetermined characteristic value of the wire harness; If the ratio is greater than or equal to a predetermined ratio threshold, then a risk of harness abnormality is determined.

[0042] In the embodiment, the predetermined ratio threshold is in the range [2.15, 2.25], and preferably the predetermined ratio threshold is 2.20.

[0043] Specifically, the reasons for determining the risk of abnormal wiring harnesses in the corresponding production chain link include: Calculate the difference between the characteristic value of the wire harness and the predetermined characteristic value of the wire harness; If the difference is less than or equal to the predetermined characteristic difference threshold, the cause is determined to be that the terminal crimping rate of the corresponding production chain link does not match the control sampling interval benchmark, resulting in abnormal sampling and causing abnormal system operation. If the difference is greater than a predetermined threshold for characterization difference, the cause is determined to be a mismatch between the operating tension and shielding effectiveness of the equipment in the corresponding production chain link, leading to equipment malfunction.

[0044] Quantifying the difference between the two can intuitively reflect the degree of deviation between actual production and standard conditions, providing accurate numerical basis for subsequent anomaly cause determination. Compared with vague qualitative descriptions, quantitative analysis makes problem definition clearer, reduces disputes caused by differing judgments of deviation magnitude, and lays the foundation for efficient troubleshooting.

[0045] Specifically, the adjustment range of the control sampling interval benchmark is positively correlated with the difference in terminal crimping rate. The terminal crimping rate difference is the difference between the terminal crimping rate and the predetermined terminal crimping rate benchmark.

[0046] In this embodiment, the terminal crimping rate benchmark is a pre-set value. Several sample data information from the same production chain link are obtained in advance, the average terminal crimping rate of the sample data information is determined, and the product of the average terminal crimping rate and the crimping deviation coefficient is determined as the terminal crimping rate benchmark. The crimping deviation coefficient is selected between [0.85, 0.95], and preferably the crimping deviation coefficient is 0.90.

[0047] In this embodiment of the invention, a larger deviation in the terminal crimping rate indicates a more significant deviation from the standard in production status. In this case, by adjusting the sampling interval simultaneously when the rate is too high or the deviation is positive, the sampling frequency can be precisely matched to the degree of production fluctuation. Compared to fixed-amplitude adjustment, this method avoids risk omissions due to sparse sampling or resource waste due to excessive sampling, making control more targeted.

[0048] When the crimping rate is abnormal, including values ​​far exceeding the baseline, positive correlation adjustment can quickly shorten the sampling interval and increase the sample collection frequency, thereby capturing abnormal details, including crimping quality fluctuations, more quickly and buying time for risk warning and intervention. Conversely, if the rate deviation is small, appropriately relaxing the sampling interval can reduce interference with the normal production rhythm and balance control intensity with production efficiency.

[0049] By establishing a linkage between "rate deviation" and "adjustment amplitude," sampling control can automatically adapt to dynamic changes in production parameters, reducing the subjectivity of manual intervention. This self-adjusting mechanism is particularly suitable for multi-batch, multi-specification wire harness production scenarios, stably maintaining control accuracy and reducing quality risks caused by human error. Specifically, the adjustment range of the equipment's operating tension is positively correlated with the difference in shielding effectiveness. The shielding effectiveness difference is the difference between the shielding effectiveness and the predetermined shielding effectiveness benchmark.

[0050] Specifically, when the difference is positive, by increasing the operating tension of the equipment, including increasing the adjustment range as the difference increases, the advantage of the operating tension of the equipment can be fully utilized, thereby improving the performance of the polymer material.

[0051] The positive correlation regulation mechanism can flexibly adjust the operating tension of the equipment according to the shielding effectiveness of the polymer material wire harness, thereby improving the efficiency of the production system.

[0052] Specifically, the present invention activates an alarm system when a significant risk to wire harness production is identified.

[0053] After a significant risk tendency triggers an alarm, the system initiates "Response Time Monitoring": If the operator confirms the alarm and uploads the adjustment record within 5 minutes, in a preferred embodiment, the crimping rate has been reduced from 40mm / s to 25mm / s, and the alarm is automatically cleared. If there is no response within 15 minutes, the system will escalate the alarm to the factory management system, send an SMS alert to the production director's mobile phone, including a location link and screenshots of the anomaly, and simultaneously freeze the production schedule for that stage until management personnel confirm and intervene to unlock it.

[0054] Thus far, the technical solutions of the present invention have been described in conjunction with the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art may make equivalent changes or substitutions to the relevant technical features, and the technical solutions after such changes or substitutions will fall within the scope of protection of the present invention.

Claims

1. A method for producing wire harnesses based on polymer materials, characterized in that, include: Based on the predetermined control sampling interval benchmark, sample data information of each production chain link in the production of polymer material wire harness in the target area of ​​the forklift vehicle is obtained. Based on the sample data, analyze the control risk complexity of a single production chain link in wire harness production, and analyze the risk tendency of wire harness production based on the difference between the control risk complexity and the predetermined control risk complexity benchmark. Based on the aforementioned risk tendency in wire harness production, the cross-sectional area of ​​polymer material wire harnesses and the terminal crimping rate in wire harness production are extracted, and the characteristic values ​​of wire harnesses are analyzed based on the cross-sectional area of ​​polymer material wire harnesses and the terminal crimping rate in wire harness production. The ratio of the stated wire harness characteristic value to a predetermined wire harness characteristic value is used to determine whether there is a wire harness anomaly risk in the corresponding production chain link. If a wire harness anomaly risk exists, the reason for the wire harness anomaly risk in the corresponding production chain link is determined based on the difference between the stated wire harness characteristic value and the predetermined wire harness characteristic value. The adjustment range of the control sampling interval reference is determined based on the difference between the terminal crimping rate and the predetermined terminal crimping rate reference, or the adjustment range of the equipment operating tension is determined based on the difference between the shielding effectiveness and the predetermined shielding effectiveness reference. The sample data information includes shielding effectiveness and equipment operating tension.

2. The method for producing wire harnesses based on polymer materials according to claim 1, characterized in that, The process of analyzing the complexity of risk management in a single production chain link includes: Extract the shielding effectiveness and equipment operating tension of individual production chain links; The ratio of shielding effectiveness to a predetermined shielding effectiveness threshold is determined as the first complexity factor; The ratio of the equipment operating tension to the predetermined equipment operating tension threshold is determined as the second complexity factor; The sum of the first complexity factor and the second complexity factor is determined as the complexity of the risk management.

3. The method for producing wire harnesses based on polymer materials according to claim 2, characterized in that, The process of analyzing the risk profile of wire harness production includes: Calculate the difference between the complexity of the managed risk and the predetermined baseline for the complexity of the managed risk; If the difference is less than or equal to the preset difference benchmark, it is determined to be a tendency to balance the risks in wire harness production; If the difference is greater than the preset difference benchmark, it is determined to be a significant tendency for wire harness production risk.

4. The method for producing wire harnesses based on polymer materials according to claim 3, characterized in that, The conditions for extracting the cross-sectional area of ​​polymer material wire harnesses and the terminal crimping rate in wire harness production are the risk balance tendency cycle of wire harness production.

5. The method for producing wire harnesses based on polymer materials according to claim 1, characterized in that, The process of analyzing the characteristic values ​​of wire harnesses includes: Extracting the cross-sectional area of ​​polymer material wire harnesses and terminal crimping rate in wire harness production; The ratio of the cross-sectional area of ​​the polymer material wire harness actually produced to the predetermined threshold of the cross-sectional area of ​​the polymer material wire harness is determined as the first characteristic factor. The ratio of the predetermined terminal crimping rate threshold to the actual terminal crimping rate is determined as the second characteristic factor; The sum of the first feature factor and the second feature factor is determined as the feature characterization value of the wire harness.

6. The method for producing wire harnesses based on polymer materials according to claim 5, characterized in that, The process of determining whether there is a risk of wire harness abnormality in the corresponding production chain includes: Calculate the ratio of the characteristic value of the wire harness to the predetermined characteristic value of the wire harness; If the ratio is greater than or equal to a predetermined ratio threshold, then a risk of harness abnormality is determined.

7. The method for producing wire harnesses based on polymer materials according to claim 1, characterized in that, The reasons for identifying abnormal risks in wiring harnesses at corresponding stages of the production chain include: Calculate the difference between the characteristic value of the wire harness and the predetermined characteristic value of the wire harness; If the difference is less than or equal to the predetermined characteristic difference threshold, the reason is determined to be that the terminal crimping rate of the corresponding production chain link does not match the control sampling interval benchmark. If the difference is greater than a predetermined threshold for characterization difference, the cause is determined to be a mismatch between the operating tension and shielding effectiveness of the equipment in the corresponding production chain link.

8. The method for producing wire harnesses based on polymer materials according to claim 7, characterized in that, The adjustment range of the control sampling interval benchmark is positively correlated with the difference in terminal crimping rate. The terminal crimping rate difference is the difference between the terminal crimping rate and the predetermined terminal crimping rate benchmark.

9. The method for producing wire harnesses based on polymer materials according to claim 7, characterized in that, The adjustment range of the equipment's operating tension is positively correlated with the difference in shielding effectiveness. The shielding effectiveness difference is the difference between the shielding effectiveness and the predetermined shielding effectiveness benchmark.

10. The method for producing wire harnesses based on polymer materials according to claim 3, characterized in that, The alarm system will be activated when there is a significant risk to the production of the wire harness.

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