A method for producing a wiring harness based on a polymer material

Abstract

The present application relates to the technical field of wire harness production, and particularly relates to a wire harness production method based on high polymer materials, which can accurately analyze the risk control complexity of a single production chain link of wire harness production by obtaining sample data information of each production chain link of the target area wire harness production, can accurately analyze the risk tendency of wire harness production through the risk control complexity, reduces the occurrence of misjudgment of wire harness production control, and improves the efficiency of wire harness production control. The wire harness characteristic representation value can be obtained by analyzing the high polymer material wire harness cross-sectional area and the terminal crimping rate, so as to comprehensively consider the target area wire harness characteristic difference, further analyze whether there is an abnormal risk of wire harness, accurately determine the adjustment range of the control sampling period and the adjustment range of the equipment running tension by analyzing the abnormal reason of the wire harness, and improve the accuracy of wire harness production control.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of wire harness production, and in particular to a wire harness production method based on high polymer materials. BACKGROUND

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

[0003] At the same time, the requirements for weather resistance and insulation of wire harnesses in the fields of automobiles, forklifts, and intelligent devices have increased, and traditional processes are difficult to adapt to flexible production demands of multiple varieties and small batches, resulting in low efficiency, high cost, and difficulty in tracing. Therefore, the intelligent production of wire harnesses based on high polymer materials has become a trend, and through automated equipment and digital systems, material processing, process control, and quality detection are optimized to meet the production demands of high precision and high reliability.

[0004] Chinese Patent Publication No. CN111724041A discloses a forklift whole vehicle wire harness intelligent production control system, which includes a production control local area network composed of a central server and various devices on the production line site, wherein the central server is wirelessly connected with each device, and further includes an identification code configured for each worker, and a wireless code reader configured for each device on the production line site, which is wirelessly connected with the central server. The central server integrates a database, a device production parameter database, a personnel identification matching program, and a production control program, and matches personnel with devices based on identification code data and its own program, and controls the operation of the devices. The present application provides an intelligent control system for the production and manufacturing of forklift whole vehicle wire harnesses, which can automatically control the production of devices after matching personnel and devices, and can realize intelligent monitoring of production efficiency, product qualification rate, and raw material consumption rate.

[0005] Chinese patent publication No. CN111489866A discloses a production process of a wiring harness special for new energy vehicles, comprising the following steps: S1, preparing materials; S2, cutting wires; S3, pre-threading the main lead into the hole of the sheath sealing rear cover, loading the sealing plug, dividing each main lead into A and B two ends, the end close to the sealing plug is the main lead A end, and the other end is the main lead B end, performing two main lead A end shielding ring crimping processing, assembling the high-voltage sheath, performing two main lead B end shielding ring crimping processing, fixing two auxiliary leads with two main leads, then twisting the wires, preloading the black double-wall heat shrink tube, ultrasonic welding, and heating the black double-wall heat shrink tube; S4, glue winding assembly; S5, performing drawing test, conduction test, size inspection, appearance inspection, finished product packaging, and storing the qualified finished products, and completing the production process of the wiring harness special for new energy vehicles. The production process disclosed by the application has high qualified rate, excellent performance of the produced wiring harness, and long service life.

[0006] However, the prior art still has the following problems:

[0007] In the existing system for intelligent production and control of wiring harness, the data representation of different production chain links in the production and control dimension of wiring harness production is not considered. In actual situations, there are obvious characteristics in some production chain links of wiring harness production, and some production chain links are more similar. If the same control risk analysis method is used for each production chain link of wiring harness production, there will be the defect of low production and control monitoring efficiency. SUMMARY

[0008] Therefore, the present application provides a wiring harness production method based on high molecular materials to overcome the problem of low production and control monitoring efficiency caused by the difference in data representation of different production chain links in the production and control dimension of wiring harness production and the difference in control risk of each production chain link of wiring harness production.

[0009] To achieve the above-mentioned purpose, the present application provides a wiring harness production method based on high molecular materials, comprising:

[0010] Obtaining sample data information of each production chain link of the target area wiring harness production based on a predetermined control sampling interval reference;

[0011] Analyzing the control risk complexity of a single production chain link of wiring harness production based on the sample data information, and analyzing the wiring harness production risk tendency based on the difference between the control risk complexity and a predetermined control risk complexity reference;

[0012] Based on the wiring harness production risk tendency, extracting the high molecular material wiring harness cross-sectional area and terminal crimping rate of wiring harness production, and analyzing the wiring harness characteristic representation value based on the high molecular material wiring harness cross-sectional area and terminal crimping rate of wiring harness production;

[0013] determining whether the corresponding production chain link exists a risk of harness abnormality based on a ratio of the harness characteristic representation value to a predetermined harness characteristic representation value, and if the risk of harness abnormality exists, determining a cause of the risk of harness abnormality of the corresponding production chain link based on a difference between the harness characteristic representation value and the predetermined harness characteristic representation value:

[0014] determining an adjustment range of the sampling interval reference based on a difference between the terminal crimping rate and a predetermined terminal crimping rate reference, or determining an adjustment range of the equipment running tension based on a difference between the shielding effectiveness and a predetermined shielding effectiveness reference;

[0015] The sample data information includes the shielding effectiveness and the equipment running tension.

[0016] Preferably, the process of analyzing the control risk complexity of the single production chain link comprises:

[0017] extracting the shielding effectiveness and the equipment running tension of the single production chain link;

[0018] determining a ratio of the shielding effectiveness to a predetermined shielding effectiveness threshold value as a first complexity factor;

[0019] determining a ratio of the equipment running tension to a predetermined equipment running tension threshold value as a second complexity factor;

[0020] determining a sum of the first complexity factor and the second complexity factor as the control risk complexity.

[0021] Preferably, the process of analyzing the harness production risk tendency comprises:

[0022] calculating a difference between the control risk complexity and a predetermined control risk complexity reference;

[0023] if the difference is less than or equal to a preset difference reference, determining a balanced tendency of the harness production risk;

[0024] if the difference is greater than the preset difference reference, determining a significant tendency of the harness production risk.

[0025] Preferably, the condition of extracting the polymer material harness cross-sectional area and the terminal crimping rate of the harness production is a balanced tendency period of the harness production risk.

[0026] Preferably, the process of analyzing the harness characteristic representation value comprises:

[0027] extracting the polymer material harness cross-sectional area and the terminal crimping rate of the harness production;

[0028] determining a ratio of the polymer material harness cross-sectional area of the actual harness production to a predetermined polymer material harness cross-sectional area threshold value of the harness production as a first characteristic factor;

[0029] determining a ratio of the predetermined terminal crimping rate threshold value and the actual terminal crimping rate as a second characteristic factor;

[0030] determining a sum of the first characteristic factor and the second characteristic factor as a wire harness characteristic representation value.

[0031] Preferably, the process of determining whether the wire harness abnormality risk exists in the corresponding production chain link comprises:

[0032] calculating a ratio of the wire harness characteristic representation value and a predetermined wire harness characteristic representation value;

[0033] if the ratio is greater than or equal to a predetermined ratio threshold value, it is determined that the wire harness abnormality risk exists.

[0034] Preferably, the process of determining the cause of the wire harness abnormality risk in the corresponding production chain link comprises:

[0035] calculating a difference value of the wire harness characteristic representation value and a predetermined wire harness characteristic representation value;

[0036] if the difference value is less than or equal to a predetermined representation difference threshold value, it is determined that the cause is that the terminal crimping rate in the corresponding production chain link does not match the control sampling interval reference, resulting in abnormal sampling and causing system operation abnormality;

[0037] if the difference value is greater than the predetermined representation difference threshold value, it is determined that the cause is that the equipment operation tension in the corresponding production chain link does not match the shielding effectiveness, resulting in equipment abnormality.

[0038] Further, the adjustment range of the control sampling interval reference is positively correlated with the terminal crimping rate difference value,

[0039] wherein the terminal crimping rate difference value is a difference value of the terminal crimping rate and a predetermined terminal crimping rate reference.

[0040] Further, the adjustment range of the equipment operation tension is positively correlated with the shielding effectiveness difference value,

[0041] wherein the shielding effectiveness difference value is a difference value of the shielding effectiveness and a predetermined shielding effectiveness reference.

[0042] Further, when it is determined that the wire harness production risk is significantly inclined, an alarm system is enabled.

[0043] Compared with the prior art, the present application can accurately analyze the control risk complexity of each production chain link of the wire harness production by obtaining sample data information of the target area wire harness, thereby comprehensively considering the data representation differences of each production chain link in the production control dimension, accurately analyzing the wire harness production risk tendency through the control risk complexity, reducing the occurrence of wire harness production control misjudgment, and improving the efficiency of wire harness production control. At the same time, by analyzing the polymer material wire harness cross-sectional area and the terminal crimping rate, the wire harness characteristic representation value can be obtained, thereby comprehensively considering the production control multi-dimensional feature difference and the target area wire harness feature difference, which can further analyze whether there is an abnormal risk of the wire harness, accurately determine the adjustment range of the control sampling period and the adjustment range of the equipment running tension through the analysis of the wire harness abnormal reason, improve the accuracy of the wire harness production control, and further improve the wire harness production efficiency.

[0044] Especially, the present application can ensure the systematicness and continuity of the sample by collecting data of each production chain link at a fixed period, avoid the randomness and one-sidedness of data collection. This provides a stable and reliable data source for subsequent analysis, makes the production state evaluation more objective, and reduces the judgment errors caused by data loss or disorder. By focusing on the risk complexity of a single production link, the weak links with high risk, including terminal crimping and polymer material wire harness cutting, can be accurately found out. This can avoid the fuzzy evaluation of the whole production chain, facilitate the concentration of management resources to high-risk links, improve the control efficiency, and reduce the overall production risk.

[0045] Especially, the present application can quantify the risk deviation degree by analyzing the difference between the control risk complexity and the reference value, which can discover whether the risk is rising, falling or fluctuating trend in advance. This predictive analysis enables production managers to take intervention measures before the risk expands, changes from passive response to active prevention and control, and reduces the probability of abnormal situation. By focusing on the two key parameters of polymer material wire harness cross-sectional area and terminal crimping rate from the risk tendency, irrelevant information interference can be excluded, and the analysis focus can be placed on the core elements that have the greatest impact on product quality. This can improve the pertinence of risk assessment and make subsequent analysis more efficient and accurate. By converting the two key parameters into a unified characteristic representation value, the standardization expression of the quality characteristics of different production links and different batches of wire harnesses is realized. This makes the quality evaluation more comparable, facilitates cross-link and cross-batch analysis of wire harness quality change law, and provides a clear direction for quality improvement.

[0046] Especially, the application quantifies the deviation degree of the feature representation value from the reference value by using the ratio of the wire harness feature representation value to the predetermined wire harness feature representation value, instead of subjective judgment, so that the abnormal risk determination has a unified and objective standard. The misjudgment caused by human experience difference is reduced, the consistency and accuracy of abnormal identification are improved, and the risk is ensured not to be missed or misreported. By associating the risk causes including the wire harness cross-sectional area of the polymer material exceeding the standard and the abnormal crimping rate, the problem source of the production link including the cutting device failure and the abnormal crimping parameter setting can be quickly locked. Blind investigation is reduced, the problem solving time is shortened, and the influence of the abnormality on production is reduced. BRIEF DESCRIPTION OF DRAWINGS

[0047] Figure 1 The step flow chart of the wire harness production method based on the polymer material of the embodiment of the application is shown in the figure.

[0048] Figure 2 The step flow chart of the analysis of the control risk complexity of a single production link of the embodiment of the application is shown in the figure.

[0049] Figure 3 The determination flow chart of the analysis of the wire harness production risk tendency of the embodiment of the application is shown in the figure.

[0050] Figure 4 The step flow chart of the analysis of the wire harness feature representation value based on the wire harness production of the polymer material wire harness cross-sectional area and terminal crimping rate of the embodiment of the application is shown in the figure. DETAILED DESCRIPTION

[0051] In order to make the objects and advantages of the present application clearer, the present application will be further described below with examples; it should be understood that the specific examples described herein are only used to explain the present application, and do not limit the present application.

[0052] The preferred embodiments of the present application will be described below with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are only used to explain the technical principles of the present application, and are not intended to limit the protection scope of the present application.

[0053] It should be noted that in the description of the present application, unless otherwise explicitly specified and limited, the term "connection" should be understood broadly, for example, it can be fixed connection, or detachable connection, or integrally connected; it can be mechanical connection, or electrical connection; it can be directly connected, or indirectly connected through an intermediate medium, or the internal communication of two elements. Those skilled in the art can understand the specific meaning of the above-mentioned term in the present application according to the specific circumstances.

[0054] Please refer to Figure 1As shown, it is the step flow chart of the wire harness production method based on the polymer material of the embodiment of the application, the application provides a wire harness production method based on polymer material, comprising:

[0055] Step S1, obtaining sample data information of each production chain link of the target area wire harness production based on the predetermined control sampling interval reference;

[0056] Step S2, analyzing the control risk complexity of the single production chain link of the wire harness production based on the sample data information, and analyzing the wire harness production risk tendency based on the difference between the control risk complexity and the predetermined control risk complexity reference;

[0057] Step S3, based on the wire harness production risk tendency, extracting the wire harness cross-sectional area of the polymer material and the terminal crimping rate of the wire harness production, and analyzing the wire harness characteristic representation value based on the wire harness cross-sectional area of the polymer material and the terminal crimping rate of the wire harness production;

[0058] Step S4, determining whether there is a wire harness abnormal risk in the corresponding production chain link based on the ratio of the wire harness characteristic representation value to the predetermined wire harness characteristic representation value, if there is a wire harness abnormal risk, determining the reason of the wire harness abnormal risk of the corresponding production chain link based on the difference between the wire harness characteristic representation value and the predetermined wire harness characteristic representation value:

[0059] Determine the adjustment range of the control sampling interval reference based on the difference between the terminal crimping rate and the predetermined terminal crimping rate reference; or, determine the adjustment range of the equipment running tension based on the difference between the shielding effectiveness and the predetermined shielding effectiveness reference;

[0060] Among them, the sample data information includes: shielding effectiveness and equipment running tension.

[0061] Specifically, the monitoring period in the embodiment is [10min, 30min].

[0062] Specifically, the control sampling interval reference is obtained in advance, and the predetermined control sampling interval reference in the embodiment is 0.95 times the average value of the control sampling period in the last two months before the system runs. Preferably, the control sampling interval reference in the embodiment is [3s, 5s].

[0063] Specifically, the production chain link of the target area wire harness production in the embodiment is divided into several wire harness workshop links, for example: wire harness first workshop link, wire harness second workshop link, wire harness third workshop link, wire harness fourth workshop link, other division methods can also be used, which will not be repeated here.

[0064] Specifically, the present application can accurately analyze the control risk complexity of each production chain link of the wire harness production by obtaining sample data information of the target area wire harness production, thereby comprehensively considering the data representation differences of each production chain link in the production control dimension, accurately analyzing the wire harness production risk tendency through the control risk complexity, reducing the occurrence of wire harness production control misjudgment, and improving the efficiency of wire harness production control. At the same time, by analyzing the polymer material wire harness cross-sectional area and the terminal crimping rate, the wire harness characteristic representation value can be obtained, thereby comprehensively considering the production control multi-dimensional feature difference and the target area wire harness feature difference, which can further analyze whether there is an abnormal risk of the wire harness, accurately determine the adjustment range of the control sampling period and the adjustment range of the equipment running tension through the analysis of the wire harness abnormal reason, improve the accuracy of the wire harness production control, and further improve the wire harness production efficiency.

[0065] Please refer to Figure 2 As shown in the figure, it is a step flow chart for analyzing the control risk complexity of a single production chain link, and the process of analyzing the control risk complexity of a single production chain link includes:

[0066] Extracting the shielding effectiveness and the equipment running tension of a single production chain link;

[0067] Determining the ratio of the shielding effectiveness to the predetermined shielding effectiveness threshold as a first complexity factor;

[0068] Determining the ratio of the equipment running tension to the predetermined equipment running tension threshold as a second complexity factor;

[0069] Determining the sum of the first complexity factor and the second complexity factor as the control risk complexity.

[0070] In the embodiment, the predetermined shielding effectiveness threshold is obtained by pre-setting, wherein the mean value of the shielding effectiveness of each production chain link is determined in advance, the shielding effectiveness threshold is set as the product of the mean value of the shielding effectiveness and the precision coefficient, the precision coefficient is selected within the interval [0.90, 0.95], and preferably the precision coefficient is 0.92.

[0071] In the embodiment, the predetermined equipment running tension threshold is obtained by pre-setting, wherein the mean value of the equipment running tension of each production chain link is determined in advance, the equipment running tension threshold is set as the product of the mean value of the equipment running tension and the tension offset coefficient, the tension offset coefficient is between the interval [1.1, 1.2], and preferably the tension offset coefficient is 1.15.

[0072] The present application can ensure the system and continuity of the sample by collecting the data of each production chain link in a fixed cycle, and avoid the randomness and one-sidedness of data collection. This provides a stable and reliable data source for subsequent analysis, making the evaluation of production status more objective and reducing the judgment errors caused by data loss or disorder. By focusing on the risk complexity of a single production link, the weak links with high risk, including terminal crimping and polymer material harness cutting, can be accurately found out. This can avoid the fuzzy evaluation of the whole production chain, facilitate the concentration of management resources to high-risk links, improve the control efficiency, and reduce the overall production risk.

[0073] Referring to Figure 3 The determination flow chart of the risk tendency of the harness production analyzed by the embodiment of the present application is shown in the figure, and the process of analyzing the risk tendency of the harness production includes:

[0074] calculating the difference between the control risk complexity and the predetermined control risk complexity benchmark;

[0075] If the difference is less than or equal to the preset difference benchmark, it is determined that the harness production risk is balanced;

[0076] If the difference is greater than the preset difference benchmark, it is determined that the harness production risk is significantly inclined.

[0077] Specifically, the control risk complexity benchmark and the control risk complexity benchmark are obtained by pre-setting, wherein the product of the control risk complexity average value in the historical period of three months of the present system and the precision coefficient is taken as the control risk complexity benchmark, the precision coefficient is between the interval [0.90, 0.95], and preferably the precision system is 0.92, and the product of the control risk complexity average value in the historical period of three months of the present system and the deviation coefficient is taken as the difference benchmark, the deviation coefficient is between the interval [0.90, 0.95].

[0078] The present application can quantify the risk deviation degree by analyzing the difference between the control risk complexity and the benchmark value, and can find out whether the risk is rising, falling or fluctuating trend in advance. This predictive analysis allows production managers to take intervention measures before the risk expands, changes from passive response to active prevention and control, and reduces the probability of abnormal situations. By focusing on the two key parameters of the polymer material harness section area and the terminal crimping rate from the risk tendency, irrelevant information interference can be excluded, and the analysis focus can be placed on the core elements that have the greatest impact on product quality. This can improve the pertinence of risk assessment and make subsequent analysis more efficient and accurate. By converting the two key parameters into a unified feature representation value, the standardization expression of the quality characteristics of different production links and different batches of harnesses is realized. This makes the quality evaluation more comparable, facilitates cross-link and cross-batch analysis of harness quality variation, and provides a clear direction for quality improvement.

[0079] Specifically, the extraction of the high molecular material wire harness cross-sectional area and the terminal crimping rate of the wire harness production is the risk balance tendency period of the wire harness production.

[0080] Referring to Figure 4 As shown in the figure, it is the step flow chart of the wire harness characteristic value analysis of the high molecular material wire harness cross-sectional area and the terminal crimping rate of the wire harness production based on the embodiment of the application, and the process of the wire harness characteristic value analysis of the application includes:

[0081] Extracting the high molecular material wire harness cross-sectional area and the terminal crimping rate of the wire harness production;

[0082] The ratio of the actual high molecular material wire harness cross-sectional area of the wire harness production to the predetermined high molecular material wire harness cross-sectional area threshold of the wire harness production is determined as the first characteristic factor;

[0083] The ratio of the predetermined terminal crimping rate threshold to the actual terminal crimping rate is determined as the second characteristic factor;

[0084] The sum of the first characteristic factor and the second characteristic factor is determined as the wire harness characteristic value.

[0085] The application quantifies the deviation degree of the characteristic value from the reference value by analyzing the ratio of the wire harness characteristic value to the predetermined wire harness characteristic value, replaces the subjective judgment, and makes the abnormal risk determination have a unified and objective standard. Reduce the misjudgment caused by human experience difference, improve the consistency and accuracy of abnormal identification, and ensure that the risk is not missed or misreported. By associating the risk reasons including the high molecular material wire harness cross-sectional area exceeding the standard and the abnormal crimping rate, the problem root of the production link including the cutting line equipment failure and the abnormal crimping parameter setting can be quickly locked. Reduce blind investigation, shorten problem solving time, and reduce the impact of abnormality on production.

[0086] Specifically, the process of determining whether there is a wire harness abnormal risk corresponding to the production chain link includes,

[0087] Calculate the ratio of the wire harness characteristic value to the predetermined wire harness characteristic value;

[0088] If the ratio is greater than or equal to the predetermined ratio threshold, it is determined that there is a wire harness abnormal risk.

[0089] In the embodiment, the predetermined ratio threshold is in the interval [2.15, 2.25], and preferably the predetermined ratio threshold is 2.20.

[0090] Specifically, the cause of the wire harness abnormal risk corresponding to the production chain link includes:

[0091] Calculate the difference between the wire harness characteristic value and the predetermined wire harness characteristic value;

[0092] If the difference value is less than or equal to a predetermined threshold value, it is determined that the reason for the abnormal sampling is that the terminal crimping rate of the corresponding production chain link is not matched with the sampling interval reference, resulting in abnormal sampling and system operation.

[0093] If the difference value is greater than the predetermined threshold value, it is determined that the reason for the abnormal sampling is that the terminal crimping rate of the corresponding production chain link is not matched with the sampling interval reference, resulting in abnormal sampling and system operation.

[0094] By quantifying the difference value, the deviation of the actual production from the standard state can be intuitively reflected, and accurate numerical basis is provided for subsequent abnormal reason determination. Compared with the vague qualitative description, the problem is defined more clearly through quantitative analysis, reducing the controversy caused by different judgments of the deviation size, and laying a foundation for efficient troubleshooting.

[0095] Specifically, the adjustment range of the sampling interval reference is positively correlated with the terminal crimping rate difference,

[0096] The terminal crimping rate difference is the difference between the terminal crimping rate and the predetermined terminal crimping rate reference.

[0097] In an embodiment, the terminal crimping rate reference is pre-set, a plurality of sample data information of the same production chain link is pre-acquired, 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 reference. The crimping deviation coefficient is selected in the interval [0.85, 0.95], and preferably the crimping deviation coefficient is 0.90.

[0098] The greater the terminal crimping rate deviation, the more obvious the deviation of the production state from the standard, and at this time, the positively correlated adjustment includes that when the deviation is positive, the sampling interval is reduced synchronously, so that the sampling frequency and the production fluctuation degree are accurately matched. Compared with the fixed amplitude adjustment, this way can avoid the risk of missing caused by sampling too sparse, or the waste of resources caused by sampling too dense, so that the control is more targeted.

[0099] When the crimping rate is abnormal, including far exceeding the reference value, the positively correlated adjustment can quickly shorten the sampling interval and improve the sample collection frequency, so as to capture the abnormal details including the crimping quality fluctuation faster, and gain time for risk warning and intervention. On the contrary, if the rate deviation is small, the sampling interval can be appropriately relaxed to reduce the interference with the normal production rhythm and balance the control intensity and production efficiency.

[0100] By establishing the linkage relationship between "rate deviation-adjustment range", the sampling control can automatically adapt to the dynamic changes of the production parameters, reducing the subjectivity of manual intervention. This self-adjusting mechanism is especially suitable for multi-batch and multi-specification wire harness production scenes, can stably maintain the control accuracy, and reduce the quality risks caused by manual judgment errors

[0101] Specifically, the adjustment range of the equipment running tension is positively correlated with the difference of shielding effectiveness,

[0102] The difference of shielding effectiveness is the difference between the shielding effectiveness and a predetermined shielding effectiveness reference.

[0103] Specifically, when the difference is positive, the equipment running tension is increased by increasing the adjustment range, and the difference increases, so that the advantages of the equipment running tension can be fully utilized, and the performance of the high molecular material is improved.

[0104] The positive correlation adjustment mechanism can flexibly adjust the size of the equipment running tension according to the wire harness shielding effectiveness of the high molecular material, and improves the efficiency of the production system operation.

[0105] Specifically, when the risk of the wire harness production is significantly inclined, the alarm system is enabled.

[0106] After the significant risk inclination triggers the alarm, the system starts the response time monitoring:

[0107] If the operator confirms the alarm and uploads the adjustment record within 5 minutes, the crimping speed is preferably reduced from 40 mm / s to 25 mm / s, and the alarm is automatically released;

[0108] If there is no response within 15 minutes, the system upgrades the alarm to the factory management system, sends a short message to the production director's mobile phone, for example, contains a positioning link and an abnormal screenshot, and synchronously freezes the production plan scheduling of the link until the management personnel confirms the intervention and unlocks.

[0109] So far, the technical solutions of the present application have been described in combination with the preferred embodiments shown in the drawings, but those skilled in the art can easily understand that the protection scope of the present application is obviously not limited to these specific embodiments. Without deviating from the principles of the present application, those skilled in the art can make equivalent changes or replacements to related technical features, and the technical solutions after these changes or replacements will fall within the protection scope of the present application.

Claims

1. A method for producing a harness based on a high molecular material, characterized by, The application comprises the following steps: acquiring sample data information of each production chain link of the high-molecular material wire harness of the whole vehicle based on a predetermined control sampling interval reference; analyzing the control risk complexity of a single production chain link based on the sample data information; wherein the process of analyzing the control risk complexity of a single production chain link comprises the following steps: extracting shielding effectiveness and equipment running tension of a single production chain link; determining the ratio of the shielding effectiveness to a predetermined shielding effectiveness threshold as a first complexity factor; determining the ratio of the equipment running tension to a predetermined equipment running tension threshold as a second complexity factor; determining the sum of the first complexity factor and the second complexity factor as the control risk complexity; analyzing the wire harness production risk tendency based on the difference between the control risk complexity and a predetermined control risk complexity reference; extracting the high-molecular material wire harness cross-sectional area and terminal crimping rate of the wire harness production based on the wire harness production risk tendency, and analyzing the wire harness characteristic representation value based on the high-molecular material wire harness cross-sectional area and terminal crimping rate of the wire harness production; wherein the process of analyzing the wire harness characteristic representation value comprises the following steps: extracting the high-molecular material wire harness cross-sectional area and terminal crimping rate of the wire harness production; determining the ratio of the actual high-molecular material wire harness cross-sectional area of the wire harness production to a predetermined high-molecular material wire harness cross-sectional area threshold of the wire harness production as a first characteristic factor; determining the ratio of a predetermined terminal crimping rate threshold to the actual terminal crimping rate as a second characteristic factor; determining the sum of the first characteristic factor and the second characteristic factor as the wire harness characteristic representation value; determining whether there is a wire harness abnormal risk in the corresponding production chain link based on the ratio of the wire harness characteristic representation value to a predetermined wire harness characteristic representation value, and if there is a wire harness abnormal risk, determining the reason for the wire harness abnormal risk in the corresponding production chain link based on the difference between the wire harness characteristic representation value and the predetermined wire harness characteristic representation value; determining the adjustment range of the control sampling interval reference based on the difference between the terminal crimping rate and a predetermined terminal crimping rate reference, or determining the adjustment range of the equipment running tension based on the difference between the shielding effectiveness and a predetermined shielding effectiveness reference; wherein the sample data information comprises shielding effectiveness and equipment running tension.

2. The method for producing a harness based on a high molecular material according to claim 1, wherein The conditions for extracting the high-molecular material wire harness cross-sectional area and terminal crimping rate of the wire harness production are the wire harness production risk balance tendency period.

3. The method for producing a harness based on a high molecular material according to claim 1, wherein The process of analyzing the wire harness production risk tendency comprises the following steps: calculating the difference between the control risk complexity and a predetermined control risk complexity reference; if the difference is less than or equal to a preset difference reference, it is determined that the wire harness production risk is balanced; if the difference is greater than the preset difference reference, it is determined that the wire harness production risk is significantly inclined.

4. The method for producing a harness based on a high molecular material according to claim 3, wherein The process of determining whether there is a wire harness abnormal risk in the corresponding production chain link comprises the following steps: calculating the ratio of the wire harness characteristic representation value to a predetermined wire harness characteristic representation value; if the ratio is greater than or equal to a predetermined ratio threshold, it is determined that there is a wire harness abnormal risk.

5. The method of claim 1, wherein the high molecular material-based harness production method is characterized by, The process of determining the reason for the wire harness abnormal risk in the corresponding production chain link comprises the following steps: calculating the difference between the wire harness characteristic representation value and a predetermined wire harness characteristic representation value. if the difference value is less than or equal to a predetermined representation difference threshold value, it is determined that the reason is that the terminal crimping rate corresponding to the production chain link is not matched with the control sampling interval reference; if the difference value is greater than the predetermined representation difference threshold value, it is determined that the reason is that the equipment running tension corresponding to the production chain link is not matched with the shielding effectiveness.

6. The method of claim 5, wherein the high molecular material is a thermoplastic resin. The adjustment range of the control sampling interval reference is positively correlated with the terminal crimping rate difference value, wherein the terminal crimping rate difference value is the difference between the terminal crimping rate and a predetermined terminal crimping rate reference.

7. The method of claim 6, wherein the high molecular material is a thermoplastic resin. The adjustment range of the equipment running tension is positively correlated with the shielding effectiveness difference value, wherein the shielding effectiveness difference value is the difference between the shielding effectiveness and a predetermined shielding effectiveness reference.

8. The method of claim 1, wherein the high molecular material-based harness production method is characterized by, The alarm system is enabled under the condition that the harness production risk is significantly inclined.

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