A closed-loop management method and system for precise machining of automobile high-speed high-frequency wire harness process

Abstract

The present application belongs to the field of automation production and control technology, and particularly relates to a closed-loop management and control method and system for precision machining of automobile high-speed high-frequency wire harness process. The present application realizes intelligent management and control of the multi-process machining process of automobile high-speed high-frequency wire harness by constructing a complete closed-loop system from machining to detection to feedback adjustment, and improves the consistency of machining precision and product quality. By obtaining the original physical characteristics such as the bending degree of the cable in the initial stage of machining, and taking it as the input parameter of the subsequent process, the compensatory adjustment is made in advance, and the state data in the machining process is collected in real time, and the error analysis is carried out on the final product, the error signal is converted into specific calibration instruction, the cutting and stripping and crimping parameters of the front end are dynamically adjusted, the process deviation caused by material difference or equipment state change is effectively compensated, and it is ensured that each product meets the strict precision standard.

Description

Technical Field

[0001] This invention belongs to the field of automated production and control technology, specifically relating to a closed-loop control method and system for precision machining of high-speed, high-frequency wiring harnesses in automobiles. Background Technology

[0002] In modern communications and automotive electronics, high-speed, high-frequency wiring harnesses are crucial components for transmitting high-frequency signals, and their manufacturing quality directly impacts the signal integrity and reliability of the entire system. During production, the wiring harness undergoes multiple precision processes, including stripping, terminal crimping, and outer conductor installation. Even minor deviations in any of these steps can lead to signal attenuation or reflection, resulting in functional malfunctions. Therefore, ensuring consistency and high precision in the multi-process manufacturing of high-speed, high-frequency automotive wiring harnesses is a prominent challenge currently facing the industry.

[0003] The existing wire harness processing methods can basically meet the usage requirements, but there are still some shortcomings. (1) Traditional wire harness processing methods mainly rely on semi-automatic equipment and manual operation. They cannot effectively cope with batch differences of raw materials and wear and aging of the equipment itself. Fixed processing parameters are difficult to adapt to these dynamic changes, resulting in large fluctuations in product quality and unstable yield. (2) Traditional wire harness processing methods mainly rely on manual sampling. The offline sampling mechanism has a lag. When unqualified products are found, a large number of scrap products are often generated, resulting in serious material waste and increased costs. (3) Traditional wire harness processing methods lack real-time feedback and dynamic adjustment capabilities, and cannot achieve refined control of the processing process, making it difficult to meet the increasingly stringent high-precision and high-reliability production requirements. Summary of the Invention

[0004] In view of this, in order to solve the problems mentioned in the background technology, a closed-loop control method and system for precision machining of high-speed and high-frequency wiring harnesses in automobiles is proposed.

[0005] The objective of this invention can be achieved through the following technical solution: The first aspect of this invention provides a closed-loop control method for precision machining of automotive high-speed and high-frequency wiring harnesses, comprising: S1, designating the automotive high-speed and high-frequency coaxial cable to be processed as the target coaxial cable, acquiring its original data and performing a precision stripping operation, generating a preprocessed wiring harness dataset of the target coaxial cable, and performing a quality judgment on it; if it is qualified, proceed to S2.

[0006] S2. Based on the preprocessed wire harness dataset, perform a center terminal crimping operation to generate a center terminal crimping status dataset of the target coaxial cable.

[0007] S3. Based on the center conductor offset angle, perform outer conductor installation and crimping operations to generate an outer conductor crimping dataset for the target coaxial cable.

[0008] S4. The outer conductor crimping dataset is processed by deviation comparison to generate the error measurement dataset of the target coaxial cable, and stored in the quality database.

[0009] S5. Based on the error measurement dataset, perform a closed-loop signal generation operation to generate a closed-loop calibration signal for the target coaxial cable, and apply it to adjust the process parameters of the precision stripping operation and the center terminal crimping operation to complete the closed-loop control.

[0010] A second aspect of the present invention provides a closed-loop control system for precision machining of high-speed, high-frequency automotive wiring harnesses through multiple processes, comprising: a wiring harness pretreatment module, a center terminal crimping module, an outer conductor mounting crimping module, an error detection module, and a closed-loop control module.

[0011] The wire harness preprocessing module is connected to the center terminal crimping module, the center terminal crimping module is connected to the outer conductor mounting crimping module, the outer conductor mounting crimping module is connected to the error detection module, and the error detection module is connected to the closed-loop control module.

[0012] The wire harness preprocessing module designates the automotive high-speed and high-frequency coaxial cable to be processed as the target coaxial cable, acquires its raw data and performs a precision stripping operation, generates a preprocessed wire harness dataset of the target coaxial cable, and performs a quality judgment on it. If it is qualified, the center terminal crimping module is executed.

[0013] The center terminal crimping module performs a center terminal crimping operation based on the preprocessed wire harness dataset, generating a center terminal crimping status dataset for the target coaxial cable.

[0014] The outer conductor installation crimping module performs outer conductor installation and crimping operations based on the center conductor offset angle, generating an outer conductor crimping dataset for the target coaxial cable.

[0015] The error detection module processes the outer conductor crimping dataset through deviation comparison to generate an error measurement dataset for the target coaxial cable, and stores it in the quality database.

[0016] The closed-loop control module, based on the error measurement dataset, performs a closed-loop signal generation operation to generate a closed-loop calibration signal for the target coaxial cable, and applies it to adjust the process parameters of the precision stripping operation and the center terminal crimping operation to complete the closed-loop control.

[0017] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. The present invention realizes intelligent control of the multi-process processing of high-speed and high-frequency wiring harnesses for automobiles by constructing a complete closed-loop system from processing to testing to feedback adjustment, thereby improving the consistency of processing accuracy and product quality.

[0018] 2. This invention obtains the original physical characteristics of the cable, such as its curvature, at the initial stage of processing and uses them as input parameters for subsequent processes to make compensatory adjustments in advance. It also collects various status data during the processing in real time and performs error analysis on the final product, converting the error signals into specific calibration instructions and dynamically adjusting the cutting, stripping, and crimping parameters at the front end. This effectively compensates for process deviations caused by material differences or changes in equipment status, ensuring that every product meets stringent precision standards. Attached Figure Description

[0019] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram illustrating the implementation process of the method of the present invention.

[0021] Figure 2 This is a schematic diagram of the system module connections of the present invention.

[0022] Figure 3 This is a flowchart illustrating the multi-stage precision machining process for high-speed, high-frequency automotive wiring harnesses according to the present invention. Detailed Implementation

[0023] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0024] Example 1

[0025] Please see Figure 1 As shown, the present invention provides a closed-loop control method for precision machining of automotive high-speed and high-frequency wiring harnesses. The specific steps are as follows: S1, the automotive high-speed and high-frequency coaxial cable to be processed is designated as the target coaxial cable, its original data is obtained and a precision stripping operation is performed to generate a preprocessed wiring harness dataset of the target coaxial cable, and its quality is judged. If it is qualified, S2 is executed.

[0026] It should be further explained that the flowchart shows the multi-stage precision machining process for automotive high-speed and high-frequency wiring harnesses. Figure 3 As shown.

[0027] It should be noted that the high-speed, high-frequency coaxial cable is a coaxial cable used for high-speed signal transmission. Its characteristic attribute is its physical structure, including a center conductor, an insulation layer, a shielding layer, and an outer sheath. The length range is 1 to 6 meters, a range determined based on industrial application requirements and optimized through analysis of multiple sets of communication equipment sample data.

[0028] In a preferred feasible example of the present invention, the specific process of generating the preprocessed wire harness dataset of the target coaxial cable includes: using a cutting device to sequentially peel off the sheath, aluminum foil, insulation layer and shielding layer of the target coaxial cable to ensure that the sheath cut gap meets the preset accuracy requirements and the shielding layer edge is smooth.

[0029] It should be noted that the cutting device can be a rotating blade, which is an external stripping device. Its function is to precisely remove each layer of the cable, and its settings are based on the manufacturer's equipment manual. When performing sequential stripping operations, the required cutting accuracy refers to the sheath cutting gap being less than 0.1 mm, and this setting is based on experimental test data.

[0030] The bending curvature of the target coaxial cable is detected by a deformation sensor, and the alignment status of the shielding layer of the target coaxial cable is scanned by a vision inspection device. The bending curvature and shielding layer alignment status parameters of the target coaxial cable are obtained and are collectively referred to as the preprocessed harness dataset of the target coaxial cable.

[0031] It should be noted that the bending arc is waveform data of the cable bending degree, reflecting the bending arc deviation of the cable; the shielding layer alignment status parameter is the degree of alignment deviation between the shielding layer and the center conductor, reflecting the relative positional accuracy between the cable's shielding layer and the inner conductor, such as alignment deviation angle, edge smoothness, etc.

[0032] For example, when a 3-meter-long high-speed, high-frequency coaxial cable is acquired, after the sheath, aluminum foil, insulation layer, and shielding layer are peeled off using a cutting device, the cutting precision is controlled by a rotating blade. The measured sheath cutting gap is 0.08 mm, the shielding layer edge is smooth without loose threads, and the insulation layer is intact and undamaged. The deformation sensor measures a bending arc signal value of 0.2 radians, and the visual inspection device detects a shielding layer alignment deviation of 0.03 mm. These values ​​are recorded as the pre-processed harness dataset for this high-speed, high-frequency coaxial cable. The data directly verifies the effectiveness of the cutting precision of less than 0.1 mm and the shielding layer alignment.

[0033] In a preferred feasible example of the present invention, the specific process of quality judgment of the pre-processed wire harness dataset of the target coaxial cable includes: determining whether the bending curvature and shielding alignment parameters of the target coaxial cable are qualified based on the quality judgment criteria; if both the bending curvature and shielding alignment parameters of the target coaxial cable are qualified, the quality judgment of the pre-processed wire harness dataset of the target coaxial cable is recorded as qualified; otherwise, the quality judgment of the pre-processed wire harness dataset of the target coaxial cable is recorded as unqualified, and the current wire harness processing flow is terminated before the center terminal crimping operation is performed.

[0034] It should be noted that the specific process for determining whether the bending curvature and shielding alignment parameters of the target coaxial cable are qualified based on the quality judgment criteria is as follows: the bending curvature of the target coaxial cable is compared with the permissible range in the quality judgment criteria. If the bending curvature is within the permissible range, the bending curvature is qualified; otherwise, the bending curvature is unqualified. The shielding alignment parameters of the target coaxial cable are compared with the corresponding standards in the quality judgment criteria. If the shielding alignment parameters meet the requirements of smooth edges without burrs and the alignment deviation angle with the inner conductor is less than the permissible difference, the shielding alignment parameters are qualified; otherwise, the shielding alignment parameters are unqualified.

[0035] The quality assessment criteria are industry precision standards or internal enterprise standards.

[0036] It should be explained that by introducing a combination of early quality screening and processing flow control, the subsequent processing of unqualified semi-finished products is avoided, thereby improving overall production efficiency and pass rate.

[0037] S2. Based on the preprocessed wire harness dataset, perform a center terminal crimping operation to generate a center terminal crimping status dataset of the target coaxial cable.

[0038] In a preferred feasible example of the present invention, the specific process of generating the crimping state dataset of the center terminal of the target coaxial cable includes: extracting the bending curvature of the target coaxial cable from the preprocessed wire harness dataset, and dynamically setting the crimping pressure according to the predefined logical rules to compensate for the crimping unevenness caused by bending.

[0039] It should be noted that the specific content of the predefined logical rule is: as the curvature value increases, the pressure increases accordingly.

[0040] For example, the dynamic setting of crimping pressure specifically involves: setting a pressure adjustment ratio based on the actual situation of the cable and production experience; when the bending radius is 0.3 radians, the corresponding crimping pressure is dynamically set to 600 Newtons; when the bending radius is 0.5 radians, the corresponding crimping pressure is dynamically set to 1000 Newtons.

[0041] The center terminal is crimped using a crimping machine based on the crimping pressure to ensure that the core wire is not exposed, and the offset angle of the center conductor of the target coaxial cable after crimping is detected and recorded as the crimping status dataset of the center terminal of the target coaxial cable.

[0042] It should be noted that the target crimping height and width are set based on industrial precision specifications. A crimping machine is used to crimp the center terminal. The target crimping height is the vertical dimension of the crimped terminal, and the target crimping width is the horizontal dimension of the crimped terminal. The target values ​​are set based on specifications, and the crimping error is controlled within 0.2 mm. During the crimping process, it is ensured that the core wire does not protrude, that is, the center conductor is not exposed or protrudes outside the terminal.

[0043] The offset angle of the center conductor of the target coaxial cable after crimping is obtained by detecting the deviation angle between the crimped position of the center conductor and the ideal position using an angle measuring instrument.

[0044] For example, when the bending radius in the preprocessed wire harness dataset is read to be 0.2 radians, the crimping pressure is dynamically set to 500 Newtons based on this value. A crimping machine is used to crimp the center terminal, with a target crimping height of 5 mm and a width of 3 mm. The actual crimping height is 5.05 mm and the width is 2.99 mm, with the error controlled within 0.2 mm and no core wire protrusion. The detected center conductor offset angle is 0.3 degrees, which is recorded as the center terminal crimping status dataset. This data directly verifies the effectiveness of the error control within 0.2 mm and the offset angle measurement.

[0045] S3. Based on the center conductor offset angle, perform outer conductor installation and crimping operations to generate an outer conductor crimping dataset for the target coaxial cable.

[0046] In a preferred feasible example of the present invention, the specific process of generating the outer conductor crimping dataset of the target coaxial cable includes: reading the center conductor offset angle of the target coaxial cable from the center terminal crimping status dataset, using it as the compensation amount for the outer conductor installation position, and adjusting it using a servo motor drive to achieve fine-tuning compensation of the offset angle. The use of a servo motor drive to adjust the mechanism ensures accurate interface dimensions. The interface dimensions are defined as the deviation between the target size and the actual size of the interface between the outer conductor and the center terminal being controlled within 0.1 mm.

[0047] The outer conductor is installed and crimped using crimping pliers, and the gap between the sleeve and the sheath, the diameter and length of the conductor, and the center line alignment parameters of the target coaxial cable are detected in real time after crimping. These are collectively referred to as the outer conductor crimping dataset of the target coaxial cable.

[0048] It should be noted that the gap between the sleeve and the sheath is the minimum distance between the outer wall of the sleeve and the inner wall of the sheath, and the centerline alignment parameter is the deviation angle between the centerline of the outer conductor and the centerline of the central conductor.

[0049] It should be further explained that the specific methods for obtaining the gap value between the sleeve and the sheath, the diameter and length of the conductor, and the center line alignment parameters of the target coaxial cable after crimping are as follows: the gap between the sleeve and the sheath after crimping is detected by a rangefinder, the outer conductor dimensions, including diameter and length, are measured by calipers, and the center line alignment parameters are detected by a laser alignment instrument.

[0050] For example, when the input center terminal crimping status dataset contains an offset angle of 0.3 degrees, the outer conductor installation position is adjusted according to this value to compensate for the 0.3-degree deviation. After installation, the measured interface size deviation is 0.05 mm. Using crimping pliers to crimp the outer conductor, the measured gap between the sleeve and the sheath is 0.8 mm, the measured outer conductor diameter is 4.5 mm, and the length is 15 mm. The centerline alignment parameter deviation is 0.2 degrees, and this is recorded as the outer conductor crimping dataset. This data directly verifies the validity of the gap not exceeding 1 mm and the centerline alignment parameter.

[0051] S4. The outer conductor crimping dataset is processed by deviation comparison to generate the error measurement dataset of the target coaxial cable, and stored in the quality database.

[0052] In a preferred feasible example of the present invention, the specific process of generating the error measurement dataset of the target coaxial cable includes: extracting the gap value between the sleeve and the sheath, the diameter and length of the conductor, and the center line alignment parameters of the target coaxial cable after crimping from the outer conductor crimping dataset, comparing the deviations of these values ​​with the corresponding preset standard values, and obtaining the deviation values ​​of the gap value between the sleeve and the sheath, the diameter and length of the conductor, and the center line alignment parameters of the target coaxial cable after crimping from the corresponding preset standard values.

[0053] The error values ​​are compared with the corresponding preset industrial precision specifications to determine the representative error values ​​of the sleeve-sheath gap, conductor diameter and length, and centerline alignment parameters of the target coaxial cable after crimping.

[0054] It should be noted that when the deviation between the sleeve and sheath of the target coaxial cable after crimping is not within the corresponding preset standard value, the error representative value of the sleeve and sheath gap of the target coaxial cable after crimping is recorded as 1; otherwise, the error representative value of the sleeve and sheath gap of the target coaxial cable after crimping is recorded as 0. Similarly, the error representative values ​​of the conductor diameter and length and centerline alignment parameters of the target coaxial cable after crimping can be obtained.

[0055] When the error representative value is 0, it indicates that an error exists; when the error representative value is 1, it indicates that no error exists.

[0056] The deviation value and the error representative value are collectively referred to as the error measurement dataset of the target coaxial cable.

[0057] It should be further explained that after generating the error measurement dataset, the following steps are also included: generating a unique identifier for the target coaxial cable being processed, associating its error measurement dataset with the unique identifier, storing it in the quality database, and establishing a traceability association between real-time error data and product identity.

[0058] For example, when the input outer conductor crimping dataset includes an outer conductor diameter of 4.5 mm, a length of 15 mm, and a centerline alignment parameter of 0.2 degrees, a high-precision camera device is used to scan the crimping results. The industrial precision specification requires a target diameter of 5 mm, a target centerline offset of 0 degrees, and no shielding layer defects. The calculated dimensional deviation error is 0.5 mm, the measured centerline offset is 0.2 degrees, and the shielding layer defect status is detected as 0 (no defects). This is recorded as the error measurement dataset. The data directly verifies the effectiveness of the dimensional deviation error calculation and the shielding layer defect status setting.

[0059] This invention obtains the original physical characteristics of the cable, such as its curvature, at the initial stage of processing and uses them as input parameters for subsequent processes to make compensatory adjustments in advance. It also collects various status data during the processing in real time and performs error analysis on the final product, converting the error signals into specific calibration instructions and dynamically adjusting the cutting, stripping, and crimping parameters at the front end. This effectively compensates for process deviations caused by material differences or changes in equipment status, ensuring that every product meets stringent precision standards.

[0060] S5. Based on the error measurement dataset, perform a closed-loop signal generation operation to generate a closed-loop calibration signal for the target coaxial cable, and apply it to adjust the process parameters of the precision stripping operation and the center terminal crimping operation to complete the closed-loop control.

[0061] In a preferred feasible example of the present invention, the specific process of generating the closed-loop calibration signal of the target coaxial cable includes: obtaining a calibration command based on the error measurement dataset according to the calibration command generation logic, and converting it into a mechanical adjustment signal.

[0062] The mechanical adjustment signal is recorded as the closed-loop calibration signal of the target coaxial cable.

[0063] It should be noted that the closed-loop signal generation operation is a functional process, representing the behavior of generating feedback control signals. The calibration command is a data command, characterized by control parameters, and set according to error analysis algorithm rules. The mechanical adjustment signal is a physical signal, characterized by an electrical pulse waveform, and set according to actuator interface standards. The closed-loop calibration signal is a data structure, characterized by a set of control commands, including crimping pressure correction and cutting position offset parameters, and set according to the MODBUS-RTU industrial communication protocol.

[0064] For example, when the input error measurement dataset contains a dimensional error of 0.5 mm, the analysis generates a correction instruction: adjust the magnitude. The millimeter value, in the direction of decreasing cutting depth, is converted into a 200-millisecond pulse width mechanical adjustment signal. A closed-loop calibration signal data packet is output, containing a crimping pressure correction of -30 Newtons and a cutting position offset of -0.4 millimeters. The data directly verifies the effectiveness of the calibration command formula and signal conversion.

[0065] In a preferred feasible example of the present invention, the calibration instruction specifically includes calibration direction and calibration amplitude information, wherein the calibration direction includes directional calibration of the cutting position and directional calibration of the pressing pressure and pressing speed, and the calibration amplitude information includes cutting depth value, pressing pressure value, and pressing speed value.

[0066] The specific content of the correction instruction generation logic includes: when the error representative value of the sleeve-sheath gap value, conductor diameter and length, and center line alignment parameter of the target coaxial cable after crimping is 1, it indicates that it needs to be corrected. Further, the deviation values ​​of the sleeve-sheath gap value, conductor diameter and length, and center line alignment parameter of the target coaxial cable after crimping are matched with the corresponding preset standard values ​​with preset correspondences to determine the correction direction and correction amplitude information.

[0067] It should be noted that the preset correspondence refers to the pre-set matching rules between the parameters after the outer conductor is crimped, namely the gap value between the sleeve and the sheath, the diameter and length of the conductor, the center line alignment parameter and the preset standard value, and the correction direction and correction amplitude information. Specifically, it is as follows: (1) Pre-set correspondence corresponding to the gap value deviation between the sleeve and the sheath: If the gap value is greater than the preset standard value, that is, the deviation value is positive, then the correction direction is to reduce the cutting depth, and the correction amplitude information is determined according to the size of the deviation value. For example, for every 0.1 mm increase in the gap value, the cutting depth is reduced by 0.08 mm.

[0068] (2) Preset correspondence of conductor diameter deviation: If the diameter is greater than the preset standard value, i.e. the deviation value is positive, the correction direction is to reduce the crimping pressure, and the correction range is that for every 0.1 mm increase in diameter, the crimping pressure is reduced by a certain value, such as 20 Newtons; if the diameter is less than the preset standard value, i.e. the deviation value is negative, the correction direction is to increase the crimping pressure, and the range is the same.

[0069] (3) Preset correspondence of conductor length deviation: If the length is greater than the preset standard value, i.e. the deviation value is positive, the correction direction is to speed up the cutting speed to reduce the cutting length, and the correction amplitude is that for every 0.5 mm of length deviation, the cutting speed is increased by a certain ratio, such as 5%; if the length is less than the preset standard value, i.e. the deviation value is negative, the correction direction is to slow down the cutting speed, and the amplitude is the same.

[0070] (3) Preset correspondence of center line alignment parameter deviation: If there is an offset angle in the center line alignment, i.e. the deviation value is positive, the correction direction is to adjust the pressing position to compensate for the offset, and the correction amplitude is that for every 0.1 degree increase in the offset angle, the pressing position is adjusted by a certain distance, such as 0.05 mm.

[0071] For example, when it is detected that the gap between the sleeve and the sheath of the target coaxial cable after crimping is 0.2 mm larger than the preset standard value, i.e., the deviation is 0.2 mm, the correction direction is determined to be to reduce the cutting depth according to the preset correspondence, and the correction range is 0.16 mm, i.e., 0.2 mm × 0.8. That is, by reducing the cutting depth by 0.16 mm, the gap between the sleeve and the sheath of the cable after subsequent processing is made to meet the standard.

[0072] In a preferred feasible example of the present invention, the specific process of adjusting the process parameters of the precision stripping operation and the center terminal crimping operation by applying the closed-loop calibration signal to complete the closed-loop control includes: reading the closed-loop calibration signal, and adjusting the cutting depth and position in the precision stripping operation in reverse based on the cutting position offset parameter contained in the closed-loop calibration signal.

[0073] Based on the crimping pressure correction parameter contained in the closed-loop calibration signal, the crimping pressure and crimping speed in the center terminal crimping operation and the outer conductor crimping operation are adjusted synchronously.

[0074] By simultaneously adjusting the parameters of two different processes, cutting and pressing, the processing accuracy is optimized in a coordinated manner, achieving faster error convergence than adjusting a single parameter.

[0075] Specifically, firstly, the closed-loop calibration signal is read, which includes cutting position offset parameters and crimping pressure correction parameters. Based on the cutting position offset value, the cutting depth and position in step S1 are adjusted in reverse. The cutting depth represents the depth to which the mechanical cutting tool cuts into the cable sheath, and the position represents the three-dimensional spatial coordinates of the cutting point. The adjustment logic directly modifies the control parameters of the cutting equipment based on the offset value; for example, when the offset value is negative, the cutting depth is reduced and the corresponding position coordinates are moved. Simultaneously, based on the crimping pressure correction, the crimping pressure setting in step S2 is adjusted. The crimping pressure represents the force applied to the terminal, and the crimping speed setting is adjusted, representing the movement speed of the crimping operation. Similarly, the crimping pressure and speed settings in step S3 are adjusted. Next, the complete sequence of steps from obtaining the original coaxial cable data in step S1 to generating the closed-loop calibration signal in step S5 is re-executed. During the re-execution, the updated error value is detected in real time using the error measurement dataset generated in step S4. This sequence is continuously executed in a loop. When the dimensional error value in the error measurement dataset is less than a preset threshold, the loop is stopped to eliminate the error, completing the closed-loop control process.

[0076] For example, when the input closed-loop calibration signal includes a cutting position offset of -0.4 mm and a crimping pressure correction of -30 N, step S1 reduces the cutting depth by 0.4 mm and the position coordinate offset by -0.4 mm; step S2 reduces the crimping pressure by 30 N and sets the crimping speed to 2 mm / s; simultaneously, step S3 adjusts the crimping pressure and speed settings. After re-executing the S1 to S5 sequence, the new error measurement dataset size error value of 0.05 mm is less than the preset threshold of 0.1 mm, and the loop stops, completing the closed-loop control. The data directly verifies the effectiveness of the cutting depth adjustment, crimping speed setting, and closed-loop termination condition.

[0077] This invention achieves intelligent control over the multi-process processing of automotive high-speed and high-frequency wiring harnesses by constructing a complete closed-loop system from processing to testing and then to feedback adjustment, thereby improving the consistency of processing accuracy and product quality.

[0078] Example 2

[0079] Please see Figure 2 As shown, the present invention provides a closed-loop control system for precision machining of high-speed and high-frequency automotive wiring harnesses through multiple processes. The specific modules are distributed as follows: wiring harness pretreatment module, center terminal crimping module, outer conductor mounting crimping module, error detection module, and closed-loop control module.

[0080] The wire harness preprocessing module is connected to the center terminal crimping module, the center terminal crimping module is connected to the outer conductor mounting crimping module, the outer conductor mounting crimping module is connected to the error detection module, and the error detection module is connected to the closed-loop control module.

[0081] The wire harness preprocessing module designates the automotive high-speed and high-frequency coaxial cable to be processed as the target coaxial cable, acquires its raw data and performs a precision stripping operation, generates a preprocessed wire harness dataset of the target coaxial cable, and performs a quality judgment on it. If it is qualified, the center terminal crimping module is executed.

[0082] The center terminal crimping module performs a center terminal crimping operation based on the preprocessed wire harness dataset, generating a center terminal crimping status dataset for the target coaxial cable.

[0083] The outer conductor installation crimping module performs outer conductor installation and crimping operations based on the center conductor offset angle, generating an outer conductor crimping dataset for the target coaxial cable.

[0084] The error detection module processes the outer conductor crimping dataset through deviation comparison to generate an error measurement dataset for the target coaxial cable, and stores it in the quality database.

[0085] The closed-loop control module, based on the error measurement dataset, performs a closed-loop signal generation operation to generate a closed-loop calibration signal for the target coaxial cable, and applies it to adjust the process parameters of the precision stripping operation and the center terminal crimping operation to complete the closed-loop control.

[0086] Example 3

[0087] In the third embodiment of the present invention, in conjunction with the above-described closed-loop control method for precision machining of automotive high-speed and high-frequency wiring harnesses, the present invention provides the following technical solution: a storage medium storing a computer program, wherein the computer program, when executed by a processor, implements the above-described closed-loop control method for precision machining of automotive high-speed and high-frequency wiring harnesses.

[0088] Those skilled in the art will understand that the data in the flowchart, or the logic and steps otherwise described herein, for example, can be considered as a sequenced data table of executable instructions for implementing logical functions, and can be embodied in any computer-readable medium for use by, or in conjunction with, an instruction execution system, apparatus, or device (such as a computer-based system, a processor-included system, or other system that can fetch and execute instructions from, an instruction execution system, apparatus, or device). For the purposes of this specification, "computer-readable medium" can mean any means that can contain, store, communicate, propagate, or transmit programs for use by, or in conjunction with, an instruction execution system, apparatus, or device.

[0089] More specific examples of readable media (a non-exhaustive list of data) include: electrical connections (electronic devices) with one or more wires, portable computer disk drives (magnetic devices), random access memory (RAM), read-only memory (ROM), erasable and editable read-only memory (EPROM or flash memory), fiber optic devices, and portable optical disc read-only memory (CDROM). Furthermore, computer-readable media can even be paper or other suitable media on which the program can be printed, because the program can be obtained electronically, for example, by optically scanning the paper or other medium, followed by editing, interpreting, or otherwise processing as necessary, and then stored in computer memory.

[0090] It should be understood that various parts of the present invention can be implemented in hardware, software, firmware, or a combination thereof. In the above embodiments, multiple steps or methods can be implemented in software or firmware stored in memory and executed by a suitable instruction execution system. For example, if implemented in hardware, as in another embodiment, it can be implemented using any one or a combination of the following techniques known in the art: discrete logic circuits having logic gates for implementing logical functions on data signals, application-specific integrated circuits (ASICs) having suitable combinational logic gates, programmable gate arrays (PGAs), field-programmable gate arrays (FPGAs), etc.

[0091] The above content is merely an example and illustration of the concept of the present invention. Those skilled in the art can make various modifications or additions to the specific embodiments described, or use similar methods to replace them, as long as they do not deviate from the concept of the invention or exceed the scope defined by the present invention, and all such modifications and additions should fall within the protection scope of the present invention.

Claims

1. A closed-loop control method for precision machining of automotive high-speed, high-frequency wiring harnesses, characterized in that: include: S1. The high-speed, high-frequency coaxial cable to be processed is designated as the target coaxial cable. Its original data is obtained and a precision stripping operation is performed to generate a preprocessed wire harness dataset of the target coaxial cable. Its quality is judged. If it is qualified, proceed to S2. The specific process for generating the preprocessed harness dataset for the target coaxial cable includes: The sheath, aluminum foil, insulation layer and shielding layer of the target coaxial cable are sequentially stripped using cutting equipment. The bending curvature of the target coaxial cable is detected by a deformation sensor, and the alignment status of the shielding layer of the target coaxial cable is scanned by a vision inspection device. Thus, the bending curvature and shielding layer alignment status parameters of the target coaxial cable are obtained, which are collectively referred to as the preprocessed wire harness dataset of the target coaxial cable. S2. Based on the preprocessed wire harness dataset, perform a center terminal crimping operation to generate a center terminal crimping status dataset of the target coaxial cable. The specific process for generating the target coaxial cable's center terminal crimping status dataset includes: Extract the bending curvature of the target coaxial cable from the preprocessed wire harness dataset, and dynamically set the crimping pressure according to the predefined logical rules. The center terminal is crimped using a crimping machine based on the crimping pressure, and the offset angle of the center conductor of the target coaxial cable after crimping is detected and recorded as the crimping status dataset of the center terminal of the target coaxial cable. S3. Based on the center conductor offset angle, perform outer conductor installation and crimping operations to generate an outer conductor crimping dataset of the target coaxial cable; The specific process for generating the outer conductor crimping dataset of the target coaxial cable includes: The offset angle of the center conductor of the target coaxial cable is read from the data of the crimping status of the center terminal. This offset angle is used as the compensation amount for the installation position of the outer conductor and adjusted by servo motor drive to achieve fine adjustment and compensation of the offset angle. The outer conductor is installed and crimped using crimping pliers, and the gap between the sleeve and the sheath, the diameter and length of the conductor, and the center line alignment parameters of the target coaxial cable are detected in real time after crimping. These are collectively referred to as the outer conductor crimping dataset of the target coaxial cable. S4. The outer conductor crimping dataset is processed by deviation comparison to generate the error measurement dataset of the target coaxial cable, and stored in the quality database. S5. Based on the error measurement dataset, perform a closed-loop signal generation operation to generate a closed-loop calibration signal for the target coaxial cable, and apply it to adjust the process parameters of the precision stripping operation and the center terminal crimping operation to complete the closed-loop control.

2. The closed-loop control method for precision machining of automotive high-speed high-frequency wiring harnesses according to claim 1, characterized in that: The specific process for quality assessment of the preprocessed wire harness dataset of the target coaxial cable includes: Based on the quality judgment criteria, determine whether the bending arc and shielding alignment parameters of the target coaxial cable are qualified. If both the bending arc and shielding alignment parameters of the target coaxial cable are qualified, the quality judgment of the pre-processed wire harness dataset of the target coaxial cable is recorded as qualified. Otherwise, the quality judgment of the pre-processed wire harness dataset of the target coaxial cable is recorded as unqualified, and the current wire harness processing flow is terminated before the center terminal crimping operation is performed.

3. The closed-loop control method for precision machining of automotive high-speed high-frequency wiring harnesses according to claim 1, characterized in that: The specific process for generating the error measurement dataset for the target coaxial cable includes: Extract the gap between the sleeve and sheath, the diameter and length of the conductor, and the center line alignment parameters of the target coaxial cable after crimping from the outer conductor crimping dataset. Compare these values ​​with the corresponding preset standard values ​​to obtain the deviation values ​​of the gap between the sleeve and sheath, the diameter and length of the conductor, and the center line alignment parameters of the target coaxial cable after crimping from the corresponding preset standard values. The error values ​​are compared with the corresponding preset industrial precision specifications to determine the representative error values ​​of the sleeve-sheath gap, conductor diameter and length, and centerline alignment parameters of the target coaxial cable after crimping. The deviation value and the error representative value are collectively referred to as the error measurement dataset of the target coaxial cable.

4. The closed-loop control method for precision machining of automotive high-speed high-frequency wiring harnesses according to claim 1, characterized in that: The specific process of generating the closed-loop calibration signal for the target coaxial cable includes: Based on the error measurement dataset, a correction command is generated according to the correction command generation logic and then converted into a mechanical adjustment signal. The mechanical adjustment signal is recorded as the closed-loop calibration signal of the target coaxial cable.

5. The closed-loop control method for precision machining of automotive high-speed high-frequency wiring harnesses according to claim 4, characterized in that: The calibration command specifically includes calibration direction and calibration amplitude information. The calibration direction includes the directional calibration of the cutting position and the directional calibration of the pressing pressure and pressing speed. The calibration amplitude information includes the cutting depth value, the pressing pressure value, and the pressing speed value. The specific content of the correction instruction generation logic includes: when the error representative value of the sleeve-sheath gap value, conductor diameter and length, and center line alignment parameter of the target coaxial cable after crimping is 1, it indicates that it needs to be corrected. Further, the deviation values ​​of the sleeve-sheath gap value, conductor diameter and length, and center line alignment parameter of the target coaxial cable after crimping are matched with the corresponding preset standard values ​​with preset correspondences to determine the correction direction and correction amplitude information.

6. The closed-loop control method for precision machining of automotive high-speed high-frequency wiring harnesses according to claim 5, characterized in that: The specific process of adjusting the process parameters of the precision stripping operation and the center terminal crimping operation using the closed-loop calibration signal to complete the closed-loop control includes: Read the closed-loop calibration signal; Based on the cutting position offset parameter contained in the closed-loop calibration signal, the cutting depth and position in the precision stripping operation are adjusted in reverse. Based on the crimping pressure correction parameter contained in the closed-loop calibration signal, the crimping pressure and crimping speed in the center terminal crimping operation and the outer conductor crimping operation are adjusted synchronously.

7. A system for executing the closed-loop control method for precision machining of automotive high-speed high-frequency wiring harnesses as described in any one of claims 1-6, characterized in that: include The wire harness preprocessing module identifies the automotive high-speed and high-frequency coaxial cable to be processed as the target coaxial cable, acquires its raw data and performs a precision stripping operation, generates a preprocessed wire harness dataset of the target coaxial cable, and performs a quality judgment on it. If it is qualified, the center terminal crimping module is executed. The center terminal crimping module performs a center terminal crimping operation based on the preprocessed wire harness dataset, generating a center terminal crimping status dataset of the target coaxial cable. The outer conductor mounting and crimping module performs outer conductor mounting and crimping operations based on the center conductor offset angle, generating an outer conductor crimping dataset for the target coaxial cable; The error detection module processes the outer conductor crimping dataset through deviation comparison to generate an error measurement dataset of the target coaxial cable, and stores it in the quality database. The closed-loop control module, based on the error measurement dataset, performs a closed-loop signal generation operation to generate a closed-loop calibration signal for the target coaxial cable, and applies it to adjust the process parameters of the precision stripping operation and the center terminal crimping operation to complete the closed-loop control.

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