Wire harness winding method and device based on end extension consistency and multi-core wire harness assembly wire

Abstract

The invention discloses a wire harness winding method and device based on end extension consistency and a multi-core wire harness assembly wire. The method comprises the following steps that a winding jig is provided; the first end of the wire harness is fixed to the first restraining mechanism; the winding module is controlled to execute winding operation, so that the wire harness is wound on the winding jig; the winding process is controlled or post-processing is executed, so that after winding is completed, the second end and the first end of the wire harness can stretch out of the winding jig and are located in the preset area, and the end portion of the first end and the end portion of the second end are aligned in the spatial position. The winding device is used for executing the winding method, and the winding device provided by the invention is applied to the multi-core wire harness assembly wire.

Description

Technical Field

[0001] This invention relates to the field of wire harness manufacturing technology, and in particular to a wire harness winding method based on consistent end extension. Background Technology

[0002] In the wire harness production process, longer wire harnesses typically require coiling to reduce their space requirements and facilitate transportation and storage. This is especially true in multi-core wire harness assembly lines, where after winding, a certain length needs to be reserved at both ends for insulation removal, terminal crimping, and other processes. However, traditional winding processes have significant drawbacks: due to differences in the inner and outer winding paths during winding, the naturally formed extension lengths at both ends of the same wire harness are inconsistent. Furthermore, after winding, the ends of the wire harness are not aligned. These length and end position differences can cause a chain reaction in multi-core wire harness assembly lines. When both ends of the same wire harness require the same processing steps, subsequent processing equipment must repeatedly reposition and adjust the ends for different lengths, increasing equipment complexity and severely impacting overall production efficiency. In addition, manually adjusting end length differences suffers from insufficient precision and high labor intensity, making it difficult to meet the precision and efficiency requirements of modern production lines. More seriously, on automated production lines, misalignment of the wire harness end position can cause robotic arms to fail to grasp the wire, leading to production line downtime and severely impacting production cycle time. Existing winding equipment generally lacks a precise control mechanism for the wire harness end extension length and spatial position, failing to meet the demands of high-precision wire harness processing. Summary of the Invention

[0003] This invention aims to at least solve one of the technical problems existing in the prior art. To this end, this invention proposes a wire harness winding method, apparatus, and multi-core wire harness assembly line based on end extension consistency, which has the advantages of improving the consistency of wire harness end length and end alignment accuracy.

[0004] In a first aspect, a wire harness winding method based on consistent end protrusion according to an embodiment of the present invention includes the following steps: Provide a winding fixture; The first end of the wire harness is fixed to the first constraint mechanism; The winding module is controlled to perform the winding operation, so that the wire harness is wound onto the winding fixture; Control the winding process or perform post-processing so that after winding is completed, the second end and the first end of the wire harness can extend out of the winding fixture and be located within a preset area, and the ends of the first end and the second end are aligned in spatial position.

[0005] The wire harness winding method based on end-end consistency according to embodiments of the present invention has at least the following beneficial effects: This application achieves end-end consistency of the wire harness by constructing a closed-loop control system. A winding fixture is provided as a basic support structure, providing a physical carrier for wire harness winding; the first end of the wire harness is fixed to a first constraint mechanism, establishing a spatial reference for the winding starting point; when the winding module performs the winding operation, motion trajectory planning ensures the winding shape of the wire harness on the fixture; finally, by dynamically adjusting winding parameters or implementing post-processing, the end-end length deviation caused by path differences during the winding process is actively compensated, and the positions of both ends are forcibly aligned based on the spatial reference. The dual-path design of "controlling the winding process or performing post-processing" allows for real-time adjustment of winding parameters (such as diameter and tension) to prevent deviation accumulation, and also supports correction of existing deviations through post-processing methods such as trimming and displacement compensation, forming a multi-dimensional control strategy. This solution, through the synergistic effect of mechanical constraints and motion control, establishes end-end symmetry during the winding stage, rather than relying on subsequent manual correction, eliminating the inherent defects of traditional processes.

[0006] According to an embodiment of the wire harness winding method based on consistent end protrusion according to an embodiment of the present invention, the step of controlling the winding module to perform the winding operation includes: The control rotation mechanism drives the winding fixture to rotate and / or drives the second constraint mechanism to rotate around the winding fixture; Simultaneously, the lifting mechanism is controlled to drive the winding fixture and / or the second constraint mechanism to move along the axial direction of the winding fixture; the rotation and the axial movement are coordinated, so that the wire bundle is wound on the winding fixture in a spiral trajectory.

[0007] A wire harness winding method based on consistent end protrusion according to an embodiment of the present invention The phrase "making the extension length of the second end of the wire harness and the first end relative to the winding fixture tend to be consistent and the ends aligned" means that after the winding operation is completed, the second end of the wire harness is trimmed and adjusted by a cutting mechanism. The cutting position of the cutting mechanism is calculated and determined based on the extension length of the first end and / or the predetermined alignment target position, so that the length of the second end after cutting is consistent with the length of the first end and achieves alignment in spatial position.

[0008] According to an embodiment of the present invention, a wire harness winding method based on consistent end protrusion is used, wherein the wire harness is continuously supplied by an unwinding machine, and the cutting and trimming process includes: First cut: After the winding reaches the predetermined number of turns or length, the cutting mechanism moves to the first preset position to perform the first cut. After the first cut, the remaining length of the second end of the wire harness is greater than the length of the first end. Secondary cutting: The cutting mechanism then moves to the second preset position according to the extension length of the first end or the predetermined standard length to perform secondary cutting and trimming of the second end allowance, so that the extension lengths of both ends of the wire harness tend to be consistent and the ends are aligned.

[0009] According to the wire harness winding method based on consistent end protrusion according to embodiments of the present invention, the phrase "the second end of the wire harness and the first end can protrude from the winding fixture and are located within a preset area, and the ends of the first end and the second end are aligned in spatial position" includes: During the winding process, the theoretical length difference between the first and second ends of the wire harness is calculated in real time based on the number of turns or layers of the wire already wound. The winding diameter of the winding fixture is dynamically adjusted by the control unit to compensate for the length difference.

[0010] According to the wire harness winding method based on consistent end protrusion according to an embodiment of the present invention, the wire harness is cut to a fixed length before winding; The phrase "fixing the first end of the wire harness" refers to clamping and fixing the first end of the wire harness at a fixed length point in a first position using a first constraint mechanism. The "control winding module performs winding operation" clamps the second end of the wire harness through the second constraint mechanism; The requirement that "the second end of the wire harness and the first end can extend out of the winding fixture and are located within a preset area, and the ends of the first end and the second end are aligned in space" is achieved by the second constraint mechanism rigidly clamping and fixing the second end of the wire harness at a fixed length point in the second position. After winding is completed, the second constraint mechanism is controlled to move, driving the second end of the wire harness to a preset alignment target position. This position is symmetrical or corresponds to the first position of the first end relative to the winding fixture. Alternatively, the second constraint mechanism clamps the second end of the wire harness by providing a controllable sliding friction force. During the winding process, the wire harness can slide relative to the second constraint mechanism under the action of winding tension. When winding stops, based on the fixed total length of the wire harness, the fixed position of the first end, and the fixed winding parameters, the area where the second end of the wire harness is located relative to the winding fixture naturally tends to be consistent with the area where the first end is located, thus achieving end alignment in any of the following ways.

[0011] According to the wire harness winding method based on end-protrusion consistency according to an embodiment of the present invention, when the second constraint mechanism rigidly clamps and fixes the second end of the wire harness at a fixed length point, if the second end of the wire harness does not reach the alignment target position after winding is completed, the second constraint mechanism can be rotated in the opposite direction by controlling the rotation mechanism to loosen the wire harness from the winding fixture by one turn, or the second constraint mechanism can be rotated in the forward direction by controlling the rotation mechanism to wind the wire harness by one more turn on the winding fixture, while the translation mechanism moves synchronously, or the second constraint mechanism can be moved backward by controlling the translation mechanism to compensate and adjust, so that the second end moves to the alignment target position.

[0012] According to the wire harness winding method based on consistent end protrusion according to an embodiment of the present invention, during the winding process, the axial movement speed of the winding fixture and / or the second constraint mechanism is controlled by the lifting mechanism to maintain a predetermined ratio with the rotation speed of the rotating mechanism, thereby achieving a constant helical winding pitch.

[0013] According to the wire harness winding method based on end protrusion consistency according to an embodiment of the present invention, before winding begins, the position of the first constraint mechanism is adjusted by a first translation component and / or a first lifting component so that the initial position of the first end of the wire harness is aligned with the axial starting point of the winding fixture.

[0014] Secondly, according to an embodiment of the present invention, a winding device includes: A wire winding fixture is used to provide support for wire harness winding. The first constraint mechanism is fixedly connected to or arranged side by side with the winding fixture and is used to fix the first end of the wire harness. The winding module includes a rotating mechanism, a lifting mechanism, and a second constraint mechanism, wherein the second constraint mechanism is used to connect the second end of the wire harness; The control unit is capable of acquiring the winding parameters of the wire harness; The control unit can control the rotating mechanism and the lifting mechanism to work together based on the winding parameters so that the wire harness is wound on the winding fixture. The control unit can also control the winding process or the post-processing process so that after the winding is completed, the second end and the first end of the wire harness can extend out of the winding fixture (100) and be located in a preset area, and the ends of the first end and the second end are aligned in space.

[0015] The winding device according to embodiments of the present invention has at least the following beneficial effects: This application systematically solves the problem of wire harness end alignment by constructing a winding device system that includes multi-mechanism collaboration. The winding fixture, as a basic support structure, achieves rigid positioning of the wire harness head end through a first constraint mechanism that is fixedly connected or arranged side-by-side, eliminating the possibility of head end offset from a physical structural perspective. The winding module forms the basic conditions for closed-loop control through the combined motion control of the rotation mechanism and the lifting mechanism, combined with the dynamic constraint of the wire harness end by the second constraint mechanism. The control unit performs collaborative control of the rotation speed and lifting displacement based on the winding parameters, dynamically adjusting the wire harness winding trajectory during the winding process, so that the end gradually tends towards the head end position during winding. In particular, through active control of the post-processing, the end position is forcibly adjusted after winding is completed, achieving geometric symmetry at both ends using a spatial position alignment mechanism. This solution deeply integrates mechanical structure and motion control, achieving end consistency through parameterized control, avoiding the error accumulation problem caused by relying solely on mechanical structure in traditional processes.

[0016] The winding device according to an embodiment of the present invention further includes a cutting mechanism, wherein the control unit is electrically connected to the cutting mechanism, and the control unit is capable of controlling the cutting mechanism to move to the calculated cutting position after the winding is completed; The cutting position is determined based on the real-time detected length of the first end, or a pre-stored fixed-length clamping parameter, or a pre-stored alignment target position, so that the second end and the first end can extend out of the winding fixture and be located within a preset area.

[0017] According to an embodiment of the present invention, the second constraint mechanism is an unwinding machine, the cutting mechanism is disposed between the unwinding machine and the winding fixture, and the control unit is capable of controlling the cutting mechanism to perform two cuttings. The two cuttings include a first cutting to separate the coil from the unwinding machine and leave a trimming allowance, and a second cutting to trim the allowance based on the length of the first end.

[0018] The winding device according to an embodiment of the present invention further includes a detection mechanism for detecting the extension length of the first end and the second end of the wire harness relative to the winding fixture. The control unit is communicatively connected to the detection mechanism, and adjusts the winding parameters or controls the lifting mechanism to perform compensatory movement based on the length information fed back by the detection mechanism.

[0019] The winding device according to an embodiment of the present invention further includes a detection mechanism, which includes photoelectric sensors or visual detection devices disposed on both sides of the winding fixture for non-contact measurement of the extension length of the wire harness end.

[0020] Thirdly, the multi-core wire harness assembly line according to embodiments of the present invention includes the winding device described above.

[0021] The multi-core wire harness assembly line according to the embodiments of the present invention has at least the following beneficial effects: by applying the winding device provided in this application, the consistency of the extension length of the two ends of the wound wire harness is ensured, and the multi-core wire harness assembly line can directly enter the processes such as insulation layer removal and terminal crimping without additional adjustment of the wire harness end position.

[0022] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0023] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which: Figure 1 This is the main flowchart of the wire harness winding method based on end extension consistency according to an embodiment of the present invention; Figure 2 This is a flowchart of the first embodiment of the wire harness winding method based on consistent end protrusion according to the present invention; Figure 3 This is a flowchart of a second embodiment of the wire harness winding method based on consistent end protrusion according to the present invention; Figure 4 This is a flowchart of the third embodiment of the wire harness winding method based on consistent end protrusion according to the present invention; Figure 5 This is a flowchart of the fourth embodiment of the wire harness winding method based on consistent end protrusion according to the present invention; Figure 6 This is a structural diagram of the winding device according to an embodiment of the present invention; Figure 7 This is a structural diagram of the winding fixture according to an embodiment of the present invention; Figure 8 This is a top view of the winding fixture according to an embodiment of the present invention; Explanation of reference numerals in the attached figures: 100 winding fixture; 110 mounting base; 120 support plate; 121 limiting block; 130 first driving component; First constraint mechanism 200; first clamping assembly 210; first translation assembly 220; first lifting assembly 230; Connector 300; Lifting mechanism 400; Second clamping assembly 500; second driving component 510; clamping plate 520; The conveying mechanism 600; the fixed bracket 610; the second lifting assembly 620; the wire reel fixing assembly 630; and the third clamping assembly 640. Detailed Implementation

[0024] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0025] In the description of this invention, it should be understood that the orientation descriptions, such as up, down, front, back, left, right, etc., are based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

[0026] In the description of the invention, "several" means one or more, "multiple" means two or more, "greater than," "less than," and "exceeding" are understood to exclude the number itself, while "above," "below," and "within" are understood to include the number itself. If the terms "first" and "second" are used, they are only for distinguishing technical features and should not be construed as indicating or implying relative importance, or implicitly indicating the number of indicated technical features, or implicitly indicating the order of the indicated technical features.

[0027] In the description of this invention, unless otherwise explicitly defined, terms such as "set up," "install," and "connect" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this invention in conjunction with the specific content of the technical solution.

[0028] Reference Figures 1 to 5 This invention provides a wire harness winding method based on consistent end extension, such as... Figure 1 As shown, it includes the following steps: Step 1: A winding fixture 100 will be provided; Step 2: Fix the first end of the wire harness to the first constraint mechanism 200; Step 3: Control the winding module to perform the winding operation, so that the wire harness is wound on the winding fixture 100; Step 4: Control the winding process or perform post-processing so that after the winding is completed, the second end and the first end of the wire harness can extend out of the winding fixture 100 and be located within a preset area, and the ends of the first end and the second end are aligned in space.

[0029] It should be noted that the first constraint mechanism 200 refers to a mechanical device with positioning and clamping functions, which can be implemented using a pneumatic clamp or an electromagnetic chuck, used to fix the starting end of the wire harness and record the initial position coordinates. The number of turns in the winding parameters refers to the total number of turns of the wire harness wound on the fixture, which can be obtained by counting with a rotary encoder and used to calculate the total unfolded length of the wire harness. The winding length refers to the actual straight-line distance of the wire harness being wound, which can be measured using a meter wheel. Both parameters can be used individually or in combination to adapt to different wire diameters. The winding module refers to a composite motion mechanism containing rotary drive and axial movement, which achieves the helical winding trajectory through coordinated control. Controlling the winding process or performing post-processing refers to a composite control strategy combining real-time adjustment of winding parameters and offline correction, which can be implemented using a PLC controller and a vision inspection system linked together, used to dynamically compensate for path differences during the winding stage or to trim and adjust the end allowance after completion.

[0030] Understandably, after the starting end of the wire harness is fixed, the winding parameters are converted by the control system into the number of rotations of the rotating mechanism and the movement distance of the translation mechanism. When the winding module drives the winding fixture 100 to rotate, the wire harness is wound in layers along a spiral path. During the winding process, the difference in length between the inner and outer ring paths is calculated in real time, and the accumulated deviation is compensated by adjusting the winding diameter or axial movement speed. For example, when the length deviation of the second end is detected to exceed a threshold, the control unit immediately increases the winding diameter to increase the circumference of the outer ring, so that the length difference generated by the subsequent winding turns can offset the existing deviation. If there is still a residual deviation after winding, the second end allowance is trimmed by the cutting mechanism according to the length benchmark of the first end, and the spatial position of the second end is adjusted to form a symmetrical layout with the first end. Advantageously, this application embeds end consistency control into the core link of the winding process, actively compensates for path differences during the winding stage, and forcibly corrects residual deviations during the post-processing stage, forming a dual guarantee mechanism. At the same time, by dynamically adjusting the diameter parameters to make the difference between the inner and outer ring paths approach zero, the automatic alignment of the extension lengths at both ends of the wire harness is achieved, eliminating the need for repeated positioning in subsequent processing equipment. In multi-core wire harness assembly scenarios, the spatial symmetry of the two ends is guaranteed, allowing processes such as wire stripping and crimping to be performed simultaneously, thus shortening equipment cycle time. A real-time compensation mechanism during winding effectively reduces material waste and avoids wire loss caused by traditional cutting and trimming.

[0031] According to some embodiments of this application, the steps of controlling the winding module to perform the winding operation include: controlling the rotation mechanism to drive the winding fixture 100 to rotate or driving the second constraint mechanism to rotate around the winding fixture 100; simultaneously controlling the lifting mechanism 400 to drive the winding fixture 100 or the second constraint mechanism to move along the axial direction of the winding fixture 100; the rotation and axial movement are carried out in coordination, so that the wire harness is wound on the winding fixture 100 in a spiral trajectory.

[0032] It should be noted that the rotating mechanism refers to the power device that drives the winding fixture 100 or the constraint mechanism to generate rotational motion. Specifically, it can be implemented using a servo motor and a reducer. Its function is to provide basic circular motion for the winding of the wire harness. The lifting mechanism 400 refers to the linear motion device that drives the winding fixture 100 or the constraint mechanism to move along the axial direction. Specifically, it can be implemented using a ball screw module or a linear motor. Its function is to form a helical layered trajectory through axial displacement. Helical trajectory layered winding refers to the winding method in which the wire harness spirals upward or downward at a constant pitch. This is achieved through the matching relationship between rotational speed and translational speed. Its function is to eliminate the end length differences caused by misalignment between winding layers.

[0033] Understandably, when the rotating mechanism drives the winding fixture 100 to rotate at a set angular velocity, the lifting mechanism 400 simultaneously drives the winding fixture 100 to move along the axial direction at a specific linear velocity. The rotational motion causes the wire harness to wind circumferentially, while the axial movement causes the wire harness to generate axial displacement after each turn. The speed ratio of these two movements is adjusted in real time by the control unit to ensure a constant helical pitch. For example, when the winding fixture 100 rotates once, the lifting mechanism 400 drives it to move axially a distance equal to the diameter of the wire harness, forming a gapless stack. During the winding process, the second end of the wire harness is continuously pulled by the second constraint mechanism. As the helical trajectory extends, both ends of the wire harness remain symmetrical relative to the extension path of the winding fixture 100, thus achieving consistency in the length of the extended ends after winding. Simultaneously, the symmetrical characteristics of the helical path naturally create a mirror-symmetric distribution of the two ends of the wire harness in space, providing a geometric reference for subsequent end alignment operations.

[0034] This application further proposes that after the winding operation is completed, the second end of the wire harness is trimmed by a cutting mechanism. The cutting position of the cutting mechanism is calculated and determined according to the extension length of the first end or a predetermined alignment target position, so that the first end and the second end of the wire harness extend out of the winding fixture and reach the preset area after being trimmed. That is, the extension length of the first end and the second end relative to the winding fixture 100 tends to be consistent and achieves spatial alignment.

[0035] The cutting mechanism refers to the actuator capable of cutting the wire harness, specifically implemented using a servo-driven blade assembly. Its movement path and cutting position are dynamically adjusted by the control unit. The cutting position refers to the target location where the second end of the wire harness needs to be cut. This can be determined through linear calculation using real-time detection data of the first end's protrusion length or pre-stored fixed-length clamping parameters, ensuring consistency in length between the two ends. The fixed-length clamping parameters are preset parameters for the initial clamping state of the wire harness before winding. Specifically, these parameters may include the axial distance between the clamping end and the winding fixture 100, used to establish a length compensation reference during the winding process.

[0036] Understandably, after winding, the second end of the wire harness may deviate in length and position due to differences in the winding path. In this case, the cutting mechanism moves to the corresponding position to cut based on the actual length of the first end or a preset standard. For example, when the first end extends 50 mm, the control unit drives the cutting mechanism to move to a position 50 mm from the edge of the winding fixture to cut, ensuring the second end's length matches the first end. Simultaneously, if the preset alignment target position is a symmetrical point along the axial center line of the winding fixture, the cutting mechanism can move along the guide rail to that coordinate point to perform the cut, ensuring spatial alignment of both ends. This application's automated cutting and dynamic calculation directly eliminate length differences and positional deviations after winding, automatically eliminating length differences between the two ends of the wire harness, ensuring spatial alignment of the ends, avoiding repeated positioning adjustments due to length inconsistencies in subsequent processing, and improving the processing efficiency and accuracy of multi-core wire harness assembly lines.

[0037] This application further proposes that the wire harness is continuously supplied by an unwinding machine, such as Figure 2 As shown, the trimming process includes a first cut and a second cut. In the first cut, after the winding reaches a predetermined number of turns or length, the cutting mechanism moves to a first preset position to perform the first cut. After the first cut, the remaining length at the second end of the wire harness is greater than the length at the first end. In the second cut, the cutting mechanism moves to a second preset position based on the extension length of the first end or a predetermined standard length to perform a second cut and trim of the remaining length at the second end, so that the extension lengths at both ends of the wire harness tend to be consistent and the ends are aligned. The continuous supply of the wire harness by the unwinding machine means that the wire harness is continuously fed during the winding process. This can be achieved using a constant tension unwinding device to avoid the accumulation of end length errors due to interruption of the wire harness supply. The first preset position for the first cut refers to the initial cutting point where the second end of the wire harness separates from the unwinding machine after winding is completed. Specifically, the wire consumption can be calculated based on the number of turns wound, and the cutting position can be set, leaving sufficient allowance for subsequent adjustments. The second preset position for secondary cutting refers to the precision cutting point dynamically calculated based on the actual measured length of the first end or a preset standard value. Specifically, a laser rangefinder can be used to obtain the extension length of the first end, and the cutting blade can be controlled to move to the corresponding coordinate to complete the precise cutting.

[0038] Understandably, after the winding reaches the set parameters, the cutting mechanism moves along the track to the initial cutting position to complete the first cut. At this time, the remaining length at the second end is set to exceed the length of the first end by a certain safety margin. For example, when the measured extension length of the first end is 50 mm, the first cut can make the remaining length at the second end reach 70 mm. Subsequently, the actual length data of the first end is obtained through a vision inspection system, and the cutting mechanism is repositioned to the precise cutting position based on this data, for example, adjusting the remaining length at the second end from 70 mm to 50 mm to achieve matching of the lengths at both ends. In the two cutting processes, the first cut is the roughing stage, and the second cut is the finishing stage. The consistency of the final length is improved by eliminating the remaining length error step by step. This application, through a staged cutting mechanism, leaves a safety margin in the first cut to avoid cutting too short, and the second cut performs dynamic compensation based on measured data, effectively overcoming the defect of insufficient precision in a single cut, realizing precise control of the remaining length at the second end after the wire harness is wound, and solving the problem of inconsistent end lengths caused by traditional single cuts. The initial cut leaves a trimming allowance to provide operational space for subsequent precise adjustments. The second cut dynamically corrects the length based on real-time measurement data, ensuring that the extended lengths at both ends meet process requirements and avoiding repositioning issues caused by length deviations in subsequent processing steps. Specifically, the initial cut determines the cutting position using preset winding parameters, leaving an allowance at the second end that exceeds the length of the first end, providing adjustment space for subsequent trimming. The second cut dynamically adjusts the cutting position by measuring the actual length of the first end in real time or calling preset standard values, eliminating cumulative errors caused by path differences during winding. The unwinding machine continuously supplies material, supporting a continuous winding process. The initial cut only separates the coil from the feeding device, while the second cut achieves precise trimming through a closed-loop feedback mechanism, ensuring consistent lengths and spatial alignment at both ends.

[0039] Or, in some other embodiments of this application, such as Figure 3 As shown, during the winding process, the theoretical length difference between the first and second ends of the wire harness is calculated in real time based on the number of turns or layers of the wire already wound. The winding diameter of the winding fixture 100 is dynamically adjusted by the control unit to compensate for this length difference.

[0040] It should be noted that real-time calculation of the theoretical length difference refers to deriving the cumulative length deviation at both ends of the wire harness due to differences in the winding path based on the geometric model of the helical winding and the number of coils or layers. This can be achieved using preset mathematical formulas or lookup tables, for example, by establishing a linear or nonlinear compensation model based on the relationship between the number of coils and the helix angle. Dynamic adjustment of the winding diameter refers to offsetting the length difference by changing the equivalent circumference of the wire harness winding trajectory. This can be achieved using a variable-diameter winding fixture 100 or by adjusting the winding tension to change the contact state between the wire harness and the fixture, for example, by using a hydraulically or pneumatically driven telescopic fixture structure.

[0041] Understandably, when the wire harness begins winding, the control unit continuously receives the revolution count signal from the rotary encoder, updating the cumulative revolution count value after each complete revolution. Based on the wire harness cross-sectional dimensions and the initial diameter of the winding fixture 100, the fixed consumption length of the first end of the wire harness per revolution and the cumulative consumption length of the second end of the wire harness as the number of winding layers increases are calculated. When the difference between the two exceeds a preset threshold, the control unit sends a command to the winding diameter adjustment mechanism to change the circumference of subsequent winding layers by increasing or decreasing the winding diameter, so that the consumption rate of the second end of the wire harness tends to be consistent with that of the first end. This dynamic adjustment process continues until the winding is completed, ultimately controlling the difference in the extension length of the two ends of the wire harness within the allowable range of the process. This application dynamically compensates for the length difference between the two ends of the wire harness during the winding process by adjusting the winding diameter in real time. This eliminates the need for subsequent trimming and directly meets the length consistency requirements of subsequent processing, effectively eliminating the problem of repeated positioning in subsequent processing caused by the length difference between the two ends during wire harness winding. This allows processes such as insulation removal and terminal crimping in multi-core wire harness assembly lines to be processed simultaneously at both ends, significantly improving production efficiency and reducing material waste. The dynamic adjustment mechanism of the winding diameter ensures the consistency of the wire harness end lengths, avoiding the waste of wire and reduced processing accuracy caused by secondary trimming in traditional processes. It is important to note that during the winding process, after each turn or layer of winding, the control unit calculates the theoretical length difference between the first and second ends based on the current winding parameters. For example, when the wire harness is wound in a helical trajectory, the difference in circumference between the inner and outer turns causes the length difference between the two ends to accumulate with the number of turns. By dynamically adjusting the winding diameter, for example, by gradually increasing the fixture diameter during winding, the equivalent circumference of subsequent winding layers increases, thereby compensating for the length difference generated by the previous winding layers. This real-time adjustment mechanism ensures that the extension length at both ends of the wire harness remains dynamically balanced during the winding process, preventing the ends from becoming misaligned due to accumulated errors after winding is completed.

[0042] Or, in some other embodiments of this application, such as Figure 4 and Figure 5As shown, the wire harness is cut to a fixed length before winding. The first end of the wire harness is clamped and fixed at a fixed length point in a first position by a first constraint mechanism 200. When the winding module performs the winding operation, the second end of the wire harness is clamped by a second constraint mechanism, so that the extension length of the second end of the wire harness is consistent with that of the first end and the ends are aligned. The second constraint mechanism rigidly clamps and fixes the second end of the wire harness at a fixed length point in a second position. After winding, the second constraint mechanism is moved to bring the second end of the wire harness to a preset alignment target position. This position is symmetrical or corresponds to the first position of the first end with respect to the winding fixture 100. Alternatively, the second constraint mechanism clamps the second end of the wire harness with controllable sliding friction. During the winding process, the wire harness slides relative to the second constraint mechanism under the action of winding tension. When winding stops, based on the fixed total length of the wire harness, the fixed position of the first end, and the winding parameters, the extension length of the second end relative to the winding fixture 100 naturally matches that of the first end, achieving end alignment. That is, the fixed-length cutting before winding ensures the certainty of the total length of the wire harness and eliminates the influence of length error on end symmetry. The first constraint mechanism 200 rigidly clamps the first end fixed-length point to form an immovable reference point. The second constraint mechanism employs two differentiated control modes during the winding process: such as... Figure 4 As shown, in rigid clamping mode, after winding is completed, the second constraint mechanism is driven to move along a preset trajectory, converting the path error generated during winding into a compensable displacement, so that the second end reaches a position symmetrical to the first end; as shown Figure 5 As shown, in the sliding clamping mode, by precisely controlling the relationship between clamping friction and winding tension, the wire harness automatically slides to the theoretical alignment position when winding stops. Both modes, through active position compensation and passive physical characteristic adjustment, respectively, transform the total length error of the wire harness into a symmetrical positional deviation and eliminate it, forming an error self-elimination mechanism. Through the synergistic effect of fixed-length cutting and the dual constraint mechanism, length deviations are eliminated in real time during winding, achieving automatic end alignment without manual intervention. Utilizing the dynamic balance between sliding friction and tension, the end position automatically returns to its original position, achieving passive adaptive adjustment for the first time. This effectively solves the problem of difficult subsequent processing positioning caused by inconsistent extension lengths at both ends of the wire harness, enabling the multi-core wire harness to automatically achieve spatial symmetry at both ends after winding, reducing the number of repeated positioning adjustments in subsequent processing equipment, and improving the continuous operation efficiency of the multi-core wire harness assembly line. The combination of fixed-length cutting and the dual constraint mechanism avoids precision fluctuations caused by manual trimming, ensuring end alignment accuracy.

[0043] In other embodiments of this application, such as Figure 4As shown, when the second constraint mechanism rigidly clamps the fixed second end of the wire harness at a fixed length point, if the second end of the wire harness does not reach the target position after winding is completed, compensation and adjustment can be made by controlling the rotation mechanism to drive the second constraint mechanism to rotate in the opposite direction so that the wire harness is released from the winding fixture 100 by one turn, or by controlling the rotation mechanism to drive the second constraint mechanism to rotate in the forward direction so that the wire harness is wound one more turn and controlling the translation mechanism to move synchronously, or by controlling the translation mechanism to drive the second constraint mechanism to move backward.

[0044] It should be noted that the reverse rotation to release one turn means that the second constraint mechanism is driven by the rotation mechanism to rotate along a path opposite to the winding direction, so as to reduce the friction between the wire harness and the winding fixture 100, thereby releasing one turn of wire harness length.

[0045] "One more turn in the forward rotation" means that the rotating mechanism drives the second constraint mechanism to continue rotating along the winding direction, while the translation mechanism moves along the axial direction of the winding fixture 100 to maintain a constant helical winding pitch.

[0046] The backward movement of the translation mechanism refers to the reverse displacement of the second constraint mechanism by the linear drive component, which directly changes the spatial coordinates of the clamping point at the second end of the wire harness.

[0047] That is, if a deviation in the position of the second end is detected after winding is completed, the type of deviation is first determined: if the second end of the harness is too short due to excessive winding turns, a reverse rotation release mechanism is activated to release one turn of the harness length; if the second end is too long due to insufficient winding turns, a forward rotation is executed to wind one more turn while simultaneously moving the translation mechanism to compensate for the length difference by increasing the number of winding turns and axial displacement; if there is an offset in the absolute position of the end, the translation mechanism is directly driven to move the second constraint mechanism to the target coordinate. The above three compensation methods can be executed independently or in combination. For example, when both axial position deviation and circumferential turn error are detected, translation compensation and rotation compensation actions can be triggered simultaneously.

[0048] Beneficially, this application establishes three mechanisms—rotational loosening, rotational superposition winding, and translational compensation—to precisely correct circumferential turn errors, axial pitch errors, and absolute coordinate offsets. It is particularly suitable for eliminating end position deviations caused by accumulated errors in multi-turn helical winding scenarios. After the wire harness winding is completed, the second end can be precisely adjusted to a preset position, eliminating inconsistencies in end length and spatial position deviations caused by differences in winding paths, and avoiding repositioning problems caused by end misalignment in subsequent processing steps. For example, in the multi-core wire harness terminal crimping process, precise alignment of both ends allows the crimping device to directly perform standardized processing operations without needing to adjust positioning parameters separately, thereby improving the automation level of the production line.

[0049] In other embodiments of this application, during the winding process, the axial movement speed of the winding fixture 100 or the second constraint mechanism is controlled by the lifting mechanism 400 to maintain a predetermined ratio with the rotation speed of the rotating mechanism, thereby achieving a constant helical winding pitch.

[0050] Specifically, the lifting mechanism 400 refers to a linear motion component capable of driving the winding fixture 100 or the second constraint mechanism to move along the axis of the winding fixture 100. This can be achieved using a servo motor and ball screw combination, and its function is to precisely control the axial displacement. The rotation mechanism refers to a power component that drives the winding fixture 100 to rotate or the second constraint mechanism to circumferentially rotate. This can be achieved using a stepper motor or servo motor combined with a reducer, and its function is to provide a controllable angular velocity. The predetermined ratio refers to the mathematical relationship between the axial movement speed and the rotational angular velocity, which can be calculated and adjusted in real time through a motion control algorithm. Its function is to ensure that the geometric parameters of the helical trajectory remain constant.

[0051] Specifically, during the winding process, the rotating mechanism drives the winding fixture 100 to rotate at a constant angular velocity, while the lifting mechanism 400 synchronously drives the winding fixture 100 or the second constraint mechanism to move along the axial direction. The ratio of the axial movement speed to the rotational angular velocity is set to a fixed value related to the helical pitch. For example, when the winding fixture 100 rotates once, the lifting mechanism 400 drives the axial movement distance equal to the helical pitch. This ratio is adjusted in real time by the motion control module in the control unit to ensure that the helical trajectory pitch of the wire harness remains consistent in each turn during the winding process. Because the axial movement and rotational movement are strictly synchronized, there will be no local accumulation or excessive gaps during the wire harness stacking process, thereby avoiding the difference in length at both ends of the wire harness caused by fluctuations in the helical pitch. This application eliminates the pitch instability problem caused by asynchronous movement by dynamically and collaboratively controlling the speed ratio of the two movements, making the geometric shape of the helical winding more uniform, ensuring that the wire harness forms a uniformly distributed helical layer structure during the winding process, and avoiding inconsistent extension lengths at both ends of the wire harness due to pitch fluctuations. The achievement of constant helical pitch ensures that the length of each winding remains stable, providing a basis for consistent length in subsequent cutting or end-processing processes, thereby reducing trimming allowance and improving processing efficiency.

[0052] This application further proposes that, before the winding begins, the position of the first constraint mechanism 200 is adjusted by the first translation component 220 and the first lifting component 230 so that the initial position of the first end of the wire harness is aligned with the axial starting point of the winding fixture 100.

[0053] Among them, such as Figure 5 As shown, the first constraint mechanism 200 includes a first clamping component 210, which is used to fix one end of the wire harness. The first clamping component 210 is fixedly connected to the winding fixture 100.

[0054] Specifically, before the winding operation begins, the first translation component 220 drives the first constraint mechanism 200 to move along the fixture axis to the target coordinates, while the first lifting component 230 adjusts its height to a preset reference plane. When the first end of the wire harness is clamped and fixed, its end position spatially coincides with the axial starting point of the winding fixture 100. This precise alignment establishes the initial reference for the winding operation, ensuring that each subsequent layer of winding trajectory is superimposed with this reference as the starting point. When the winding fixture 100 performs axial movement, the initial alignment state avoids interlayer misalignment caused by reference offset, thereby eliminating the accumulation of end length differences caused by initial positioning errors.

[0055] Beneficially, when changing to winding fixtures 100 of different diameters or lengths, the starting end of the wire harness cannot be precisely aligned with the new winding reference, causing the end length deviation to amplify with the increase in the number of winding layers during the winding process. This solution, through adjustable translation and lifting components, achieves rapid adaptation to winding fixtures 100 of different specifications, fundamentally eliminating the impact of initial positioning errors on end consistency, solving the problem of inconsistent end lengths caused by deviations in the starting position of the wire harness winding, and ensuring a unified starting reference for the wire harness stacking trajectory during the winding process. This solution, through improved mechanical positioning accuracy, avoids systematic deviations caused by initial positioning errors, significantly improves end length consistency in multi-specification winding fixture 100 application scenarios, and reduces the frequency of positioning adjustments in subsequent processing steps.

[0056] This application also provides a winding apparatus for performing the above-described winding method.

[0057] Specifically, such as Figures 6 to 8 As shown, the winding device includes a winding fixture 100, a first constraint mechanism 200, a winding module, and a control unit. The winding fixture 100 provides support for winding the wire harness; the first constraint mechanism 200 is fixedly connected to or arranged side-by-side with the winding fixture 100 and is used to fix the first end of the wire harness; the winding module includes a rotating mechanism, a lifting mechanism 400, and a second constraint mechanism, the second constraint mechanism being used to connect the second end of the wire harness; the control unit can acquire the winding parameters of the wire harness; based on the winding parameters, the control unit can control the rotating mechanism and the lifting mechanism 400 to work together to wind the wire harness onto the winding fixture 100, and the control unit can control the winding process or the post-processing process so that after winding, the extension length of the second end of the wire harness relative to the first end of the winding fixture 100 tends to be consistent.

[0058] The winding fixture 100 is a rigid support component with a cylindrical or prismatic structure, specifically made of metal material with a surface textured for anti-slip. Its function is to provide a stable winding reference surface for the wire harness. The first constraint mechanism 200 is a positioning component with clamping function, specifically made of pneumatic grippers or electromagnetic clamps. Its function is to ensure initial positioning accuracy by fixing the starting end of the wire harness. The rotation mechanism in the winding module is the power device that drives the winding fixture 100 to rotate around its axis, specifically made of a servo motor and reducer. Its function is to achieve uniform winding of the wire harness by precisely controlling the rotation speed. The lifting mechanism 400 is a linear drive device that moves along the axial direction of the winding fixture 100, specifically made of a ball screw module or linear motor. Its function is to form a helical winding trajectory by controlling axial displacement. The second constraint mechanism is the execution unit that dynamically constrains the end of the wire harness, specifically made of a clamping device with a tension sensor. Its function is to maintain the tension of the wire harness during winding. The control unit refers to the processing module that integrates motion control algorithms. Specifically, it can be implemented using a PLC or an industrial computer. Its function is to calculate the winding parameters in real time and coordinate the actions of various mechanisms.

[0059] Understandably, during the operation of the winding device, after the first end of the wire harness is fixed to the first constraint mechanism 200, the control unit generates motion commands based on the input winding parameters. When the rotating mechanism drives the winding fixture 100 to rotate, the lifting mechanism 400 simultaneously drives the second constraint mechanism to move axially, forming a spiral winding path. During the winding process, the control unit dynamically adjusts the ratio of rotation speed to translation speed by monitoring the changes in wire harness length in real time. When the winding reaches a predetermined number of turns or length, the control unit triggers a post-processing procedure, such as correcting the length of the wire harness end through a cutting mechanism or eliminating accumulated errors through axial compensation movement. The geometric accuracy of the winding fixture 100, combined with the synchronous control of each motion mechanism, ensures the symmetry of the protruding lengths at both ends when the wire harness is layered and wound.

[0060] Beneficially, compared to existing technologies, traditional winding devices typically only focus on the regularity of the winding shape, without actively controlling for differences in the length of the wire harness ends. The fixed constraint mechanisms in existing technologies cannot adapt to the dynamic winding process, causing the wire harness end position to shift as the number of winding layers increases. This solution introduces an axially movable second constraint mechanism, combined with a control unit for closed-loop adjustment of the winding trajectory, achieving dynamic balance of the extension lengths at both ends of the wire harness. Compared to the shortcomings of traditional devices that passively accept length differences, this device actively corrects the end position during the winding process, eliminating the length deviation at the two ends at its source, effectively solving the problem of repeated positioning in subsequent processing devices caused by inconsistent extension lengths at both ends after winding. The consistency of the extension lengths at both ends of the wound wire harness is guaranteed, allowing it to directly proceed to processes such as insulation removal and terminal crimping on multi-core wire harness assembly lines without additional adjustment of the wire harness end position. The device, by replacing manual trimming with automated control, significantly improves the production efficiency of multi-core wire harness assembly while reducing wire waste caused by end length errors.

[0061] Or, in some other embodiments of this application, such as Figure 6 As shown, the second constraint mechanism surrounds the axis of the winding fixture 100. Specifically, the first clamping component 210 of the first constraint mechanism 200 moves to a suitable position under the drive of the first translation component 220 and / or the first lifting component 230, taking over and firmly clamping the beginning end of the wire harness. At this time, the operator or a sensor can record the initial position of the beginning end of the wire harness relative to the edge of the winding fixture 100 (i.e., the fixed-length clamping parameter), or control the first constraint mechanism 200 to move so that the length of the beginning end extends to a preset value. Subsequently, the second clamping component 500 of the second constraint mechanism (whose clamping plate 520 opens under the action of the second drive component 510) takes over and clamps the other end of the wire harness. It should be noted that the clamping here can be a "flexible" clamping that allows the wire harness to slide under certain damping to maintain tension during winding. After the preparation is completed, the control unit starts the winding program. The rotating mechanism begins to drive the second constraint mechanism to rotate around the winding fixture 100. Simultaneously, the lifting mechanism begins to drive the winding fixture 100 to move slowly and uniformly along its axis. The rotational motion and axial movement combine to form a spiral motion trajectory, and the wire bundle is evenly and layer by layer spirally wound onto the support plate 120 of the winding fixture 100, with its axial movement range limited by the limiting block 121 on it to ensure neat arrangement. When the predetermined number of turns or length of winding is reached, the winding action stops.

[0062] Specifically, such as Figure 6 and Figure 7As shown, the second constraint mechanism includes a second clamping assembly 500, which is connected to a rotating mechanism and to the other end of the wire harness. The second clamping assembly 500 can fix the end of the wire harness or allow it to slide. The rotating mechanism can drive the second clamping assembly 500 to rotate around the winding fixture 100. Although the end of the wire harness is clamped by the second clamping assembly 500, it is in a slidable state and moves circumferentially along the winding fixture 100 under the drive of the rotating mechanism. At the same time, the lifting mechanism 400 drives the winding fixture 100 or the second clamping assembly 500 to move axially, so that the wire harness forms a spiral arrangement in three-dimensional space. The clamping method that allows the wire harness to slide can adapt to different wire diameters and tension requirements, while the fixed clamping method ensures that the winding position is precise and controllable.

[0063] Furthermore, the winding device provided in this application also includes a cutting mechanism (not shown in the figure). It should be understood that the cutting mechanism is an execution device that trims the length of the second end after the wire harness is wound. Specifically, it can be implemented using a servo-driven cutting blade or a laser cutting device, and its movement trajectory is driven by the control unit based on calculated data. The control unit is a computational module that coordinates the winding and cutting processes. Specifically, it can be implemented using a PLC or an embedded controller, and completes the cutting position calculation by receiving sensor signals or calling stored data. Real-time length detection refers to obtaining dynamic data on the actual extension of the first end of the wire harness through a measuring device. Specifically, it can be implemented using a contact encoder or a non-contact laser rangefinder to compensate for wire deformation errors during the winding process. The pre-stored fixed-length clamping parameters refer to the reference length value recorded when the wire harness is initially fixed. Specifically, it can be stored in the memory module of the control unit, suitable for standardized production scenarios.

[0064] Specifically, after the winding process is completed, the control unit calculates the target length to be retained at the second end based on the actual detected length of the first end of the wire harness at the first constraint mechanism 200, or by calling pre-stored clamping parameters. The cutting mechanism receives coordinate instructions from the control unit and moves along the guide rail to the calculated position to perform the cutting action. When using real-time detection mode, the detection device continuously monitors changes in the extension of the first end, and the control unit dynamically updates the cutting position to eliminate cumulative errors caused by wire stretching or slippage. When using pre-stored parameter mode, the cutting position is directly determined based on the product of the initial clamping length and the number of winding coils, ensuring consistency in batch production. The switching between the two data sources is completed through the human-machine interface of the control unit, forming a dual guarantee mechanism.

[0065] In some specific embodiments, the cutting mechanism can be mounted on an independent mobile platform, which can be equipped with a linear motor drive system. The detection device uses two sets of symmetrically arranged laser sensors to monitor the wire end positions on both sides of the winding fixture 100. The control unit has a built-in compensation algorithm that automatically triggers a secondary calibration procedure for the cutting mechanism when the length deviation of the first end exceeds a threshold. This application achieves high-precision matching of end lengths through a dual calculation mechanism of real-time detection and pre-stored parameters, combined with closed-loop control of the cutting mechanism's movement. This effectively solves the problem of inconsistent extension lengths at both ends of the wire harness after winding, which requires repeated positioning in subsequent processing. After precise cutting, the second end of the wire harness is made to the same length as the first end, so that the positioning fixtures in subsequent processes do not need to be adjusted for different end lengths, and the synchronous processing of both ends can be completed directly, significantly improving the continuous operation efficiency of the multi-core wire harness assembly line.

[0066] Furthermore, when the second constraint mechanism is an unwinding machine, the cutting mechanism is located between the unwinding machine and the winding fixture 100. The control unit can control the cutting mechanism to perform two cuts. The two cuts include the first cut separating the coil from the unwinding machine and leaving a trimming allowance, and the second cut trimming the allowance based on the length of the first end.

[0067] Specifically, after the wire harness is output from the unwinding machine, it is spirally wound on the winding fixture 100, at which point the second end remains connected to the unwinding machine. The first cut is performed after the wire harness reaches the predetermined winding length, separating the coil from the unwinding machine while leaving a trimming allowance at the second end. The length of the trimming allowance is determined by preset parameters or real-time detection of the first end length. The second cut is performed after the winding fixture 100 stops moving, adjusting the cutting position according to the actual extension length of the first end, and eliminating allowance errors through closed-loop control to ensure that the extension length of the second end is consistent with that of the first end. This application uses two-stage cutting processes. The first cut ensures the integrity of the coil and leaves room for adjustment, while the second cut dynamically corrects based on actual measurement data. This avoids the problem of length loss due to material springback in a single cut, and solves the problem of inconsistent allowance lengths at both ends of the wire harness after winding, which requires repeated positioning in subsequent processing. This eliminates the need for repeated adjustments to the wire end position in processes such as insulation removal and terminal crimping in multi-core wire harness assembly lines, improving processing efficiency. Furthermore, the consistency error of the lengths at both ends can be controlled, reducing the positioning time and equipment idle wear in subsequent processes.

[0068] Furthermore, the winding device is also equipped with a transport mechanism 600.

[0069] like Figure 6As shown, the conveying mechanism 600 is located above the winding fixture 100. Specifically, the conveying mechanism 600 includes a fixed bracket 610, a second lifting assembly 620, at least two wire coil fixing assemblies 630, and two third clamping assemblies 640. The second lifting assembly 620 is connected to the fixed bracket 610. The wire coil fixing assemblies 630 and the third clamping assemblies 640 are both mounted on the fixed bracket 610. The wire coil fixing assemblies 630 are used to clamp the main body of the wire harness coil, and the third clamping assemblies 640 are used to clamp the ends of the wire harness. The second lifting assembly 620 can move the wire coil fixing assemblies 630 and the third clamping assemblies 640 away from or closer to the winding fixture 100.

[0070] Specifically, after the winding fixture 100 completes the winding of the wire harness, the second lifting component 620 lowers the fixed bracket 610 to a predetermined height. Simultaneously, the wire coil fixing component 630 clamps the outer surface of the wire coil, while the third clamping component 640 clamps both ends of the wire harness. After clamping, the second lifting component 620 raises the fixed bracket 610, disengaging the wire coil from the winding fixture 100. The wire coil is then transferred to a designated position via a translation module. During this process, the wire coil fixing component 630 and the third clamping component 640 provide double fixation, preventing the wire coil from unraveling and avoiding loosening of the wire ends during transport. The rigid structure of the fixed bracket 610 ensures that the relative positions of each clamping component remain unchanged during movement, and the precise control of the second lifting component 620 achieves seamless integration with the winding process.

[0071] The wire harness winding device in some embodiments of this application operates as follows: Figure 1 and Figure 4 As shown, the first clamping component 210 of the first constraint mechanism 200 moves to a suitable position under the drive of the first translation component 220 and / or the first lifting component 230, taking over and firmly clamping the beginning end of the wire harness. At this time, the operator or a sensor can record the initial position of the beginning end of the wire harness relative to the edge of the winding fixture 100 (i.e., the fixed-length clamping parameter), or control the first constraint mechanism 200 to move so that the length of the beginning end extends to a preset value. Subsequently, the second clamping component 500 of the second constraint mechanism (whose clamping plate 520 opens under the action of the second driving member 510) takes over and clamps the other end of the wire harness. It should be noted that the clamping here can be a "flexible" clamping that allows the wire harness to slide under certain damping to maintain tension during winding.

[0072] After preparation, the control unit initiates the winding program. The rotating mechanism begins to drive the second constraint mechanism to rotate around the winding fixture 100. Simultaneously, the lifting mechanism begins to drive the winding fixture 100 to move slowly and uniformly along its axis. The rotational motion and axial movement combine to form a spiral motion trajectory, and the wire bundle is evenly and layered spirally wound around the support plate 120 of the winding fixture 100, with its axial movement range limited by the limiting block 121 on it, ensuring neat arrangement.

[0073] The winding process stops once the predetermined number of turns or length is reached. At this point, because the starting point of the winding is fixed, the extension length of the tail end of the wire harness may not be consistent with that of the beginning end. The control unit calculates the position where the tail end needs to be trimmed based on the previously recorded extension length of the beginning end (or a preset value). The trimming mechanism moves to the calculated position and performs a one-time trimming of the tail end of the wire harness. After trimming, the extension length of the tail end of the wire harness is basically the same as that of the beginning end.

[0074] Finally, the conveying mechanism 600 descends again, and its wire coil fixing component 630 tightens the coiled wire harness body. The two third clamping components 640 clamp the beginning and end ends respectively, and the finished wire harness coil is removed, completing one work cycle.

[0075] Alternatively, in some other embodiments of this application, the wire harness winding device operates as follows: The wire harness is continuously supplied by an unwinding machine (as a second constraint mechanism). Before winding begins, the first end of the wire harness is pulled out and clamped and fixed to a fixed length by the first constraint mechanism 200. During the winding process, the unwinding machine continuously unwinds the wire, and the lifting mechanism drives the winding fixture 100 to move axially, performing helical winding.

[0076] After winding, the cutting mechanism first performs a cut at the end closest to the unwinding machine, separating the coil from the unwinding machine. This first cut leaves a relatively long slack at the end of the coil. Then, based on the fixed-length clamping parameters at the beginning, the cutting mechanism moves to a precise position to perform a second cut and trim of the slack at the end, ultimately ensuring that both ends are of equal length. This method offers high precision and is particularly suitable for applications requiring extremely high consistency in end length.

[0077] Alternatively, in some other embodiments of this application, the wire harness winding device, such as Figure 7 and Figure 8As shown, the winding fixture 100 includes a mounting base 110, a support plate 120, and a first driving member 130. The support plate 120 is slidably connected to the mounting base 110, and the output end of the first driving member 130 is connected to the support plate 120. Multiple support plates 120 are circumferentially spaced around the axis of the mounting base 110. The first driving member 130 can drive the support plates 120 to move to adjust the winding diameter. Specifically, the slide rail of the mounting base 110 and the guide groove of the support plate 120 form a sliding pair. The first driving member 130 drives the support plates 120 to move radially along the mounting base 110 through a push-pull action. When the winding diameter needs to be increased, all support plates 120 slide outwards synchronously, expanding the outer contour of the winding; when the winding diameter needs to be decreased, the support plates 120 shrink inwards synchronously. The uniform circumferential distribution of multiple support plates 120 ensures balanced pressure at each contact point during winding, avoiding local deformation. By adjusting the position of the support plates 120, different winding diameter requirements can be matched, achieving flexible adjustment of the winding diameter.

[0078] As a further improvement to the plan, such as Figure 7 As shown, a limit block 121 is provided on the support plate 120. The two limit blocks 121 are spaced apart along the axial extension direction of the mounting base 110. The two limit blocks 121 cooperate to form a constraint space for the wire harness winding arrangement.

[0079] The workflow of this solution is as follows: The winding fixture 100 is designed with an adjustable diameter, and its first drive component 130 can drive multiple support plates 120 to synchronously extend and retract radially. During the winding process, the control unit calculates the theoretical length difference ΔL between the tail end and the head end of the wire harness in real time based on the number of turns (n) and the current diameter (D) of the winding fixture 100. The control unit compares this length difference with zero (target value) and generates a control signal to drive the first drive component 130 to fine-tune the position of the support plates 120, thereby changing the winding diameter D to compensate for the length difference ΔL. Through this real-time, closed-loop feedback control, the winding diameter is continuously fine-tuned throughout the winding process, so that when the winding is completed, the extension lengths of the head and tail ends of the wire harness automatically reach a basic consistency, without any subsequent trimming operations.

[0080] In some embodiments of this application, the second restraint mechanism may optionally be an unwinding machine.

[0081] Alternatively, in some other embodiments of this application, such as Figure 6 As shown, the second constraint mechanism includes a second clamping component 500, which is connected to a rotating mechanism and to the other end of the wire harness. The second clamping component 500 can fix the end of the wire harness or allow the wire harness to slide. The rotating mechanism can drive the second clamping component 500 to rotate around the winding fixture 100.

[0082] It is understood that the second clamping component 500 refers to a device used to fix or guide the end of the wire harness. Specifically, it can be implemented using a gripper structure with a pressure sensor. By adjusting the clamping force, the wire harness can be kept in a sliding or fixed state during the winding process. The rotating mechanism refers to a device that drives the second clamping component 500 to move around the winding fixture 100100. Specifically, it can be implemented using a servo motor-driven rotating arm structure. By controlling the rotation speed and linking it with the translation mechanism, a helical winding trajectory is formed.

[0083] Specifically, such as Figure 6 As shown, when the second clamping component 500 is used, although the end of the wire harness is clamped by the second clamping component 500, it is in a sliding state. Driven by the rotating mechanism, it moves circumferentially along the winding fixture 100. At the same time, the lifting mechanism 400 drives the winding fixture 100 or the second clamping component 500 to move axially, so that the wire harness forms a spiral arrangement in three-dimensional space. The clamping method that allows the wire harness to slide can adapt to different wire diameters and tension requirements, while the fixed clamping method ensures that the winding position is precise and controllable.

[0084] Furthermore, such as Figure 6 As shown, the second clamping assembly 500 includes a second driving member 510 and clamping plates 520. The two clamping plates 520 are arranged opposite each other to form a clamping cavity. One or both of the clamping plates 520 are connected to the second driving member 510. The second driving member 510 can drive the clamping plates 520 to move to adjust the opening and closing of the clamping cavity. When the wire harness enters the clamping cavity, the second driving member 510 drives the clamping plates 520 to move according to preset parameters or real-time detection signals, so that the width of the clamping cavity matches the outer diameter of the wire harness. For example, when the diameter of the wire harness is large, the second driving member 510 drives the clamping plates 520 to move outward to expand the clamping cavity, avoiding excessive compression that could damage the insulation layer. Through the linkage control of the driving member and the clamping plates 520, the clamping force can be adjusted in real time, which not only eliminates the mechanical damage caused by rigid clamping, but also avoids insufficient tension during the wire harness traction process, ensuring that the wire harness remains stable during rotational traction, thus improving the reliability of the winding process and the quality of the finished wire harness. This application utilizes composite motion trajectory control at the constraint end to simultaneously generate circumferential winding and axial displacement of the wire harness during the winding process, completely eliminating planar stacking. Compared to manual operation or a single rotating mechanism, this technology achieves automated spiral winding, with both implementations adapting to the different process requirements of continuous production and precision winding, respectively. Simultaneously, it effectively avoids packaging and handling difficulties caused by planar stacking of wire harnesses, and improves the space utilization of the wire harness roll through the spiral layered structure. The combination of the unwinding machine and the cutting mechanism enables fully automated continuous operation, while the adjustable clamping mode of the second clamping component 500 meets the tension control requirements of different wire harness materials, enabling the device to adapt to winding processes for various specifications of wire harnesses.

[0085] Furthermore, this application also proposes a multi-core wire harness assembly line (not shown) that uses the above-mentioned winding device.

[0086] By applying the winding device provided in this application, the multi-core wire harness assembly line ensures the consistency of the extended length at both ends of the wound wire harness. The wire harness can then directly proceed to processes such as insulation removal and terminal crimping without requiring additional adjustments to the wire harness end positions. The winding device, through automated control replacing manual trimming, significantly improves the production efficiency of multi-core wire harness assembly.

[0087] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0088] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. A wire harness winding method based on consistent end extension, characterized in that, include: Provide a winding fixture; The first end of the wire harness is fixed to the first constraint mechanism; The winding module is controlled to perform the winding operation, so that the wire harness is wound onto the winding fixture; Control the winding process or perform post-processing so that after winding is completed, the second end and the first end of the wire harness can extend out of the winding fixture and be located within a preset area, and the ends of the first end and the second end are aligned in spatial position.

2. The wire harness winding method based on consistent end extension according to claim 1, characterized in that, The steps for the control winding module to perform the winding operation include: The control rotation mechanism drives the winding fixture to rotate and / or drives the second constraint mechanism to rotate around the winding fixture; Simultaneously, the lifting mechanism is controlled to drive the winding fixture and / or the second constraint mechanism to move along the axial direction of the winding fixture; Rotation and axial movement are performed in tandem, causing the wire harness to be wound in a spiral trajectory onto the winding fixture.

3. The wire harness winding method based on consistent end protrusion according to claim 1 or 2, characterized in that, The phrase "the second end of the wire harness and the first end can extend out of the winding fixture and are located within a preset area, and the ends of the first end and the second end are aligned in spatial position" means that after the winding operation is completed, the second end of the wire harness is trimmed by a cutting mechanism. The cutting position of the cutting mechanism is calculated and determined based on the extension length of the first end and / or the predetermined alignment target position, so that the length of the second end after cutting is consistent with the length of the first end and achieves alignment in spatial position.

4. The wire harness winding method based on consistent end extension according to claim 3, characterized in that, The wire harness is continuously supplied by an unwinding machine, and the cutting and trimming process includes: First cut: After the winding reaches the predetermined number of turns or length, the cutting mechanism moves to the first preset position to perform the first cut. After the first cut, the remaining length of the second end of the wire harness is greater than the length of the first end. Secondary cutting: The cutting mechanism then moves to the second preset position according to the extension length of the first end or the predetermined standard length to perform secondary cutting and trimming of the second end allowance, so that the extension lengths of both ends of the wire harness tend to be consistent and the ends are aligned.

5. The wire harness winding method based on consistent end protrusion according to claim 2, characterized in that, The phrase "the second end of the wire harness and the first end can extend out of the winding fixture and are located within a preset area, and the ends of the first end and the second end are aligned in spatial position" includes: During the winding process, the theoretical length difference between the first and second ends of the wire harness is calculated in real time based on the number of turns or layers of the wire already wound. The winding diameter of the winding fixture is dynamically adjusted by the control unit to compensate for the length difference.

6. The wire harness winding method based on consistent end protrusion according to claim 2, characterized in that, Cut the wire bundle to a fixed length before winding; The phrase "fixing the first end of the wire harness" refers to using a first constraint mechanism to clamp and fix the first end of the wire harness at a fixed length point in a first position. The "control winding module performs winding operation" clamps the second end of the wire harness through the second constraint mechanism; The phrase "the second end of the wire harness can extend out of the winding fixture and be located within a preset area, and the second end of the wire harness is aligned with the first end" is achieved by the second constraint mechanism rigidly clamping and fixing the second end of the wire harness at a fixed length point in the second position. After winding is completed, the second constraint mechanism is controlled to move, driving the second end of the wire harness to a preset alignment target position. This position is symmetrical or corresponds to the first position of the first end relative to the winding fixture. Alternatively, the second constraint mechanism clamps the second end of the wire harness by providing a controllable sliding friction force. During the winding process, the wire harness can slide relative to the second constraint mechanism under the action of winding tension. When winding stops, based on the fixed total length of the wire harness, the fixed position of the first end, and the fixed winding parameters, the area where the second end of the wire harness is located relative to the winding fixture naturally tends to be consistent with the area where the first end is located, thus achieving end alignment in any of the following ways.

7. The wire harness winding method based on consistent end protrusion according to claim 6, characterized in that, When the second constraint mechanism rigidly clamps and fixes the second end of the wire harness at a fixed length point, if the second end of the wire harness does not reach the alignment target position after winding is completed, the second constraint mechanism can be rotated in the opposite direction by controlling the rotation mechanism to loosen the wire harness from the winding fixture by one turn, or the second constraint mechanism can be rotated in the forward direction by controlling the rotation mechanism to wind the wire harness by one more turn on the winding fixture, while the translation mechanism moves synchronously, or the second constraint mechanism can be moved backward by controlling the translation mechanism to compensate and adjust, so that the second end moves to the alignment target position.

8. The wire harness winding method based on consistent end extension according to claim 2, characterized in that, During the winding process, the axial movement speed of the winding fixture and / or the second constraint mechanism is controlled by the lifting mechanism to maintain a predetermined ratio with the rotation speed of the rotating mechanism, thereby achieving a constant helical winding pitch.

9. The wire harness winding method based on consistent end protrusion according to claim 2, characterized in that, Before the winding begins, the position of the first constraint mechanism is adjusted by the first translation component and / or the first lifting component so that the initial position of the first end of the wire harness is aligned with the axial starting point of the winding fixture.

10. A winding apparatus for performing the wire harness winding method based on end-protrusion consistency as described in any one of claims 1 to 9, characterized in that, include: A winding fixture (100) is used to provide support for winding the wire harness; The first constraint mechanism (200) is fixedly connected to or arranged side by side with the winding fixture (100) and is used to fix the first end of the wire harness; The winding module includes a rotating mechanism, a lifting mechanism (400), and a second constraint mechanism, the second constraint mechanism being used to connect the second end of the wire harness; The control unit is capable of acquiring the winding parameters of the wire harness; The control unit can control the rotating mechanism and the lifting mechanism (400) to work together based on the winding parameters so that the wire harness is wound on the winding fixture (100). The control unit can also control the winding process or the post-processing process so that after the winding is completed, the second end and the first end of the wire harness can extend out of the winding fixture (100) and be located in a preset area, and the ends of the first end and the second end are aligned in space.

11. The winding device according to claim 10, characterized in that, It also includes a cutting mechanism, and the control unit is electrically connected to the cutting mechanism. The control unit can control the cutting mechanism to move to the calculated cutting position after the winding is completed. The cutting position is determined based on the real-time detected length of the first end, or a pre-stored fixed-length clamping parameter, or a pre-stored alignment target position, so that the second end and the first end can extend out of the winding fixture and be located within a preset area.

12. The winding device according to claim 11, characterized in that, The second constraint mechanism is an unwinding machine. The cutting mechanism is located between the unwinding machine and the winding fixture (100). The control unit can control the cutting mechanism to perform two cuts. The two cuts include a first cut to separate the coil from the unwinding machine and leave a trimming allowance, and a second cut to trim the allowance based on the length of the first end.

13. The winding device according to claim 10, characterized in that, It also includes a detection mechanism for detecting the extension length of the first and second ends of the wire harness relative to the winding fixture (100). The control unit is communicatively connected to the detection mechanism. Based on the length information fed back by the detection mechanism, the control unit adjusts the winding parameters or controls the lifting mechanism (400) to perform compensatory movement.

14. The winding device according to claim 13, characterized in that, The detection mechanism includes photoelectric sensors or visual detection devices disposed on both sides of the winding fixture (100) for non-contact measurement of the extension length of the wire harness end.

15. A multi-core wire harness assembly line, characterized in that, Includes the wire harness winding device as described in any one of claims 10-14.

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