New energy automobile connector assembly state identification system and method

Abstract

The invention provides a new energy automobile connector assembly state recognition system and method, and relates to the technical field of assembly material level recognition. Extracting a guide turning instruction of a main positioning pin of the preassembled connector on the preassembled hole site from the hole inspection deviation correction data, and further determining an insertion check gradient when the connector is preassembled according to the guide turning instruction and the preassembled posture identifier; performing assembly quality judgment on the alignment gap label to obtain a meshing coplanar tolerance between a connector pin reference axis and an assembly positioning hole, and further determining a guide adaptation level during insertion and extraction of a contact position in connector assembly according to the meshing coplanar tolerance; and carrying out linkage butt joint identification on the assembly state of the new energy automobile connector according to the plugging verification gradient and the guiding adaptation level. According to the method, the assembly state of the connector can be accurately identified under a collaborative framework considering process dynamic adjustment and result precision verification, so that the management and control level of the assembly quality of the connector is improved.

Description

Technical Field

[0001] This application relates to the field of assembly level recognition technology, and more specifically, to a new energy vehicle connector assembly status recognition system and method. Background Technology

[0002] Assembly position identification refers to the core step in the assembly of connectors in new energy vehicles, which involves accurately detecting and identifying the relative positions of connector pins and corresponding assembly positioning holes to ensure stable circuit conduction. This process requires pre-detection, position verification, and final fixing, involving multiple requirements such as mechanical structure alignment and sensor accuracy assurance. Due to the high-voltage and high-current operating characteristics of new energy vehicles, assembly accuracy directly affects conductivity and safety performance. Excessive deviation can lead to poor contact, insulation failure, or even arcing. Therefore, accurately identifying the assembly status is crucial for improving the stability of the electrical connection system in new energy vehicles.

[0003] However, existing methods for identifying the assembly status of automotive connectors mostly rely on single-dimensional detection, focusing only on the static parameters of the assembly result. This lack of correlation analysis between dynamic process deviations and static accuracy results leads to an inability to fully reflect the true quality of the assembly status, making it difficult to detect hidden defects in a timely manner and thus affecting the reliability of the electrical connection system of new energy vehicles. Therefore, how to accurately identify the connector assembly status within a collaborative framework that considers both dynamic process adjustment and accuracy verification of results, in order to improve the control level of connector assembly quality, is a problem facing the industry. Summary of the Invention

[0004] This application provides a new energy vehicle connector assembly status identification system and method, which can accurately identify the connector assembly status under a collaborative framework that takes into account both dynamic process adjustment and result accuracy verification, so as to improve the control level of connector assembly quality.

[0005] Firstly, this application provides a method for identifying the assembly status of a connector in a new energy vehicle, the method comprising the following steps: The pre-assembly posture markings of connectors in the pre-assembly area are identified by sensors in the industrial automatic control system. Real-time detection of hole correction data of pre-installed connectors in the connector assembly area; extraction of guiding direction command of the main positioning pin of the pre-installed connector on the pre-installed hole from the hole correction data; and determination of the mating verification gradient of the connector during pre-installation by the guiding direction command and the pre-installation posture mark. After the new energy vehicle connector is assembled, the alignment gap label of the assembly connection part is obtained, the assembly quality of the alignment gap label is judged, the tooth coplanar tolerance between the connector pin reference axis and the assembly positioning hole is obtained, and then the guide adaptation level when the contact position is inserted and removed in the connector assembly is determined by the tooth coplanar tolerance. The assembly status of the new energy vehicle connector is identified through linkage and docking based on the mating verification gradient and the guiding adaptation level.

[0006] In this embodiment, the pre-assembly posture identifier refers to the set of parameters of the connector's position, rotational deviation, and feature point coordinates in the pre-assembly area.

[0007] In this embodiment, the real-time detection of hole-tracking and correction data of pre-assembled connectors in the connector assembly area specifically includes: The holes of pre-installed connectors in the connector assembly area are detected in real time to obtain real-time position data of the holes; The deviation type identifier of the pre-installed connector hole position is determined based on the real-time position data; The hole inspection and correction data for pre-installed connectors in the connector assembly area are determined based on the deviation type identifier.

[0008] In this embodiment, the guiding direction command refers to the control information that instructs the main positioning pin to accurately adjust its posture to align with the pre-installed hole.

[0009] In this embodiment, determining the mating verification gradient of the connector during pre-assembly based on the guiding direction command and the pre-assembly posture identifier specifically includes: The offset component limits of the positioning pin on the horizontal and vertical axes are analyzed based on the guide direction change command. The offset component limit is compared with the allowable tolerance threshold of each axis in the pre-installed attitude identifier to generate an axial difference sequence for each axis. The mating verification gradient during connector pre-assembly is determined by the axial difference sequence.

[0010] In this embodiment, the mating verification gradient refers to the level of assembly mating verification during connector pre-assembly.

[0011] In this embodiment, the alignment gap label refers to the marking of the gap and coplanar deviation between the pin reference axis and the positioning hole after the connector is assembled.

[0012] In this embodiment, the coplanar tolerance of the teeth refers to the comprehensive deviation value of the overall coplanar accuracy between the reference axes of all pins of the connector and the assembly positioning holes.

[0013] In this embodiment, the guide adaptation level for insertion and removal of the contact position during connector assembly, determined by the coplanar tolerance of the teeth, specifically includes: The insertion / removal adaptation gradient during connector assembly is determined based on the coplanar tolerance of the teeth. The guide adaptation trajectory of the contact position in the connector assembly is determined based on the insertion and removal adaptation gradient; The guide adaptation level is determined based on the guide adaptation trajectory during the insertion and removal of the contact position in the connector assembly.

[0014] Secondly, this application provides a new energy vehicle connector assembly status identification system for executing a new energy vehicle connector assembly status identification method, the assembly status identification system comprising: The information recognition module is used to identify the pre-assembly posture markings of connectors in the pre-assembly area through the sensor head in the industrial automatic control system; The hole guidance module is used to detect the hole correction data of the pre-installed connector in the connector assembly area in real time, extract the guiding direction command of the main positioning pin of the pre-installed connector on the pre-installed hole from the hole correction data, and then determine the mating verification gradient of the connector during pre-installation by the guiding direction command and the pre-installation posture mark. The assembly judgment module is used to obtain the alignment gap label of the assembly connection part after the new energy vehicle connector is assembled, judge the assembly quality of the alignment gap label, obtain the tooth coplanar tolerance between the connector pin reference axis and the assembly positioning hole, and then determine the guide adaptation level when the contact position is inserted and removed during the connector assembly based on the tooth coplanar tolerance. The assembly identification module is used to identify the assembly status of the new energy vehicle connector based on the mating verification gradient and the guide adaptation level.

[0015] The technical solutions provided by the embodiments disclosed in this application have the following beneficial effects: The system uses a sensor head in an industrial automatic control system to identify the pre-assembly posture markings of the connector in the pre-assembly area; it monitors the hole correction data of the pre-assembled connectors in the connector assembly area in real time, extracts the guiding direction command of the main positioning pin of the pre-assembled connector on the pre-assembly hole from the hole correction data, and then determines the mating verification gradient of the connector during pre-assembly based on the guiding direction command and the pre-assembly posture markings; it obtains the alignment gap label of the assembly connection part of the new energy vehicle connector after assembly, judges the assembly quality of the alignment gap label, obtains the coplanar tolerance of the tooth contact between the connector pin reference axis and the assembly positioning hole, and then determines the guiding adaptation level of the connector during contact position insertion and removal based on the tooth contact coplanar tolerance; and it performs linkage docking identification of the assembly status of the new energy vehicle connector based on the mating verification gradient and the guiding adaptation level.

[0016] Therefore, this application demonstrates that it improves the accuracy of assembly status identification by addressing the shortcomings of existing automotive connector assembly status identification methods, which suffer from single-dimensional detection and a lack of correlation between process and result. Specifically, by using a sensor in an industrial automatic control system to identify the pre-assembly posture of the connector in the pre-assembly area, a unified benchmark is provided for subsequent assembly processes, avoiding cumulative errors caused by initial position deviations. This ensures that all detection and adjustments are based on a reliable initial coordinate system, significantly improving the accuracy of assembly data. By real-time detection of hole correction data, extraction of guiding direction commands, and determination of mating verification gradients, deviations during the mating process can be managed hierarchically, allowing for timely detection and handling of potential problems, preventing component damage caused by forced mating, and improving the safety and controllability of the assembly process. By acquiring alignment gap labels, judging assembly quality, and determining the guide adaptation level, the accuracy level of the assembly result can be clearly defined, providing a basis for connector applications in different components, ensuring the use of high-precision adapter connectors for core components, and enhancing the stability and safety of the entire vehicle operation. By linking and identifying the assembly status based on the interlocking verification gradient and the guide adaptation level, the assembly status can be comprehensively evaluated by integrating process and result data, avoiding the limitations of single-dimensional judgment and achieving accurate evaluation of the assembly status.

[0017] In summary, the technical solution adopted in this application can accurately identify the connector assembly status within a collaborative framework that balances dynamic process adjustment and result accuracy verification, thereby improving the control level of connector assembly quality. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only for this embodiment of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is an exemplary flowchart of a method for identifying the assembly status of a connector in a new energy vehicle, provided in this application. Figure 2 This is a flowchart illustrating the process of determining the guiding direction change instruction provided in this application; Figure 3 This is a flowchart illustrating the process for determining the coplanar tolerance of teeth according to the present application. Figure 4 This is a module structure diagram of a new energy vehicle connector assembly status identification system provided in this application. Detailed Implementation

[0020] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0021] This application provides a system and method for recognizing the assembly status of a new energy vehicle connector. The core of this system is to use a sensor in an industrial automatic control system to identify the pre-assembly posture marker of the connector in the pre-assembly area; to detect in real-time the hole-tracking and correction data of the pre-assembled connector in the connector assembly area, extracting the guiding direction command of the main positioning pin of the pre-assembled connector on the pre-assembly hole position from the hole-tracking and correction data, and then determining the mating verification gradient of the connector during pre-assembly based on the guiding direction command and the pre-assembly posture marker; to obtain the alignment gap label of the assembly connection part of the new energy vehicle connector after assembly, to judge the assembly quality of the alignment gap label, to obtain the coplanar tolerance of the tooth engagement between the connector pin reference axis and the assembly positioning hole, and then determine the guiding adaptation level of the connector during contact position insertion and removal based on the coplanar tolerance; and to perform linkage docking identification of the assembly status of the new energy vehicle connector based on the mating verification gradient and the guiding adaptation level.

[0022] Example 1: To better understand the above technical solution, the following will provide a detailed description of the technical solution in conjunction with the accompanying drawings and specific implementation methods. (Refer to...) Figure 1 As shown in the figure, this is an exemplary flowchart of a method for identifying the assembly status of a connector in a new energy vehicle according to this embodiment of the present application. The method for identifying the assembly status includes the following steps: In step S1, the pre-assembly posture markings of the connector in the pre-assembly area are identified by the sensor head in the industrial automatic control system.

[0023] In practice, three sets of laser sensors for industrial automation systems are mounted on a fixed bracket in the pre-assembly area, arranged in a triangular pattern to cover the entire connector. The sensors emit visible laser light, forming a cross-scanning beam. When the connector is transported to the pre-assembly area and the positioning sensor is triggered, the laser beam illuminates the connector surface, including the positioning pins, side grooves, and the top reference surface. The reflected light is captured by the CMOS receiving module built into the sensor, generating a raw light spot image. The image is processed using an edge detection algorithm to extract the coordinates of the positioning pin center point, the straight line parameters of the groove side, and the tilt angle of the reference surface. These data are compared with preset standard attitude parameters to calculate the positional deviations in the X / Y / Z axes and the rotational deviations around these three axes. These positional deviations, rotational deviations around the three axes, and feature point coordinate data can be used as the pre-assembly attitude markers for the connector in the pre-assembly area.

[0024] It should be noted that, in this application, the pre-assembly posture identifier refers to a set of parameters that reflect the position, rotational deviation, and feature point coordinates of the connector in the pre-assembly area.

[0025] In step S2, the hole inspection and correction data of the pre-installed connector in the connector assembly area is detected in real time. The guiding direction command of the main positioning pin of the pre-installed connector on the pre-installed hole is extracted from the hole inspection and correction data. Then, the mating verification gradient of the connector during pre-installation is determined by the guiding direction command and the pre-installation posture mark.

[0026] In this embodiment, the real-time detection of hole alignment data of pre-assembled connectors in the connector assembly area can be achieved through the following steps: The holes of pre-installed connectors in the connector assembly area are detected in real time to obtain real-time position data of the holes; The deviation type identifier of the pre-installed connector hole position is determined based on the real-time position data; The hole inspection and correction data for pre-installed connectors in the connector assembly area are determined based on the deviation type identifier.

[0027] In practice, firstly, a miniature millimeter-wave radar is installed at the end of the assembly robotic arm. The radar emits 10GHz electromagnetic waves to scan the pre-assembled connector holes. After the electromagnetic waves are reflected by the edge of the hole, they are captured by the radar receiving module, generating a reflected signal. The signal is converted into a digital signal by an analog-to-digital converter and input into a positioning algorithm to calculate the real-time coordinates of the hole's center point on the X, Y, and Z axes. This data can be updated and stored every 0.1 seconds, serving as the real-time position data of the hole. Then, the standard coordinates of the hole are retrieved from the database and compared with the real-time position data to calculate the translational deviation values ​​in the X and Y axes and the rotational deviation values ​​around the Z axis. When the translational deviation exceeds 0.3mm, it is identified as a translational deviation; when the rotational deviation exceeds 1°, it is identified as a rotational deviation; when both exceed the limits, it is identified as a composite deviation. All deviations are integrated as the deviation type identifier for the pre-assembled connector hole. Finally, the corresponding calculation model is called according to the deviation type identifier. For translation deviation, the displacement adjustment of the X and Y axes is generated based on the difference between the real-time coordinates and the standard coordinates; for rotation deviation, the rotation center and rotation radius are calculated based on the rotation angle to generate the angle adjustment value; for compound deviation, the translation is adjusted first and then the rotation is corrected. The displacement adjustment amount, angle adjustment value, adjustment direction, and execution order are integrated into the hole inspection and correction data, which yields the hole inspection and correction data for the pre-installed connectors in the connector assembly area.

[0028] It should be noted that, in this application, real-time position data refers to the dynamic information of the spatial coordinates of the pre-installed connector hole positions within the assembly area; deviation type identification refers to the labeling of the category of deviation of the pre-installed connector hole positions from the standard position; and hole inspection and correction data refers to the specific parameters for adjusting the connector hole positions during connector installation.

[0029] Preferably, in this embodiment, the guiding direction change command of the pre-installed connector main positioning pin on the pre-installed hole position is extracted from the hole inspection and correction data, with reference to... Figure 2 As shown in the figure, this is a flowchart illustrating the process of determining the guiding direction change instruction in some embodiments of this application. In this embodiment, the determination of the guiding direction change instruction can be achieved by the following steps: In step S21, the hole inspection and correction data is parsed, and the current center deviation of the main positioning pin of the pre-assembled connector relative to the pre-assembled hole position is extracted. In step S22, the guiding attribute features required for aligning the main positioning pin with the target hole are determined based on the current center deviation. In step S23, the dynamic guidance description of the pre-installed hole position is determined based on the guidance attribute characteristics; In step S24, the dynamic guidance description is corrected to generate a guidance reversal command for the pre-installed connector main positioning pin on the pre-installed hole.

[0030] In practice, firstly, the real-time center coordinates (X1, Y1, Z1) of the main locating pin and the standard center coordinates (X0, Y0, Z0) of the pre-installed hole position are retrieved from the hole inspection and correction data. The coordinate differences are calculated to obtain the X-axis deviation ΔX = X1 - X0, the Y-axis deviation ΔY = Y1 - Y0, and the Z-axis deviation ΔZ = Z1 - Z0. These three deviations are integrated into the current center deviation, which is the current center deviation of the pre-installed connector's main locating pin relative to the pre-installed hole position. Next, the adjustment direction is determined based on the sign of the current center deviation (e.g., if ΔX is positive, adjustment should be made along the negative X-axis direction); the adjustment range is determined by the absolute value of the deviation (e.g., if ΔX = 0.8mm, the range is 0.8mm); and the adjustment speed is set according to the connector material (5mm / s for metal locating pins, 3mm / s for plastic locating pins). The adjustment direction, adjustment range, and adjustment speed are integrated into the guiding attribute characteristics required for the main locating pin to align with the target hole position. Then, based on the guiding attribute characteristics, the adjustment process is decomposed into single-axis step-by-step movements. For example, first adjust the X-axis direction and amplitude, then perform the Y-axis adjustment, and finally complete the Z-axis adjustment. Label each step with the starting coordinates, ending coordinates, and movement speed, forming a dynamic guidance description text: "Move 0.8mm along the negative X-axis (speed 5mm / s) → Move 0.3mm along the positive Y-axis (speed 5mm / s)". This dynamic guidance description text is used as the dynamic guidance description for the pre-installed hole position. Finally, call the robot arm's motion limit parameters (e.g., maximum acceleration 2mm / s²) to correct the speed changes in the dynamic guidance description, avoiding vibration of the positioning pin caused by sudden stops and starts. Convert the corrected motion sequence into pulse signals recognizable by the robot arm control system (e.g., 1000 pulses per mm), label the execution sequence and trigger conditions, and form an operation command. This operation command is used as the guiding direction command for the main positioning pin of the pre-installed connector on the pre-installed hole position.

[0031] It should be noted that, in this application, the current center deviation refers to the numerical value of the spatial deviation between the center of the pre-installed connector main locating pin and the center of the pre-installed hole; the guiding attribute characteristics refer to the set of attributes of the direction, magnitude, and speed that the main locating pin needs to adjust to align with the target hole; the dynamic guiding description refers to the adjustment process of the main locating pin from its current position to the target hole; and the guiding direction change command refers to the control information that guides the main locating pin to accurately adjust its posture to align with the pre-installed hole.

[0032] In this embodiment, determining the mating verification gradient of the connector during pre-assembly using the guiding direction command and the pre-assembly posture identifier can be achieved through the following steps: The offset component limits of the positioning pin on the horizontal and vertical axes are analyzed based on the guide direction change command. The offset component limit is compared with the allowable tolerance threshold of each axis in the pre-installed attitude identifier to generate an axial difference sequence for each axis. The mating verification gradient during connector pre-assembly is determined by the axial difference sequence.

[0033] In practice, firstly, the motion parameters of the positioning pin are extracted from the guiding direction command, including the maximum adjustment amounts of the horizontal X and Y axes, and the maximum adjustment amount of the vertical Z axis. For example, if the command states "X-axis adjustment range -0.5mm to 0.5mm," then the X-axis offset component limit is 0.5mm. Similarly, the maximum adjustment values ​​of the Y and Z axes are extracted to form the deviation amounts of the three axes. These deviation amounts are used as the offset component limits of the positioning pin in the horizontal and vertical axes. Then, the allowable tolerance thresholds for the X, Y, and Z axes are retrieved from the pre-installed attitude identifiers, for example, an X-axis threshold of 0.6mm, a Y-axis threshold of 0.6mm, and a Z-axis threshold of 0.4mm. Subtract the limit of each axial offset component from its corresponding threshold. For example, X-axis: 0.5mm - 0.6mm = -0.1mm, Y-axis: 0.5mm - 0.6mm = -0.1mm, Z-axis: 0.3mm - 0.4mm = -0.1mm. Arrange these differences in X, Y, and Z axis order, and use the results as the axial difference sequence for each axis. Finally, set the mating gradient judgment rules: when all axial differences are ≥ -0.2mm (i.e., the offset limit does not exceed the threshold by too much), it is level 1; when there are 1 to 2 axial differences < -0.2mm but ≥ -0.5mm, it is level 2; when there is an axial difference < -0.5mm, it is level 3. Compare the axial difference sequence with the rules. If it meets the corresponding level rule, it is determined as the mating verification gradient during connector pre-assembly.

[0034] It should be noted that in this application, the offset component limit refers to the maximum allowable offset of the locating pin on the horizontal and vertical axes; the axial allowable tolerance threshold refers to the set of differences between the offset component limit of each axis and the corresponding axial allowable tolerance threshold in the pre-assembly attitude mark; the axial difference sequence refers to; and the mating verification gradient refers to the level of assembly mating degree verification when the connector is pre-assembled.

[0035] In step S3, the alignment gap label of the assembly connection part of the new energy vehicle connector is obtained after assembly. The assembly quality of the alignment gap label is judged to obtain the coplanar tolerance between the connector pin reference axis and the assembly positioning hole. Then, the guide adaptation level during the insertion and removal of the contact position in the connector assembly is determined by the coplanar tolerance.

[0036] In specific implementation, obtaining the alignment gap label of the assembly connection part after the new energy vehicle connector is assembled can be achieved in the following way: First, after assembly, industrial cameras are installed on both sides of the connection part, and ring LED lights are used as the light source to ensure uniform illumination. The cameras capture high-definition images of the connection part, and the pin reference axis and the edge contour of the positioning hole are extracted by edge detection. The radial gap value and axial coplanar deviation of the two are calculated. The gap value, maximum deviation value and other data of each pin are integrated to generate information containing coordinate position and deviation value. This information is used as the alignment gap label of the assembly connection part after the new energy vehicle connector is assembled. In other embodiments, other methods can also be used to determine the alignment gap label of the assembly connection part after the new energy vehicle connector is assembled. This is not limited here.

[0037] It should be noted that, in this application, the alignment gap label refers to the marking of the gap and coplanar deviation between the pin reference axis and the positioning hole after the connector is assembled.

[0038] Preferably, in this embodiment, the alignment gap label is subjected to assembly quality judgment to obtain the coplanar tolerance of the tooth contact between the connector pin reference axis and the assembly positioning hole, with reference to... Figure 3 As shown in the figure, this is a flowchart illustrating the process of determining the coplanar tolerance of teeth in some embodiments of this application. In this embodiment, the determination of the coplanar tolerance of teeth can be achieved by the following steps: In step S31, the steady-state alignment deviation between each pin of the connector and the corresponding assembly positioning hole in the alignment gap label is obtained; In step S32, the individual tolerance state of each pin of the connector is determined based on the steady-state alignment deviation; In step S33, the elastic tolerance rule for the entire connector pin array is determined based on all individual tolerance states; In step S34, the coplanar tolerance between the connector pin reference axis and the assembly positioning hole is determined according to the elastic tolerance rule.

[0039] In practice, firstly, the coordinate data of each pin and the standard coordinates of the corresponding positioning hole are retrieved from the alignment gap label. A coordinate difference algorithm is then used to calculate the radial (horizontal) and axial (vertical) deviation values ​​for each pin. For example, the differences between the actual coordinates (X3, Y3, Z3) and the standard coordinates (X03, Y03, Z03) of pin 3 are ΔX3=X3-X03, ΔY3=Y3-Y03, and ΔZ3=Z3-Z03. These values ​​are then integrated to form the steady-state alignment deviation of each pin. Next, preset single-item tolerance thresholds (e.g., radial deviation ≤ 0.03 mm, axial deviation ≤ 0.02 mm) are retrieved, and the steady-state alignment deviation of each pin is compared with these thresholds. If all deviations are within the threshold, it is marked as "qualified"; if the radial or axial deviation exceeds the threshold, it is marked as "out of tolerance"; if the deviation is close to the threshold (e.g., 90%–100% of the threshold), it is marked as "critical". Record the marking results for each pin to form the individual tolerance status of each pin in the connector. Then, count the number and distribution of "qualified," "critical," and "out-of-tolerance" pins. If the number of out-of-tolerance pins is ≤5% and concentrated in the non-core area, the rule allows a 0.005mm relaxation in the critical pin deviation; if the number of out-of-tolerance pins is >5% or located in the core area, the rule tightens the critical pin deviation to 90% of the threshold. Integrate the correspondence between these quantity ratios, area restrictions, and deviation adjustment ranges to form the elastic tolerance rule for the entire connector pin array. Finally, according to the elastic tolerance rule, perform a weighted calculation on the axial deviation of each pin (the weight of core pins can be set to 1.2 and the weight of non-core pins to 0.8 based on expert experience and repeated experiments). Take the arithmetic mean of the weighted deviation values. If there are out-of-tolerance pins that are within the rule's allowable range, the out-of-tolerance value is included in the calculation; if it exceeds the rule's range, the maximum deviation value is taken as the result. The final value is the coplanar tolerance between the connector pin reference axis and the assembly positioning hole.

[0040] It should be noted that, in this application, steady-state alignment deviation refers to the positional deviation value formed between each pin of the connector and the corresponding assembly positioning hole after the assembly is stable; single-item tolerance state refers to the judgment result of whether the steady-state alignment deviation of a single pin meets the preset standard; elastic tolerance rule refers to the judgment standard set considering the synergy between pins during connector assembly; and tooth coplanar tolerance refers to the comprehensive deviation value of the overall coplanar accuracy between the reference axis of all pins of the connector and the assembly positioning hole.

[0041] In this embodiment, determining the guide adaptation level during connector assembly and insertion / removal based on the tooth coplanar tolerance can be achieved through the following steps: The insertion / removal adaptation gradient during connector assembly is determined based on the coplanar tolerance of the teeth. The guide adaptation trajectory of the contact position in the connector assembly is determined based on the insertion and removal adaptation gradient; The guide adaptation level is determined based on the guide adaptation trajectory during the insertion and removal of the contact position in the connector assembly.

[0042] In practical implementation, firstly, the coplanar tolerance threshold range for tooth contact can be set according to the machine installation standard manual or expert experience. For example, ≤0.02mm is Level 1 (low difficulty), 0.02~0.05mm is Level 2 (medium difficulty), and >0.05mm is Level 3 (high difficulty). The actual coplanar tolerance value is compared with the threshold. If it falls within the corresponding range, it is marked as the insertion / removal adaptation gradient at the contact position in the corresponding connector assembly. For example, if the measured tolerance is 0.03mm, it is determined to be Level 2. Then, based on the insertion / removal adaptation gradient, a preset trajectory template is called. Level 1 gradient uses a straight trajectory (no offset on X / Y / Z axes) at a speed of 5mm / s; Level 2 gradient uses a curved trajectory with a slight arc (such as ±0.01mm fluctuation on the X axis) at a speed of 3mm / s; Level 3 gradient uses a multi-segment correction trajectory (adjusting the direction every 0.5mm) at a speed of 2mm / s. Considering the connector material, the trajectory arc is reduced by 10% for metal materials and increased by 10% for plastic materials. All straight, curved, and corrected trajectories are used as guide adaptation trajectories for contact positions in connector assembly. Finally, the criteria for determining the guide adaptation level are set: a straight trajectory without correction is Class A (suitable for core high-voltage components); a trajectory with minor curved correction is Class B (suitable for general circuit components); and a trajectory with multi-segment correction is Class C (suitable for low-power auxiliary components). The guide adaptation trajectory is compared with the standard, and the category of characteristics it meets determines the corresponding level, thus obtaining the guide adaptation level for insertion and removal at contact positions in connector assembly.

[0043] It should be noted that in this application, the mating adaptation gradient refers to the graded index of the difficulty of adaptation caused by the coplanar tolerance of the teeth when the connector is mated and removed; the guide adaptation trajectory refers to the installation sequence that guides the connector to be mated and removed accurately and reduces friction caused by tolerance; the guide adaptation level refers to the adaptation level that distinguishes the application scenarios corresponding to different assembly precision to ensure that the connector meets the installation requirements.

[0044] In step S4, the assembly status of the new energy vehicle connector is identified by linkage docking based on the mating verification gradient and the guide adaptation level.

[0045] In specific implementation, the linkage identification of the assembly status of the new energy vehicle connector based on the mating verification gradient and the guide adaptation level can be achieved in the following way: First, obtain the specific parameters of the mating verification gradient and the guide adaptation level, and establish a linkage analysis matrix between the two. The matrix is ​​divided into 1-3 level mating verification gradients horizontally and AC level guide adaptation levels vertically, with each intersection corresponding to a preset assembly status judgment rule. When the mating verification gradient is 1-2 and the guide adaptation level is AB, it is judged as "qualified" and a normal assembly record is generated; if the mating verification gradient is 3, regardless of the guide adaptation level, it is marked as "process abnormal" and the robotic arm calibration process is triggered; if the mating verification gradient is 1-2 but the guide adaptation level is C, it is judged as "initial positioning deviation" and the pre-installed posture identifier is called for re-verification. The judgment result is transmitted to the assembly control system in real time. If qualified, it proceeds to the next process; if abnormal, the corresponding correction program is started, which will not be elaborated here.

[0046] It should be noted that, in this application, the assembly state refers to the degree to which the position and gap of each component after the connector is assembled meet the design requirements; the linkage docking identification refers to the dynamic process of judging the assembly state of the source vehicle connector.

[0047] Therefore, this application demonstrates that it improves the accuracy of assembly status identification by addressing the shortcomings of existing automotive connector assembly status identification methods, which suffer from single-dimensional detection and a lack of correlation between process and result. Specifically, by using a sensor in an industrial automatic control system to identify the pre-assembly posture of the connector in the pre-assembly area, a unified benchmark is provided for subsequent assembly processes, avoiding cumulative errors caused by initial position deviations. This ensures that all detection and adjustments are based on a reliable initial coordinate system, significantly improving the accuracy of assembly data. By real-time detection of hole correction data, extraction of guiding direction commands, and determination of mating verification gradients, deviations during the mating process can be managed hierarchically, allowing for timely detection and handling of potential problems, preventing component damage caused by forced mating, and improving the safety and controllability of the assembly process. By acquiring alignment gap labels, judging assembly quality, and determining the guide adaptation level, the accuracy level of the assembly result can be clearly defined, providing a basis for connector applications in different components, ensuring the use of high-precision adapter connectors for core components, and enhancing the stability and safety of the entire vehicle operation. By linking and identifying the assembly status based on the interlocking verification gradient and the guide adaptation level, the assembly status can be comprehensively evaluated by integrating process and result data, avoiding the limitations of single-dimensional judgment and achieving accurate evaluation of the assembly status.

[0048] In summary, the technical solution adopted in this application can accurately identify the connector assembly status within a collaborative framework that balances dynamic process adjustment and result accuracy verification, thereby improving the control level of connector assembly quality.

[0049] Example 2: This application provides a new energy vehicle connector assembly status identification system, referring to... Figure 4 As shown in the figure, this is a modular structure diagram of a new energy vehicle connector assembly status identification system according to this embodiment of the present application. The assembly status identification system includes: Information recognition module 100 is used to identify the pre-assembly posture mark of the connector in the pre-assembly area through the sensor head in the industrial automatic control system; The hole guidance module 200 is used to detect the hole correction data of the pre-installed connector in the connector assembly area in real time, extract the guiding direction command of the main positioning pin of the pre-installed connector on the pre-installed hole from the hole correction data, and then determine the mating verification gradient of the connector during pre-installation by the guiding direction command and the pre-installation posture mark. The assembly judgment module 300 is used to obtain the alignment gap label of the assembly connection part after the new energy vehicle connector is assembled, to judge the assembly quality of the alignment gap label, to obtain the tooth coplanar tolerance between the connector pin reference axis and the assembly positioning hole, and then to determine the guide adaptation level when the contact position is inserted and removed during the connector assembly based on the tooth coplanar tolerance. The assembly identification module 400 is used to identify the assembly status of the new energy vehicle connector based on the mating verification gradient and the guide adaptation level.

[0050] This application is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of this application. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0051] Those skilled in the art will understand that all or part of the steps in the various methods of the above embodiments can be implemented by a program instructing related hardware. The program can be stored in a computer-readable storage medium, including read-only memory (ROM), random access memory (RAM), programmable read-only memory (PROM), erasable programmable read-only memory (EPROM), one-time programmable read-only memory (OTPROM), electrically-Erasable Programmable Read-Only Memory (EEPROM), compactdisc read-only memory (CD-ROM) or other optical disc storage, disk storage, magnetic tape storage, or any other computer-readable medium capable of carrying or storing data.

[0052] It should also be noted that the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus. Unless otherwise specified, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element.

Claims

1. A method for identifying the assembly status of connectors in new energy vehicles, characterized in that, The assembly status identification method includes the following steps: The pre-assembly posture markings of connectors in the pre-assembly area are identified by sensors in the industrial automatic control system. Real-time detection of hole correction data of pre-installed connectors in the connector assembly area; extraction of guiding direction command of the main positioning pin of the pre-installed connector on the pre-installed hole from the hole correction data; and determination of the mating verification gradient of the connector during pre-installation by the guiding direction command and the pre-installation posture mark. After the new energy vehicle connector is assembled, the alignment gap label of the assembly connection part is obtained, the assembly quality of the alignment gap label is judged, the tooth coplanar tolerance between the connector pin reference axis and the assembly positioning hole is obtained, and then the guide adaptation level when the contact position is inserted and removed in the connector assembly is determined by the tooth coplanar tolerance. The assembly status of the new energy vehicle connector is identified through linkage and docking based on the mating verification gradient and the guiding adaptation level.

2. The method for identifying the assembly status of a connector in a new energy vehicle as described in claim 1, characterized in that, The pre-assembly posture marking refers to the set of parameters including the connector's position, rotational deviation, and feature point coordinates in the pre-assembly area.

3. The method for identifying the assembly status of a connector in a new energy vehicle as described in claim 1, characterized in that, The real-time monitoring data for hole alignment correction of pre-assembled connectors in the connector assembly area specifically includes: The holes of pre-installed connectors in the connector assembly area are detected in real time to obtain real-time position data of the holes; The deviation type identifier of the pre-installed connector hole position is determined based on the real-time position data; The hole inspection and correction data for pre-installed connectors in the connector assembly area are determined based on the deviation type identifier.

4. The method for identifying the assembly status of a connector in a new energy vehicle as described in claim 1, characterized in that, The aforementioned guiding direction command refers to the control information that instructs the main positioning pin to precisely adjust its posture to align with the pre-installed hole.

5. The method for identifying the assembly status of a connector in a new energy vehicle as described in claim 1, characterized in that, Determining the mating verification gradient of the connector during pre-assembly using the guiding direction command and the pre-assembly posture identifier specifically includes: The offset component limits of the positioning pin on the horizontal and vertical axes are analyzed based on the guide direction change command. The offset component limit is compared with the allowable tolerance threshold of each axis in the pre-installed attitude identifier to generate an axial difference sequence for each axis. The mating verification gradient during connector pre-assembly is determined by the axial difference sequence.

6. The method for identifying the assembly status of a connector in a new energy vehicle as described in claim 1, characterized in that, The mating verification gradient refers to the level of assembly mating verification during connector pre-assembly.

7. The method for identifying the assembly status of a connector in a new energy vehicle as described in claim 1, characterized in that, The alignment gap label refers to the marking of the gap and coplanar deviation between the pin reference axis and the positioning hole after the connector is assembled.

8. The method for identifying the assembly status of a connector in a new energy vehicle as described in claim 1, characterized in that, The aforementioned coplanar tolerance refers to the comprehensive deviation value of the overall coplanar accuracy between the reference axes of all connector pins and the assembly positioning holes.

9. The method for identifying the assembly status of a connector in a new energy vehicle as described in claim 1, characterized in that, The guide adaptation level for insertion and removal during connector assembly, determined by the coplanar tolerance of the teeth, specifically includes: The insertion / removal adaptation gradient during connector assembly is determined based on the coplanar tolerance of the teeth. The guide adaptation trajectory of the contact position in the connector assembly is determined based on the insertion and removal adaptation gradient; The guide adaptation level during connector assembly is determined based on the guide adaptation trajectory.

10. A new energy vehicle connector assembly status identification system, used to execute a new energy vehicle connector assembly status identification method as described in any one of claims 1 to 9, characterized in that, The assembly status identification system includes: The information recognition module is used to identify the pre-assembly posture markings of connectors in the pre-assembly area through the sensor head in the industrial automatic control system; The hole guidance module is used to detect the hole correction data of the pre-installed connector in the connector assembly area in real time, extract the guiding direction command of the main positioning pin of the pre-installed connector on the pre-installed hole from the hole correction data, and then determine the mating verification gradient of the connector during pre-installation by the guiding direction command and the pre-installation posture mark. The assembly judgment module is used to obtain the alignment gap label of the assembly connection part after the new energy vehicle connector is assembled, judge the assembly quality of the alignment gap label, obtain the tooth coplanar tolerance between the connector pin reference axis and the assembly positioning hole, and then determine the guide adaptation level when the contact position is inserted and removed during the connector assembly based on the tooth coplanar tolerance. The assembly identification module is used to identify the assembly status of the new energy vehicle connector based on the mating verification gradient and the guide adaptation level.

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