Detection device and method for automobile wire harness

Abstract

The invention discloses a detection device and method for an automobile wire harness, and the device comprises a machine frame, a main transmission shaft and an auxiliary transmission shaft which are symmetrically and rotatably disposed at the left and right sides of the bottom of the machine frame through bearing pedestals, and a lower platen which is fixed in the machine frame above the main transmission shaft and the auxiliary transmission shaft, and the two sides of the top end of the lower platen are fixedly provided with guide rails. A linear top plate and a U-shaped bottom frame are slidably mounted at the upper end and the lower end of the surface of the guide rail correspondingly, and a double-shaft pneumatic adjusting table is mounted at the bottom end of the linear top plate. The lower platen and the double-shaft pneumatic adjusting table are driven by the double-rocker-arm tensioning assembly to be far away from each other, then drawing force is synchronously applied to the fixed male and female connecting ends of the multiple sets of wire harnesses, the tension between the male and female connecting ends is continuously detected by the tension sensor until the connecting plug of the wire harnesses is damaged; compared with the traditional single-station pulling force detection, the automobile wire harness terminal synchronous pulling force detection device has the advantages that the detection efficiency, the accuracy and the synchronism of the automobile wire harness terminal are effectively improved.

Description

Technical Field

[0001] This invention relates to the field of automotive wiring harness testing technology, specifically to a testing device and method for automotive wiring harnesses. Background Technology

[0002] The core of mechanical pull-out force testing for wiring harness terminals in new energy vehicles lies in rigorously verifying the mechanical strength and reliability of the connection point between the terminal and the wire conductor by simulating actual external forces, ensuring that it does not fail throughout the vehicle's entire lifecycle. Its core functions are: preventing loosening or detachment of the connection due to pulling during assembly; resisting the stress caused by continuous vibration, impact, temperature changes, and occasional pulling during vehicle operation; and using a dedicated tensile testing machine. One end clamps firmly hold a specific part of the terminal body, while the other end clamps firmly hold the wire conductor (often requiring partial stripping of the insulation layer). This ensures that the tensile force is strictly applied along the wire's axial direction. The equipment smoothly applies the tensile load at a preset constant rate, continuously recording the tensile force and wire displacement data until the wire conductor is completely pulled out of the terminal crimping cylinder or breaks at the crimping point. The entire test monitors and records the peak tensile force (pull-out force) and the specific failure mode. Finally, the measured pull-out force is compared with the minimum value specified in the standard, and the failure mode is evaluated to determine if it meets the requirements.

[0003] For example, the detection device for wire harness production disclosed in application publication number CN118817465A includes a wire harness detection and repositioning arm assembly. The wire harness detection and repositioning arm assembly has upper wire harness arm assemblies at both its top and bottom. A wire harness clamping arm assembly is mounted on the upper wire harness arm assembly. The wire harness assembly is in a vertically positioned detection structure on the wire harness detection and repositioning arm assembly. The lower wire harness clamping arm assembly is in a self-clamping structure that follows the movement of the wire harness assembly, while the higher wire harness clamping arm assembly is in a self-clamping structure that follows the movement of the wire harness assembly. When the upper wire harness arm assembly performs a high-low repositioning action on the wire harness detection and repositioning arm assembly, a follow-up force-applying structure for wire harness detection is formed on the upper wire harness arm assembly. Through the synchronous occurrence of the clamping structure and the force-applying structure, the detection is achieved... The current testing of wire harness assemblies is limited by the fact that the aforementioned technical solutions primarily target the two connected wire harnesses and terminal connectors. This results in the two wire harnesses experiencing opposing forces after the terminal connectors are connected, essentially a single-station mechanical pull-out force test. This makes multi-station, batch-based synchronous mechanical pull-out force testing difficult because each test requires manual or semi-automatic sample installation, adjustment, and disassembly, leading to a long testing cycle and low efficiency. For the large-scale testing of wire harnesses on new energy vehicle production lines, single-station equipment cannot meet the demands for rapid and efficient testing. Furthermore, it can only test one connection point at a time, and the test results are significantly affected by factors such as operator skill, equipment condition, and sample clamping method, easily leading to large data fluctuations and making it difficult to comprehensively reflect the quality status of the entire batch of products. Summary of the Invention

[0004] The purpose of this invention is to provide a testing device and method for automotive wiring harnesses. Multiple female terminals of the automotive wiring harness to be tested are fixed by a lower chuck on a lower platform. Male terminals of the automotive wiring harness, which are inserted into and correspond one-to-one with the female terminals, are placed below a dual-axis pneumatic adjustment platform and fixed by an upper chuck equipped with a tension sensor. A rotary drive assembly drives the main drive shaft and the auxiliary drive shaft to rotate synchronously in opposite directions. Subsequently, both the main drive shaft and the auxiliary drive shaft drive the double rocker arm tensioning assembly at their respective ends to work. The double rocker arm tensioning assembly causes the lower platform and the dual-axis pneumatic adjustment platform to move away from each other. Then, the multiple fixed sets of male and female terminals of the wiring harness are simultaneously subjected to a pulling force. The tension sensor continuously detects the tension between the male and female terminals until the wiring harness connector is damaged, thereby solving the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a testing device for automotive wiring harnesses, comprising a frame, a main drive shaft and a secondary drive shaft symmetrically rotated and mounted on the left and right sides of the bottom of the frame via bearing seats, and a lower platform fixed inside the frame above the main drive shaft and the secondary drive shaft. Guide rails are fixed on both sides of the top of the lower platform. A straight top plate and a U-shaped bottom frame are slidably mounted on the upper and lower ends of the guide rail surfaces, respectively. A dual-axis pneumatic adjustment platform is mounted on the bottom end of the straight top plate. A plurality of equally spaced tension sensors are mounted on the moving end of the dual-axis pneumatic adjustment platform, and the lower ends of the tension sensors are fixed... The machine frame is equipped with an upper chuck, and a lower chuck with the same number of force sensors is installed at the bottom of the U-shaped base frame. Both ends of the main drive shaft and the auxiliary drive shaft are equipped with double rocker arm tensioning assemblies. The double rocker arm tensioning assemblies are used to drive the U-shaped base frame and the straight top plate on the same side to move away from each other. The bottom of the machine frame is equipped with a rotary drive assembly for driving the main drive shaft and the auxiliary drive shaft to rotate synchronously in opposite directions. A PLC control panel is installed on one outer wall of the machine frame and is electrically connected to the input end of the rotary drive assembly and the dual-axis pneumatic adjustment table. The input end of the PLC control panel is electrically connected to the output end of the force sensors.

[0006] Preferably, T-shaped hollow slide cylinders are fixed at the left and right positions inside the U-shaped bottom frame and the straight top plate, and the U-shaped bottom frame and the straight top plate slide in cooperation with the guide rail through the T-shaped hollow slide cylinders.

[0007] Preferably, the rotary drive assembly includes a first sprocket fixed to one end of the surface of the main drive shaft, a driven gear shaft rotatably mounted on one side of the bottom of the frame, and a second sprocket fixed to one end of the surface of the driven gear shaft. A chain is installed between the second sprocket and the first sprocket. A reversing gear for meshing with the driven gear shaft is also fixed to one end of the surface of the auxiliary drive shaft.

[0008] Preferably, the rotary drive assembly further includes a stepper motor mounted on the outer wall of one side of the frame. The drive shaft of the stepper motor is fixedly connected to one end of the main drive shaft via a coupling. The input end of the stepper motor is electrically connected to the output end of the PLC control panel.

[0009] Preferably, the lower platform, guide rail, U-shaped bottom frame, and straight top plate are all made of stainless steel, and U-shaped notches are provided on the outer walls of the two lower platforms that are close to each other.

[0010] Preferably, the double rocker arm tensioning assembly includes a balance cantilever fixed to both ends of the surface of the main drive shaft, and a long tie rod and a short tie rod respectively hinged to both ends of the balance cantilever.

[0011] Preferably, the upper end of the balance cantilever is hinged to one side of the outer wall of the I-shaped top plate, and the upper end of the short tie rod is hinged to one side of the outer wall of the U-shaped bottom frame.

[0012] Preferably, the dual-axis pneumatic adjustment table includes a U-shaped frame fixed to the top of a straight top plate, a rodless cylinder mounted on the upper surface of the U-shaped frame, a sliding plate mounted on the moving end of the rodless cylinder, a Z-axis cylinder mounted on the top of the sliding plate, and a base platform with the bottom end of the piston rod of the Z-axis cylinder fixed. The tension sensor is fixed on the lower surface of the base platform, and the input ends of the rodless cylinder and the Z-axis cylinder are electrically connected to the output end of the PLC control panel.

[0013] Preferably, horizontal rails are fixed at both the front and rear positions of the top of the U-shaped frame, the slide plate and the horizontal rails are slidably engaged, and an upwardly extending guide rod is fixed at the top of the base, with the upper end of the guide rod passing through the slide plate.

[0014] The present invention also provides a method for detecting automotive wiring harnesses, as described above in the detection device for automotive wiring harnesses, comprising the following steps:

[0015] S101: Place the female terminals of the multiple wire harnesses to be tested sequentially into the lower chuck of the U-shaped base frame, and secure them firmly with the U-shaped base frame to ensure that the female terminals of the wire harnesses are not loose. Insert the male terminals of the corresponding wire harnesses into the female terminals, ensuring that they are fully inserted. By operating the dual-axis pneumatic adjustment table, adjust the position of the upper chuck so that after the upper chuck fixes the male terminals of the wire harnesses, the male and female terminals are axially aligned. Repeat the above steps until the male and female terminals of all stations are inserted and fixed.

[0016] S102: The rotary drive assembly is started via the PLC control panel. The PLC control panel drives the main drive shaft and the auxiliary drive shaft to rotate synchronously in opposite directions. The main drive shaft and the auxiliary drive shaft drive the double rocker arm tensioning assembly at their respective ends to unfold. The double rocker arm tensioning assembly pushes the U-shaped bottom frame with the female end to move downward and drives the double-axis pneumatic adjustment table with the male end to move upward. The two move away from each other synchronously in opposite directions. The male and female ends are subjected to axial pull-out force due to the separation of the fixed ends. The pull-out force is transmitted to the tension sensor. The tension sensor at each station continuously collects the pull-out force value between the male and female ends and transmits it to the PLC control panel in real time.

[0017] S103: When a connector failure is detected at any workstation, i.e., the tensile force drops sharply, indicating that the terminal has come loose or the cable has broken, the PLC control panel immediately stops the rotation drive assembly, thereby stopping the application of force and completing the test. After the test, the operator performs a reset operation through the PLC control panel to restore the U-shaped base frame and the dual-axis pneumatic adjustment table to their initial positions. Then, the upper and lower chucks are released in sequence and the tested wire harness male and female connectors are removed. At this time, the operator needs to inspect the wire harness connection to confirm the damaged part and the form of damage, and record the test results.

[0018] Compared with the prior art, the beneficial effects of the present invention are as follows: The detection device and method for automotive wiring harnesses, through a structure comprising a PLC control panel, a rotary drive assembly, a main drive shaft, a secondary drive shaft, a double rocker arm tensioning assembly, a lower platform, a lower chuck, a straight top plate, and a dual-axis pneumatic adjustment table, etc., cooperate with each other. This allows multiple female terminals of the automotive wiring harnesses to be detected to be fixed by the lower chuck on the lower platform, while the male terminals of the automotive wiring harnesses, which are inserted into the female terminals and correspond one-to-one, are placed below the dual-axis pneumatic adjustment table and fixed by the upper chuck equipped with a tension sensor. The rotary drive assembly then drives the device. The main drive shaft and the auxiliary drive shaft rotate synchronously in opposite directions. Then, the main drive shaft and the auxiliary drive shaft drive the double rocker arm tensioning assembly at their respective ends to work. The double rocker arm tensioning assembly drives the lower platform and the dual-axis pneumatic adjustment platform to move away from each other. Then, multiple sets of fixed wire harness male and female terminals are synchronously pulled out by a pulling force. The tension sensor continuously detects the tension between the male and female terminals until the wire harness connector is damaged. This achieves synchronous mechanical testing of multiple sets of wire harness male and female terminal connectors. Compared with the traditional single-station pulling force test, it effectively improves the testing efficiency, accuracy and synchronization of automotive wire harness terminals.

[0019] The system uses the synchronous reverse rotation of the main and auxiliary drive shafts to drive two double rocker arm tensioning assemblies with a mirror-symmetrical structure. The double rocker arm tensioning assemblies drive the lower platform and the dual-axis pneumatic adjustment platform to move in opposite directions at the same time. This allows multiple sets of male and female connectors fixed on the upper and lower chucks to be subjected to axial pull-out force simultaneously. A single test can complete the destructive testing of multiple connection points, directly solving the efficiency bottleneck and technical problems of "one test per station". In addition, all male and female connectors to be tested are centrally fixed by the chucks, and multiple test points can be covered by clamping once. This avoids the repetitive operation of frequently changing samples in a single station, greatly reduces manual intervention time, and reduces operator fatigue and error rate.

[0020] Secondly, the rigid connection and synchronous reverse rotation mechanism of the main and auxiliary drive shafts ensure that the displacement and speed output of all double rocker arm tensioning assemblies are strictly synchronized. Combined with the positioning capability of the dual-axis pneumatic adjustment table, the initial position of the male end can be precisely adjusted to ensure that the male and female terminals of each group of connectors are strictly aligned axially. This eliminates the test errors caused by asynchronous force application or force skew in multiple stations, ensuring that all test points bear tension at the same time, at the same rate, and along the correct axis, greatly improving data comparability. Finally, the equipped tension sensor can monitor the tension changes between the male and female ends of each group of wire harnesses in real time, providing continuous and accurate force feedback. This helps to accurately determine the moment of failure of the connection point and also enables dynamic monitoring of the testing process, facilitating timely detection of abnormalities and ensuring the effectiveness of the test. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the front cross-sectional structure of the present invention;

[0022] Figure 2 This is a three-dimensional cross-sectional structural diagram of the present invention;

[0023] Figure 3 This is a three-dimensional structural diagram of the present invention;

[0024] Figure 4 This is a side view of the structure of the present invention;

[0025] Figure 5 This is a schematic diagram of the upper and lower isometric isometric solid structure of the present invention;

[0026] Figure 6 This is a schematic diagram of the three-dimensional structure of the rotation drive assembly according to Embodiment 2 of the present invention;

[0027] Figure 7 This is a schematic diagram of the three-dimensional structure of the double rocker arm tensioning assembly according to Embodiment 2 of the present invention;

[0028] Figure 8 This is a three-dimensional structural diagram of the dual-axis pneumatic adjustment table according to Embodiment 3 of the present invention.

[0029] In the diagram: 1. Machine frame; 2. Main drive shaft; 3. Secondary drive shaft; 4. Rotary drive assembly; 401. Stepper motor; 402. First sprocket; 403. Second sprocket; 404. Chain; 405. Driven gear shaft; 406. Reversing gear; 5. Lower platform; 6. Guide rail; 7. U-shaped bottom frame; 8. I-shaped top plate; 9. Dual-axis pneumatic adjustment table; 901. Retractable frame; 902. Horizontal rail; 903. Slide plate; 904. Rodless cylinder; 905. Z-axis cylinder; 906. Base platform; 907. Guide rod; 10. Tension sensor; 11. Upper chuck; 12. Lower chuck; 13. Double rocker arm tensioning assembly; 1301. Balance cantilever; 1302. Long tie rod; 1303. Short tie rod; 14. PLC control panel. Detailed Implementation

[0030] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0031] Example 1, by Figures 1 to 5 The present invention includes a frame 1, a main drive shaft 2 and a secondary drive shaft 3 symmetrically rotated and mounted on the left and right sides of the bottom of the frame 1 via bearing seats, and a lower platform 5 fixed inside the frame 1 above the main drive shaft 2 and the secondary drive shaft 3. Guide rails 6 are fixed on both sides of the top of the lower platform 5. A straight top plate 8 and a U-shaped bottom frame 7 are slidably mounted on the upper and lower ends of the guide rails 6, respectively. A dual-axis pneumatic adjustment table 9 is mounted on the bottom of the straight top plate 8. Several tension sensors 10 with equal spacing are mounted on the moving end of the dual-axis pneumatic adjustment table 9, and an upper chuck 11 is fixed to the lower end of each tension sensor 10. The bottom of the U-shaped bottom frame 7 is... The machine frame 1 is equipped with a lower chuck 12 equal in number to the tension sensor 10. Both ends of the main drive shaft 2 and the auxiliary drive shaft 3 are equipped with a double rocker arm tensioning assembly 13. The double rocker arm tensioning assembly 13 is used to drive the U-shaped bottom frame 7 and the straight top plate 8 on the same side to move away from each other. The bottom of the machine frame 1 is equipped with a rotary drive assembly 4 for driving the main drive shaft 2 and the auxiliary drive shaft 3 to rotate synchronously in opposite directions. A PLC control panel 14 is installed on one outer wall of the machine frame 1 and is electrically connected to the input end of the rotary drive assembly 4 and the dual-axis pneumatic adjustment table 9. The input end of the PLC control panel 14 is electrically connected to the output end of the tension sensor 10.

[0032] Both the upper chuck 11 and the lower chuck 12 can firmly clamp the wire harness connector without damaging the wire harness body. Through precise positioning and stable clamping, the position accuracy and force uniformity of each wire harness during the testing process are guaranteed.

[0033] T-shaped hollow slide cylinders are fixed at the left and right positions inside the U-shaped bottom frame 7 and the straight top plate 8. The U-shaped bottom frame 7 and the straight top plate 8 slide with the guide rail 6 through the T-shaped hollow slide cylinders. The lower platform 5 provides a stable fixed platform and guides the U-shaped bottom frame 7 and the straight top plate 8 to slide in the Z-axis direction through the guide rail 6, ensuring the overall rigidity and stability of the device.

[0034] This embodiment provides a method for detecting automotive wiring harnesses, as described above with the detection device for automotive wiring harnesses, comprising the following steps:

[0035] S101: Place the female terminals of the multiple wire harnesses to be tested sequentially into the lower chuck 12 of the U-shaped base frame 7 and secure them firmly with the U-shaped base frame 7 to ensure that the female terminals of the wire harnesses are not loose. Insert the male terminals of the corresponding wire harnesses into the female terminals to ensure that they are fully inserted. By operating the dual-axis pneumatic adjustment table 9, adjust the position of the upper chuck 11 so that after the upper chuck 11 fixes the male terminals of the wire harnesses, the male and female terminals are axially aligned. Repeat the above steps until the male and female terminals of all stations are inserted and fixed.

[0036] S102: The rotary drive assembly 4 is started to work through the PLC control panel 14. The PLC control panel 14 drives the main drive shaft 2 and the auxiliary drive shaft 3 to rotate synchronously in opposite directions. The main drive shaft 2 and the auxiliary drive shaft 3 drive the double rocker arm tensioning assembly 13 at their respective ends to unfold. The double rocker arm tensioning assembly 13 pushes the U-shaped bottom frame 7 with the female end to move downward and drives the double-axis pneumatic adjustment table 9 with the male end to move upward. The two move away from each other synchronously in opposite directions. The male and female ends are subjected to axial pull-out force due to the separation of the fixed ends. The pull-out force is transmitted to the tension sensor 10. The tension sensor 10 of each station continuously collects the tension value between the male and female ends and transmits it to the PLC control panel 14 in real time.

[0037] S103: When a connector failure is detected at any workstation, i.e., the tensile force drops sharply, indicating that the terminal has come loose or the cable has broken, the PLC control panel 14 immediately stops rotating the drive assembly 4, thereby stopping the application of force and completing the test. After the test, the operator performs a reset operation through the PLC control panel 14 to restore the U-shaped base frame 7 and the dual-axis pneumatic adjustment table 9 to their initial positions. Then, the upper chuck 11 and the lower chuck 12 are released in sequence and the tested wire harness male and female connectors are removed. At this time, the operator needs to inspect the wire harness connection to confirm the damaged part and the damage mode, and record the test results.

[0038] Example 2, based on Example 1, is... Figure 6 and Figure 7The rotary drive assembly 4 includes a first sprocket 402 fixed to one end of the surface of the main drive shaft 2, a driven gear shaft 405 rotatably mounted on one side of the bottom of the frame 1, and a second sprocket 403 fixed to one end of the surface of the driven gear shaft 405. A chain 404 is installed between the second sprocket 403 and the first sprocket 402. A reversing gear 406 for meshing with the driven gear shaft 405 is also fixed to one end of the surface of the auxiliary drive shaft 3. The rotary drive assembly 4 also includes a stepper motor 401 mounted on the outer wall of one side of the frame 1. The drive shaft of the stepper motor 401 is fixedly connected to one end of the main drive shaft 2 via a coupling. The input end of the stepper motor 401 is connected to the PLC control panel 14. With electrical connection at the output end, the operator starts the stepper motor 401 through the PLC control panel 14. The stepper motor 401 drives the main drive shaft 2 to rotate. At this time, the main drive shaft 2 drives the second sprocket 403 and the driven gear shaft 405 to rotate through the first sprocket 402 and the chain 404. Since the driven gear shaft 405 and the reversing gear 406 mesh with each other, the rotational power after reversal is transmitted to the auxiliary drive shaft 3, so that the main drive shaft 2 and the auxiliary drive shaft 3 rotate synchronously and in opposite directions. Thus, the rotation drive assembly 4 ensures that the pull-out force applied during the test is stable and continuous, avoiding unnecessary damage to the wire harness connection caused by the impact force, and improving the repeatability and reliability of the test.

[0039] The lower platform 5, guide rail 6, U-shaped bottom frame 7, and straight top plate 8 are all made of stainless steel. The outer walls of the two lower platform 5 that are close to each other are provided with U-shaped notches. The double rocker arm tensioning assembly 13 includes a balance cantilever 1301 fixed at both ends of the surface of the main drive shaft 2, and a long tie rod 1302 and a short tie rod 1303 respectively hinged at both ends of the balance cantilever 1301.

[0040] The upper end of the balance cantilever 1301 is hinged to one side of the outer wall of the straight top plate 8, and the upper end of the short tie rod 1303 is hinged to one side of the outer wall of the U-shaped bottom frame 7. The double rocker arm tensioning assembly 13 converts the rotational motion into linear displacement, amplifies the output force and keeps the motion trajectory stable, ensuring that the force application process is smooth and controllable, and avoiding errors caused by mechanical imbalance.

[0041] Taking the double rocker arm tensioning assembly 13 at the end of the main drive shaft 2 as an example, the balance cantilever 1301 rotates under the drive of the main drive shaft 2 and is at a certain angle. When the balance cantilever 1301 pushes the straight top plate 8, the dual-axis pneumatic adjustment table 9, the tension sensor 10, and the upper chuck 11 upward through the long tie rod 1302, the other end of the balance cantilever 1301 will drive the U-shaped bottom frame 7 and the lower chuck 12 downward through the short tie rod 1303. At this time, the male and female connectors in the plugging state are subjected to mechanical tension.

[0042] Example 3, based on Example 2, by Figure 8The dual-axis pneumatic adjustment table 9 includes a U-shaped frame 901 fixed to the top of a straight top plate 8, a rodless cylinder 904 mounted on the upper surface of the U-shaped frame 901, a slide plate 903 mounted on the moving end of the rodless cylinder 904, a Z-axis cylinder 905 mounted on the top of the slide plate 903, and a base 906 with the bottom end of the piston rod of the Z-axis cylinder 905 fixed. A tension sensor 10 is fixed on the lower surface of the base 906. The input ends of the rodless cylinder 904 and the Z-axis cylinder 905 are electrically connected to the output end of the PLC control panel 14. Horizontal rails 902 are fixed at the front and rear positions of the top of the U-shaped frame 901. The slide plate 903 and the horizontal rails 902 slide in cooperation. An upwardly extending guide rod 907 is fixed to the top of the base 906. The upper end of the guide rod 907 passes through the slide plate 903.

[0043] When adjusting the tension sensor 10, upper chuck 11, and wire harness male connector using the dual-axis pneumatic adjustment table 9, the operator controls the rodless cylinder 904 via the PLC control panel 14. The rodless cylinder 904 drives the Z-axis cylinder 905, slide plate 903, base platform 906, tension sensor 10, and upper chuck 11 to move in the axial extension direction of the horizontal rail 902, thereby changing the position of the tension sensor 10 and upper chuck 11 so that the male and female connectors of the wire harness can remain aligned.

[0044] The Z-axis cylinder 905 drives the base 906, guide rod 907, tension sensor 10, and upper chuck 11 to lift and lower the Z-axis, so as to ensure that the male terminal fixed on the upper chuck 11 can be connected to the female terminal, and to meet the needs of wire harness connectors of different specifications and models.

[0045] In this embodiment of the application, the main power supply of the device is first connected, the PLC control panel 14 is started, the detection action is initialized, the pressure of the pneumatic circuit connected to the dual-axis pneumatic adjustment table 9 is checked to see if it is normal, and it is confirmed that the rotary drive assembly 4 and the dual-axis pneumatic adjustment table 9 are in the standby position. Then, the male and female connectors of the wire harness to be tested are prepared, ensuring that they meet the testing requirements and performing a visual inspection to eliminate obvious damage or defects. The multiple female connectors of the wire harness to be tested are placed in the lower chuck 12 of the U-shaped base frame 7 in sequence, and the U-shaped base frame 7 is used to secure them. Secure the female connector of the wire harness to ensure it is not loose. Insert the male connector of the corresponding wire harness into the female connector, ensuring it is fully inserted. Use the dual-axis pneumatic adjustment table 9 to adjust the position of the upper chuck 11, so that the male and female terminals are axially aligned after the male connector of the wire harness is secured. Repeat the above steps until the male and female connectors of all stations are successfully inserted and secured. Start the rotary drive assembly 4 through the PLC control panel 14, which drives the main drive shaft 2 and the auxiliary drive shaft 3 synchronously. Reverse rotation causes the main drive shaft 2 and auxiliary drive shaft 3 to unfold the double rocker arm tensioning assembly 13 at their respective ends. The double rocker arm tensioning assembly 13 pushes the U-shaped base frame 7 with the female connector downward and drives the dual-axis pneumatic adjustment table 9 with the male connector upward. The two move away from each other synchronously in opposite directions. The male and female connectors are subjected to axial tensile force due to the separation of the fixed ends. The tension is transmitted to the tension sensor 10. The tension sensor 10 at each station continuously collects the tension value between the male and female ends and transmits it to the PLC control panel 14 in real time. When any station detects a joint failure, i.e. When the tensile force drops precipitously, indicating that the terminal has come loose or the cable has broken, the PLC control panel 14 immediately stops rotating the drive assembly 4, thereby stopping the application of force and completing the test. After the test, the operator performs a reset operation through the PLC control panel 14 to restore the U-shaped base frame 7 and the dual-axis pneumatic adjustment table 9 to their initial positions. Then, the upper chuck 11 and the lower chuck 12 are released in sequence, and the tested wire harness male and female connectors are removed. At this time, the operator needs to inspect the wire harness connection points to confirm the damaged parts and the form of damage, and record the test results.

[0046] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, 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.

[0047] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art 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 appended claims and their equivalents.

Claims

1. A testing device for automotive wiring harnesses, characterized in that: The system includes a frame (1), a main drive shaft (2) and a secondary drive shaft (3) symmetrically rotated and mounted on the left and right sides of the bottom of the frame (1) via bearing seats, and a lower platform (5) fixed inside the frame (1) above the main drive shaft (2) and the secondary drive shaft (3). Guide rails (6) are fixed on both sides of the top of the lower platform (5). A straight top plate (8) and a U-shaped bottom frame (7) are slidably mounted on the upper and lower ends of the surface of the guide rails (6). A dual-axis pneumatic adjustment table (9) is installed at the bottom of the straight top plate (8). Several tension sensors (10) with equal spacing are installed on the moving end of the dual-axis pneumatic adjustment table (9), and an upper chuck (11) is fixed at the lower end of the tension sensor (10). The bottom of the U-shaped bottom frame (7) is equipped with a... The machine frame (1) is equipped with a lower chuck (12) equal in number to the tension sensor (10). Both ends of the main drive shaft (2) and the auxiliary drive shaft (3) are equipped with a double rocker arm tensioning assembly (13). The double rocker arm tensioning assembly (13) is used to drive the U-shaped bottom frame (7) and the straight top plate (8) on the same side to move away from each other. The bottom of the machine frame (1) is equipped with a rotary drive assembly (4) for driving the main drive shaft (2) and the auxiliary drive shaft (3) to rotate synchronously in opposite directions. A PLC control panel (14) is installed on one outer wall of the machine frame (1) and is electrically connected to the input end of the rotary drive assembly (4) and the dual-axis pneumatic adjustment table (9). The input end of the PLC control panel (14) is electrically connected to the output end of the tension sensor (10).

2. The detection device for automotive wiring harnesses according to claim 1, characterized in that: T-shaped hollow slide tubes are fixed at the left and right positions inside the U-shaped bottom frame (7) and the straight top plate (8). The U-shaped bottom frame (7) and the straight top plate (8) slide in cooperation with the guide rail (6) through the T-shaped hollow slide tubes.

3. The detection device for automotive wiring harnesses according to claim 1, characterized in that: The rotary drive assembly (4) includes a first sprocket (402) fixed to one end of the surface of the main drive shaft (2), a driven gear shaft (405) rotatably mounted on one side of the bottom of the frame (1), and a second sprocket (403) fixed to one end of the surface of the driven gear shaft (405). A chain (404) is installed between the second sprocket (403) and the first sprocket (402). One end of the surface of the auxiliary drive shaft (3) is also fixed with a reversing gear (406) for meshing with the driven gear shaft (405).

4. The detection device for automotive wiring harnesses according to claim 3, characterized in that: The rotary drive assembly (4) also includes a stepper motor (401) mounted on the outer wall of one side of the frame (1). The drive shaft of the stepper motor (401) is fixedly connected to one end of the main drive shaft (2) via a coupling. The input end of the stepper motor (401) is electrically connected to the output end of the PLC control panel (14).

5. The detection device for automotive wiring harnesses according to claim 2, characterized in that: The lower platform (5), guide rail (6), U-shaped bottom frame (7), and straight top plate (8) are all made of stainless steel. U-shaped notches are provided on the outer walls of the two lower platforms (5) that are close to each other.

6. The detection device for automotive wiring harnesses according to claim 3, characterized in that: The double rocker arm tensioning assembly (13) includes a balance cantilever (1301) fixed at both ends of the surface of the main drive shaft (2) and a long tie rod (1302) and a short tie rod (1303) respectively hinged at both ends of the balance cantilever (1301).

7. The detection device for automotive wiring harnesses according to claim 6, characterized in that: The upper end of the balance cantilever (1301) is hinged to one side of the outer wall of the straight top plate (8), and the upper end of the short tie rod (1303) is hinged to one side of the outer wall of the U-shaped bottom frame (7).

8. The detection device for automotive wiring harnesses according to claim 7, characterized in that: The dual-axis pneumatic adjustment table (9) includes a U-shaped frame (901) fixed to the top of the straight top plate (8), a rodless cylinder (904) mounted on the upper surface of the U-shaped frame (901), a sliding plate (903) mounted on the moving end of the rodless cylinder (904), a Z-axis cylinder (905) mounted on the top of the sliding plate (903), and a base (906) with the bottom end of the piston rod of the Z-axis cylinder (905) fixed. The tension sensor (10) is fixed on the lower surface of the base (906). The input ends of the rodless cylinder (904) and the Z-axis cylinder (905) are electrically connected to the output end of the PLC control panel (14).

9. A testing device for automotive wiring harnesses according to claim 8, characterized in that: The top of the spiral frame (901) is fixed with horizontal rails (902) at both the front and rear positions. The slide plate (903) and the horizontal rails (902) are slidably engaged. The top of the base (906) is fixed with an upwardly extending guide rod (907), the upper end of which passes through the slide plate (903).

10. A method for detecting automotive wiring harnesses, comprising the detection device for automotive wiring harnesses as described in any one of claims 1-9, characterized in that: Includes the following steps: S101: Place the female terminals of the multiple wire harnesses to be tested in the lower chuck (12) of the U-shaped bottom frame (7) in sequence, and fix them firmly by the U-shaped bottom frame (7) to ensure that the female terminals of the wire harnesses are not loose. Insert the male terminals of the corresponding wire harnesses into the female terminals to ensure that they are fully inserted. By operating the dual-axis pneumatic adjustment table (9), adjust the position of the upper chuck (11) so that after the upper chuck (11) fixes the male terminals of the wire harnesses, the male and female terminals are axially aligned. Repeat the above steps until the male and female terminals of all stations are inserted and fixed. S102: The rotary drive assembly (4) is turned on by the PLC control panel (14) to start working. The main drive shaft (2) and the auxiliary drive shaft (3) are driven to rotate synchronously in opposite directions by the PLC control panel (14). The main drive shaft (2) and the auxiliary drive shaft (3) drive the double rocker arm tensioning assembly (13) at their respective ends to unfold. The double rocker arm tensioning assembly (13) pushes the U-shaped bottom frame (7) with the female end to move downward and drives the double-axis pneumatic adjustment table (9) with the male end to move upward. The two move away from each other synchronously in opposite directions. The male and female ends are subjected to axial pull force due to the separation of the fixed ends. The pull force is transmitted to the tension sensor (10). The tension sensor (10) of each station continuously collects the tension value between the male and female ends and transmits it to the PLC control panel (14) in real time. S103: When a joint failure is detected at any workstation, i.e. the tensile value drops sharply, indicating that the terminal is detached or the cable is broken, the PLC control panel (14) immediately stops the rotation drive assembly (4) to stop applying force and complete the test. After the test, the staff performs a reset operation through the PLC control panel (14) to restore the U-shaped bottom frame (7) and the dual-axis pneumatic adjustment table (9) to their initial positions. Then, the upper chuck (11) and the lower chuck (12) are released in sequence and the tested wire harness male and female connectors are taken out. At this time, the staff needs to check the wire harness connection to confirm the damaged part and the damaged form, and record the test results.

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