High-voltage wiring harness test system and control method thereof

Abstract

According to the high-voltage wiring harness testing system and the control method thereof, the high-voltage wiring harness testing system integrates the mechanical strength testing unit, the environment testing unit and the electrical performance testing unit, vibration, high-low temperature and strong current can be applied at the same time, electric, thermal and mechanical vibration multi-physical field coupling is achieved, and the testing efficiency is improved. The test units are synchronously controlled by the central control system, so that the actual influence of a multi-scene superposition factor on the wire harness can be simulated; a sensor network in the system collects vibration test data, temperature test data, current test data and insulation performance data in real time and transmits the data to a central control system, and the central control system analyzes the performance of a to-be-tested high-voltage wire harness under the current test working condition by using the test data and then generates a test report. Therefore, the accuracy of the test result and the test efficiency are effectively improved.

Description

Technical Field

[0001] This application relates to the field of wire harness testing technology, and more specifically, to a high-voltage wire harness testing system and its control method. Background Technology

[0002] High-voltage wiring harnesses are a critical component of electric vehicle powertrain systems, and their safety and reliability directly impact the overall vehicle performance and safety. High-voltage wiring harness testing comprehensively assesses their performance under various operating conditions, including electrical performance, mechanical strength, and environmental adaptability, ensuring safe and stable operation in real-world use. Currently, OTS (Off-Tool Sample) testing of high-voltage wiring harnesses commonly employs a segmented, independent testing approach. However, in actual vehicle operation, electrical, thermal, and mechanical vibrations act simultaneously, and segmented, independent testing cannot reproduce the field coupling effects of these multiple physical fields, potentially leading to lower accuracy in test results. Summary of the Invention

[0003] The purpose of this application is to provide a high-voltage wiring harness testing system and its control method, which aims to solve the problem that the high-voltage wiring harness testing methods in the related technology cannot reproduce the field coupling effect of multi-physics fields, which easily leads to low accuracy of test results.

[0004] In a first aspect, this application provides a high-voltage wiring harness testing system, comprising: testing equipment, a sensor network, and a central control system; wherein: the testing equipment includes a mechanical strength testing unit, an environmental testing unit, and an electrical performance testing unit; the mechanical strength testing unit is used to simulate the mechanical vibration of the high-voltage wiring harness under test in a real vehicle; the environmental testing unit is used to simulate a specified temperature environment; the electrical performance testing unit is used to simulate a current environment; the sensor network is used to collect test data of the high-voltage wiring harness under test; the test data includes vibration test data, temperature test data, current test data, and insulation performance data; the central control system is used to synchronously control each unit of the testing equipment during the testing of the high-voltage wiring harness under test, and to receive the test data collected by the sensor network, and then use the test data to generate a test report.

[0005] In the above implementation process, a high-voltage wiring harness testing system integrating multi-physics field coupling of electrical, thermal, and mechanical vibration is provided. This system integrates mechanical strength testing units, environmental testing units, and electrical performance testing units, and is synchronously controlled by a central control system to simulate the actual impact of multiple overlapping factors on the wiring harness. During testing of the high-voltage wiring harness under test, the system's sensor network collects vibration test data, temperature test data, current test data, and insulation performance data in real time and transmits them to the central control system. The central control system uses this test data to analyze the performance of the high-voltage wiring harness under test under the current test conditions and then generates a test report. This effectively improves the accuracy and efficiency of the test results.

[0006] Furthermore, in some examples, the mechanical strength testing unit includes an electromagnetic vibration table; the environmental testing unit includes a temperature and humidity control box; the electrical performance testing unit includes a controllable DC power supply; the sensor network includes distributed sensors and a partial discharge probe; the distributed sensors are used to detect the actual amplitude, vibration frequency, temperature, and current values ​​of the high-voltage line harness under test; and the partial discharge probe is used to detect insulation defects in the high-voltage line harness under test.

[0007] In the above implementation process, a specific implementation method for test equipment and sensor network is provided.

[0008] Furthermore, in some examples, the central control system is used to: acquire the target test parameters for the high-voltage harness under test; process the target test parameters using a Bayesian optimization algorithm to generate an initial test parameter combination; input the initial test parameter combination into the test equipment; the initial test parameter combination includes initial amplitude, initial vibration frequency, initial temperature, and initial current; the Bayesian optimization algorithm predicts the lifespan of the high-voltage harness under test under different test parameter combination conditions based on historical test data, and generates the initial test parameter combination based on the prediction results.

[0009] In the above implementation process, a Bayesian optimization algorithm is used to generate test plans. Based on historical test data, the algorithm predicts the lifespan of the tested wiring harness under different combinations of test parameters, thereby selecting the parameter combination most likely to detect problems. This effectively improves testing efficiency.

[0010] Furthermore, in some examples, the central control system is also used to: optimize the initial test parameter combination based on the test data using a model predictive controller to obtain an optimized test parameter combination, and input the optimized test parameter combination into the test equipment.

[0011] In the above implementation process, based on the test data collected in real time by the sensor network, the test parameters are dynamically adjusted by the MPC controller to ensure that the test conditions conform to the evolution law of the real scene.

[0012] Furthermore, in some examples, the central control system is also used to: determine whether the high-voltage harness under test is abnormal based on the test data and a preset threshold; if the determination result is yes, identify the type of the abnormality; when the high-voltage harness under test has a non-destructive abnormality, control the test equipment to operate at a reduced derating rate; when the high-voltage harness under test has a destructive abnormality, send an emergency shutdown command to the test equipment.

[0013] In the above implementation process, a safety protection mechanism is provided: in the event of a minor anomaly, the equipment operates at a reduced capacity, allowing testing to continue to collect more failure evolution data; in the event of a serious anomaly, the equipment shuts down immediately, interrupting the testing. This improves both testing efficiency and safety.

[0014] Furthermore, in some examples, the central control system is also used to: when an abnormality is detected in the high-voltage harness under test, perform spatiotemporal alignment of the test data at the time of the abnormality, calculate the contribution of vibration test data, temperature test data and current test data to the abnormality respectively, and analyze the root cause of the fault based on the calculation results.

[0015] The above implementation process enables automated analysis of the root causes of failures, improving efficiency and accuracy.

[0016] Furthermore, in some examples, the central control system includes a three-dimensional visualization display unit; the three-dimensional visualization display unit is used to monitor the failure area of ​​the high-voltage harness under test through three-dimensional visualization analysis technology; the central control system is also used to generate design optimization suggestions in the test report based on the root cause of the fault and the monitoring results of the three-dimensional visualization display unit.

[0017] In the above implementation process, the software analysis layer of the central control system provides 3D visualization for monitoring the failure area of ​​the wiring harness. In this way, combined with the root cause analysis results, design optimization suggestions can be generated, thereby reducing the cost of manual analysis and promoting product quality improvement.

[0018] Secondly, this application provides a control method for a high-voltage wire harness testing system, the high-voltage wire harness testing system including the high-voltage wire harness testing system as described in any of the first aspects; the method is applied to the central control system of the high-voltage wire harness testing system; the method includes: acquiring test target parameters for the high-voltage wire harness to be tested, processing the test target parameters using a Bayesian optimization algorithm to generate an initial test parameter combination; the Bayesian optimization algorithm predicts the lifespan of the high-voltage wire harness to be tested under different test parameter combination conditions based on historical test data, and generates the initial test parameter combination according to the prediction result; inputting the initial test parameter combination into the testing equipment; the initial test parameter combination includes initial amplitude, initial vibration frequency, initial temperature, and initial current; receiving test data collected by the sensor network, and then using the test data to generate a test report.

[0019] Furthermore, in some examples, the method further includes: optimizing the initial test parameter combination based on the test data using a model prediction controller to obtain an optimized test parameter combination; and inputting the optimized test parameter combination into the test device.

[0020] Furthermore, in some examples, the method further includes: determining whether the high-voltage harness under test is abnormal based on the test data and a preset threshold; if the determination result is yes, identifying the type of the abnormality; when the high-voltage harness under test exhibits a non-destructive abnormality, controlling the test equipment to operate at a reduced derating rate; when the high-voltage harness under test exhibits a destructive abnormality, sending an emergency shutdown command to the test equipment.

[0021] Furthermore, in some examples, the method further includes: when an anomaly is detected in the high-voltage harness under test, performing spatiotemporal alignment of the test data at the time of the anomaly; calculating the contribution of vibration test data, temperature test data, and current test data to the anomaly; and analyzing the root cause of the fault based on the calculation results.

[0022] Furthermore, in some examples, the method also includes: monitoring the failure area of ​​the high-voltage harness under test using three-dimensional visualization analysis technology; and generating design optimization suggestions in the test report based on the root cause of the failure and the monitoring results.

[0023] Thirdly, this application provides a control device for a high-voltage wire harness testing system, the high-voltage wire harness testing system including the high-voltage wire harness testing system as described in any of the first aspects; the device is applied to the central control system of the high-voltage wire harness testing system; the device includes: an acquisition module, used to acquire test target parameters for the high-voltage wire harness under test, process the test target parameters using a Bayesian optimization algorithm, and generate an initial test parameter combination; the Bayesian optimization algorithm predicts the lifespan of the high-voltage wire harness under test under different test parameter combination conditions based on historical test data, and generates the initial test parameter combination according to the prediction result; an input module, used to input the initial test parameter combination into the testing equipment; the initial test parameter combination includes initial amplitude, initial vibration frequency, initial temperature, and initial current; and a generation module, used to receive test data collected by the sensor network, and then use the test data to generate a test report.

[0024] Fourthly, this application provides an electronic device comprising: a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor, when executing the computer program, implements the steps of the method as described in any of the second aspects.

[0025] Fifthly, this application provides a computer-readable storage medium storing instructions that, when executed on a computer, cause the computer to perform the method as described in any of the second aspects.

[0026] Sixthly, this application provides a computer program product that, when run on a computer, causes the computer to perform the method described in any of the second aspects.

[0027] Other features and advantages disclosed in this application will be set forth in the following description, or some features and advantages may be inferred from the description or determined without doubt, or may be learned by practicing the above-described technology disclosed in this application.

[0028] To make the above-mentioned objectives, features and advantages of this application more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0029] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments of this application will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0030] Figure 1 A schematic diagram of a high-voltage wiring harness testing system provided in an embodiment of this application; Figure 2 A schematic diagram of the architecture of a multi-physics coupling integrated testing system for high-voltage wiring harnesses provided in this application embodiment; Figure 3 A schematic diagram illustrating the workflow of the central control system in a multi-physics coupling integrated testing system for high-voltage wiring harnesses provided in this application embodiment during the testing process; Figure 4 A flowchart illustrating a control method for a high-voltage wiring harness testing system provided in this application embodiment; Figure 5 A block diagram of a control device for a high-voltage wire harness testing system provided in this application embodiment; Figure 6 This is a structural block diagram of an electronic device provided in an embodiment of this application. Detailed Implementation

[0031] The technical solutions in the embodiments of this application will now be described with reference to the accompanying drawings.

[0032] It should be noted that similar reference numerals and letters in the following figures indicate similar items; therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures. Furthermore, in the description of this application, terms such as "first," "second," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0033] High-voltage wiring harnesses are key components in new energy vehicles used for transmitting high-voltage electrical energy. They typically consist of multiple conductors or cables, bound and protected by insulating materials. The safety and reliability of high-voltage wiring harnesses directly affect the performance and safety of the entire vehicle; therefore, they must be tested before installation. High-voltage wiring harness testing comprehensively examines their performance under various operating conditions, including electrical performance, mechanical strength, and environmental adaptability, ensuring safe and stable operation in actual use.

[0034] Currently, OST testing of high-voltage wiring harnesses generally adopts a separate, independent testing mode. For example, when conducting environmental tests on the OTS of high-voltage wiring harnesses, only static temperature is simulated in high and low temperature chambers, without considering the dynamic temperature rise caused by changes in current load. When conducting mechanical strength tests on the OTS of high-voltage wiring harnesses, an electromagnetic vibration table is used to apply mechanical vibration alone, without simultaneously applying current and temperature stress. When conducting electrical performance tests on the OTS of high-voltage wiring harnesses, parameters such as insulation resistance and contact resistance are measured at room temperature, ignoring the long-term effects of temperature, vibration, and other multi-scenario coupling on electrical performance. In actual vehicle operation, electrical, thermal, and mechanical vibration physical fields act simultaneously, and separate, independent testing cannot reproduce the field coupling effect of multiple physical fields, which can easily lead to erroneous test results, such as underestimating the aging rate of wiring harness insulation and failing to detect intermittent contact problems caused by connector fretting wear.

[0035] To address the aforementioned issues, this application provides a high-voltage wiring harness testing system. This system integrates mechanical strength testing units, environmental testing units, and electrical performance testing units. A central control system synchronously controls these units to simulate the actual impact of multiple overlapping factors on the wiring harness. During testing of the high-voltage wiring harness, the central control system receives test data collected by a sensor network and uses this data to generate a test report. This effectively improves the accuracy and efficiency of the test results.

[0036] The embodiments of this application will be described below: like Figure 1 As shown, Figure 1 This is a schematic diagram of a high-voltage wiring harness testing system provided in an embodiment of this application. The high-voltage wiring harness testing system includes a testing device 11, a sensor network 12, and a central control system 13; wherein: the testing device 11 includes a mechanical strength testing unit 111, an environmental testing unit 112, and an electrical performance testing unit 113; the mechanical strength testing unit 111 is used to simulate the mechanical vibration of the high-voltage wiring harness 14 under test in a real vehicle; the environmental testing unit 112 is used to simulate a specified temperature environment; the electrical performance testing unit 113 is used to simulate a current environment; the sensor network 12 is used to collect test data of the high-voltage wiring harness 14 under test; the test data includes vibration test data, temperature test data, current test data, and insulation performance data; the central control system 13 is used to synchronously control each unit of the testing device 11 during the testing of the high-voltage wiring harness 14 under test, and to receive the test data collected by the sensor network 12, and then use the test data to generate a test report.

[0037] The aforementioned high-voltage wiring harness testing system is a comprehensive testing system integrating multi-physics field coupling of electrical, thermal, and mechanical vibration. Optionally, the mechanical strength testing unit may include an electromagnetic vibration table; the environmental testing unit may include a temperature and humidity control box; and the electrical performance testing unit may include a controllable DC power supply. The electromagnetic vibration table can simulate the vibration environment during vehicle operation, testing the mechanical strength performance of the high-voltage wiring harness through vibrations of different frequencies and amplitudes; the temperature and humidity control box can adjust the temperature and humidity of the testing environment, simulating the working state of the high-voltage wiring harness under different temperature and humidity conditions; and the controllable DC power supply can provide a stable current input to the high-voltage wiring harness, thereby testing its electrical characteristics under different load conditions.

[0038] In this embodiment, the high-voltage harness under test (OT) mentioned can refer to the OST of the high-voltage harness to be tested. During testing, the OT is placed in the testing equipment, and the central control system synchronously controls each unit of the testing equipment. At this time, the mechanical strength testing unit, environmental testing unit, and electrical performance testing unit are simultaneously loaded, and vibration, high and low temperatures, and strong current are applied simultaneously to simulate the actual impact of multiple superimposed factors on the harness. For example, the central control system can send instructions to each unit of the testing equipment to control the temperature and humidity control box to provide a -30°C environment, synchronously start the electromagnetic vibration table to simulate engine idling vibration, and control the controllable DC power supply to output a 300A current, thereby simulating the high-voltage system startup condition of an electric vehicle in an extremely cold environment of -30°C.

[0039] The sensor network in this high-voltage line harness testing system is responsible for real-time acquisition of vibration, temperature, current, and insulation performance data of the high-voltage line harness under test during the testing process. In some embodiments, the sensor network may include distributed sensors and partial discharge probes; the distributed sensors are used to detect the actual amplitude, vibration frequency, temperature, and current values ​​of the high-voltage line harness under test; the partial discharge probes are used to detect insulation defects in the high-voltage line harness under test. Here, the partial discharge probe is a sensor device that can detect the insulation status of electrical equipment based on the electromagnetic waves, ultrasonic waves, or ultra-high frequency signals generated by partial discharge, and promptly detect latent faults. The sensor network communicates with the central control system via wired or wireless connections. The sensor network transmits the real-time acquired test data to the central control system, which analyzes the test data to determine the performance of the high-voltage line harness under test under the current test conditions, and then generates a test report for analysis by the testing personnel. In implementation, the installation positions of these distributed sensors and partial discharge probes can be set according to the test location of the high-voltage line harness under test.

[0040] In some embodiments, the central control system can be used to: acquire test target parameters for the high-voltage line harness under test; process the test target parameters using a Bayesian optimization algorithm to generate an initial test parameter combination; input the initial test parameter combination into the test equipment; the initial test parameter combination includes initial amplitude, initial vibration frequency, initial temperature, and initial current; the Bayesian optimization algorithm predicts the lifespan of the high-voltage line harness under test under different test parameter combination conditions based on historical test data, and generates the initial test parameter combination based on the prediction results. In other words, the central control system can use a Bayesian optimization algorithm to generate a test plan. Bayesian optimization is a sequential optimization method based on a probabilistic model, specifically designed for the global optimization of black-box functions. Its core idea is to construct a probabilistic model of the objective function and use this model to guide the next evaluation point, finding the global optimum with as few samples as possible. The aforementioned test target parameters indicate the purpose of this test. In implementation, the Bayesian optimization algorithm constructs a probabilistic model based on historical test data to predict the impact of different combinations of test parameters on the test results. It then selects the parameter combination most likely to reveal the problem as the initial test parameter combination, i.e., the test plan. For example, when the test objective is to verify the current-carrying capacity of a wiring harness at -30℃, the Bayesian optimization algorithm uses models such as Gaussian processes to predict the impact of different combinations of test parameters (including amplitude, vibration frequency, temperature, and current) on the test results (such as the failure probability of the wiring harness) based on historical test data. It then uses the prediction results for optimization iteration, ultimately selecting the parameter combination most likely to expose the problem as the test plan, such as an initial amplitude of 5mm, an initial vibration frequency of 50Hz, an initial temperature of -30℃, and an initial current of 300A. After generating the test plan, the central control system inputs it to the testing equipment, causing the equipment to execute the test according to the plan. Specifically, the temperature and humidity control chamber is cooled to -30℃, the electromagnetic vibration table simulates engine idling vibration, and a controllable DC power supply applies a 300A pulse current. This effectively improves testing efficiency.

[0041] Furthermore, in some embodiments, the central control system can also be used to: optimize the initial test parameter combination based on the test data using a model predictive controller to obtain an optimized test parameter combination, and input the optimized test parameter combination into the test equipment. That is, during the testing process, the central control system can utilize an MPC (Model Predictive Control) controller for parameter optimization. MPC is an optimization control algorithm based on a mathematical model. It predicts future system behavior and solves for the optimal control strategy through a dynamic model. In implementation, the MPC controller establishes a mathematical model by integrating the coupling relationship between temperature, vibration, and current, and uses this mathematical model combined with real-time data from the sensor network to predict future states. Then, it determines the optimal control sequence through optimization algorithms, such as quadratic programming, thereby dynamically adjusting the test parameters to ensure that the test conditions conform to the evolution law of the real scenario. Optionally, the mathematical model established by the model predictive controller may include a dynamic resistance model and a temperature field model; the dynamic resistance model describes the change in contact resistance of the high-voltage harness under test due to vibration; the temperature field model describes the temperature change of the high-voltage harness under test due to Joule heating, convection heat dissipation, and vibration frictional heat generation.

[0042] In some embodiments, the central control system can also be used to: determine whether the high-voltage harness under test is abnormal based on the test data and a preset threshold; if the determination result is yes, identify the type of the abnormality; when the high-voltage harness under test exhibits a non-destructive abnormality, control the testing equipment to operate at a reduced derating rate; when the high-voltage harness under test exhibits a destructive abnormality, send an emergency shutdown command to the testing equipment. In other words, the central control system can provide a safety protection mechanism. Based on test data collected in real time by the sensor network and combined with a preset threshold, it determines whether the high-voltage harness under test is abnormal. For example, when the temperature value collected by the sensor network exceeds a preset temperature threshold, it is determined that the high-voltage harness under test has a temperature abnormality. Then, it identifies whether the abnormality is non-destructive, which is a minor abnormality. If a minor abnormality occurs, the equipment operates at a reduced derating rate, allowing continued testing to collect more failure evolution data. If a serious abnormality occurs, the equipment shuts down immediately, interrupting the test. This improves detection efficiency and safety.

[0043] In traditional high-voltage wiring harness testing, after a fault occurs, components typically need to be disassembled and the root cause determined by engineers' experience, which is time-consuming and prone to misjudgment. Therefore, in some embodiments, the central control system can also be used to: when an anomaly is detected in the high-voltage wiring harness under test, perform spatiotemporal alignment of the test data at the time of the anomaly, calculate the contribution of vibration test data, temperature test data, and current test data to the anomaly, and analyze the root cause of the fault based on the calculation results. In other words, the high-voltage wiring harness testing system of this application can also achieve a self-diagnostic function. Specifically, it performs spatiotemporal alignment of temperature, vibration, and current data at the time of the anomaly, such as establishing the phase relationship between the vibration spectrum and the temperature rise curve, and then uses the SHAP (SHapley Additive exPlanations) method to calculate the contribution value of each parameter to the anomaly, thereby analyzing the root cause of the fault. For example, when the contribution value of vibration data is 52%, the root cause is determined to be an abnormality in the wiring harness connector terminals; when the contribution value of temperature data is 30%, the root cause is determined to be poor heat dissipation performance of the wiring harness. This achieves automated analysis of the root cause of the fault, improving efficiency and accuracy.

[0044] Furthermore, in some embodiments, the central control system may also include a 3D visualization display unit; the 3D visualization display unit is used to monitor the failure area of ​​the high-voltage harness under test through 3D visualization analysis technology; the central control system is also used to generate design optimization suggestions in the test report based on the root cause of the fault and the monitoring results of the 3D visualization display unit. In other words, the software analysis layer of the central control system provides 3D visualization display for monitoring the failure area of ​​the harness. Thus, combined with the root cause analysis results, design optimization suggestions can be generated. For example, when a connector terminal abnormality is located through temperature anomalies, and a connector plating defect is located through 3D visualization analysis, a design optimization suggestion can be triggered to replace it with a more conductive metal terminal. This reduces the cost of manual analysis and promotes product quality improvement.

[0045] This application provides a high-voltage wiring harness testing system integrating multi-physics field coupling of electrical, thermal, and mechanical vibration. The system integrates mechanical strength testing units, environmental testing units, and electrical performance testing units, all synchronously controlled by a central control system. This simulates the actual impact of multiple overlapping factors on the wiring harness. During testing of the high-voltage wiring harness, the system's sensor network collects vibration test data, temperature test data, current test data, and insulation performance data in real time and transmits them to the central control system. The central control system uses this test data to analyze the performance of the high-voltage wiring harness under the current test conditions and generates a test report. This effectively improves the accuracy and efficiency of the test results.

[0046] To provide a more detailed explanation of the solution in this application, a specific embodiment is described below: This embodiment provides a multi-physics coupling integrated testing system for high-voltage wiring harnesses. The system architecture is as follows: Figure 2 As shown, the system includes: a multi-axis electromagnetic vibration test bench 21, a temperature and humidity control box 22, a programmable DC power supply 23, distributed sensors 24, a partial discharge probe 25, and a central control system 26. The multi-axis electromagnetic vibration test bench 21 can simulate mechanical vibration of a real vehicle according to test or standard requirements; the temperature and humidity control box 22 can be set with temperature and humidity values ​​according to test needs, with a temperature range of -40℃ to 150℃ and a relative humidity range of 10% to 95%; the programmable DC power supply 23 can deliver a specified current according to instructions, with a current range of 0 to 1000A; the distributed sensors 24 collect data such as temperature, vibration, and current in real time; and the partial discharge probe 25 detects insulation defects. The central control system 26 includes a control module 27 and a software analysis module 28. The control module includes a multi-scenario coupling controller 271 and a safety protection system 272. The multi-scenario coupling controller 271 can dynamically adjust vibration frequency, temperature, and current parameters based on sensor data. The safety protection system 272 can trigger an emergency shutdown when an anomaly is detected. The software analysis module 28 can monitor the failure area of ​​the wiring harness through 3D visualization and perform fault prediction and root cause analysis based on the data. Based on this system, the simultaneous application of mechanical stress, temperature stress, and current can be achieved to comprehensively detect the performance of the high-voltage wiring harness assembly 29 under various operating conditions, including electrical performance (insulation resistance, withstand voltage), mechanical strength, and environmental adaptability.

[0047] The workflow of the central control system 26 during the testing process is as follows: Figure 3 As shown, it includes: S301. Initialization and parameter settings; Specifically, after initialization, the CAD model, thermal conductivity, temperature coefficient of resistance, and other parameters of the wire harness under test are obtained. S302, Digital Twin Pre-generation Test Solution; Specifically, a digital twin model of the harness under test is constructed, and the initial test parameter combination is generated through Bayesian optimization by combining the target test parameters. S303, Multiphysics loading startup; Specifically, according to the test plan, the equipment inputs current, vibration, and temperature. For example, if the test plan is: first cool down to -30℃, then use a vibration table to simulate engine idling vibration, and then apply a 300A pulse current, the command can be broken down as follows: the temperature and humidity control box controls the temperature to drop to -30℃ at a rate of 5℃ / min, and simultaneously starts the multi-axis electromagnetic vibration test bench to simulate engine idling vibration at a frequency of 50Hz; after monitoring that the temperature reaches the target, the programmable DC power supply is triggered to output a current of 300A, with a rise time of approximately 0.2s. S304: Receives real-time data collected by distributed sensors and partial discharge probes; S305: Based on real-time data collected by distributed sensors and partial discharge probes, test parameters are dynamically adjusted through a multi-scenario coupling controller. Specifically, the multi-scenario coupled controller predicts future states through a coupled model and optimizes parameters based on the prediction results. This coupled model includes a dynamic resistance model and a temperature field model; the dynamic resistance model describes the change in the contact resistance of the wiring harness due to vibration, and can be expressed as:

[0048] In the formula, For dynamic resistance; The initial resistance; The initial temperature in the initial test parameter combination; The amplitude values ​​are collected by distributed sensors; The vibration frequency values ​​collected by distributed sensors; Temperature values ​​collected by distributed sensors; Temperature coefficient; The vibration wear coefficient; For testing time; The temperature field model describing the temperature rise of the high-voltage wiring harness, considering Joule heating, convective heat dissipation, and vibration-induced frictional heat generation, can be expressed as:

[0049] The left side of the equation represents the temperature rise of the high-voltage wiring harness. The density of the material; Specific heat capacity under constant pressure; This represents the rate of change of temperature over time. Thermal conductivity; This indicates the contribution of heat conduction to energy change; The current value is collected by a distributed sensor. This indicates the Joule heating term, which is the heat generated when an electric current passes through a resistor; The convective heat transfer coefficient; The ambient temperature; This indicates the energy loss caused by convective heat transfer; This indicates the energy input caused by mechanical vibration; S306. Based on the data collected in real time by the distributed sensors, monitor whether there is any abnormality in the tested wire harness. If so, execute S307; otherwise, execute S311. Specifically, when the distributed sensor detects that the temperature at a connection point of the tested wiring harness is greater than a preset temperature threshold, such as 140°C, it determines that the temperature rise is abnormal. S307. Determine whether the abnormality is a minor abnormality. If yes, proceed to S308; otherwise, proceed to S309. S308: Control the equipment to operate at reduced capacity, allow continued testing, then execute S310; S309. Control the equipment to stop immediately and interrupt the test. Then execute S310. S310, Fault Prediction and Root Cause Analysis; Specifically, the temperature, vibration, and current data at abnormal moments are spatiotemporally aligned, the contribution of each parameter to the anomaly is calculated, and the root cause of the fault is analyzed. S311. Generate a test report; Specifically, design optimization suggestions are generated based on the test results. If a certain parameter combination does not trigger a new fault, its weight is reduced; if a new fault is found, the sampling density of the relevant operating conditions is increased.

[0050] This embodiment can simultaneously simulate multiple environmental factors such as electrical, thermal, and mechanical vibration in the OTS test of high-voltage wiring harnesses, more realistically reflecting product performance, thereby improving the accuracy and efficiency of testing.

[0051] Corresponding to the embodiments of the aforementioned system, this application also provides embodiments of a control method for a high-voltage wiring harness testing system: like Figure 4 As shown, Figure 4 This is a flowchart of a control method for a high-voltage wire harness testing system provided in an embodiment of this application. The high-voltage wire harness testing system is the high-voltage wire harness testing system shown in any of the preceding system embodiments. The method is applied to the central control system of the high-voltage wire harness testing system. The method includes: S401. Obtain the target test parameters for the high-voltage line harness to be tested, process the target test parameters using a Bayesian optimization algorithm, and generate an initial test parameter combination; the Bayesian optimization algorithm predicts the lifespan of the high-voltage line harness to be tested under different test parameter combination conditions based on historical test data, and generates the initial test parameter combination based on the prediction results; S402. Input the initial test parameter combination into the test equipment; the initial test parameter combination includes initial amplitude, initial vibration frequency, initial temperature and initial current; S403. Receive the test data collected by the sensor network, and then use the test data to generate a test report.

[0052] In some embodiments, the method further includes: optimizing the initial test parameter combination based on the test data using a model prediction controller to obtain an optimized test parameter combination; and inputting the optimized test parameter combination into the test device.

[0053] In some embodiments, the method further includes: determining whether the high-voltage harness under test is abnormal based on the test data and a preset threshold; if the determination result is yes, identifying the type of the abnormality; when the high-voltage harness under test is abnormal due to a non-destructive abnormality, controlling the test equipment to operate at a reduced derating rate; when the high-voltage harness under test is abnormal due to a destructive abnormality, sending an emergency shutdown command to the test equipment.

[0054] In some embodiments, the method further includes: when an abnormality is detected in the high-voltage harness under test, performing spatiotemporal alignment of the test data at the time of the abnormality; calculating the contribution of vibration test data, temperature test data, and current test data to the abnormality; and analyzing the root cause of the fault based on the calculation results.

[0055] In some embodiments, the method further includes: monitoring the failure area of ​​the high-voltage harness under test using three-dimensional visualization analysis technology; and generating design optimization suggestions in the test report based on the root cause of the failure and the monitoring results.

[0056] The implementation process of the corresponding steps in the above method can be found in the specific description in the above system, and will not be repeated here.

[0057] This application also provides embodiments of a control device for a high-voltage wiring harness testing system and its application terminals: like Figure 5 As shown, Figure 5 This is a block diagram of a control device for a high-voltage wire harness testing system provided in this application embodiment. The high-voltage wire harness testing system is the high-voltage wire harness testing system shown in any of the preceding system embodiments. The device is applied to the central control system of the high-voltage wire harness testing system. The device includes: The acquisition module 51 is used to acquire the test target parameters for the high-voltage line harness under test, process the test target parameters through a Bayesian optimization algorithm, and generate an initial test parameter combination. The Bayesian optimization algorithm predicts the lifespan of the high-voltage line harness under test under different test parameter combination conditions based on historical test data, and generates the initial test parameter combination based on the prediction results. Input module 52 is used to input the initial test parameter combination into the test equipment; the initial test parameter combination includes initial amplitude, initial vibration frequency, initial temperature and initial current; The generation module 53 is used to receive the test data collected by the sensor network and then use the test data to generate a test report.

[0058] Similarly, the specific implementation process of the functions and roles of each module in the above-mentioned device can be found in the detailed description of the corresponding unit in the above-mentioned system, and will not be repeated here.

[0059] This application also provides an electronic device, please refer to [link to application]. Figure 6 , Figure 6 This is a structural block diagram of an electronic device provided in an embodiment of this application. The electronic device may include a processor 610, a communication interface 620, a memory 630, and at least one communication bus 640. The communication bus 640 is used to enable direct communication between these components. In this embodiment, the communication interface 620 of the electronic device is used for signaling or data communication with other node devices. The processor 610 may be an integrated circuit chip with signal processing capabilities.

[0060] The processor 610 described above can be a general-purpose processor, including a central processing unit (CPU), a network processor (NP), etc.; it can also be a digital signal processor (DSP), an application-specific integrated circuit (ASIC), an off-the-shelf programmable gate array (FPGA), or other programmable logic devices, discrete gate or transistor logic devices, or discrete hardware components. It can implement or execute the methods, steps, and logic block diagrams disclosed in the embodiments of this application. The general-purpose processor can be a microprocessor, or the processor 610 can be any conventional processor.

[0061] The memory 630 may be, but is not limited to, random access memory (RAM), read-only memory (ROM), programmable read-only memory (PROM), erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), etc. The memory 630 stores computer-readable instructions. When these computer-readable instructions are executed by the processor 610, the electronic device can perform the aforementioned operations. Figure 1 The various steps involved in the method implementation examples.

[0062] Alternatively, the electronic device may also include a storage controller and an input / output unit.

[0063] The memory 630, storage controller, processor 610, peripheral interface, and input / output unit are electrically connected directly or indirectly to achieve data transmission or interaction. For example, these components can be electrically connected to each other through one or more communication buses 640. The processor 610 is used to execute executable modules stored in the memory 630, such as software function modules or computer programs included in electronic devices.

[0064] The input / output unit is used to provide users with the ability to create tasks and to set optional start periods or preset execution times for those tasks, thereby enabling user-server interaction. The input / output unit may be, but is not limited to, a mouse and keyboard.

[0065] Understandable. Figure 6 The structure shown is for illustrative purposes only; the electronic device may also include components that are more advanced than those shown. Figure 6 The more or fewer components shown, or having the same Figure 6 The different configurations shown. Figure 6 The components shown can be implemented using hardware, software, or a combination thereof.

[0066] This application also provides a storage medium storing instructions. When the instructions are run on a computer, the computer program is executed by a processor to implement the method described in the method embodiment. To avoid repetition, the method will not be described again here.

[0067] This application also provides a computer program product that, when run on a computer, causes the computer to perform the method described in the method embodiment.

[0068] In the several embodiments provided in this application, it should be understood that the disclosed apparatus and methods can also be implemented in other ways. The apparatus embodiments described above are merely illustrative. For example, the flowcharts and block diagrams in the accompanying drawings illustrate the architecture, functionality, and operation of possible implementations of apparatus, methods, and computer program products according to various embodiments of this application. In this regard, each block in a flowchart or block diagram may represent a module, segment, or portion of code containing one or more executable instructions for implementing a specified logical function. It should also be noted that in some alternative implementations, the functions marked in the blocks may occur in a different order than those marked in the drawings. For example, two consecutive blocks may actually be executed substantially in parallel, and they may sometimes be executed in reverse order, depending on the functions involved. It should also be noted that each block in a block diagram and / or flowchart, and combinations of blocks in block diagrams and / or flowcharts, can be implemented using a dedicated hardware-based system that performs the specified function or action, or using a combination of dedicated hardware and computer instructions.

[0069] In addition, the functional modules in the various embodiments of this application can be integrated together to form an independent part, or each module can exist independently, or two or more modules can be integrated to form an independent part.

[0070] If the aforementioned functions are implemented as software functional modules and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, or a portion of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this application. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0071] The above description is merely an embodiment of this application and is not intended to limit the scope of protection of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of protection of this application. It should be noted that similar reference numerals and letters in the following figures indicate similar items; therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0072] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

[0073] 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 a process, method, article, or apparatus. Without further limitations, 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 said element.

Claims

1. A high-voltage wiring harness testing system, characterized in that, This includes testing equipment, sensor networks, and a central control system; among which: The testing equipment includes a mechanical strength testing unit, an environmental testing unit, and an electrical performance testing unit; the mechanical strength testing unit is used to simulate the mechanical vibration of the high-voltage wiring harness under test in a real vehicle; the environmental testing unit is used to simulate a specified temperature environment; and the electrical performance testing unit is used to simulate a current environment. The sensor network is used to collect test data of the high-voltage line harness under test; the test data includes vibration test data, temperature test data, current test data, and insulation performance data. The central control system is used to synchronously control each unit of the testing equipment during the testing of the high-voltage harness under test, and to receive the test data collected by the sensor network, and then use the test data to generate a test report.

2. The high-voltage wiring harness testing system according to claim 1, characterized in that, The mechanical strength testing unit includes an electromagnetic vibration table; the environmental testing unit includes a temperature and humidity control box; and the electrical performance testing unit includes a controllable DC power supply. The sensor network includes distributed sensors and partial discharge probes; the distributed sensors are used to detect the actual amplitude, vibration frequency, temperature and current values ​​of the high-voltage line harness under test; the partial discharge probes are used to detect insulation defects in the high-voltage line harness under test.

3. The high-voltage wiring harness testing system according to claim 2, characterized in that, The central control system is used to: acquire the target test parameters for the high-voltage line harness under test; process the target test parameters using a Bayesian optimization algorithm to generate an initial test parameter combination; input the initial test parameter combination into the test equipment; the initial test parameter combination includes initial amplitude, initial vibration frequency, initial temperature, and initial current; the Bayesian optimization algorithm predicts the lifespan of the high-voltage line harness under test under different test parameter combination conditions based on historical test data, and generates the initial test parameter combination based on the prediction results.

4. The high-voltage wiring harness testing system according to claim 3, characterized in that, The central control system is also used to: optimize the initial test parameter combination based on the test data using a model predictive controller to obtain an optimized test parameter combination, and input the optimized test parameter combination into the test equipment.

5. The high-voltage wiring harness testing system according to claim 1, characterized in that, The central control system is also used to: determine whether the high-voltage harness under test is abnormal based on the test data and preset thresholds; if the determination result is yes, identify the type of the abnormality; when the high-voltage harness under test is abnormal due to non-destructive behavior, control the testing equipment to operate at reduced derating; when the high-voltage harness under test is abnormal due to destructive behavior, send an emergency shutdown command to the testing equipment.

6. The high-voltage wiring harness testing system according to claim 5, characterized in that, The central control system is also used to: when an abnormality is detected in the high-voltage harness under test, to perform spatiotemporal alignment of the test data at the time of the abnormality, to calculate the contribution of vibration test data, temperature test data and current test data to the abnormality, and to analyze the root cause of the fault based on the calculation results.

7. The high-voltage wiring harness testing system according to claim 6, characterized in that, The central control system includes a three-dimensional visualization display unit; the three-dimensional visualization display unit is used to monitor the failure area of ​​the high-voltage harness under test through three-dimensional visualization analysis technology; The central control system is also used to generate design optimization suggestions in the test report based on the root cause of the fault and the monitoring results of the three-dimensional visualization display unit.

8. A control method for a high-voltage wiring harness testing system as described in any one of claims 1 to 7, characterized in that, The method includes: a central control system applied to the high-voltage harness testing system; the method includes: The test target parameters for the high-voltage line harness to be tested are obtained, and the test target parameters are processed by a Bayesian optimization algorithm to generate an initial test parameter combination. The Bayesian optimization algorithm predicts the lifespan of the high-voltage line harness under different test parameter combinations based on historical test data, and generates the initial test parameter combination based on the prediction results. The initial test parameter combination is input into the test equipment; the initial test parameter combination includes initial amplitude, initial vibration frequency, initial temperature, and initial current; The system receives test data collected by the sensor network and then uses the test data to generate a test report.

9. The method according to claim 8, characterized in that, Also includes: Based on the test data, the initial test parameter combination is optimized using a model prediction controller to obtain an optimized test parameter combination. The optimized test parameter combination is input into the test equipment.

10. The method according to claim 8, characterized in that, Also includes: Based on the test data and preset threshold, it is determined whether the high-voltage harness under test is abnormal; If the judgment result is yes, identify the category of the anomaly; When a non-destructive anomaly occurs in the high-voltage harness under test, the testing equipment is controlled to operate at a reduced derating rate. When the high-voltage harness under test exhibits a destructive abnormality, an emergency shutdown command is sent to the testing equipment.

11. The method according to claim 9, characterized in that, Also includes: When an anomaly is detected in the high-voltage harness under test, the test data at the time of the anomaly will be spatiotemporally aligned. Calculate the contribution of vibration test data, temperature test data, and current test data to the anomaly; Analyze the root causes of the failure based on the calculation results.

12. The method according to claim 11, characterized in that, Also includes: The failure area of ​​the high-voltage harness under test is monitored using three-dimensional visualization analysis technology. Based on the root causes of the failures and the monitoring results, design optimization suggestions are generated in the test report.

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