224g high-speed wire harness assembly method and system based on ultrasonic riveting

Abstract

The application relates to the technical field of ultrasonic riveting, and relates to a 224G high-speed wire harness assembly method and system based on ultrasonic riveting, which comprises the following steps: pretreating high-speed wire harness raw materials to obtain pre-riveting wire harness; aligning the pre-riveting wire harness with a pre-constructed target connector to obtain a wire harness to be riveted; riveting the wire harness to be riveted by using ultrasonic parameter values, environmental temperature values and riveting time, monitoring the wire harness to be riveted in real time based on a riveting monitoring instruction, obtaining a compression offset value and an energy absorption value; obtaining an updated ultrasonic frequency value by using a fuzzy control algorithm based on the compression offset value and the energy absorption value, obtaining a pre-confirmed high-speed wire harness by using the updated ultrasonic frequency value; performing quality detection on the pre-confirmed high-speed wire harness to obtain a target high-speed wire harness, and realizing the assembly of the high-speed wire harness based on the target high-speed wire harness. The application can realize high-precision assembly of high-speed wire harness by using ultrasonic riveting.

Description

Technical Field

[0001] This invention relates to the field of ultrasonic riveting technology, and in particular to a method and system for assembling a 224G high-speed wire harness based on ultrasonic riveting. Background Technology

[0002] With the rapid development of electronic devices towards higher frequencies and miniaturization, 224G and higher speed wire harnesses, as the core transmission medium of modern communication systems, directly affect signal transmission quality and system performance through their assembly precision and reliability.

[0003] Currently, traditional assembly processes suffer from problems such as large heat-affected zones and unstable impedance, making it difficult to meet the stringent requirements of high-speed transmission.

[0004] However, ultrasonic riveting technology, with its solid-state bonding characteristics, offers advantages such as low-temperature operation and low energy consumption, providing a technical path to solve this problem. However, existing methods still have shortcomings in multi-layer conductor alignment and ultrasonic energy control, leading to significant fluctuations in high-frequency signal transmission performance. Furthermore, current technologies struggle to achieve precise crimping of high-speed wire harnesses, affecting the integrity of high-frequency signals. Therefore, how to achieve high-precision assembly of high-speed wire harnesses using ultrasonic riveting has become an urgent problem to be solved. Summary of the Invention

[0005] This invention provides a method for assembling a 224G high-speed wire harness based on ultrasonic riveting and a computer-readable storage medium. Its main purpose is to achieve high-precision assembly of high-speed wire harnesses using ultrasonic riveting.

[0006] To achieve the above objectives, the present invention provides a method for assembling a 224G high-speed wire harness based on ultrasonic riveting, comprising:

[0007] Receive a wire harness assembly instruction, and confirm the wire harness assembly environment based on the wire harness assembly instruction. The wire harness assembly environment includes a wire harness assembly system and high-speed wire harness raw materials to be assembled. The wire harness assembly system includes a high-precision alignment unit, an ultrasonic riveting monitoring unit, and a quality inspection unit.

[0008] Pre-processing of high-speed wire harness raw materials yields pre-riveted wire harnesses;

[0009] Receive a precise alignment command from a high-precision alignment unit, and align the pre-riveted wire harness with the pre-built target connector based on the precise alignment command to obtain the wire harness to be riveted;

[0010] The wire harness to be riveted is riveted using preset ultrasonic parameter values, preset ambient temperature values, and preset riveting time. The riveting monitoring command is received from the ultrasonic riveting monitoring unit. Based on the riveting monitoring command, the wire harness to be riveted is monitored in real time to obtain compression offset value and energy absorption value.

[0011] Based on the compression offset value and energy absorption value, an updated ultrasonic frequency value is obtained using a pre-constructed fuzzy control algorithm, and a pre-confirmed high-speed wire harness is obtained using the updated ultrasonic frequency value.

[0012] The system receives a quality inspection command from the quality inspection unit, performs quality inspection on the pre-confirmed high-speed wire harness based on the quality inspection command, obtains the target high-speed wire harness, and assembles the high-speed wire harness based on the target high-speed wire harness.

[0013] Optionally, the pretreatment of the high-speed wire harness raw materials to obtain the pre-riveted wire harness includes:

[0014] The initial contact area of ​​the high-speed wire harness raw material was identified in the target connector. The dielectric layer of the initial contact area was stripped using a pre-constructed dielectric layer stripping method to obtain the high-speed transmission contact area.

[0015] The high-speed transmission contact area is polished using a pre-constructed polishing method to obtain a polished contact area harness, and the polished contact area of ​​the polished contact area harness is identified in the target connector.

[0016] The polished contact area is laser-textured using a pre-constructed laser texturing method to obtain the riveting wire bundle to be confirmed;

[0017] A pre-built quality inspection method is used to inspect the riveted wire harness to be confirmed, and a pre-riveted wire harness is obtained.

[0018] Optionally, the method of using a pre-built quality inspection method to inspect the riveted wire harness to obtain a pre-riveted wire harness includes:

[0019] In the target connector, the target contact area of ​​the riveted wire harness to be confirmed is identified, and the target contact area is divided using a pre-constructed division method to obtain a detection area set;

[0020] For each detection area in the detection area set, perform the following operations:

[0021] The detection area is tested using quality inspection methods to obtain a set of detection parameters. The set of detection parameters includes multiple detection parameters, which are surface roughness detection value, dielectric residue detection value, and contact resistance detection value, respectively.

[0022] Obtain the surface roughness detection threshold, dielectric residue detection threshold, and contact resistance detection threshold;

[0023] The detection parameter sets are summarized to obtain multiple detection parameter sets, and each detection parameter set corresponds to a detection area. If the surface roughness detection value, dielectric residue detection value, and contact resistance detection value of each detection parameter set in the multiple detection parameter sets are less than the surface roughness detection threshold, the dielectric residue detection value is less than the dielectric residue detection threshold, and the contact resistance detection value is less than the contact resistance detection threshold, then the riveting wire harness to be confirmed is the pre-riveting wire harness.

[0024] If multiple detection parameter sets contain a surface roughness detection value greater than or equal to the surface roughness detection threshold, a dielectric residue detection value greater than or equal to the dielectric residue detection threshold, or a contact resistance detection value greater than or equal to the contact resistance detection threshold, then return to the step of polishing the high-speed transmission contact area using the pre-constructed polishing method to obtain the polished contact area wire harness, until the pre-riveted wire harness is obtained.

[0025] Optionally, aligning the pre-riveted wire harness with the pre-built target connector based on the precise alignment command to obtain the wire harness to be riveted includes:

[0026] Based on the precise alignment command, obtain the three-dimensional spatial data of the target contact area and the target connector in the pre-riveted wire harness, and obtain the spatial position of the contact area and the spatial position of the connector.

[0027] The geometric features of the target contact area and the target connector are identified using a pre-constructed projection method, resulting in the geometric features of the contact area and the connector.

[0028] Using a pre-built positioning method, the spatial positions of the contact area, connector, contact area geometry, and connector geometry are spatially aligned to obtain alignment reference points;

[0029] The target contact area and target connector are aligned using a pre-constructed positioning device and alignment reference point to obtain the wire harness to be riveted.

[0030] Optionally, the riveting of the wire harness to be riveted using preset ultrasonic parameter values, preset ambient temperature values, and preset riveting time includes:

[0031] Target ultrasound is obtained using a pre-built ultrasonic generator and ultrasonic parameter values;

[0032] The target ultrasonic wave is converted using a pre-constructed transducer and a pre-constructed amplitude transformer to obtain the ultrasonic vibration amplitude, which is shown below:

[0033]

[0034] in, Indicates the amplitude of ultrasonic vibration. This represents the conversion efficiency factor of the transducer. This represents the piezoelectric strain constant of the transducer. This represents the drive voltage of the transducer. This indicates the quality factor of the transducer. Indicates the frequency of the ultrasonic wave. Indicates the riveting time. This represents the input cross-sectional area of ​​the amplitude transformer. This indicates the output cross-sectional area of ​​the amplitude transformer;

[0035] The wire harness to be riveted is riveted using a pre-built riveting tool head, ultrasonic vibration amplitude, riveting time, and ambient temperature. Ambient temperature monitoring values ​​are obtained at preset time intervals. Based on the ambient temperature monitoring values ​​and the pre-built riveting cooling unit, the wire harness to be riveted is cooled during riveting.

[0036] Optionally, the cooling of the wire harness to be riveted during riveting based on the ambient temperature monitoring value and the pre-constructed riveting cooling unit includes:

[0037] Calculate the difference between the monitored ambient temperature value and the actual ambient temperature value to obtain the ambient temperature difference.

[0038] If the ambient temperature difference is greater than the preset ambient temperature difference threshold, the target contact area is cooled by using the preset cooling temperature, the riveting cooling unit and the preset cooling time. The time is recorded in real time starting from the cooling time to obtain the recording interval time. When the recording interval time is equal to the cooling time, the updated ambient temperature monitoring value is obtained.

[0039] Based on the updated ambient temperature monitoring value, an updated ambient temperature difference is obtained. If the updated ambient temperature difference is greater than the ambient temperature difference threshold, the difference between the updated ambient temperature difference and the ambient temperature difference threshold is calculated to obtain the temperature control value.

[0040] Calculate the difference between the ambient temperature difference and the updated ambient temperature difference to obtain the change in temperature difference;

[0041] The target control value is the updated ambient temperature difference, temperature control value, and temperature difference change value.

[0042] Based on the target control value and the pre-built PID control algorithm, the temperature drop value is obtained. Based on the temperature drop value and the temperature drop value, the updated temperature drop value is obtained. The updated temperature drop value is used as the temperature drop value. The process of cooling the target contact area using the preset temperature drop value and the preset temperature drop value is returned until the updated ambient temperature difference is less than or equal to the ambient temperature difference threshold is reached.

[0043] Optionally, the step of obtaining the updated ultrasonic frequency value based on the compression offset value and energy absorption value using a pre-built fuzzy control algorithm includes:

[0044] Obtain the compression offset standard range and the energy absorption standard range, wherein the compression offset standard range includes the minimum compression offset range value and the maximum compression offset range value, and the energy absorption standard range includes the minimum energy absorption range value and the maximum energy absorption range value;

[0045] Calculate the mean of the minimum compression offset interval value and the maximum compression offset interval value to obtain the mean of the compression offset interval. Based on the minimum energy absorption interval value and the maximum energy absorption interval value, obtain the mean of the energy absorption interval.

[0046] Calculate the absolute difference between the compression offset value and the mean of the compression offset interval, and the absolute difference between the energy absorption value and the mean of the energy absorption interval, respectively, to obtain the compression offset deviation value and the energy absorption deviation value;

[0047] By summing the compression offset deviation value and the energy absorption deviation value, a reference control value set is obtained;

[0048] The updated ultrasonic frequency value is obtained based on the reference control value set and the pre-constructed fuzzy control algorithm, wherein the calculation formula for the updated ultrasonic frequency value is:

[0049]

[0050] in, This indicates an update to the ultrasonic frequency. Indicates the fuzzy control weights. This represents the ultrasonic frequency correction amount output by the fuzzy control algorithm. The weights representing the compression offset deviation values. The weights representing deviations from energy absorption values. This indicates the compression offset deviation value. This represents the mean of the compressed offset interval. This indicates the deviation value of energy absorption. This represents the mean of the energy absorption range. This indicates the maximum allowable adjustment range of the ultrasonic frequency.

[0051] Optionally, obtaining the pre-confirmed high-speed harness using the updated ultrasonic frequency value includes:

[0052] The updated ultrasonic frequency value is used to rivet the wire harness to be riveted, and the updated compression offset value and updated energy absorption value of the wire harness to be riveted are monitored during the riveting process.

[0053] Based on the updated compression offset value and the updated energy absorption value, obtain the updated compression offset deviation value and the updated energy absorption deviation value;

[0054] If the updated compression offset deviation value is less than the preset compression offset deviation threshold and the updated energy absorption deviation value is less than the preset energy absorption deviation threshold, a pre-confirmed high-speed harness is obtained.

[0055] If the updated compression offset deviation value is greater than or equal to the compression offset deviation threshold or the updated energy absorption deviation value is greater than or equal to the energy absorption deviation threshold, then return to the step of obtaining the updated ultrasonic frequency value based on the reference control value set and the pre-constructed fuzzy control algorithm until a pre-confirmed high-speed harness is obtained.

[0056] Optionally, the step of performing quality inspection on the pre-confirmed high-speed harness based on the quality inspection command to obtain the target high-speed harness includes:

[0057] Based on the quality inspection command, a performance testing method is obtained, and the pre-confirmed high-speed harness is tested based on the performance testing method to obtain the insertion loss value and return loss value.

[0058] The insertion and removal durability test was performed on the pre-confirmed high-speed wiring harness to obtain the wear value of the high-speed wiring harness.

[0059] Vibration tests were performed on the pre-confirmed high-speed wiring harness to obtain the change in contact resistance.

[0060] Obtain the insertion loss threshold, return loss threshold, high-speed harness wear threshold, and contact resistance change threshold;

[0061] If the insertion loss value is less than the insertion loss threshold, the return loss value is less than the return loss threshold, the high-speed harness wear value is less than the high-speed harness wear threshold, and the contact resistance change value is less than the contact resistance change threshold, then the pre-confirmed high-speed harness is taken as the target high-speed harness.

[0062] To achieve the above objectives, the present invention also provides a 224G high-speed wire harness assembly system based on ultrasonic riveting, comprising:

[0063] The riveting environment confirmation module is used to receive wire harness assembly instructions and confirm the wire harness assembly environment based on the wire harness assembly instructions. The wire harness assembly environment includes a wire harness assembly system and high-speed wire harness raw materials to be assembled. The wire harness assembly system includes a high-precision alignment unit, an ultrasonic riveting monitoring unit, and a quality detection unit.

[0064] The riveting material processing module is used to pre-process the raw materials of high-speed wire harnesses to obtain pre-riveted wire harnesses;

[0065] Receive a precise alignment command from a high-precision alignment unit, and align the pre-riveted wire harness with the pre-built target connector based on the precise alignment command to obtain the wire harness to be riveted;

[0066] The ultrasonic riveting module is used to rivet the wire harness to be riveted using preset ultrasonic parameter values, preset ambient temperature values ​​and preset riveting time, and to receive riveting monitoring instructions from the ultrasonic riveting monitoring unit. Based on the riveting monitoring instructions, the module monitors the wire harness to be riveted in real time to obtain compression offset value and energy absorption value.

[0067] Based on the compression offset value and energy absorption value, a pre-constructed fuzzy control algorithm is used to obtain an updated ultrasonic frequency value, which is beneficial for obtaining a pre-confirmed high-speed wire harness using the updated ultrasonic frequency value.

[0068] The wire harness quality inspection module is used to receive quality inspection instructions from the quality inspection unit, perform quality inspection on the pre-confirmed high-speed wire harness based on the quality inspection instructions, obtain the target high-speed wire harness, and assemble the high-speed wire harness based on the target high-speed wire harness.

[0069] To address the above problems, the present invention also provides an electronic device, the electronic device comprising:

[0070] A memory that stores at least one instruction; and a processor that executes the instructions stored in the memory to implement the above-described ultrasonic riveting-based 224G high-speed wire harness assembly method.

[0071] To address the aforementioned problems, the present invention also provides a computer-readable storage medium storing at least one instruction, which is executed by a processor in an electronic device to implement the above-described 224G high-speed wire harness assembly method based on ultrasonic riveting.

[0072] To address the problems described in the background art, this invention pre-processes high-speed wire harness raw materials to obtain pre-riveted wire harnesses. It is evident that this invention considers the impact of high-speed wire harness raw materials on signal transmission rates before riveting. Therefore, it performs dielectric layer stripping, polishing, and laser texturing operations on the high-speed wire harness raw materials, and conducts quality inspection to ensure that the high-speed wire harness raw materials meet the requirements for high-speed signal transmission. Furthermore, it receives precise alignment instructions from a high-precision alignment unit, and based on these instructions, it aligns the pre-riveted wire harness with the pre-constructed target connector. The alignment process yields the wire harness to be riveted. It is evident that this invention addresses the issue of inaccurate connection between the high-speed wire harness and the target connector during alignment. Therefore, a high-precision alignment unit ensures more accurate alignment, laying the foundation for subsequent ultrasonic riveting of the wire harness. The process utilizes preset ultrasonic parameters, ambient temperature, and riveting time to rivet the wire harness, while receiving riveting monitoring commands from the ultrasonic riveting monitoring unit. Based on these commands, the riveting process is monitored in real-time. The wire harness is monitored to obtain compression offset and energy absorption values. This invention also considers the potential damage to the wire harness caused by increased ambient temperature during ultrasonic riveting. A riveting cooling unit is used to cool the riveting process. Based on the compression offset and energy absorption values, a pre-built fuzzy control algorithm is used to obtain an updated ultrasonic frequency value. This updated ultrasonic frequency value is then used to obtain a pre-confirmed high-speed wire harness. During ultrasonic riveting, the wire harness parameters are monitored in real-time, and the ultrasonic parameters are dynamically adjusted to ensure more precise riveting. A quality inspection command is received from the quality inspection unit, and the pre-confirmed high-speed wire harness is inspected to obtain the target high-speed wire harness. The high-speed wire harness is then assembled based on the target high-speed wire harness. Therefore, after ultrasonic riveting, this invention considers whether the pre-confirmed high-speed wire harness meets the 224G high-speed signal transmission requirements. The performance of the pre-confirmed high-speed wire harness is tested using a quality inspection method to obtain the target high-speed wire harness, which is then used to assemble the high-speed wire harness. Therefore, the present invention enables high-precision assembly of high-speed wire harnesses using ultrasonic riveting. Attached Figure Description

[0073] Figure 1 This is a flowchart illustrating a method for assembling a 224G high-speed wire harness based on ultrasonic riveting, according to an embodiment of the present invention.

[0074] Figure 2 This is a functional block diagram of a 224G high-speed wire harness assembly system based on ultrasonic riveting provided in an embodiment of the present invention;

[0075] Figure 3 This is a schematic diagram of the structure of an electronic device that implements the ultrasonic riveting-based 224G high-speed wire harness assembly method according to an embodiment of the present invention.

[0076] Explanation of reference numerals in the attached figures:

[0077] 10. Electronic device; 11. Processor; 12. Memory; 13. Bus.

[0078] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0079] It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0080] This application provides a method for assembling a 224G high-speed wire harness based on ultrasonic riveting. The execution entity of the ultrasonic riveting-based 224G high-speed wire harness assembly method includes, but is not limited to, at least one of the following electronic devices that can be configured to execute the method provided in this application: a server, a terminal, etc. In other words, the ultrasonic riveting-based 224G high-speed wire harness assembly method can be executed by software or hardware installed on a terminal device or a server device, and the software can be a blockchain platform. The server includes, but is not limited to, a single server, a server cluster, a cloud server, or a cloud server cluster.

[0081] Reference Figure 1 The diagram shown is a flowchart illustrating a method for assembling a 224G high-speed wire harness based on ultrasonic riveting according to an embodiment of the present invention. In this embodiment, the method for assembling a 224G high-speed wire harness based on ultrasonic riveting includes:

[0082] S1. Receive wire harness assembly instructions, and confirm the wire harness assembly environment based on the wire harness assembly instructions. The wire harness assembly environment includes a wire harness assembly system and high-speed wire harness raw materials to be assembled. The wire harness assembly system includes a high-precision alignment unit, an ultrasonic riveting monitoring unit, and a quality inspection unit.

[0083] It should be explained that the wire harness assembly instruction is an instruction issued by personnel who wish to assemble a high-speed wire harness. The wire harness assembly environment refers to the necessary environment for assembling the wire harness. The wire harness assembly system refers to the software or application used to assemble the wire harness, and it can control the units or mechanisms. The high-speed wire harness raw material consists of multiple high-speed branch wires, and each high-speed branch wire is composed of a metal conductor material wrapped with an insulating material layer. For example, the high-speed wire harness raw material is composed of high-purity copper wire wrapped with multiple insulating material layers. The wire harness assembly system includes a high-precision alignment unit, an ultrasonic riveting monitoring unit, and a quality inspection unit. For the specific application of these units, please refer to the following embodiments. The main purpose of this invention is to achieve the assembly of wire harnesses using ultrasonic riveting.

[0084] For example, Xiao Zhang, as the worker responsible for assembling high-speed wire harnesses, in order to use ultrasonic riveting to assemble high-speed wire harnesses and avoid problems such as damage to the high-speed wire harnesses caused by riveting temperature during the riveting process, therefore, Xiao Zhang issues the wire harness assembly command and confirms the wire harness assembly environment.

[0085] S2. Pre-treat the high-speed wire harness raw materials to obtain a pre-riveted wire harness.

[0086] Furthermore, the pretreatment of the high-speed wire harness raw materials to obtain the pre-riveted wire harness includes:

[0087] The initial contact area of ​​the high-speed wire harness raw material was identified in the target connector. The dielectric layer of the initial contact area was stripped using a pre-constructed dielectric layer stripping method to obtain the high-speed transmission contact area.

[0088] The high-speed transmission contact area is polished using a pre-constructed polishing method to obtain a polished contact area harness, and the polished contact area of ​​the polished contact area harness is identified in the target connector.

[0089] The polished contact area is laser-textured using a pre-constructed laser texturing method to obtain the riveting wire bundle to be confirmed;

[0090] A pre-built quality inspection method is used to inspect the riveted wire harness to be confirmed, and a pre-riveted wire harness is obtained.

[0091] Understandably, the target connector refers to a specific model or standard connector that meets the requirements for 224G data signal transmission and mating in high-speed wiring harness design. Examples include high-speed backplane connectors and optoelectronic hybrid connectors.

[0092] It is clear that identifying the initial contact area of ​​the high-speed wire harness material in the target connector means identifying an area of ​​the same length as the connecting hole at the end of the high-speed wire harness material using the length of the connecting hole in the target connector, and using this area as the initial contact area. The initial contact area refers to the area at the end of the high-speed wire harness material that is the same length as the connecting hole in the target connector.

[0093] It should be explained that dielectric layer stripping of the initial contact area refers to the process of removing the dielectric layer in the initial contact area using a dielectric layer stripping method to expose the metallic conductor material. For example, this involves stripping the dielectric layer in the initial contact area of ​​each high-speed branch in a high-speed harness to expose the metallic conductor material within the high-speed branch. The dielectric layer refers to the insulating material layer in the raw material of the high-speed harness that encapsulates the high-speed harness conductor. Optionally, a laser ablation method can be used as the dielectric layer stripping method. For example, starting from the outermost edge of the initial contact area in the high-speed branch, a 0.1 mJ laser emitted from an ultraviolet laser is used to etch the insulating material layer of the initial contact area. A high-speed CMOS camera is used to monitor the surface reflectivity of the area being laser-etched. When the surface reflectivity changes abruptly, it indicates that the metallic conductor material is exposed. Laser ablation continues until the metallic conductor material of all high-speed branches in the target contact area of ​​the high-speed harness is exposed, at which point the laser ablation ends, and the dielectric layer stripping is completed. The high-speed transmission contact area refers to the initial contact area after the insulating material layer has been removed.

[0094] It should be explained that polishing the high-speed transmission contact area refers to the process of removing residual dielectric layer in the high-speed transmission contact area, improving the corrosion resistance of the high-speed transmission contact area, and reducing surface roughness. Optionally, an acidic polishing solution can be used to polish the high-speed transmission contact area. The polished contact area harness refers to the high-speed wire harness with smooth contact areas obtained after the polishing process. The method for identifying the polished contact area harness in the target connector is the same as the method for identifying the initial contact area, and will not be repeated here.

[0095] Understandably, laser texturing of the polished contact area refers to laser processing of the contact area to create a periodic grid texture, resulting in multiple periodic grids within the polished contact area. Laser texturing reduces the contact resistance and suppresses the skin effect. Optionally, a nanosecond laser can be used for laser texturing of the polished contact area. The riveting harness to be confirmed refers to the harness that requires quality inspection after the aforementioned preprocessing method.

[0096] Furthermore, the method of using a pre-constructed quality inspection method to inspect the riveted wire harness to obtain a pre-riveted wire harness includes:

[0097] In the target connector, the target contact area of ​​the riveted wire harness to be confirmed is identified, and the target contact area is divided using a pre-constructed division method to obtain a detection area set;

[0098] For each detection area in the detection area set, perform the following operations:

[0099] The detection area is tested using quality inspection methods to obtain a set of detection parameters. The set of detection parameters includes multiple detection parameters, which are surface roughness detection value, dielectric residue detection value, and contact resistance detection value, respectively.

[0100] Obtain the surface roughness detection threshold, dielectric residue detection threshold, and contact resistance detection threshold;

[0101] The detection parameter sets are summarized to obtain multiple detection parameter sets, and each detection parameter set corresponds to a detection area. If the surface roughness detection value, dielectric residue detection value, and contact resistance detection value of each detection parameter set in the multiple detection parameter sets are less than the surface roughness detection threshold, the dielectric residue detection value is less than the dielectric residue detection threshold, and the contact resistance detection value is less than the contact resistance detection threshold, then the riveting wire harness to be confirmed is the pre-riveting wire harness.

[0102] If multiple detection parameter sets contain a surface roughness detection value greater than or equal to the surface roughness detection threshold, a dielectric residue detection value greater than or equal to the dielectric residue detection threshold, or a contact resistance detection value greater than or equal to the contact resistance detection threshold, then return to the step of polishing the high-speed transmission contact area using the pre-constructed polishing method to obtain the polished contact area wire harness, until the pre-riveted wire harness is obtained.

[0103] It should be explained that the method for identifying the target contact area of ​​the riveted wire harness to be confirmed in the target connector is the same as the method for identifying the initial contact area, and will not be repeated here. Dividing the target contact area means dividing the target contact area into a predetermined number of segments of equal length, resulting in multiple monitoring areas of equal length. For example, dividing the target contact area into five segments of equal length yields five monitoring areas of equal length. The detection area set refers to the collection of detection areas divided on the target contact area.

[0104] Understandably, using quality inspection methods to inspect the inspection area refers to inspecting the surface roughness, dielectric residue, and contact resistance of the inspection area. Optionally, white light interferometers can be used for surface roughness inspection, EDS energy dispersive spectroscopy and FTIR infrared spectroscopy can be used for dielectric residue inspection, and Kelvin four-line detection can be used for contact resistance detection.

[0105] It should be explained that the surface roughness detection value refers to the degree of microscopic profile undulation in the target contact area that affects contact impedance and signal transmission rate. For example, multiple roughness detection points are divided in the detection area, and the surface roughness of multiple roughness detection points is detected using a white light interferometer to obtain a set of roughness detection values. The average of the roughness detection values ​​in the set is taken as the surface roughness detection value of the detection area. The dielectric residue detection value refers to the content of insulating residue remaining in the target contact area after the dielectric layer is stripped. For example, the infrared spectrum of the detection area is scanned to obtain the infrared spectrum, and the peak area of ​​the infrared spectrum is calculated to obtain the dielectric residue detection value. The contact resistance detection value refers to the resistance value generated when current flows through the detection area in the target contact area. For example, the contact resistance of the detection area is detected using a Kelvin four-wire detector to obtain the contact resistance detection value of the detection area.

[0106] It is clear that the surface roughness detection threshold refers to the maximum permissible surface roughness of the riveted wire harness under inspection within the quality inspection acceptance standard. The dielectric residue detection threshold refers to the maximum permissible dielectric residue of the riveted wire harness under inspection within the quality inspection acceptance standard. The contact resistance detection threshold refers to the maximum permissible contact resistance of the riveted wire harness under inspection within the quality inspection acceptance standard. The quality inspection acceptance standard is obtained from existing wire harness process standards.

[0107] Understandably, when the surface roughness detection value, dielectric residue detection value, and contact resistance detection value of the wire harness to be riveted are all less than the surface roughness detection threshold, the dielectric residue detection value is less than the dielectric residue detection threshold, and the contact resistance detection value is less than the contact resistance detection threshold, it indicates that the mechanical properties, electrical properties, and signal transmission rate of the wire harness to be riveted all meet the quality inspection standards for 224G high-speed wire harness raw materials. Therefore, the wire harness to be riveted is considered a pre-riveted wire harness. A pre-riveted wire harness refers to a wire harness that can be used for subsequent ultrasonic riveting.

[0108] It should be explained that if multiple detection parameters contain surface roughness detection values ​​greater than or equal to the surface roughness detection threshold, dielectric residue detection values ​​greater than or equal to the dielectric residue detection threshold, or contact resistance detection values ​​greater than or equal to the contact resistance detection threshold, it indicates that improper pretreatment of high-speed wire harness raw materials has led to quality inspection failure to meet the inspection standards. The high-speed wire harness raw materials need to be re-polished and laser textured. For example, during the polishing process, if a certain position in the initial contact area is not completely immersed in the acidic polishing solution, it will result in its failure to pass the inspection.

[0109] S3. Receive a precise alignment command from the high-precision alignment unit, and align the pre-riveted wire harness with the pre-built target connector based on the precise alignment command to obtain the wire harness to be riveted.

[0110] It is clear that the high-precision alignment unit is a functional module in the wire harness assembly system used to align the wire harness to be riveted with the target connector. For example, a multispectral vision alignment system can be used as the high-precision positioning unit.

[0111] Furthermore, the step of aligning the pre-riveted wire harness with the pre-constructed target connector based on the precise alignment command to obtain the wire harness to be riveted includes:

[0112] Based on the precise alignment command, obtain the three-dimensional spatial data of the target contact area and the target connector in the pre-riveted wire harness, and obtain the spatial position of the contact area and the spatial position of the connector.

[0113] The geometric features of the target contact area and the target connector are identified using a pre-constructed projection method, resulting in the geometric features of the contact area and the connector.

[0114] Using a pre-built positioning method, the spatial positions of the contact area, connector, contact area geometry, and connector geometry are spatially aligned to obtain alignment reference points;

[0115] The target contact area and target connector are aligned using a pre-constructed positioning device and alignment reference point to obtain the wire harness to be riveted.

[0116] It should be explained that the precise alignment command is an operation command issued by the high-precision alignment unit to begin aligning the target contact area and the target connector.

[0117] Understandably, obtaining the three-dimensional spatial data of the target contact area and target connector in a pre-riveted wire harness refers to placing and fixing the pre-riveted wire harness and target connector on a platform suitable for riveting, calibrating a three-dimensional coordinate system on the platform, and performing multi-angle scanning of the pre-riveted wire harness and target connector to obtain the three-dimensional spatial data. Optionally, a fully automatic high-precision riveting worktable of model Schunk Sonix 224G-Pro can be used as the riveting platform. Optionally, a laser scanner can be used to perform multi-angle scanning of the pre-riveted wire harness and target connector to obtain the three-dimensional spatial data. The spatial position of the contact area refers to the x, y, and z coordinates of the target contact area in the three-dimensional coordinate system, and the spatial position of the connector refers to the x, y, and z coordinates of the target connector in the three-dimensional coordinate system.

[0118] Optionally, orthographic projection is used as the projection method. The target contact area and the target connector are projected facing the projection direction to identify the projected shape of the connection holes in the target contact area and the target connector, thereby obtaining the corresponding geometric features. The geometric features of the contact area refer to the shape of the cross-section of the contact area, for example, the cross-section of the contact area is circular. The geometric features of the connector refer to the cross-sectional shape of the connection holes in the target connector, for example, the cross-section of the connection holes in the target connector is rectangular.

[0119] It should be explained that spatial alignment of the contact area spatial position, connector spatial position, contact area geometric features, and connector geometric features refers to identifying the spatial position of the center point of the connection surface of the connection area geometric features within the connector spatial position, and the spatial position of the center point of the contact surface of the contact area geometric features within the contact area spatial position. The center point of the connection surface refers to the spatial position of the center point of the projected shape of the outermost cross-section of the connection hole in the target connector, and the center point of the contact surface refers to the spatial position of the center point of the projected shape of the outermost cross-section of the target contact area. Identifying the center point of the contact area geometric features using the contact area spatial position is existing technology and will not be elaborated further here. The alignment reference point refers to the reference point used for alignment between the pre-riveted wire harness and the target connector, for example, using the spatial positions of the center points of the connection surface and the contact surface as alignment reference points.

[0120] Understandably, aligning the target contact area and the target connector using a positioning device and alignment reference points means placing the target contact area within the target connector using the positioning device until the spatial position of the center point of the connection surface completely overlaps with the spatial position of the center point of the contact surface. Optionally, a six-axis robot can be used as the positioning device. The wire harness to be riveted refers to the wire harness assembly after the pre-riveted wire harness and the target connector have been aligned and connected.

[0121] S4. Using preset ultrasonic parameter values, preset ambient temperature values, and preset riveting time, the wire harness to be riveted is riveted, and a riveting monitoring command is received from the ultrasonic riveting monitoring unit. Based on the riveting monitoring command, the wire harness to be riveted is monitored in real time to obtain the compression offset value and energy absorption value.

[0122] Furthermore, the riveting of the wire harness to be riveted using preset ultrasonic parameter values, preset ambient temperature values, and preset riveting time includes:

[0123] Target ultrasound is obtained using a pre-built ultrasonic generator and ultrasonic parameter values;

[0124] The target ultrasonic wave is converted using a pre-constructed transducer and a pre-constructed amplitude transformer to obtain the ultrasonic vibration amplitude, which is shown below:

[0125]

[0126] in, Indicates the amplitude of ultrasonic vibration. This represents the conversion efficiency factor of the transducer. This represents the piezoelectric strain constant of the transducer. This represents the drive voltage of the transducer. This indicates the quality factor of the transducer. Indicates the frequency of the ultrasonic wave. Indicates the riveting time. This represents the input cross-sectional area of ​​the amplitude transformer. This indicates the output cross-sectional area of ​​the amplitude transformer;

[0127] The wire harness to be riveted is riveted using a pre-built riveting tool head, ultrasonic vibration amplitude, riveting time, and ambient temperature. Ambient temperature monitoring values ​​are obtained at preset time intervals. Based on the ambient temperature monitoring values ​​and the pre-built riveting cooling unit, the wire harness to be riveted is cooled during riveting.

[0128] Understandably, obtaining target ultrasonic waves using an ultrasonic generator and its parameter values ​​refers to emitting ultrasonic waves of a specific frequency using an ultrasonic generator; optionally, a digital resonant generator can be used. An ultrasonic generator is an electronic device that converts electrical energy into high-frequency electrical signals (typically 20kHz-100kHz). Ultrasonic parameter values ​​refer to the frequency of the ultrasonic waves. Target ultrasonic waves refer to the ultrasonic waves used in subsequent riveting operations.

[0129] It is clear that a transducer is a device that uses the piezoelectric effect to convert high-frequency electrical signals into mechanical vibrations; optionally, a piezoelectric ceramic transducer can be used as a pre-built transducer. An amplitude transformer is a device that amplifies the minute vibrations generated by the transducer to the vibration amplitude required for the riveting operation; optionally, a stepped amplitude transformer can be used as a pre-built amplitude transformer. The ultrasonic vibration amplitude refers to the vibration amplitude of the riveting tool head during the riveting process.

[0130] It should be explained that the unit of the transducer's piezoelectric strain constant is m / V, the transducer's conversion efficiency factor is dimensionless, the transducer's quality factor is dimensionless, the unit of the transducer's driving voltage is V, the unit of the ultrasonic frequency is Hz, the unit of the riveting time is s, the units of the input cross-sectional area and the output cross-sectional area of ​​the amplitude transformer are square meters, and the unit of the calculated ultrasonic vibration amplitude is m. The input cross-sectional area of ​​the amplitude transformer refers to the area of ​​the cross-section at the connection between the amplitude transformer and the transducer. The output cross-sectional area of ​​the amplitude transformer refers to the area of ​​the cross-section at the connection between the amplitude transformer and the riveting tool head. The piezoelectric strain constant of the transducer is obtained from the piezoelectric material in the transducer. For example, the piezoelectric strain constant of barium titanate is 190. The driving voltage of the transducer refers to the power supply voltage of the transducer. The quality factor of the transducer is determined by the type of transducer. For example, under normal circumstances, the quality factor of a piezoelectric ceramic transducer is in the range of 50-1000. When the ultrasonic frequency is small, the quality factor is the maximum value of 1000. When the ultrasonic frequency is large, the quality factor is the minimum value of 50. In this embodiment of the invention, the quality factor is in the range of 50-500. The average value of the corresponding range, 275, is taken as the quality factor of the transducer. The conversion efficiency factor of the transducer is determined by the type of transducer. For example, the conversion efficiency factor of a piezoelectric ceramic transducer is 80%.

[0131] Understandably, a riveting tool head refers to a device used to rivet wire harnesses, such as hexagonal crimp heads, double-wing crimp heads, and square crimp heads. Riveting time refers to the duration of the riveting process. Ambient temperature refers to the ambient temperature before riveting begins.

[0132] Optionally, a temperature sensor is used to acquire ambient temperature monitoring values ​​at preset time intervals, for example, acquiring ambient temperature monitoring values ​​every 10 seconds.

[0133] Furthermore, the cooling of the wire harness to be riveted during riveting based on the ambient temperature monitoring value and the pre-constructed riveting cooling unit includes:

[0134] Calculate the difference between the monitored ambient temperature value and the actual ambient temperature value to obtain the ambient temperature difference.

[0135] If the ambient temperature difference is greater than the preset ambient temperature difference threshold, the target contact area is cooled by using the preset cooling temperature, the riveting cooling unit and the preset cooling time. The time is recorded in real time starting from the cooling time to obtain the recording interval time. When the recording interval time is equal to the cooling time, the updated ambient temperature monitoring value is obtained.

[0136] Based on the updated ambient temperature monitoring value, an updated ambient temperature difference is obtained. If the updated ambient temperature difference is greater than the ambient temperature difference threshold, the difference between the updated ambient temperature difference and the ambient temperature difference threshold is calculated to obtain the temperature control value.

[0137] Calculate the difference between the ambient temperature difference and the updated ambient temperature difference to obtain the change in temperature difference;

[0138] The target control value is the updated ambient temperature difference, temperature control value, and temperature difference change value.

[0139] Based on the target control value and the pre-built PID control algorithm, the temperature drop value is obtained. Based on the temperature drop value and the temperature drop value, the updated temperature drop value is obtained. The updated temperature drop value is used as the temperature drop value. The process of cooling the target contact area using the preset temperature drop value and the preset temperature drop value is returned until the updated ambient temperature difference is less than or equal to the ambient temperature difference threshold is reached.

[0140] It is clear that the ambient temperature monitoring value refers to the temperature of the surrounding environment during the riveting process. The ambient temperature difference refers to the difference between the current ambient temperature during the riveting process and the ambient temperature at the start of riveting. The ambient temperature difference threshold is a value used to determine whether cooling is required during the riveting process. When the ambient temperature difference exceeds the ambient temperature difference threshold, cooling treatment of the riveting environment is required.

[0141] It should be explained that the cooling temperature refers to the temperature at which the riveting environment is cooled, and the cooling time refers to the time during which the riveting environment is cooled. For example, cooling the riveting environment to 25 degrees Celsius for 1 minute. The recording interval time refers to the actual cooling time during the riveting process.

[0142] Understandably, the updated ambient temperature monitoring value refers to the ambient temperature value during the riveting process after cooling. The updated ambient temperature difference refers to the difference between the current ambient temperature value after cooling during the riveting process and the ambient temperature at the start of riveting. For example, if the ambient temperature at the start of riveting is 20 degrees Celsius, and the current ambient temperature after starting riveting is 40 degrees Celsius, then the ambient temperature difference is 20 degrees Celsius. After cooling the environment, the updated ambient temperature monitoring value is 35 degrees Celsius, then the updated ambient temperature difference is 15 degrees Celsius.

[0143] It should be explained that the temperature control value refers to the value by which the ambient temperature still needs to decrease after cooling. For example, if the ambient temperature difference threshold is 10 degrees Celsius and the updated ambient temperature difference is 15 degrees Celsius, then the temperature control value is 5 degrees Celsius, meaning the ambient temperature still needs to be reduced by 5 degrees Celsius. The temperature difference change value refers to the decrease in ambient temperature after cooling. For example, if the ambient temperature difference is 20 degrees Celsius and the updated ambient temperature difference is 15 degrees Celsius, then the temperature difference change value is 5 degrees Celsius, meaning the temperature has decreased by 5 degrees Celsius.

[0144] It is clear that the target control value refers to the input parameter value of the PID control algorithm, used to precisely control the temperature drop. The PID control algorithm is an algorithm that obtains the temperature drop value through differential proportional control, integral proportional control, and derivative proportional control. For example, updating the ambient temperature difference is used as the differential proportional control part to represent the current ambient temperature difference; the temperature control value is used as the derivative proportional control part to represent the changing trend of the ambient temperature difference; and the change in temperature difference is used as the integral proportional control part to represent the degree of ambient temperature deviation after cooling. The PID control algorithm sets the control ratios for updating the ambient temperature difference, temperature regulation value, and temperature difference change value. It then calculates the sum of the products of these ratios to obtain the temperature drop. For example, if the updated ambient temperature difference is 15 degrees Celsius, the temperature regulation value is 5 degrees Celsius, and the temperature difference change value is 5 degrees Celsius, and the PID control algorithm sets the control ratio for updating the ambient temperature difference to 0.2, the control ratio for the temperature regulation value to 0.4, and the control ratio for the temperature difference change value to 0.2, then the temperature drop value is 15*0.2 + 5*0.4 + 5*0.2 = 6 degrees Celsius. The PID control algorithm's setting of these control ratios is existing technology and will not be elaborated further. The updated cooling temperature refers to the cooling temperature reset based on the temperature drop value. For example, if the cooling temperature is 25 degrees Celsius and the temperature drop value is 6 degrees Celsius, then the updated cooling temperature is 19 degrees Celsius.

[0145] It should be explained that the riveting cooling unit is a functional module used to cool the ambient temperature. Its function is to prevent the riveting wire harness from being damaged due to excessively high ambient temperature. Optionally, an industrial chiller can be used as the riveting cooling unit.

[0146] Understandably, the ultrasonic riveting monitoring unit is a functional module in the wire harness assembly system that monitors the wire harness to be riveted in real time during the riveting process. Optionally, a laser displacement sensor can be used as the ultrasonic riveting monitoring unit, and the riveting monitoring command is the operation command issued by the ultrasonic riveting monitoring unit to start riveting monitoring.

[0147] Optionally, a laser displacement sensor is used to monitor the wire harness to be riveted to obtain a compression offset value. An amplitude-compression offset curve is then plotted using the compression offset value and the ultrasonic vibration amplitude. The energy absorption value is calculated by integrating the amplitude-compression offset curve. The compression offset value refers to the deformation value of the wire harness after riveting, and the energy absorption value refers to the energy absorbed by the wire harness during the riveting process.

[0148] S5. Based on the compression offset value and energy absorption value, an updated ultrasonic frequency value is obtained using a pre-constructed fuzzy control algorithm, and a pre-confirmed high-speed wire harness is obtained using the updated ultrasonic frequency value.

[0149] Furthermore, the step of obtaining the updated ultrasonic frequency value based on the compression offset value and energy absorption value using a pre-built fuzzy control algorithm includes:

[0150] Obtain the compression offset standard range and the energy absorption standard range, wherein the compression offset standard range includes the minimum compression offset range value and the maximum compression offset range value, and the energy absorption standard range includes the minimum energy absorption range value and the maximum energy absorption range value;

[0151] Calculate the mean of the minimum compression offset interval value and the maximum compression offset interval value to obtain the mean of the compression offset interval. Based on the minimum energy absorption interval value and the maximum energy absorption interval value, obtain the mean of the energy absorption interval.

[0152] Calculate the absolute difference between the compression offset value and the mean of the compression offset interval, and the absolute difference between the energy absorption value and the mean of the energy absorption interval, respectively, to obtain the compression offset deviation value and the energy absorption deviation value;

[0153] By summing the compression offset deviation value and the energy absorption deviation value, a reference control value set is obtained;

[0154] The updated ultrasonic frequency value is obtained based on the reference control value set and the pre-constructed fuzzy control algorithm, wherein the calculation formula for the updated ultrasonic frequency value is:

[0155]

[0156] in, This indicates an update to the ultrasonic frequency. Indicates the fuzzy control weights. This represents the correction amount of the ultrasonic parameters output by the fuzzy control algorithm. The weights representing the compression offset deviation values. The weights representing deviations from energy absorption values. This indicates the compression offset deviation value. This represents the mean of the compressed offset interval. This indicates the deviation value of energy absorption. This represents the mean of the energy absorption range. This indicates the maximum allowable adjustment range of the ultrasonic frequency.

[0157] It is clear that the compression offset standard range and energy absorption standard range are obtained through existing riveting industry process standards. The compression offset standard range refers to the range within which the compression offset value of the wire harness to be riveted needs to be during ultrasonic riveting. The energy absorption standard range refers to the range within which the energy absorption value of the wire harness to be riveted needs to be during ultrasonic riveting.

[0158] It should be explained that the mean of the compression offset interval refers to the arithmetic mean of the minimum and maximum compression offset interval values. The mean of the energy absorption interval refers to the arithmetic mean of the minimum and maximum energy absorption interval values.

[0159] Understandably, the compression offset deviation value indicates the degree of deviation of the compression offset value from the average value of the compression offset interval. A larger compression offset value requires increasing the ultrasonic frequency needed for riveting. For example, if the compression offset interval is [0.4, 0.6], the average value is 0.5, the compression offset value before riveting begins is 0, and during riveting, the compression offset value is 0.1, then the compression offset deviation value is 0.4, requiring an increase in the ultrasonic frequency. The energy absorption deviation value indicates the degree of deviation of the energy absorption value from the average value of the energy absorption interval. For example, if the energy absorption interval is [100, 120], the average value is 110, the energy absorption value before riveting begins is 0, and during riveting, the energy absorption value is 80, then the energy absorption deviation value is 30, requiring an increase in the ultrasonic frequency.

[0160] It should be explained that the reference control value set refers to the set of values ​​that use the compression offset deviation value and the energy absorption deviation value as input values ​​for the fuzzy control algorithm.

[0161] It is clear that the method of obtaining ultrasonic parameter correction values ​​using fuzzy control algorithms to obtain compression offset deviation values ​​and energy absorption deviation values ​​is existing technology and will not be elaborated here. Optionally, Sugeno fuzzy control can be used as the fuzzy control algorithm. The updated ultrasonic frequency is obtained using the ultrasonic frequency correction value and the aforementioned calculation formula. The updated ultrasonic frequency refers to the ultrasonic frequency that changes according to the compression offset deviation value and energy absorption deviation value during the riveting process. The maximum allowable adjustment range of the ultrasonic frequency refers to the maximum ultrasonic frequency that the ultrasonic generator can emit. For example, if the ultrasonic generator converts electrical energy into high-frequency electrical signals in the range of 20kHz-100kHz, then the maximum allowable adjustment range is 100kHz.

[0162] Furthermore, the step of obtaining the pre-confirmed high-speed harness using the updated ultrasonic frequency value includes:

[0163] The updated ultrasonic frequency value is used to rivet the wire harness to be riveted, and the updated compression offset value and updated energy absorption value of the wire harness to be riveted are monitored during the riveting process.

[0164] Based on the updated compression offset value and the updated energy absorption value, obtain the updated compression offset deviation value and the updated energy absorption deviation value;

[0165] If the updated compression offset deviation value is less than the preset compression offset deviation threshold and the updated energy absorption deviation value is less than the preset energy absorption deviation threshold, a pre-confirmed high-speed harness is obtained.

[0166] If the updated compression offset deviation value is greater than or equal to the compression offset deviation threshold or the updated energy absorption deviation value is greater than or equal to the energy absorption deviation threshold, then return to the step of obtaining the updated ultrasonic frequency value based on the reference control value set and the pre-constructed fuzzy control algorithm until a pre-confirmed high-speed harness is obtained.

[0167] It should be explained that using updated ultrasonic frequency values ​​to rivet the wire harness to be riveted means using ultrasonic parameters, ambient temperature values, and riveting time to rivet the wire harness to be riveted, and monitoring the ambient temperature values ​​at preset time intervals. If the ambient temperature difference is higher than the ambient temperature difference threshold, the riveting cooling unit is used to cool the wire harness to be riveted. The ultrasonic parameter values ​​are adjusted in real time according to the compression offset value and energy absorption value of the wire harness to be riveted, and finally a pre-confirmed high-speed wire harness is obtained.

[0168] Understandably, the updated compression offset value refers to the compression offset value of the wire harness to be riveted after riveting using updated ultrasonic parameters. The updated energy absorption value refers to the energy absorption value of the wire harness to be riveted after riveting using updated ultrasonic parameters.

[0169] It is clear that the updated compression offset deviation value refers to the absolute difference between the updated compression offset value and the mean of the compression offset interval. Similarly, the updated energy absorption deviation value refers to the absolute difference between the updated energy absorption value and the mean of the energy absorption interval.

[0170] Understandably, the compression offset deviation threshold refers to the compression offset deviation value used to determine whether riveting is complete. The energy absorption deviation threshold refers to the energy absorption deviation value used to determine whether riveting is complete. For example, if the compression offset deviation threshold is 0.1 and the updated compression offset deviation value is 0.05, and the energy absorption deviation threshold is 5 and the updated energy absorption deviation value is 4, then if both the updated compression offset deviation value and the updated energy absorption deviation value are less than the compression offset deviation threshold and the updated energy absorption deviation value are less than the energy absorption deviation threshold, it indicates that riveting is complete, and a pre-confirmed high-speed wire harness is obtained. A pre-confirmed high-speed wire harness refers to a high-speed wire harness obtained after ultrasonic riveting that requires quality inspection.

[0171] It should be explained that when the updated compression offset deviation value is close to or greater than the compression offset deviation threshold, the ultrasonic frequency correction amount output by the fuzzy control algorithm can be negative, which is used to reduce the ultrasonic frequency.

[0172] S6. Receive a quality inspection instruction from the quality inspection unit, perform quality inspection on the pre-confirmed high-speed wire harness based on the quality inspection instruction, obtain the target high-speed wire harness, and assemble the high-speed wire harness based on the target high-speed wire harness.

[0173] It is clear that the quality inspection unit refers to the functional module in the wire harness assembly system used to inspect and confirm whether the quality of the high-speed wire harness is up to standard.

[0174] Furthermore, the step of performing quality inspection on the pre-confirmed high-speed harness based on the quality inspection command to obtain the target high-speed harness includes:

[0175] Based on the quality inspection command, a performance testing method is obtained, and the pre-confirmed high-speed harness is tested based on the performance testing method to obtain the insertion loss value and return loss value.

[0176] The insertion and removal durability test was performed on the pre-confirmed high-speed wiring harness to obtain the wear value of the high-speed wiring harness.

[0177] Vibration tests were performed on the pre-confirmed high-speed wiring harness to obtain the change in contact resistance.

[0178] Obtain the insertion loss threshold, return loss threshold, high-speed harness wear threshold, and contact resistance change threshold;

[0179] If the insertion loss value is less than the insertion loss threshold, the return loss value is less than the return loss threshold, the high-speed harness wear value is less than the high-speed harness wear threshold, and the contact resistance change value is less than the contact resistance change threshold, then the pre-confirmed high-speed harness is taken as the target high-speed harness.

[0180] Understandably, the quality inspection command is an operational instruction issued by the quality inspection unit to begin quality inspection of the pre-confirmed high-speed wire harness. Obtaining the performance test method based on the quality inspection command means that after the quality inspection unit issues the quality inspection command, the performance tester receives and confirms the performance test method. Optionally, a vector network analyzer is used as the performance detector required for the performance test method. The vector network analyzer is used to perform performance testing on the pre-confirmed crimped wire harness to obtain insertion loss and return loss values. Insertion loss refers to the power loss caused by the insertion of the high-speed wire harness during signal transmission, and return loss refers to the signal energy reflected back to the source during high-speed signal transmission.

[0181] It is clear that performing a mating and extraction durability test on a pre-confirmed high-speed harness refers to conducting 1000 mating and extraction tests on the pre-confirmed high-speed harness and measuring the wear value of the high-speed harness in the target connector area of ​​the pre-confirmed high-speed harness. Optionally, the wear value of the high-speed harness can be measured using a laser confocal scanning microscope. The high-speed harness wear value refers to the reduction in surface thickness of the pre-confirmed high-speed harness after the mating and extraction test compared to the initial pre-confirmed high-speed harness.

[0182] Understandably, vibration testing of a pre-confirmed high-speed wiring harness involves placing the harness on a vibration machine and subjecting it to random frequency vibration for one hour. After vibration, the harness is left to stand for 10 minutes, and then contact resistance is measured. Optionally, an electric vibration table can be used as the vibration machine. The change in contact resistance refers to the difference between the contact resistance value of the pre-confirmed high-speed wiring harness after the vibration test and the initial contact resistance value of the pre-confirmed high-speed wiring harness.

[0183] It should be explained that, optionally, the insertion loss threshold, return loss threshold, high-speed harness wear threshold, and contact resistance variation threshold can be obtained through existing riveting process industry standards. The insertion loss threshold refers to the maximum insertion loss that meets the pre-qualification high-speed harness quality testing conditions. The return loss threshold refers to the maximum return loss that meets the pre-qualification high-speed harness quality testing conditions. The high-speed harness wear threshold refers to the maximum wear value of the high-speed harness that meets the pre-qualification high-speed harness quality testing conditions. The contact resistance variation threshold refers to the maximum change in contact resistance that meets the pre-qualification high-speed harness quality testing conditions.

[0184] It is clear that when the insertion loss value is less than the insertion loss threshold, the return loss value is less than the return loss threshold, the high-speed harness wear value is less than the high-speed harness wear threshold, and the contact resistance change value is less than the contact resistance change threshold, it means that the signal transmission performance and mechanical performance of the pre-confirmed high-speed harness meet the quality standard of 224G high-speed harness. Therefore, the pre-confirmed high-speed harness is taken as the target high-speed harness.

[0185] It should be explained that, in this embodiment of the invention, the process of identifying the target high-speed wire harness refers to the process of sampling and testing multiple pre-identified high-speed wire harnesses. For example, 100 pre-identified high-speed wire harnesses are randomly selected from 10,000 pre-identified high-speed wire harnesses, and quality testing is performed on these 100 pre-identified high-speed wire harnesses. Among them, 99 meet the quality testing standards in this embodiment, that is, the pass rate is 99%, and the pass rate is greater than the pass rate threshold of 98%. Therefore, the remaining pre-identified high-speed wire harnesses in the 10,000 pre-identified high-speed wire harnesses are considered to meet the quality testing standards.

[0186] To address the problems described in the background art, this invention pre-processes high-speed wire harness raw materials to obtain pre-riveted wire harnesses. It is evident that this invention considers the impact of high-speed wire harness raw materials on signal transmission rates before riveting. Therefore, it performs dielectric layer stripping, polishing, and laser texturing operations on the high-speed wire harness raw materials, and conducts quality inspection to ensure that the high-speed wire harness raw materials meet the requirements for high-speed signal transmission. Furthermore, it receives precise alignment instructions from a high-precision alignment unit, and based on these instructions, it aligns the pre-riveted wire harness with the pre-constructed target connector. The alignment process yields the wire harness to be riveted. It is evident that this invention addresses the issue of inaccurate connection between the high-speed wire harness and the target connector during alignment. Therefore, a high-precision alignment unit ensures more accurate alignment, laying the foundation for subsequent ultrasonic riveting of the wire harness. The process utilizes preset ultrasonic parameters, ambient temperature, and riveting time to rivet the wire harness, while receiving riveting monitoring commands from the ultrasonic riveting monitoring unit. Based on these commands, the riveting process is monitored in real-time. The wire harness is monitored to obtain compression offset and energy absorption values. This invention also considers the potential damage to the wire harness caused by increased ambient temperature during ultrasonic riveting. A riveting cooling unit is used to cool the riveting process. Based on the compression offset and energy absorption values, a pre-built fuzzy control algorithm is used to obtain an updated ultrasonic frequency value. This updated ultrasonic frequency value is then used to obtain a pre-confirmed high-speed wire harness. During ultrasonic riveting, the wire harness parameters are monitored in real-time, and the ultrasonic parameters are dynamically adjusted to ensure more precise riveting. A quality inspection command is received from the quality inspection unit, and the pre-confirmed high-speed wire harness is inspected to obtain the target high-speed wire harness. The high-speed wire harness is then assembled based on the target high-speed wire harness. Therefore, after ultrasonic riveting, this invention considers whether the pre-confirmed high-speed wire harness meets the 224G high-speed signal transmission requirements. The performance of the pre-confirmed high-speed wire harness is tested using a quality inspection method to obtain the target high-speed wire harness, which is then used to assemble the high-speed wire harness. Therefore, the present invention enables high-precision assembly of high-speed wire harnesses using ultrasonic riveting.

[0187] like Figure 2 The diagram shown is a functional block diagram of a 224G high-speed wire harness assembly system based on ultrasonic riveting provided in an embodiment of the present invention.

[0188] The 224G high-speed wire harness assembly system 100 based on ultrasonic riveting described in this invention can be installed in electronic devices. Depending on the functions implemented, the 224G high-speed wire harness assembly system 100 based on ultrasonic riveting may include a riveting environment verification module 101, a riveting material processing module 102, an ultrasonic riveting module 103, and a wire harness quality detection module 104. The module described in this invention can also be called a unit, referring to a series of computer program segments that can be executed by the processor of an electronic device and can perform a fixed function, stored in the memory of the electronic device.

[0189] The riveting environment confirmation module 101 is used to receive wire harness assembly instructions and confirm the wire harness assembly environment based on the wire harness assembly instructions. The wire harness assembly environment includes a wire harness assembly system and high-speed wire harness raw materials to be assembled. The wire harness assembly system includes a high-precision alignment unit, an ultrasonic riveting monitoring unit, and a quality detection unit.

[0190] The riveting material processing module 102 is used to pre-process the high-speed wire harness raw materials to obtain a pre-riveted wire harness.

[0191] Receive a precise alignment command from a high-precision alignment unit, and align the pre-riveted wire harness with the pre-built target connector based on the precise alignment command to obtain the wire harness to be riveted;

[0192] The ultrasonic riveting module 103 is used to rivet the wire harness to be riveted using preset ultrasonic parameter values, preset ambient temperature values ​​and preset riveting time, and to receive riveting monitoring instructions from the ultrasonic riveting monitoring unit. Based on the riveting monitoring instructions, the module monitors the wire harness to be riveted in real time to obtain compression offset value and energy absorption value.

[0193] Based on the compression offset value and energy absorption value, a pre-constructed fuzzy control algorithm is used to obtain an updated ultrasonic frequency value, which is beneficial for obtaining a pre-confirmed high-speed wire harness using the updated ultrasonic frequency value.

[0194] The wire harness quality inspection module 104 is used to receive quality inspection instructions from the quality inspection unit, perform quality inspection on the pre-confirmed high-speed wire harness based on the quality inspection instructions, obtain the target high-speed wire harness, and assemble the high-speed wire harness based on the target high-speed wire harness.

[0195] In detail, the modules in the 224G high-speed wire harness assembly system 100 based on ultrasonic riveting described in this embodiment of the invention employ the same methods as described above during use. Figure 1 The method used is the same as the ultrasonic riveting-based 224G high-speed wire harness assembly method described above, and can produce the same technical effect, so it will not be repeated here.

[0196] like Figure 3The diagram shown is a structural schematic of an electronic device that implements a 224G high-speed wire harness assembly method based on ultrasonic riveting, according to an embodiment of the present invention.

[0197] The electronic device 1 may include a processor 10, a memory 11 and a bus 12, and may also include a computer program stored in the memory 11 and executable on the processor 10, such as a program for a 224G high-speed wire harness assembly method based on ultrasonic riveting.

[0198] The memory 11 includes at least one type of readable storage medium, such as flash memory, portable hard drive, multimedia card, card-type memory (e.g., SD or DX memory), magnetic memory, magnetic disk, optical disk, etc. In some embodiments, the memory 11 can be an internal storage unit of the electronic device 1, such as a portable hard drive. In other embodiments, the memory 11 can be an external storage device of the electronic device 1, such as a plug-in portable hard drive, smart media card (SMC), secure digital card (SD), flash card, etc., equipped on the electronic device 1. Furthermore, the memory 11 includes both internal storage units and external storage devices of the electronic device 1. The memory 11 can be used not only to store application software and various types of data installed on the electronic device 1, such as the code of a 224G high-speed wire harness assembly method program based on ultrasonic riveting, but also to temporarily store data that has been output or will be output.

[0199] In some embodiments, the processor 10 may be composed of integrated circuits, such as a single packaged integrated circuit or multiple integrated circuits with the same or different functions, including combinations of one or more central processing units (CPUs), microprocessors, digital processing chips, graphics processors, and various control chips. The processor 10 is the control unit of the electronic device, connecting various components of the entire electronic device through various interfaces and lines. It executes programs or modules stored in the memory 11 (e.g., a program for assembling a 224G high-speed wire harness based on ultrasonic riveting), and calls data stored in the memory 11 to perform various functions of the electronic device 1 and process data.

[0200] The bus 12 can be a peripheral component interconnect (PCI) bus or an extended industry standard architecture (EISA) bus, etc. The bus 12 can be divided into an address bus, a data bus, a control bus, etc. The bus 12 is configured to realize the connection and communication between the memory 11 and at least one processor 10, etc.

[0201] Figure 3 Only electronic devices with components are shown; it will be understood by those skilled in the art that... Figure 3 The structure shown does not constitute a limitation on the electronic device 1, and may include fewer or more components than shown, or combine certain components, or have different component arrangements.

[0202] For example, although not shown, the electronic device 1 may also include a power supply (such as a battery) to power the various components. Preferably, the power supply can be logically connected to the at least one processor 10 through a power management device, thereby enabling functions such as charging management, discharging management, and power consumption management. The power supply may also include one or more DC or AC power supplies, recharging devices, power fault detection circuits, power converters or inverters, power status indicators, and other arbitrary components. The electronic device 1 may also include various sensors, Bluetooth modules, Wi-Fi modules, etc., which will not be described in detail here.

[0203] Furthermore, the electronic device 1 may also include a network interface. Optionally, the network interface may include a wired interface and / or a wireless interface (such as a Wi-Fi interface, a Bluetooth interface, etc.), which is typically used to establish communication connections between the electronic device 1 and other electronic devices.

[0204] Optionally, the electronic device 1 may further include a user interface, which may be a display, an input unit (such as a keyboard), and optionally, a standard wired interface or a wireless interface. Optionally, in some embodiments, the display may be an LED display, a liquid crystal display, a touch-sensitive liquid crystal display, or an OLED (Organic Light-Emitting Diode) touchscreen, etc. The display may also be appropriately referred to as a screen or display unit, used to display information processed in the electronic device 1 and to display a visual user interface.

[0205] The program for assembling a 224G high-speed wire harness based on ultrasonic riveting, stored in the memory 11 of the electronic device 1, is a combination of multiple instructions. When run in the processor 10, it can achieve the following:

[0206] Receive a wire harness assembly instruction, and confirm the wire harness assembly environment based on the wire harness assembly instruction. The wire harness assembly environment includes a wire harness assembly system and high-speed wire harness raw materials to be assembled. The wire harness assembly system includes a high-precision alignment unit, an ultrasonic riveting monitoring unit, and a quality inspection unit.

[0207] Pre-processing of high-speed wire harness raw materials yields pre-riveted wire harnesses;

[0208] Receive a precise alignment command from a high-precision alignment unit, and align the pre-riveted wire harness with the pre-built target connector based on the precise alignment command to obtain the wire harness to be riveted;

[0209] The wire harness to be riveted is riveted using preset ultrasonic parameter values, preset ambient temperature values, and preset riveting time. The riveting monitoring command is received from the ultrasonic riveting monitoring unit. Based on the riveting monitoring command, the wire harness to be riveted is monitored in real time to obtain compression offset value and energy absorption value.

[0210] Based on the compression offset value and energy absorption value, an updated ultrasonic frequency value is obtained using a pre-constructed fuzzy control algorithm, and a pre-confirmed high-speed wire harness is obtained using the updated ultrasonic frequency value.

[0211] The system receives a quality inspection command from the quality inspection unit, performs quality inspection on the pre-confirmed high-speed wire harness based on the quality inspection command, obtains the target high-speed wire harness, and assembles the high-speed wire harness based on the target high-speed wire harness.

[0212] Specifically, the processor 10's implementation method for the above instructions can be found in [reference needed]. Figures 1 to 3 The descriptions of the relevant steps in the corresponding embodiments are not repeated here.

[0213] Furthermore, if the modules / units integrated in the electronic device 1 are implemented as software functional units and sold or used as independent products, they can be stored in a computer-readable storage medium. The computer-readable storage medium can be volatile or non-volatile. For example, the computer-readable medium may include: any entity or device capable of carrying the computer program code, a recording medium, a USB flash drive, a portable hard drive, a magnetic disk, an optical disk, a computer memory, or a read-only memory (ROM).

[0214] The present invention also provides a computer-readable storage medium storing a computer program, which, when executed by a processor of an electronic device, can perform the following:

[0215] Receive a wire harness assembly instruction, and confirm the wire harness assembly environment based on the wire harness assembly instruction. The wire harness assembly environment includes a wire harness assembly system and high-speed wire harness raw materials to be assembled. The wire harness assembly system includes a high-precision alignment unit, an ultrasonic riveting monitoring unit, and a quality inspection unit.

[0216] Pre-processing of high-speed wire harness raw materials yields pre-riveted wire harnesses;

[0217] Receive a precise alignment command from a high-precision alignment unit, and align the pre-riveted wire harness with the pre-built target connector based on the precise alignment command to obtain the wire harness to be riveted;

[0218] The wire harness to be riveted is riveted using preset ultrasonic parameter values, preset ambient temperature values, and preset riveting time. The riveting monitoring command is received from the ultrasonic riveting monitoring unit. Based on the riveting monitoring command, the wire harness to be riveted is monitored in real time to obtain compression offset value and energy absorption value.

[0219] Based on the compression offset value and energy absorption value, an updated ultrasonic frequency value is obtained using a pre-constructed fuzzy control algorithm, and a pre-confirmed high-speed wire harness is obtained using the updated ultrasonic frequency value.

[0220] The system receives a quality inspection command from the quality inspection unit, performs quality inspection on the pre-confirmed high-speed wire harness based on the quality inspection command, obtains the target high-speed wire harness, and assembles the high-speed wire harness based on the target high-speed wire harness.

[0221] In the embodiments provided by this invention, it should be understood that the disclosed devices, systems, and methods can be implemented in other ways. For example, the system embodiments described above are merely illustrative, and actual implementations may have other classification methods.

[0222] The modules described as separate components may or may not be physically separate. The components shown as modules may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs.

[0223] Furthermore, the functional modules in the various embodiments of the present invention can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or in the form of hardware plus software functional modules.

[0224] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the present invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the present invention.

[0225] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. A method for assembling a 224G high-speed wire harness based on ultrasonic riveting, characterized in that, The method includes: Receive a wire harness assembly instruction, and confirm the wire harness assembly environment based on the wire harness assembly instruction. The wire harness assembly environment includes a wire harness assembly system and high-speed wire harness raw materials to be assembled. The wire harness assembly system includes a high-precision alignment unit, an ultrasonic riveting monitoring unit, and a quality inspection unit. Pre-processing of high-speed wire harness raw materials yields pre-riveted wire harnesses; Receive a precise alignment command from a high-precision alignment unit, and align the pre-riveted wire harness with the pre-built target connector based on the precise alignment command to obtain the wire harness to be riveted; The wire harness to be riveted is riveted using preset ultrasonic parameter values, preset ambient temperature values, and preset riveting time. The riveting monitoring command is received from the ultrasonic riveting monitoring unit. Based on the riveting monitoring command, the wire harness to be riveted is monitored in real time to obtain compression offset value and energy absorption value. The step of riveting the wire harness to be riveted using preset ultrasonic parameter values, preset ambient temperature values, and preset riveting time includes: Target ultrasound is obtained using a pre-built ultrasonic generator and ultrasonic parameter values; The target ultrasonic wave is converted using a pre-built transducer and a pre-built amplitude transformer to obtain the ultrasonic vibration amplitude. The wire harness to be riveted is riveted using a pre-built riveting tool head, the ultrasonic vibration amplitude, the riveting time, and the ambient temperature value. The ambient temperature monitoring value is obtained at a preset time interval. The wire harness to be riveted is cooled based on the ambient temperature monitoring value and the pre-built riveting cooling unit. Based on the compression offset value and energy absorption value, an updated ultrasonic frequency value is obtained using a pre-constructed fuzzy control algorithm, and a pre-confirmed high-speed wire harness is obtained using the updated ultrasonic frequency value. The step of obtaining the updated ultrasonic frequency value using a pre-constructed fuzzy control algorithm based on the compression offset value and energy absorption value includes: Obtain the compression offset standard range and the energy absorption standard range, wherein the compression offset standard range includes the minimum compression offset range value and the maximum compression offset range value, and the energy absorption standard range includes the minimum energy absorption range value and the maximum energy absorption range value; Calculate the mean of the minimum compression offset interval value and the maximum compression offset interval value to obtain the mean of the compression offset interval. Based on the minimum energy absorption interval value and the maximum energy absorption interval value, obtain the mean of the energy absorption interval. Calculate the absolute difference between the compression offset value and the mean of the compression offset interval, and the absolute difference between the energy absorption value and the mean of the energy absorption interval, respectively, to obtain the compression offset deviation value and the energy absorption deviation value; By summing the compression offset deviation value and the energy absorption deviation value, a reference control value set is obtained; The updated ultrasonic frequency value is obtained based on the reference control value set and the pre-constructed fuzzy control algorithm; The system receives a quality inspection command from the quality inspection unit, performs quality inspection on the pre-confirmed high-speed wire harness based on the quality inspection command, obtains the target high-speed wire harness, and assembles the high-speed wire harness based on the target high-speed wire harness.

2. The 224G high-speed wire harness assembly method based on ultrasonic riveting as described in claim 1, characterized in that, The pretreatment of high-speed wire harness raw materials to obtain pre-riveted wire harnesses includes: The initial contact area of ​​the high-speed wire harness raw material was identified in the target connector. The dielectric layer of the initial contact area was stripped using a pre-constructed dielectric layer stripping method to obtain the high-speed transmission contact area. The high-speed transmission contact area is polished using a pre-constructed polishing method to obtain a polished contact area harness, and the polished contact area of ​​the polished contact area harness is identified in the target connector. The polished contact area is laser-textured using a pre-constructed laser texturing method to obtain the riveting wire bundle to be confirmed; A pre-built quality inspection method is used to inspect the riveted wire harness to be confirmed, and a pre-riveted wire harness is obtained.

3. The 224G high-speed wire harness assembly method based on ultrasonic riveting as described in claim 2, characterized in that, The method of using a pre-constructed quality inspection method to inspect the riveted wire harness to be confirmed, thereby obtaining a pre-riveted wire harness, includes: In the target connector, the target contact area of ​​the riveted wire harness to be confirmed is identified, and the target contact area is divided using a pre-constructed division method to obtain a detection area set; For each detection area in the detection area set, perform the following operations: The detection area is tested using quality inspection methods to obtain a set of detection parameters. The set of detection parameters includes multiple detection parameters, which are surface roughness detection value, dielectric residue detection value, and contact resistance detection value, respectively. Obtain the surface roughness detection threshold, dielectric residue detection threshold, and contact resistance detection threshold; The detection parameter sets are summarized to obtain multiple detection parameter sets, and each detection parameter set corresponds to a detection area. If the surface roughness detection value, dielectric residue detection value, and contact resistance detection value of each detection parameter set in the multiple detection parameter sets are less than the surface roughness detection threshold, the dielectric residue detection value is less than the dielectric residue detection threshold, and the contact resistance detection value is less than the contact resistance detection threshold, then the riveting wire harness to be confirmed is the pre-riveting wire harness. If multiple detection parameter sets contain a surface roughness detection value greater than or equal to the surface roughness detection threshold, a dielectric residue detection value greater than or equal to the dielectric residue detection threshold, or a contact resistance detection value greater than or equal to the contact resistance detection threshold, then return to the step of polishing the high-speed transmission contact area using the pre-constructed polishing method to obtain the polished contact area wire harness, until the pre-riveted wire harness is obtained.

4. The 224G high-speed wire harness assembly method based on ultrasonic riveting as described in claim 3, characterized in that, The process of aligning the pre-riveted wire harness with the pre-constructed target connector based on the precise alignment command to obtain the wire harness to be riveted includes: Based on the precise alignment command, obtain the three-dimensional spatial data of the target contact area and the target connector in the pre-riveted wire harness, and obtain the spatial position of the contact area and the spatial position of the connector. The geometric features of the target contact area and the target connector are identified using a pre-constructed projection method, resulting in the geometric features of the contact area and the connector. Using a pre-built positioning method, the spatial positions of the contact area, connector, contact area geometry, and connector geometry are spatially aligned to obtain alignment reference points; The target contact area and target connector are aligned using a pre-constructed positioning device and alignment reference point to obtain the wire harness to be riveted.

5. The 224G high-speed wire harness assembly method based on ultrasonic riveting as described in claim 4, characterized in that, The ultrasonic vibration amplitude is as follows: in, Indicates the amplitude of ultrasonic vibration. This represents the conversion efficiency factor of the transducer. This represents the piezoelectric strain constant of the transducer. This represents the drive voltage of the transducer. This indicates the quality factor of the transducer. Indicates the frequency of the ultrasonic wave. Indicates the riveting time. This represents the input cross-sectional area of ​​the amplitude transformer. This indicates the output cross-sectional area of ​​the amplitude transformer.

6. The 224G high-speed wire harness assembly method based on ultrasonic riveting as described in claim 5, characterized in that, The cooling of the wire harness to be riveted during riveting, based on the ambient temperature monitoring value and the pre-constructed riveting cooling unit, includes: Calculate the difference between the monitored ambient temperature value and the actual ambient temperature value to obtain the ambient temperature difference. If the ambient temperature difference is greater than the preset ambient temperature difference threshold, the target contact area is cooled by using the preset cooling temperature, the riveting cooling unit and the preset cooling time. The time is recorded in real time starting from the cooling time to obtain the recording interval time. When the recording interval time is equal to the cooling time, the updated ambient temperature monitoring value is obtained. Based on the updated ambient temperature monitoring value, an updated ambient temperature difference is obtained. If the updated ambient temperature difference is greater than the ambient temperature difference threshold, the difference between the updated ambient temperature difference and the ambient temperature difference threshold is calculated to obtain the temperature control value. Calculate the difference between the ambient temperature difference and the updated ambient temperature difference to obtain the change in temperature difference; The target control value is the updated ambient temperature difference, temperature control value, and temperature difference change value. Based on the target control value and the pre-built PID control algorithm, the temperature drop value is obtained. Based on the temperature drop value and the temperature drop value, the updated temperature drop value is obtained. The updated temperature drop value is used as the temperature drop value. The process of cooling the target contact area using the preset temperature drop value and the preset temperature drop value is returned until the updated ambient temperature difference is less than or equal to the ambient temperature difference threshold is reached.

7. The 224G high-speed wire harness assembly method based on ultrasonic riveting as described in claim 6, characterized in that, The formula for calculating the updated ultrasonic frequency value is as follows: in, This indicates an update to the ultrasonic frequency. Indicates the fuzzy control weights. This represents the ultrasonic frequency correction amount output by the fuzzy control algorithm. The weights representing the compression offset deviation values. The weight representing the deviation from energy absorption. This indicates the compression offset deviation value. This represents the mean of the compressed offset interval. This indicates the deviation value of energy absorption. This represents the mean of the energy absorption range. This indicates the maximum allowable adjustment range of the ultrasonic frequency.

8. The 224G high-speed wire harness assembly method based on ultrasonic riveting as described in claim 7, characterized in that, The step of obtaining a pre-confirmed high-speed harness using the updated ultrasonic frequency value includes: The updated ultrasonic frequency value is used to rivet the wire harness to be riveted, and the updated compression offset value and updated energy absorption value of the wire harness to be riveted are monitored during the riveting process. Based on the updated compression offset value and the updated energy absorption value, obtain the updated compression offset deviation value and the updated energy absorption deviation value; If the updated compression offset deviation value is less than the preset compression offset deviation threshold and the updated energy absorption deviation value is less than the preset energy absorption deviation threshold, a pre-confirmed high-speed harness is obtained. If the updated compression offset deviation value is greater than or equal to the compression offset deviation threshold or the updated energy absorption deviation value is greater than or equal to the energy absorption deviation threshold, then return to the step of obtaining the updated ultrasonic frequency value based on the reference control value set and the pre-constructed fuzzy control algorithm until a pre-confirmed high-speed harness is obtained.

9. The 224G high-speed wire harness assembly method based on ultrasonic riveting as described in claim 8, characterized in that, The process of performing quality inspection on the pre-confirmed high-speed wiring harness based on the quality inspection command to obtain the target high-speed wiring harness includes: Based on the quality inspection command, a performance testing method is obtained, and the pre-confirmed high-speed harness is tested based on the performance testing method to obtain the insertion loss value and return loss value. The insertion and removal durability test was performed on the pre-confirmed high-speed wiring harness to obtain the wear value of the high-speed wiring harness. Vibration tests were performed on the pre-confirmed high-speed wiring harness to obtain the change in contact resistance. Obtain the insertion loss threshold, return loss threshold, high-speed harness wear threshold, and contact resistance change threshold; If the insertion loss value is less than the insertion loss threshold, the return loss value is less than the return loss threshold, the high-speed harness wear value is less than the high-speed harness wear threshold, and the contact resistance change value is less than the contact resistance change threshold, then the pre-confirmed high-speed harness is taken as the target high-speed harness.

10. A 224G high-speed wire harness assembly system based on ultrasonic riveting, characterized in that, The system includes: The riveting environment confirmation module is used to receive wire harness assembly instructions and confirm the wire harness assembly environment based on the wire harness assembly instructions. The wire harness assembly environment includes a wire harness assembly system and high-speed wire harness raw materials to be assembled. The wire harness assembly system includes a high-precision alignment unit, an ultrasonic riveting monitoring unit, and a quality detection unit. The riveting material processing module is used to pre-process the raw materials of high-speed wire harnesses to obtain pre-riveted wire harnesses; Receive a precise alignment command from a high-precision alignment unit, and align the pre-riveted wire harness with the pre-built target connector based on the precise alignment command to obtain the wire harness to be riveted; The ultrasonic riveting module is used to rivet the wire harness to be riveted using preset ultrasonic parameter values, preset ambient temperature values ​​and preset riveting time, and to receive riveting monitoring instructions from the ultrasonic riveting monitoring unit. Based on the riveting monitoring instructions, the module monitors the wire harness to be riveted in real time to obtain compression offset value and energy absorption value. The step of riveting the wire harness to be riveted using preset ultrasonic parameter values, preset ambient temperature values, and preset riveting time includes: Target ultrasound is obtained using a pre-built ultrasonic generator and ultrasonic parameter values; The target ultrasonic wave is converted using a pre-built transducer and a pre-built amplitude transformer to obtain the ultrasonic vibration amplitude. The wire harness to be riveted is riveted using a pre-built riveting tool head, the ultrasonic vibration amplitude, the riveting time, and the ambient temperature value. The ambient temperature monitoring value is obtained at a preset time interval. The wire harness to be riveted is cooled based on the ambient temperature monitoring value and the pre-built riveting cooling unit. Based on the compression offset value and energy absorption value, a pre-constructed fuzzy control algorithm is used to obtain an updated ultrasonic frequency value, which is beneficial for obtaining a pre-confirmed high-speed wire harness using the updated ultrasonic frequency value. The step of obtaining the updated ultrasonic frequency value using a pre-constructed fuzzy control algorithm based on the compression offset value and energy absorption value includes: Obtain the compression offset standard range and the energy absorption standard range, wherein the compression offset standard range includes the minimum compression offset range value and the maximum compression offset range value, and the energy absorption standard range includes the minimum energy absorption range value and the maximum energy absorption range value; Calculate the mean of the minimum compression offset interval value and the maximum compression offset interval value to obtain the mean of the compression offset interval. Based on the minimum energy absorption interval value and the maximum energy absorption interval value, obtain the mean of the energy absorption interval. Calculate the absolute difference between the compression offset value and the mean of the compression offset interval, and the absolute difference between the energy absorption value and the mean of the energy absorption interval, respectively, to obtain the compression offset deviation value and the energy absorption deviation value; By summing the compression offset deviation value and the energy absorption deviation value, a reference control value set is obtained; The updated ultrasonic frequency value is obtained based on the reference control value set and the pre-constructed fuzzy control algorithm; The wire harness quality inspection module is used to receive quality inspection instructions from the quality inspection unit, perform quality inspection on the pre-confirmed high-speed wire harness based on the quality inspection instructions, obtain the target high-speed wire harness, and assemble the high-speed wire harness based on the target high-speed wire harness.

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