An automatic detection method and system for a special-shaped connector of a tool plate

Abstract

The application discloses a kind of automatic detection method and system of tooling plate special-shaped connector, belong to electric power equipment intelligent manufacturing and intelligent detection technical field, comprising: probe matrix module is switched to probe matrix;Based on the current tooling plate alignment image acquisition jacking drive signal, to be based on jacking module based on jacking drive signal control probe matrix module and the special-shaped connector group electric connection;Obtain preset connection relationship matrix, based on a plurality of to-be-tested electrical connection points and preset connection relationship matrix obtain target detection path, based on target detection path acquisition connection point contact resistance data;Based on connection point contact resistance data and preset connection relationship matrix obtain test point detection report.The automatic detection method and system of tooling plate special-shaped connector disclosed in the application solve the technical problems that multiple special-shaped connectors cannot be connected at one time, multiple test points cannot be processed in parallel and comprehensive detection cannot be achieved in the prior art, and efficient automatic detection of special-shaped connectors is achieved.

Description

Technical Field

[0001] This invention relates to the field of intelligent manufacturing and intelligent testing technology for power equipment, and in particular to an automatic testing method and system for irregularly shaped connectors on tooling boards. Background Technology

[0002] Substation secondary equipment is a key core system supporting the dispatching and control and safe and stable operation of large power grids. However, the existing manufacturing and operation and maintenance industry chain has a low degree of automation. Only the equipment itself has a high level of intelligence. The design, manufacturing, installation, commissioning, operation and maintenance and transformation of substation secondary equipment throughout its entire life cycle still follow the traditional mode. For example, the "terminal block + manual plug-in" technology is used, which requires a high degree of manual labor. This results in technical problems such as the quality and efficiency being greatly affected by the subjective factors of personnel, low operating efficiency and easy errors.

[0003] For example, due to the wide variety of power secondary switchgear products and the different interface definitions from various manufacturers, as well as significant differences in electrical wiring, the manufacturing process is highly complex. Each switchgear requires process breakdown and analysis based on the specific project drawings, necessitating customized manual processing. This fails to meet the prerequisite for automated production—product modularization. Currently, there are no application cases of automated flexible production of secondary switchgear, either domestically or internationally. In the production process of power secondary switchgear, after decomposing the product BOM, the electrical wiring diagram for each switchgear involves approximately 400 electrical wire harnesses of different lengths, diameters, and terminal types, resulting in a huge workload. Furthermore, it involves over 50 different connector types with varying sizes, hole diameters, and hole spacings in different areas such as protection devices, monitoring and control devices, circuit breakers, pressure plates, and backplanes. This leads to problems such as messy manual wiring, high error rates, and long production cycles. Moreover, there are no effective means to test and inspect the reliability of electrical wiring, making manual inspection extremely labor-intensive and prone to errors. In the commissioning and installation phase, on-site primary and secondary wiring relies heavily on customized manual work, making it difficult to effectively control efficiency and quality. These problems severely restrict the efficient operation of substation protection and control equipment throughout its entire lifecycle.

[0004] In summary, currently, in the production and commissioning stages of customized products such as substation secondary switchgear, the detection of complex wiring harness connections mainly faces the following problems: 1. Complete reliance on manual labor, resulting in extremely low efficiency and reliability: Traditionally, multimeters are used for continuity measurement, requiring two operators to measure and record point by point according to a complex wiring diagram; facing the detection volume of 400 wiring harnesses, the workload is enormous, time-consuming (usually several hours), and prone to missed or incorrect detections due to human fatigue and negligence, making it impossible to guarantee reliability; 2. Lack of dedicated and efficient testing tools: Existing technology lacks dedicated automated tools capable of simultaneously connecting 50 irregularly shaped connectors and processing 400 test points in parallel. The testing equipment cannot quickly and comprehensively verify wiring quality during the production process. Problems often only surface during later debugging or even on-site operation, resulting in extremely high rectification costs. Secondly, it cannot effectively diagnose hidden defects: multimeters can only perform simple continuity tests and cannot quantitatively and efficiently determine potential faults such as excessive contact resistance (loose connections) or decreased insulation resistance. These defects are the main causes of overheating and unstable signal transmission during equipment operation. Thirdly, it lacks process data traceability: manual inspection makes it difficult to generate electronic inspection records, hindering the automated collection, storage, and traceability of quality data, which does not meet the digital management requirements of modern intelligent manufacturing. Therefore, there is an urgent need for a monitoring method and equipment that can meet the needs of flexible production and support the digitalization and intelligentization of the monitoring process. Summary of the Invention

[0005] This invention provides an automatic detection method and system for irregularly shaped connectors on tooling boards, which can solve the technical problems in the prior art of not being able to connect multiple irregularly shaped connectors at one time, process multiple test points in parallel, and achieve comprehensive detection, thereby realizing efficient automatic detection of irregularly shaped connectors.

[0006] This invention provides an automatic detection method for irregularly shaped connectors on a tooling board, implemented using an automatic detection system for irregularly shaped connectors on a tooling board. The automatic detection system includes a lifting module and a probe matrix module. The method includes:

[0007] Obtain pin distribution data of the irregular connector group on the test fixture board, and switch the probe matrix module based on the pin distribution data to obtain the target probe matrix module;

[0008] Acquire the current tooling plate alignment image, and acquire the lifting drive signal based on the current tooling plate alignment image, so that the lifting module controls the target probe matrix module to electrically connect with the irregular connector group based on the lifting drive signal, forming a number of electrical connection points to be tested;

[0009] Obtain a preset connection relationship matrix, obtain a target detection path based on several electrical connection points to be tested and the preset connection relationship matrix, and perform connection point resistance detection based on the target detection path to obtain connection point contact resistance data;

[0010] Based on the contact resistance data of the connection points and the preset connection relationship matrix, a test report is obtained to realize the automatic detection of irregular connectors.

[0011] This invention provides an automatic detection method for irregularly shaped connectors on a tooling board. The method employs an automatic detection system comprising a lifting module and a probe matrix module. During detection, firstly, pin distribution data of the irregularly shaped connector group on the tooling board to be tested is acquired. Based on this pin distribution data, the probe matrix module is switched to obtain target probe matrix modules adapted to several irregularly shaped connectors on the current tooling board. Next, an alignment image of the current tooling board is acquired. Based on the alignment image, a corresponding lifting drive signal is generated to control the lifting module to raise the corresponding probe matrix module, making the probe matrix electrically connected to the irregularly shaped connector, forming several electrical connection points to be tested. This allows for simultaneous detection of all detection points on the current tooling board, enabling compatibility with various irregularly shaped connector groups and rapid switching between probe matrices with different compatibility. Then, based on a pre-set connection relationship matrix of the tooling board to be tested and the electrical connection points to be tested, a detection path is planned to ensure short detection time and improve automatic detection efficiency. Finally, based on the contact resistance data of the detected connection points and the pre-set connection relationship matrix, the connection status of the test point circuit is determined, and a test point detection report is output, achieving comprehensive and efficient automatic detection of irregularly shaped connectors.

[0012] Furthermore, the step of obtaining a preset connection relationship matrix, obtaining a target detection path based on a plurality of electrical connection points to be tested and the preset connection relationship matrix, performing connection point resistance detection based on the target detection path, and obtaining connection point contact resistance data includes: obtaining a preset connection relationship matrix; constructing a node graph model based on a plurality of electrical connection points to be tested; obtaining a target detection path based on the node graph model, the preset connection relationship matrix, and a preset path optimization algorithm; obtaining loop resistance data based on the target detection path, and obtaining connection point contact resistance data based on the loop resistance data and a preset contact point resistance compensation algorithm.

[0013] In the above scheme, the preset connection relationship matrix of the tooling board to be tested is first obtained, and the state of the electrical connection points to be tested under normal conditions is analyzed so as to facilitate automatic detection and analysis based on the loop resistance data. A node diagram model is constructed based on the electrical connection points to be tested, and path planning is performed in combination with the preset connection relationship matrix to shorten the detection path as much as possible and increase the detection efficiency.

[0014] Further, the step of constructing a node graph model based on several electrical connection points under test, and obtaining a target detection path based on the node graph model and a preset path optimization algorithm, includes: obtaining several continuity test clusters based on a preset connection relationship matrix and a preset node arrangement method; obtaining an initial test sequence based on the several test clusters; constructing a node graph model based on several electrical connection points under test; randomly obtaining several node pairs based on the node graph model; obtaining corresponding node paths and node path weights based on any node pair; obtaining several node paths and several node path weights corresponding to all node pairs; constructing a node path model based on the several node paths and several node path weights; and obtaining a target detection path based on the initial test sequence, the node path model, and the preset path optimization algorithm.

[0015] In the above scheme, since continuity testing can be performed by quickly scanning within the same electrical network without large-scale switching on physical channels, and switching to the next network only after testing all points within a network, large-scale switching between networks can be minimized. Therefore, during path planning, all nodes belonging to the same electrical network are first arranged together according to the preset connection matrix and preset node arrangement method to form several test clusters, thereby generating an initial test sequence, which greatly reduces debugging complexity. Then, based on the initial test sequence, a node graph model is constructed according to the electrical connection points under test, and any node pair is selected to obtain the node path and node path weight. The node path weight represents the switching time between nodes, and a node path model combining the number of switching times and the switching time is constructed. Thus, the initial test sequence is reordered according to the preset path optimization algorithm to minimize the total switching time and the number of switching times, and obtain the shortest target detection path, effectively increasing the efficiency of automatic detection.

[0016] Furthermore, the step of obtaining loop resistance data based on the target detection path and obtaining connection point contact resistance data based on the loop resistance data and a preset contact point resistance compensation algorithm includes: obtaining calibration resistance data based on a four-wire measurement method; performing resistance measurement based on the target detection path to obtain loop resistance data; and obtaining connection point contact resistance data based on the loop resistance data, calibration resistance data, and the preset contact point resistance compensation algorithm.

[0017] In the above scheme, when acquiring the contact resistance data of the connection point, the four-wire measurement method is used to first acquire the resistance value of the section from the measuring device cable to the probe outlet when the connection point is not connected, and then acquire the calibration resistance data. Next, the loop resistance data is acquired according to the target detection path. Finally, the actual contact resistance data of the connection point is calculated using a preset contact point resistance compensation algorithm, so as to achieve accurate measurement of the connection point and avoid errors in the detection results caused by measuring the line resistance.

[0018] Furthermore, the step of obtaining a test point detection report based on the connection point contact resistance data and a preset connection relationship matrix to achieve automatic detection of irregular connectors includes: obtaining connection point status detection results based on the connection point contact resistance data and a preset qualified threshold; performing automatic data judgment and fault test point location based on the preset connection relationship matrix and the connection point status detection results, obtaining a test point detection report, and achieving automatic detection of irregular connectors.

[0019] In the above scheme, when obtaining the test point detection report based on the preset connection relationship matrix and the connection point contact resistance data, the connection point contact resistance data is first compared with the preset qualified threshold to obtain the connection point status detection result including the connection point wiring status. Then, the data is automatically judged and the fault test point is located by comparing the required preset connection relationship matrix with the actual connection point status detection result. The system automatically analyzes whether there is an abnormal connection point and can directly locate the abnormal connection point, realizing a deeper and more quantifiable assessment of wiring reliability. It can accurately diagnose hidden quality hazards that are difficult to detect manually and by traditional equipment.

[0020] This invention provides an automatic inspection method for irregularly shaped connectors on tooling boards. It utilizes a probe matrix module to quickly adapt to new products, effectively shortening changeover time and improving compatibility with irregularly shaped connector groups. Combined with a lifting module, it performs alignment and electrical connection based on the current tooling board alignment image, ensuring uniform and reliable contact force between the probes and connector pins. This guarantees good electrical contact without excessive pressure that could damage the pins, achieving an automated inspection process. Next, a preset path optimization algorithm transforms complex wiring diagrams into an optimal set of inspection instructions, achieving efficient automated inspection. During data analysis and processing, a preset contact point resistance compensation algorithm analyzes and processes the connection point test data, ultimately outputting a test point inspection report. This enables comprehensive quality data traceability, allowing for a deeper, quantifiable assessment of wiring reliability. It accurately diagnoses hidden quality hazards that are difficult to detect manually or with traditional equipment, thereby improving the long-term operational reliability of tooling board products from the source. This method achieves flexible automatic inspection adaptable to complex electrical wiring scenarios.

[0021] This invention also provides an automatic detection system for irregularly shaped connectors on tooling boards, used to implement the aforementioned automatic detection method for irregularly shaped connectors on tooling boards, comprising: a probe matrix module, a lifting module, an image module, a control connection module, a detection module, and a result output module; wherein:

[0022] The probe matrix module includes several probe matrix units adapted to connectors of different specifications. The probe matrix module is used to acquire pin distribution data of irregular connector groups on the test fixture board, and to switch probe matrices based on the pin distribution data and several probe matrix units to acquire the target probe matrix module.

[0023] The image module is used to acquire the alignment image of the current tooling plate;

[0024] The control connection module is used to acquire a lifting drive signal based on the current tooling plate alignment image, so that the lifting module controls the target probe matrix module to electrically connect with the irregular connector group based on the lifting drive signal, forming a number of electrical connection points to be tested;

[0025] The detection module is used to obtain a preset connection relationship matrix, obtain a target detection path based on a number of electrical connection points to be tested and the preset connection relationship matrix, perform connection point resistance detection based on the target detection path, and obtain connection point contact resistance data.

[0026] The result output module is used to obtain a test point detection report based on the contact resistance data of the connection point and a preset connection relationship matrix, so as to realize the automatic detection of irregular connectors.

[0027] This invention provides an automatic detection system for irregularly shaped connectors on a tooling board. During detection, the probe matrix module first acquires the pin distribution data of the irregularly shaped connector group on the tooling board to be tested. Based on the pin distribution data, the probe matrix module switches to obtain target probe matrix modules adapted to several irregularly shaped connectors on the current tooling board. Next, the image module acquires the alignment image of the current tooling board, so that the control connection module analyzes the alignment image and generates a corresponding lifting drive signal to control the lifting module to raise the corresponding probe matrix module, so that the probe matrix is ​​electrically connected to the irregularly shaped connector, forming several electrical connection points to be tested. This achieves one-time detection of all detection points on the current tooling board, enabling compatibility with various irregularly shaped connector groups and rapid switching of probe matrices with different compatibility. Then, the detection module plans the detection path according to the preset connection relationship matrix of the tooling board to be tested and the electrical connection points to be tested, so as to ensure short detection time and improve automatic detection efficiency. Finally, the result output module judges the connection status of the test point circuit based on the contact resistance data of the detected connection points and the preset connection relationship matrix, and outputs a test point detection report, realizing comprehensive and efficient automatic detection of irregularly shaped connectors.

[0028] Furthermore, the detection module includes a path optimization submodule and a data detection submodule, wherein:

[0029] The path optimization submodule is used to obtain a preset connection relationship matrix, construct a node graph model based on several electrical connection points to be tested, and obtain a target detection path based on the node graph model, the preset connection relationship matrix, and the preset path optimization algorithm.

[0030] The data detection submodule is used to obtain loop resistance data based on the target detection path, and to obtain connection point contact resistance data based on the loop resistance data and a preset contact point resistance compensation algorithm.

[0031] In the above scheme, the path optimization submodule first obtains the preset connection relationship matrix of the test fixture board and analyzes the state of the electrical connection points under normal conditions so that the subsequent data detection submodule can automatically detect and analyze based on the loop resistance data. The node graph model is constructed based on the electrical connection points under test, and the path is planned in combination with the preset connection relationship matrix to shorten the detection path as much as possible and increase the detection efficiency.

[0032] Furthermore, the path optimization submodule includes:

[0033] An initial test sequence unit is used to obtain several continuity test clusters based on a preset connection relationship matrix and a preset node arrangement method, and to obtain an initial test sequence based on the several test clusters.

[0034] The path optimization unit is used to construct a node graph model based on a number of electrical connection points to be tested; randomly obtain a number of node pairs based on the node graph model; obtain the corresponding node path and node path weight based on any node pair; obtain a number of node paths and node path weights corresponding to all node pairs; construct a node path model based on the number of node paths and node path weights; and obtain the target detection path based on the initial test sequence, the node path model, and the preset path optimization algorithm.

[0035] In the above scheme, since continuity testing can be performed by quickly scanning within the same electrical network without large-scale switching on physical channels, and switching to the next network only after testing all points within one network, large-scale switching between networks can be minimized. Therefore, during path planning, the initial test sequence unit first arranges all nodes belonging to the same electrical network together according to the preset connection relationship matrix and preset node arrangement method to form several test clusters, thereby generating the initial test sequence, which greatly reduces debugging complexity. Then, based on the initial test sequence, the path optimization unit constructs a node graph model based on the electrical connection points to be tested, selects arbitrary node pairs to obtain node paths and node path weights, and uses the node path weights to represent the switching time between nodes to construct a node path model that combines the number of switching times and the switching time. Thus, the initial test sequence is reordered according to the preset path optimization algorithm to minimize the total switching time and the number of switching times required, obtaining the shortest target detection path, effectively increasing the efficiency of automatic detection.

[0036] Furthermore, the data detection submodule includes:

[0037] The measurement unit is used to acquire calibration resistance data based on the four-wire measurement method; and to perform resistance measurement based on the target detection path to acquire loop resistance data.

[0038] The data compensation analysis unit is used to obtain the connection point contact resistance data based on the loop resistance data, the calibration resistance data, and the preset contact point resistance compensation algorithm.

[0039] In the above scheme, when acquiring the contact resistance data of the connection point, the measurement unit first uses a four-wire measurement method to acquire the resistance value of the section from the measuring device cable to the probe outlet when the connection point is not connected, and then acquires the calibration resistance data. Next, it acquires the loop resistance data according to the target detection path. Finally, the data compensation and analysis unit uses a preset contact point resistance compensation algorithm to calculate the true contact resistance data of the connection point, thereby achieving accurate measurement of the connection point and avoiding errors in the detection results caused by measuring the line resistance.

[0040] Furthermore, the result output module includes:

[0041] The node judgment unit is used to obtain the connection point status detection result based on the connection point contact resistance data and the preset qualified threshold.

[0042] The report output unit is used to automatically determine data and locate fault measurement points based on the preset connection relationship matrix and the connection point status detection results, obtain the measurement point detection report, and realize the automatic detection of irregular connectors.

[0043] In the above scheme, when the node judgment unit obtains the test point detection report based on the preset connection relationship matrix and the connection point contact resistance data, it first compares the connection point contact resistance data with the preset qualified threshold to obtain the connection point status detection result including the connection point wiring status. The report output unit then compares the required preset connection relationship matrix with the actual connection point status detection result to realize automatic data judgment and fault test point location, automatically analyzes whether there is connection point abnormality, can directly locate abnormal connection points, realize a deeper and more quantifiable assessment of wiring reliability, and can accurately diagnose hidden quality hazards that are difficult to detect manually and with traditional equipment.

[0044] This invention provides an automatic inspection system for irregularly shaped connectors on tooling boards. Through a probe matrix module, it enables rapid adaptation to new products, effectively shortening changeover time and improving compatibility with irregularly shaped connector groups. Combined with a lifting module, it performs alignment and electrical connection based on the current tooling board alignment image, ensuring uniform and reliable contact force between the probes and connector pins. This guarantees good electrical contact without excessive pressure that could damage the pins, achieving an automated inspection process. Next, a preset path optimization algorithm transforms complex wiring diagrams into optimal inspection instruction sets, achieving efficient automated inspection. During data analysis and processing, a preset contact point resistance compensation algorithm analyzes and processes the connection point test data, ultimately outputting a test point inspection report. This enables comprehensive quality data traceability, allowing for a deeper, quantifiable assessment of wiring reliability, accurately diagnosing hidden quality hazards that are difficult to detect manually or with traditional equipment, thereby improving the long-term operational reliability of tooling board products from the source. This system achieves flexible automatic inspection adaptable to complex electrical wiring scenarios. Attached Figure Description

[0045] To more clearly illustrate the technical solution of this application, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0046] Figure 1 This is a schematic diagram of an automatic detection method for irregularly shaped connectors on a tooling board provided in an embodiment of the present invention;

[0047] Figure 2 This is a schematic diagram of a multi-protocol compatible irregular connector intelligent testing equipment provided in an embodiment of the present invention. Detailed Implementation

[0048] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions of this application will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0049] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the application; the terms “comprising” and “having”, and any variations thereof, in the specification, claims, and foregoing description of the drawings are intended to cover non-exclusive inclusion.

[0050] In the description of the embodiments of this application, technical terms such as "first" and "second" are used only to distinguish different objects and should not be construed as indicating or implying relative importance or implicitly specifying the number, specific order, or primary and secondary relationship of the indicated technical features. In the description of the embodiments of this application, "multiple" means two or more, unless otherwise explicitly defined.

[0051] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0052] In the description of the embodiments in this application, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, and B existing alone. Additionally, the character " / " in this document generally indicates that the preceding and following related objects have an "or" relationship.

[0053] In the description of the embodiments of this application, the term "multiple" refers to two or more (including two), similarly, "multiple sets" refers to two or more (including two sets), and "multiple pieces" refers to two or more (including two pieces).

[0054] In the description of the embodiments of this application, unless otherwise expressly specified and limited, technical terms such as "installation," "connection," "joining," and "fixing" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. For those skilled in the art, the specific meaning of the above terms in the embodiments of this application can be understood according to the specific circumstances.

[0055] Example 1:

[0056] This embodiment provides an automatic detection method for irregularly shaped connectors on a tooling board, implemented using an automatic detection system for irregularly shaped connectors on a tooling board. The automatic detection system includes a lifting module and a probe matrix module, such as... Figure 1 As shown, the method includes:

[0057] S1. Obtain pin distribution data of the irregular connector group on the test fixture board, and switch the probe matrix module based on the pin distribution data to obtain the target probe matrix module.

[0058] S2. Obtain the current tooling plate alignment image, and obtain the lifting drive signal based on the current tooling plate alignment image, so that the lifting module controls the target probe matrix module to electrically connect with the irregular connector group based on the lifting drive signal to form a number of electrical connection points to be tested;

[0059] S3. Obtain a preset connection relationship matrix, obtain a target detection path based on several electrical connection points to be tested and the preset connection relationship matrix, and perform connection point resistance detection based on the target detection path to obtain connection point contact resistance data.

[0060] S4. Based on the contact resistance data of the connection point and the preset connection relationship matrix, obtain the test point detection report to realize the automatic detection of irregular connectors.

[0061] This embodiment provides an automatic detection method for irregularly shaped connectors on a tooling board. It employs an automatic detection system including a lifting module and a probe matrix module. During detection, firstly, pin distribution data of the irregularly shaped connector group on the tooling board to be tested is acquired. Based on this pin distribution data, the probe matrix module is switched to obtain target probe matrix modules adapted to several irregularly shaped connectors on the current tooling board. Next, an alignment image of the current tooling board is acquired. Based on the analysis of this alignment image, a corresponding lifting drive signal is generated to control the lifting module to raise the corresponding probe matrix module, making the probe matrix electrically connected to the irregularly shaped connector, forming several electrical connection points to be tested. This achieves simultaneous detection of all detection points on the current tooling board, enabling compatibility with various irregularly shaped connector groups and rapid switching between probe matrices with different compatibility. Then, based on a pre-set connection relationship matrix of the tooling board to be tested and the electrical connection points to be tested, a detection path is planned to ensure short detection time and improve automatic detection efficiency. Finally, based on the contact resistance data of the detected connection points and the pre-set connection relationship matrix, the connection status of the test point circuit is determined, and a test point detection report is output, achieving comprehensive and efficient automatic detection of irregularly shaped connectors.

[0062] In practical implementation, the irregularly shaped connectors used in this embodiment include more than 50 connectors of different sizes, hole diameters, and hole spacings in different areas such as protection devices, measurement and control devices, circuit breakers, pressure plates, and back plates. The test fixture includes a flexible fixture and the aforementioned irregularly shaped connectors. The flexible fixture is used to fix the more than 50 connectors and manage them by section. The connectors in each section can be replaced according to different production orders. Each section of the test fixture is designed with an elastic fixing device to secure the connectors.

[0063] In the specific implementation process, the probe matrix module includes several probe matrix units adapted to connectors of different specifications. Before the test begins, the pin distribution data of the irregular connector group on the test fixture is obtained. Based on the pin distribution data, a robotic arm or manual operation is used to switch the probe matrix of several probe matrix units and probes to obtain the target probe matrix module adapted to the current test fixture.

[0064] In practical implementation, the automatic detection method provided in this embodiment is applied to the detection station, such as detecting a flexible tooling board with approximately 400 wire harnesses already connected and nearly 50 irregularly shaped connectors mounted on it: First, during the preparation and transfer stage, it is transferred to the detection station of this embodiment. The pin distribution data of the irregularly shaped connector group on the tooling board to be tested is acquired. Based on the pin distribution data, the probe matrix module is switched to obtain the target probe matrix module, ensuring that each probe on the target probe matrix module is precisely designed to correspond one-to-one with the metal pins on the B-side of the 50 connectors on the tooling board. Next, a machine vision camera at the detection station is used to photograph the positioning marks on the tooling board or the connectors themselves, acquiring the current tooling board alignment image. Image recognition technology is used to accurately locate the position of the tooling board to generate a lifting drive signal, ensuring the accuracy of subsequent lifting and alignment. Then, the lifting module, driven by a servo motor, moves precisely upward according to the lifting drive signal, pushing the probe matrix module on it to rise smoothly to electrically connect with the irregularly shaped connector group, achieving reliable electrical contact. Next, intelligent detection is performed. The system combines the preset connection relationship matrix to obtain the continuity and insulation status of the connection points, and uses resistance data to determine the actual connection point status. The system compares and analyzes the data to output a test point detection report, automatically determines the connection status of each line (including qualified, open circuit, short circuit, and loose connection), and accurately locates the specific location of the fault point, i.e., which pin of a certain connector.

[0065] Optionally, the step of obtaining a preset connection relationship matrix, obtaining a target detection path based on a plurality of electrical connection points to be tested and the preset connection relationship matrix, performing connection point resistance detection based on the target detection path, and obtaining connection point contact resistance data includes: obtaining a preset connection relationship matrix; constructing a node graph model based on a plurality of electrical connection points to be tested; obtaining a target detection path based on the node graph model, the preset connection relationship matrix, and a preset path optimization algorithm; obtaining loop resistance data based on the target detection path, and obtaining connection point contact resistance data based on the loop resistance data and a preset contact point resistance compensation algorithm.

[0066] Optionally, the step of constructing a node graph model based on a plurality of electrical connection points under test, and obtaining a target detection path based on the node graph model and a preset path optimization algorithm, includes: obtaining a plurality of continuity test clusters based on a preset connection relationship matrix and a preset node arrangement method; obtaining an initial test sequence based on the plurality of test clusters; constructing a node graph model based on a plurality of electrical connection points under test; randomly obtaining a plurality of node pairs based on the node graph model; obtaining a corresponding node path and node path weight based on any node pair; obtaining a plurality of node paths and a plurality of node path weights corresponding to all node pairs; constructing a node path model based on the plurality of node paths and a plurality of node path weights; and obtaining a target detection path based on the initial test sequence, the node path model, and the preset path optimization algorithm.

[0067] In the specific implementation process, the preset path optimization algorithm used in this embodiment is an adaptive test path planning algorithm to solve the technical problem of long detection paths and low efficiency when scanning 400 electrical connection points to be tested in a simple sequence during actual measurement. This algorithm treats the electrical connection points to be tested as nodes, constructs a node graph model, and finds the shortest detection path through the preset path optimization algorithm, minimizing the switching time of the multiplexer (MUX) in the probe matrix. In this embodiment, the detection efficiency function E is defined as the total detection time T. total The reciprocal of the total test time. The total test time consists of a node path model composed of a fixed test time and a switching time, as shown in the following expression:

[0068]

[0069] Where N is the total number of tests, t test The time taken for a single test is M, where M is the number of switches and t is the time taken for a single test. switch (i) represents the time taken for the i-th switch. The algorithm aims to minimize the total number of switches M and the total switch time ∑t by reordering the test sequence. switch The target detection path is obtained, and a predetermined program is generated based on the target detection path to perform scanning detection on 400 measurement points.

[0070] Specifically, first, define nodes: each electrical connection point to be tested (i.e., a channel on the probe matrix or a pin of a connector) is considered a node in the graph. Let the set of all nodes be V = {v1, v2, v3, ..., v...} n (n≈400). Define edges and weights: for any two nodes v i and v j Create an edge e between them ij The weight w of this edge ij Defined as: After testing node v i Then, immediately test node v jThe required switching time for the multiplexer (MUX). This switching time t switch (i, j) is determined by hardware characteristics. Crucially, if the two measurement points belong to the same electrical network (i.e., they are theoretically conductive, like the two ends of a wire), then the switching weight w between them... ij The value is extremely low, even zero. Because MUX can quickly scan within the same network when testing continuity, it doesn't require large-scale switching across physical channels. Therefore, this path optimization algorithm doesn't search from scratch, but rather has a high-quality initial solution, namely the initial test sequence. The initial sequence is directly generated from a preset wiring relationship matrix. This preset wiring relationship matrix is ​​determined by the flexible fixture board under test, defining which nodes should be conductive (belonging to the same network) and which should be insulated. When generating this initial test sequence using a preset node arrangement method: all nodes belonging to the same electrical network are first arranged together to obtain a test cluster, generating an initial test sequence containing several test clusters. When testing according to the test clusters, after testing all points within a network, the algorithm switches to the next network, minimizing large-scale switching between networks.

[0071] Optionally, the step of obtaining loop resistance data based on the target detection path and obtaining connection point contact resistance data based on the loop resistance data and a preset contact point resistance compensation algorithm includes: obtaining calibration resistance data based on a four-wire measurement method; performing resistance measurement based on the target detection path to obtain loop resistance data; and obtaining connection point contact resistance data based on the loop resistance data, calibration resistance data, and the preset contact point resistance compensation algorithm.

[0072] In the specific implementation process, when acquiring connection point contact resistance data, the calibration resistance data includes the inherent resistance values ​​corresponding to all electrical connection points under test, the connection point contact resistance data includes the actual connection point resistances, and the loop resistance data includes the loop resistance values ​​corresponding to all electrical connection points under test. Because the measured loop resistance value R... measured Including cable resistance R cable Probe contact resistance R probe Contact resistance R at the actual connection point contact The first two will interfere with the effect on R. contact Therefore, this embodiment uses a preset contact point resistance compensation algorithm based on the four-wire (Kelvin) measurement method for software compensation. Prior calibration using the four-wire measurement method eliminates the influence of the system's inherent impedance on the measurement results. During the system calibration phase, calibration resistance data is obtained based on the four-wire measurement method, i.e., the inherent resistance value R of the path from the measuring device cable to the probe outlet is measured. cal :

[0073] R cal =Rcable +R probe

[0074] In the formal measurement of the resistance R of the object under test measured At that time, the actual connection point resistance R contact It can be calculated using the following formula:

[0075] R contact =R measured -R cal

[0076] Obtain the required contact resistance data at the connection points.

[0077] Optionally, the step of obtaining a test point detection report based on the connection point contact resistance data and a preset connection relationship matrix to achieve automatic detection of irregular connectors includes: obtaining connection point status detection results based on the connection point contact resistance data and a preset qualified threshold; performing automatic data judgment and fault test point location based on the preset connection relationship matrix and the connection point status detection results, obtaining a test point detection report, and achieving automatic detection of irregular connectors.

[0078] In the specific implementation process, the contact resistance data R at the connection point will be used. contact By comparing the connection status of the electrical connection point under test with a preset acceptable threshold, the connection status can be obtained. For example, comparing it with a preset loose connection threshold of 50mΩ can accurately determine whether a loose connection exists. During this process, the testing station collects test data in real time and compares it with the preset acceptable threshold to achieve automatic data judgment and fault point location. It automatically determines the connection status of each line (acceptable, open circuit, short circuit, loose connection) and accurately locates the specific location of the fault point, i.e., which pin of a certain connector. After the test is completed, a detailed report containing all test point data is automatically generated and uploaded to the host computer or MES system via the network interface. The operator can quickly view the results through the human-machine interface (HMI). For unacceptable points, precise rework can be carried out based on the report. The test includes not only "continuity / discontinuity" judgment, but also loop resistance measurement (to determine whether a loose connection exists) and insulation resistance test between adjacent points (to determine whether a short circuit or poor insulation exists).

[0079] This embodiment provides an automatic detection method for irregularly shaped connectors on a tooling board. It utilizes a probe matrix module to quickly adapt to new products, effectively shortening changeover time and improving compatibility with irregularly shaped connector groups. Combined with a lifting module, it performs alignment and electrical connection based on the current tooling board alignment image, ensuring uniform and reliable contact force between the probes and connector pins. This guarantees good electrical contact without excessive pressure that could damage the pins, thus achieving an automated detection process. Next, a preset path optimization algorithm transforms the complex wiring diagram into an optimal set of detection instructions, achieving efficient automated detection. During data analysis and processing, a preset contact point resistance compensation algorithm analyzes and processes the connection point test data, ultimately outputting a test point detection report. This enables comprehensive quality data traceability, allowing for a deeper, quantifiable assessment of wiring reliability. It accurately diagnoses hidden quality hazards that are difficult to detect manually or with traditional equipment, thereby improving the long-term operational reliability of the tooling board product from the source. This method achieves flexible automatic detection adaptable to complex electrical wiring scenarios.

[0080] Example 2:

[0081] This embodiment provides an automatic detection system for irregularly shaped connectors on a tooling board, used to implement the aforementioned automatic detection method for irregularly shaped connectors on a tooling board. The system includes: a probe matrix module, a lifting module, an image module, a control connection module, a detection module, and a result output module; wherein:

[0082] The probe matrix module includes several probe matrix units adapted to connectors of different specifications. The probe matrix module is used to acquire pin distribution data of irregular connector groups on the test fixture board, and to switch probe matrices based on the pin distribution data and several probe matrix units to acquire the target probe matrix module.

[0083] The image module is used to acquire the alignment image of the current tooling plate;

[0084] The control connection module is used to acquire a lifting drive signal based on the current tooling plate alignment image, so that the lifting module controls the target probe matrix module to electrically connect with the irregular connector group based on the lifting drive signal, forming a number of electrical connection points to be tested;

[0085] The detection module is used to obtain a preset connection relationship matrix, obtain a target detection path based on a number of electrical connection points to be tested and the preset connection relationship matrix, perform connection point resistance detection based on the target detection path, and obtain connection point contact resistance data.

[0086] The result output module is used to obtain a test point detection report based on the contact resistance data of the connection point and a preset connection relationship matrix, so as to realize the automatic detection of irregular connectors.

[0087] This embodiment provides an automatic detection system for irregularly shaped connectors on a tooling board. During detection, the probe matrix module first acquires the pin distribution data of the irregularly shaped connector group on the tooling board to be tested. Based on the pin distribution data, the probe matrix module switches to obtain target probe matrix modules adapted to several irregularly shaped connectors on the current tooling board. Next, the image module acquires the alignment image of the current tooling board, so that the control connection module analyzes the alignment image of the current tooling board and generates a corresponding lifting drive signal to control the lifting module to raise the corresponding probe matrix module, so that the probe matrix is ​​electrically connected to the irregularly shaped connector, forming several electrical connection points to be tested. This achieves one-time detection of all detection points on the current tooling board, enabling compatibility with multiple irregularly shaped connector groups and rapid switching of probe matrices with different compatibility. Then, the detection module plans the detection path according to the preset connection relationship matrix of the tooling board to be tested and the electrical connection points to be tested, so as to ensure short detection time and improve automatic detection efficiency. Finally, the result output module judges the connection status of the test point circuit according to the contact resistance data of the detected connection points and the preset connection relationship matrix, and outputs the test point detection report, realizing comprehensive and efficient automatic detection of irregularly shaped connectors.

[0088] In this implementation, the image module used is a machine vision system, which includes a machine vision camera; the detection module is a programmable unit instruction multi-protocol set detection instrument (integrating a low resistance tester, continuity tester, etc.), used to perform scanning detection on 400 test points according to a predetermined program. The probe matrix module adopts a modular design, including several probe matrix units adapted to different connector specifications. It can be quickly replaced or combined according to the different connector models and pin distributions, which is the key mechanical foundation for realizing the flexibility of the automatic detection system.

[0089] In practice, the probe matrix module, which includes several probe matrix units that are adapted to connectors of different specifications, is combined with software configuration to form a programmable probe matrix. New products can be quickly adapted simply by replacing the modular probe blocks and updating the detection program, reducing changeover time to the hour level and significantly reducing overall costs. This perfectly matches the customized production mode of multiple varieties and small batches.

[0090] Optionally, the detection module includes a path optimization submodule and a data detection submodule, wherein:

[0091] The path optimization submodule is used to obtain a preset connection relationship matrix, construct a node graph model based on several electrical connection points to be tested, and obtain a target detection path based on the node graph model, the preset connection relationship matrix, and the preset path optimization algorithm.

[0092] The data detection submodule is used to obtain loop resistance data based on the target detection path, and to obtain connection point contact resistance data based on the loop resistance data and a preset contact point resistance compensation algorithm.

[0093] In the specific implementation process, the path optimization submodule first obtains the preset connection relationship matrix of the test fixture board and analyzes the state of the electrical connection points under normal conditions, so that the subsequent data detection submodule can automatically detect and analyze based on the loop resistance data; a node graph model is constructed based on the electrical connection points under test, and path planning is performed in combination with the preset connection relationship matrix to shorten the detection path as much as possible and increase detection efficiency.

[0094] Optionally, the path optimization submodule includes:

[0095] An initial test sequence unit is used to obtain several continuity test clusters based on a preset connection relationship matrix and a preset node arrangement method, and to obtain an initial test sequence based on the several test clusters.

[0096] The path optimization unit is used to construct a node graph model based on a number of electrical connection points to be tested; randomly obtain a number of node pairs based on the node graph model; obtain the corresponding node path and node path weight based on any node pair; obtain a number of node paths and node path weights corresponding to all node pairs; construct a node path model based on the number of node paths and node path weights; and obtain the target detection path based on the initial test sequence, the node path model, and the preset path optimization algorithm.

[0097] In practical implementation, since continuity testing can be performed by rapidly scanning within the same electrical network without large-scale switching on physical channels, and switching to the next network only after testing all points within one network, large-scale switching between networks can be minimized. Therefore, during path planning, the initial test sequence unit first generates an initial test sequence based on a preset connection matrix and a preset node arrangement method, prioritizing the arrangement of all nodes belonging to the same electrical network together to form a test cluster, greatly reducing debugging complexity. Then, based on the test cluster, the path optimization unit constructs a node graph model based on the electrical connection points under test, selects arbitrary node pairs to obtain node paths and node path weights, and uses the node path weights to represent the switching time between nodes, constructing a node path model that combines the number of switching times and the switching time. Thus, the initial test sequence is reordered according to the preset path optimization algorithm to minimize the total switching time and the number of switching times required, obtaining the shortest target detection path, effectively increasing the efficiency of automatic detection.

[0098] Optionally, the data detection submodule includes:

[0099] The measurement unit is used to acquire calibration resistance data based on the four-wire measurement method; and to perform resistance measurement based on the target detection path to acquire loop resistance data.

[0100] The data compensation analysis unit is used to obtain the connection point contact resistance data based on the loop resistance data, the calibration resistance data, and the preset contact point resistance compensation algorithm.

[0101] In the specific implementation process, when acquiring the contact resistance data of the connection point, the measurement unit first uses a four-wire measurement method to acquire the resistance value of the section from the measuring device cable to the probe outlet when the connection point is not connected, and then acquires the calibration resistance data. Next, it acquires the loop resistance data according to the target detection path. Finally, the data compensation and analysis unit uses a preset contact point resistance compensation algorithm to calculate the actual contact resistance data of the connection point, thereby achieving accurate measurement of the connection point and avoiding errors in the detection results caused by measuring the line resistance.

[0102] Optionally, the result output module includes:

[0103] The node judgment unit is used to obtain the connection point status detection result based on the connection point contact resistance data and the preset qualified threshold.

[0104] The report output unit is used to automatically determine data and locate fault measurement points based on the preset connection relationship matrix and the connection point status detection results, obtain the measurement point detection report, and realize the automatic detection of irregular connectors.

[0105] In the specific implementation process, when the node judgment unit obtains the test point detection report based on the preset connection relationship matrix and the connection point contact resistance data, it first compares the connection point contact resistance data with the preset qualified threshold to obtain the connection point status detection result including the connection point wiring status. The report output unit then compares the required preset connection relationship matrix with the actual connection point status detection result to realize automatic data judgment and fault test point location. It automatically analyzes whether there is connection point abnormality, can directly locate abnormal connection points, realize a deeper and more quantifiable assessment of wiring reliability, and can accurately diagnose hidden quality hazards that are difficult to detect manually and with traditional equipment.

[0106] This embodiment provides an automatic inspection system for irregularly shaped connectors on a tooling board. Through a probe matrix module, it enables rapid adaptation to new products, effectively shortening changeover time and improving compatibility with irregularly shaped connector groups. Combined with a lifting module, it performs alignment and electrical connection based on the current tooling board alignment image, ensuring uniform and reliable contact force between the probes and connector pins. This guarantees good electrical contact without excessive pressure that could damage the pins, achieving an automated inspection process. Next, a preset path optimization algorithm transforms complex wiring diagrams into an optimal set of inspection instructions, achieving efficient automated inspection. During data analysis and processing, a preset contact point resistance compensation algorithm analyzes and processes the connection point test data, ultimately outputting a test point inspection report. This enables comprehensive quality data traceability, allowing for a deeper, quantifiable assessment of wiring reliability. It accurately diagnoses hidden quality hazards that are difficult to detect manually or with traditional equipment, thereby improving the long-term operational reliability of tooling board products from the source. This system achieves flexible automatic inspection adaptable to complex electrical wiring scenarios.

[0107] Example 3:

[0108] This embodiment provides a multi-protocol compatible irregular-shaped connector intelligent inspection equipment, which is implemented using the above-mentioned automatic inspection method for tooling board irregular-shaped connectors, such as... Figure 2 As shown, its core system mainly includes: a probe matrix module 1, a lifting mechanism 2 (lifting module), a pressing mechanism 3, a programmable multi-protocol integrated testing instrument 4, a machine vision system 5, and an intelligent control system; wherein: the intelligent control system includes a control connection module and a result output module; the intelligent control system is electrically connected to the probe matrix module 1, the lifting mechanism 2, the pressing mechanism 3, the programmable multi-protocol integrated testing instrument 4, and the machine vision system 5 respectively; the programmable multi-protocol integrated testing instrument 4 is electrically connected to the probe matrix module 1; when the probe matrix module 1 is electrically connected to the connector on the test fixture board, the probes on the probe matrix module 1 are electrically connected to the connector pins on the connector; the pressing mechanism is used to control and ensure that the contact force between the probe and the connector pin is uniform and reliable when the lifting mechanism performs precise lifting contact based on the lifting drive signal, so as to ensure good electrical contact without excessive pressing that could damage the pins;

[0109] Preferably, the intelligent testing equipment forms an integrated testing station for placing the tooling plate to be tested;

[0110] Preferably, the intelligent control system includes a MES system.

[0111] In the specific implementation process, when the above-mentioned multi-protocol compatible irregular connector intelligent testing equipment is used to test the fixture board, the fixture board is installed on the upper surface of the probe matrix module 1 and electrically connected to the probes on the upper surface of the probe matrix module 1 through the connector pins on the lower surface of the fixture board; the lifting mechanism 2 is located on the lower surface of the probe matrix module 1, and the pressing mechanism 3 is located above the fixture board.

[0112] The process of automatic detection and online monitoring using this intelligent detection equipment includes:

[0113] Transfer and positioning: Transfer the test fixture to the integrated testing station;

[0114] Lifting Contact: The machine vision system 5 acquires the current tooling plate alignment image, and the intelligent control system acquires the lifting drive signal based on the current tooling plate alignment image. Based on the lifting drive signal, the lifting module 2 controls the target probe matrix module 1 to electrically connect with the irregular connector group to form several electrical connection points to be tested.

[0115] Based on the preset wiring matrix, the multi-protocol integrated testing instrument 4 is called to perform automated scanning and testing (including continuity, resistance, and insulation): a preset connection relationship matrix (i.e., the preset wiring matrix) is obtained; a target detection path is obtained based on several electrical connection points to be tested and the preset connection relationship matrix; the connection point resistance is detected based on the target detection path; and the connection point contact resistance data is obtained.

[0116] Automatic data judgment and fault location: The connection point status detection result is obtained based on the connection point contact resistance data and the preset qualified threshold.

[0117] Generate a digital report; based on the preset connection relationship matrix and the connection point status detection results, automatically determine the data and locate the fault measurement points, obtain the measurement point detection report, and realize the automatic detection of irregular connectors.

[0118] This embodiment provides a multi-protocol compatible intelligent testing equipment for irregularly shaped connectors. Combined with the aforementioned automatic testing method for irregularly shaped connectors on a tooling board, it realizes a multi-protocol compatible intelligent testing equipment and online monitoring method for irregularly shaped connectors, providing a flexible, intelligent, and reconfigurable automatic testing strategy. Specifically: a mechanical structure capable of simultaneously adapting to 50 irregularly shaped connectors, ensuring reliable contact of 400 contacts, and facilitating type changeover is designed. A modular mechanical structure for the probe matrix is ​​set, particularly its adaptation method and quick-change mechanism with the irregularly shaped connector group. A high-density, flexible probe matrix design is achieved through multi-protocol testing logic and scheduling algorithms. Different functions (on / off, resistance) of the integrated testing instrument are efficiently and safely scheduled, performing scanning testing according to the optimal path, and processing real-time comparison and judgment of large amounts of data. A testing matrix (preset connection relationship matrix) is automatically generated based on the wiring table. A compiler is developed that can automatically convert manually entered Excel wiring tables into a system-executable testing relationship matrix, greatly reducing debugging complexity. Precision motion control of the lifting contact ensures uniform and reliable contact force between the probe and the connector pins, guaranteeing good electrical contact without excessive pressure that could damage the pins. This results in a revolutionary improvement in testing efficiency: reducing manual testing from hours to minutes; the testing of 400 wire harnesses can be completed within minutes after a single pressurization and triggering, increasing efficiency by over 100 times; fundamentally guaranteeing testing quality and reliability: automated testing eliminates human error, 100% full coverage testing ensures no defects are missed, and advanced electrical performance testing can detect hidden dangers such as loose connections that are undetectable by humans, improving product reliability from the source; it has extremely high flexibility and adaptability: through the combination of programmable probe matrix and testing protocol software configuration, one set of equipment can handle the testing needs of different projects and different connector combinations, realizing the flexibility of the automated testing process; and it empowers digital management: automatically generating structured testing reports (including pass / fail details), with all data uploaded in real time, providing a solid data foundation for production quality big data analysis, process optimization, and full lifecycle management. The main objectives are: to achieve one-time, automated, and high-precision testing of various types of non-standard connectors with different sizes, apertures, and hole spacings after wiring, replacing inefficient manual inspection and greatly improving production efficiency and wiring reliability; to achieve advanced electrical performance testing, including resistance measurement and insulation testing, to accurately diagnose hidden quality defects such as loose connections and short circuits; to build a flexible and programmable testing platform that can quickly adapt to different cabinet models and wiring schemes through software, meeting the flexible production needs of "multiple varieties and small batches"; and to achieve the digitalization and intelligentization of the testing process, automatically generating test reports and uploading them to the MES (Manufacturing Execution System) to achieve full lifecycle quality traceability.

[0119] In summary, the automatic detection method, system, and multi-protocol compatible intelligent detection equipment for irregularly shaped connectors on tooling boards provided by this invention have achieved a dimensional upgrade in detection capabilities. It can not only determine continuity but also quantitatively measure circuit resistance and insulation resistance, enabling a deeper and more quantifiable assessment of wiring reliability. It can accurately diagnose hidden quality hazards that are difficult to detect manually or with traditional equipment, thereby improving the long-term operational reliability of products from the source. It achieves a leap in full-process automation and digitalization, deeply integrating mechanical transmission, visual positioning, and intelligent control to achieve fully unmanned operation from workpiece flow, precise positioning, test execution to result analysis. Simultaneously, all detection data automatically generates structured reports and uploads them to the management system, enabling comprehensive quality data traceability and providing a foundation for process optimization and big data analysis, where existing technologies are very weak. In terms of application cost and scenario adaptability, this invention provides a flexible set of equipment to cope with constantly changing production needs, greatly improving equipment utilization and return on investment. It is particularly suitable for production scenarios with numerous product models and complex electrical wiring, such as substation secondary switchgear, filling the gap in efficient and flexible automated detection in this field.

[0120] The above description represents the preferred embodiments of the present invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles of the present invention, and these improvements and modifications are also considered to be within the scope of protection of the present invention.

Claims

1. An automatic detection method for irregularly shaped connectors on a tooling board, characterized in that, An automated inspection system for irregularly shaped connectors on a tooling board is used. The automated inspection system includes a lifting module and a probe matrix module, comprising: Obtain pin distribution data of the irregular connector group on the test fixture board, and switch the probe matrix module based on the pin distribution data to obtain the target probe matrix module; Acquire the current tooling plate alignment image, and acquire the lifting drive signal based on the current tooling plate alignment image, so that the lifting module controls the target probe matrix module to electrically connect with the irregular connector group based on the lifting drive signal, forming a number of electrical connection points to be tested; A preset connection relationship matrix is ​​obtained; a target detection path is obtained based on several electrical connection points to be tested and the preset connection relationship matrix; connection point resistance is detected based on the target detection path; and connection point contact resistance data is obtained. Specifically: a preset connection relationship matrix is ​​obtained; a node graph model is constructed based on several electrical connection points to be tested; and a target detection path is obtained based on the node graph model, the preset connection relationship matrix, and a preset path optimization algorithm. Specifically: several continuity test clusters are obtained based on the preset connection relationship matrix and a preset node arrangement method; an initial test sequence is obtained based on the several test clusters; a node graph model is constructed based on several electrical connection points to be tested; several node pairs are randomly obtained based on the node graph model; and corresponding node paths and node path weights are obtained based on any node pair; several node paths and several node path weights are obtained for all node pairs; a node path model is constructed based on several node paths and several node path weights; a target detection path is obtained based on the initial test sequence, the node path model, and the preset path optimization algorithm; loop resistance data is obtained based on the target detection path; and connection point contact resistance data is obtained based on the loop resistance data and a preset contact point resistance compensation algorithm. Based on the contact resistance data of the connection points and the preset connection relationship matrix, a test report is obtained to realize the automatic detection of irregular connectors.

2. The automatic detection method for irregularly shaped connectors on a tooling board as described in claim 1, characterized in that, The step of obtaining loop resistance data based on the target detection path and obtaining connection point contact resistance data based on the loop resistance data and a preset contact point resistance compensation algorithm includes: The calibration resistance data was obtained using the four-wire measurement method. Resistance is measured based on the target detection path to obtain loop resistance data; The connection point contact resistance data is obtained based on the loop resistance data, the calibration resistance data, and the preset contact point resistance compensation algorithm.

3. The automatic detection method for irregularly shaped connectors on a tooling board as described in claim 1, characterized in that, The step of obtaining a test point detection report based on the contact resistance data of the connection points and a preset connection relationship matrix to achieve automatic detection of irregularly shaped connectors includes: The connection point status detection result is obtained based on the connection point contact resistance data and the preset qualified threshold. Based on the preset connection relationship matrix and the connection point status detection results, automatic data judgment and fault measurement point location are performed, and measurement point detection reports are obtained to realize automatic detection of irregular connectors.

4. An automatic detection system for irregularly shaped connectors on a tooling board, characterized in that, An automatic detection method for a tooling board irregular connector as described in any one of claims 1 to 3, comprising: a probe matrix module, a lifting module, an image module, a control connection module, a detection module, and a result output module; wherein: The probe matrix module includes several probe matrix units adapted to connectors of different specifications. The probe matrix module is used to acquire pin distribution data of irregular connector groups on the test fixture board, and to switch probe matrices based on the pin distribution data and several probe matrix units to acquire the target probe matrix module. The image module is used to acquire the alignment image of the current tooling plate; The control connection module is used to acquire a lifting drive signal based on the current tooling plate alignment image, so that the lifting module controls the target probe matrix module to electrically connect with the irregular connector group based on the lifting drive signal, forming a number of electrical connection points to be tested; The detection module is used to acquire a preset connection relationship matrix, acquire a target detection path based on a plurality of electrical connection points to be tested and the preset connection relationship matrix, perform connection point resistance detection based on the target detection path, and acquire connection point contact resistance data; the detection module includes a path optimization submodule and a data detection submodule, wherein: the path optimization submodule is used to acquire a preset connection relationship matrix, construct a node graph model based on a plurality of electrical connection points to be tested, and acquire a target detection path based on the node graph model, the preset connection relationship matrix, and a preset path optimization algorithm; specifically, the path optimization submodule includes: an initial test sequence unit, used to acquire a plurality of continuity test clusters based on the preset connection relationship matrix and a preset node arrangement method, based on a plurality of The test cluster acquires an initial test sequence; the path optimization unit is used to construct a node graph model based on several electrical connection points to be tested; randomly acquire several node pairs based on the node graph model, and acquire corresponding node paths and node path weights based on any node pair; acquire several node paths and several node path weights corresponding to all node pairs; construct a node path model based on several node paths and several node path weights; acquire a target detection path based on the initial test sequence, the node path model, and a preset path optimization algorithm; the data detection submodule is used to acquire loop resistance data based on the target detection path, and acquire connection point contact resistance data based on the loop resistance data and a preset contact point resistance compensation algorithm. The result output module is used to obtain a test point detection report based on the contact resistance data of the connection point and a preset connection relationship matrix, so as to realize the automatic detection of irregular connectors.

5. The automatic detection system for irregularly shaped connectors on a tooling board as described in claim 4, characterized in that, The data detection submodule includes: The measurement unit is used to acquire calibration resistance data based on the four-wire measurement method; and to perform resistance measurement based on the target detection path to acquire loop resistance data. The data compensation analysis unit is used to obtain the connection point contact resistance data based on the loop resistance data, the calibration resistance data, and the preset contact point resistance compensation algorithm.

6. The automatic detection system for irregularly shaped connectors on a tooling board as described in claim 4, characterized in that, The result output module includes: The node judgment unit is used to obtain the connection point status detection result based on the connection point contact resistance data and the preset qualified threshold. The report output unit is used to automatically determine data and locate fault measurement points based on the preset connection relationship matrix and the connection point status detection results, obtain the measurement point detection report, and realize the automatic detection of irregular connectors.

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