Flexible wiring system with automatic control function and wiring method thereof

Abstract

The invention belongs to the technical field of wiring, and discloses a flexible wiring system with an automatic control function and a wiring method thereof.The wiring system comprises wiring software, a control system and a tool wiring mechanism, and the wiring software generates a lifting control point information file and a projection information file; the control system processes a lifting control point information file and a projection information file, the tool wiring mechanism comprises a projector, an automatic lifting mechanism and a dot-matrix wiring plate, the automatic lifting mechanism comprises a PLC and lifting rods which are distributed in an array mode and can ascend and descend, and the top of each lifting rod is provided with an integrated dot-matrix wiring plate of a terminal block. The PLC receives a displacement instruction of the control system and controls the lifting rod to move up and down, the projector projects a projection information file to the dot-matrix wiring board, and finally wiring of the wiring harness is completed on the wiring board projected with wiring information. According to the wiring system and method, paperless information from a design file to a process file to a production site is realized, the work preparation time is shortened, and the assembly quality is improved.

Description

Technical Field

[0001] This invention belongs to the field of cabling technology, and mainly relates to a flexible cabling system with automated control function and its cabling method. Background Technology

[0002] Tooling harnesses are prefabricated electrical equipment connection and wiring systems formed by combining wires, cables, conduits, etc., according to certain wiring rules. They act as a "bridge" connecting the various electrical circuits within equipment, featuring centralized wiring, high reliability, and strong anti-interference capabilities. In tooling harnesses, wires and cables undergo stripping, welding, and insulation treatment before assembly, followed by bundling and fixing. Appropriate bundling materials and fixing methods are used to ensure proper spacing and positioning of the wires and cables within the harness, preventing mutual interference. In particular, cable harnesses play a crucial role in radar systems as a medium for power and signal transmission; their quality directly affects the quality of the entire system. Therefore, their manufacturing process must be carefully considered.

[0003] Traditional cable harness fabrication relies primarily on manual labor. Workers arrange and fix cables on wiring boards or physical components based on circuit diagrams and wiring diagrams. In the discrete electronics equipment industry, electrical harnesses, to meet the electrical performance requirements of the equipment, are designed based on electrical architecture to output electrical schematics. Based on the structural positions of electronic components and the harness layout, they are divided into independent harness modules. A two-dimensional topology harness is established based on the three-dimensional routing. The dimensions in the drawing are unfolded and laid out at a 1:1 scale to form a two-dimensional harness fixture drawing. Then, using this two-dimensional harness drawing, the harness is laid out, electrically connected, and protected on the working wiring board.

[0004] However, in actual processing, due to the varying complexity of wire harnesses and different application requirements, the preparation time and the time required to digest 2D drawings differ. This makes it difficult to economically achieve automated wiring in discrete manufacturing industries with multiple varieties and small batches. Therefore, improving the automation and flexibility of the manufacturing process of multiple varieties and small batches of cable harnesses will effectively improve the manufacturing efficiency of cable harnesses and enhance the consistency of product quality. How to quickly complete the transformation of tooling wiring boards and information exchange is an urgent issue that needs to be considered and solved. Summary of the Invention

[0005] To address the problems in the prior art, the present invention first provides a flexible cabling system with automated control function, which can realize the automated generation of tooling cabling mechanisms and the display of wire harness information, thereby improving the flexibility and efficiency of tooling cabling mechanisms.

[0006] To achieve the above objectives, the present invention is implemented through the following technical solution: A flexible cabling system with automated control functions, characterized in that it includes: The cabling software generates lifting control point information files and projection information files from the cabling plan; The control system receives and processes lifting control point information files and projection information files, and transmits them to the tooling wiring mechanism. The tooling cabling mechanism includes a projector, an automatic lifting mechanism, and a dot matrix cabling board. The automatic lifting mechanism includes a PLC controller and an array of liftable lifting rods. Terminal blocks are set on the top of the lifting rods, and the terminal blocks are integrated into a dot matrix cabling board. The PLC controller receives displacement commands from the control system and controls the lifting rods to move up and down. The projector projects projection information files onto the dot matrix cabling board, and finally completes the wiring of the wire harness on the cabling board with the projected wiring information.

[0007] Furthermore, the automatic lifting mechanism also includes a servo driver, a servo motor, a reducer, and a ball screw. Each lifting rod has a servo driver, a servo motor, a reducer, and a ball screw on its lower side. The PLC controller sends control signals to each servo driver. After receiving the signal, the servo driver drives the servo motor to rotate. The rotation output shaft of the servo motor is connected to the reducer, and the output end of the reducer is connected to the ball screw. The nut in the ball screw pushes the lifting mechanism to rise or fall.

[0008] Furthermore, the automatic lifting mechanism also includes a displacement sensor, which feeds back the real-time position of the lifting rod to the PLC controller.

[0009] Furthermore, the displacement sensor employs a grating ruler.

[0010] Furthermore, the cabling software supports file conversion output, which expresses the collected electrical connection information, physical path information, termination processing information, component and identification information, and test and inspection information through a wiring harness topology diagram, transmits termination processing information through process documents, converts the electrical connection information, component and identification information, and test and inspection information into projection information files and transmits them to a projector through the control system, and converts the physical path information into lifting control point information files and transmits them to the automatic lifting mechanism through the control system.

[0011] The present invention also provides a wiring method for the above-mentioned flexible wiring system, the wiring method comprising the following steps: Step 1: The cabling software generates lifting control point information files and projection information files; Step 2: The control system generates control point information and transmits it to the automatic lifting mechanism and the projector respectively; Step 3: The automatic lifting mechanism raises or lowers the lifting pole according to the control point information, and the projector projects the wiring information onto the dot matrix wiring board. Step 4: Complete the wiring on the dot matrix wiring board; Step 5: Reset the tooling wiring mechanism.

[0012] Furthermore, in step one, the wiring software generates corresponding parameters based on the wiring harness topology diagram, completes the drawing of the wiring harness body and the wiring harness assembly information, forms wiring information parameters, and exports the wiring harness design file and production BOM list to form wiring harness file report and process file report. The information in the two reports is converted into lifting control point information file and projection information file.

[0013] Furthermore, in step three, the motion control module in the PLC controller of the automatic lifting mechanism, or the motion controller connected via communication, performs calculations, including: Trajectory planning generates smooth motion curves to avoid impacts when the lifting boom starts and stops; Multi-axis synchronous control: The PLC controller uses a virtual spindle or electronic gear / cam algorithm to ensure that the displacement, speed and acceleration of all lifting rods are completely synchronized, preventing the dot matrix wiring board from jamming or tilting. In closed-loop control, the PLC controller compares the actual position fed back by the displacement sensor with the target position of the command, calculates the error, and adjusts the signal output to the servo driver in real time through the PID control algorithm to eliminate the error and achieve precise positioning.

[0014] Furthermore, in step three, the displacement sensor measures the actual position of the lifting rod and feeds it back to the PLC controller in real time. When the error between the actual position fed back by the displacement sensor and the target position is within the allowable range, the PLC controller determines that the positioning is complete, instructs the servo driver to stop, the servo motor enters the zero-speed lock state, and the lifting rod stops stably at the target position.

[0015] Compared with the prior art, the present invention has the following beneficial effects: The flexible cabling system with automated control function provided by this invention, based on a cabling design model, forms cabling information points and transmits them to a flexible cabling workbench and projector. By converting the signals into displacement information of a transmission mechanism, a specialized cabling template is formed. It has the following advantages and features: 1) The wiring board no longer requires manual preparation of nailing boards and printing of wiring cardboard information, saving time and reducing production and management costs; 2) The cabling system has a high degree of informatization. The cabling software at the design end can communicate with the industrial network, and design changes can be reflected in a timely manner, which solves the problem of poor timeliness of information transmission in traditional cabling boards. 3) The automatic lifting mechanism and information projection method adopted in this invention solves the problems of long preparation time and poor operability of existing wiring auxiliary tooling, which requires manual arrangement of wiring harness constraint points and wiring harness diagrams; 4) The wire harness manufacturing process of the present invention realizes paperless information from design documents to process documents to the production site, and solves the problems of paper wiring diagrams having little information, being not durable, and being inconvenient to manage; 5) The flexible cabling system provided by this invention can greatly reduce the preparation time and improve the quality of assembly. It is suitable for multi-variety, small-batch wire harness production in various industries. Attached Figure Description

[0016] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used together with the following detailed description to explain the invention, but do not constitute a limitation thereof.

[0017] Figure 1 This is a schematic diagram of the present invention.

[0018] Figure 2 This is a hardware layout diagram of the present invention.

[0019] Figure 3 This is a diagram of the software interface of the cabling software of the present invention.

[0020] Figure 4 This is a schematic diagram of the automatic lifting mechanism of the present invention.

[0021] Figure 5 This is a wiring embodiment diagram of the present invention.

[0022] The diagram shows: 1. Control system; 2. Projector; 3. Cabling workbench; 4. Modular shape; 5. Wire harness drawing interface; 6. Cabling information parameters; 7. Automatic lifting mechanism; 8. Lifting rod; 9. Signal transmission interface; 10. Binding point control block; 11. End control block; 12. Wire harness control block; 13. Projected cabling information. Detailed Implementation

[0023] The specific embodiments of the present invention will be further explained below with reference to the accompanying drawings.

[0024] like Figures 1-5 As shown, this is a flexible cabling system with automated control functions, including cabling software, a control system, and a tooling cabling mechanism.

[0025] The cabling software, installed on a computer, is used to design and plan cabling schemes. It employs customized cabling design software, including 3D and 2D modules. The 3D module is used to design and plan cabling schemes, is compatible with mainstream MCAD tools, and completes wire wiring through automatic path planning, generating 2D layouts containing wire lengths and electrical connection information. The 2D module is used for two-dimensional layout design of wire harnesses, and supports the automatic generation of parts lists for cable assemblies, identification information, and test and inspection information.

[0026] The cabling software supports file conversion output, which takes the collected electrical connection information, physical path information, termination processing information, component and identification information, and test and inspection information, expresses the electrical connection information, physical path information, component and identification information, and test and inspection information through a wiring harness topology diagram, transmits the termination processing information through process documents, and finally converts the electrical connection information, component and identification information, and test and inspection information into projection information files for projection onto a projector, and converts the physical path information into lifting control point information files for automatic lifting mechanism.

[0027] It should be noted that the above electrical connection information mainly includes connection point definition, wire specifications, etc.; component and identification information mainly includes connector information, wire harness identification, auxiliary materials, etc.; testing and inspection information mainly includes continuity test requirements, withstand voltage test, functional test, etc.; physical path information mainly includes wiring path / direction, length dimensions, bending radius, fixing method, etc.; and termination processing information mainly includes terminal type, crimping specifications, soldering requirements, etc.

[0028] Specifically, such as Figures 1-2 As shown, the wiring software includes a wire harness drawing interface 5 and modular shapes 4 representing various functions of the dot matrix wiring board. In the wiring software, the modular shapes 4 are dragged and dropped into the wire harness drawing interface 5, and the corresponding parameters are modified according to the wire harness topology diagram to complete the drawing of the wire harness body and the wire harness assembly information, forming wiring information parameters 6, such as the electrical connection information, physical path information, termination processing information, component and identification information, and test and inspection information mentioned above. The wire harness design documents and production BOM list are exported to form wire harness document reports and process document reports. The information in the two reports is converted into lifting control point information files for the automatic lifting mechanism 7 and projection information files for the projector 2.

[0029] The control system 1 is used to receive and process the lifting control point information file of the automatic lifting mechanism 7 and the projection information file for the projector 2, convert the lifting control point information file into control point information (i.e., displacement command) of the automatic lifting mechanism 7, and transmit it to the automatic lifting mechanism 7, and transmit the projection information file to the projector 2.

[0030] The tooling cabling mechanism provides the final visual support for the cabling operation, including a projector 2, a cabling workbench 3, an automatic lifting mechanism 7, and a dot matrix cabling board.

[0031] The projector 2 is used to project the information file onto the end of the automatic lifting mechanism 7, providing a display of the wire harness production information and realizing paperless information transmission.

[0032] The wiring workbench 3 is equipped with an automatic lifting mechanism 7 and a dot matrix wiring board as hardware support.

[0033] The automatic lifting mechanism 7 includes a PLC controller, a servo driver, a servo motor, a reducer, a displacement sensor, a ball screw, lifting rods 8, and a signal transmission interface 9. The lifting rods are arranged in an array, and each lifting rod has a servo driver, a servo motor, a reducer, a ball screw, and a displacement sensor on its lower side. A dot matrix wiring board is set at the top of the lifting rod. The automatic lifting mechanism 7 receives displacement commands from the control system to realize the raising or lowering of the lifting rods, providing space and fixation for the wiring harness and terminal blocks.

[0034] Specifically, the signal transmission interface 9 is the entry point for receiving control information. The PLC controller, as the control core of the automatic lifting mechanism 7, receives instructions from the automatic control system 1 and sends motion commands to the servo driver, servo motor, reducer, displacement sensor, ball screw, and lifting rod through complex calculations. The servo driver is connected to the servo motor, and the servo motor is connected to the reducer. The three together form a drive structure to provide power for the movement of the ball screw and lifting rod. The ball screw is connected to the reducer and drives the lifting rod to rise or fall. The displacement sensor can be a grating ruler, used to feed back the real-time position of the lifting rod to the PLC controller.

[0035] The dot matrix wiring board is an integration of arrayed terminal blocks located on top of the automatic lifting mechanism, used for the final presentation of wire harnesses and terminals.

[0036] The working process of the automatic lifting mechanism is as follows: The host computer of the industrial control computer receives the target displacement (such as rising 100.0 mm) and motion parameters (speed, acceleration) set in the wiring software, and sends the instruction to the PLC controller of the automatic lifting mechanism 7 via industrial Ethernet. The PLC controller (as the logic control core) receives the instruction and simultaneously reads the real-time position feedback from all displacement sensors (such as grating rulers).

[0037] The motion control module in the PLC controller or a dedicated motion controller connected via communication performs complex calculations, including: (1) Trajectory planning: Generate smooth motion curves, such as S-curves or trapezoidal curves, to avoid impacts when the lifting pole starts and stops.

[0038] (2) Multi-axis synchronous control: The PLC controller uses algorithms such as virtual spindle or electronic gear / cam to ensure that the displacement, speed and acceleration of all lifting rods are completely synchronized, preventing the dot matrix wiring board from jamming or tilting.

[0039] (3) Closed-loop control: The PLC controller compares the actual position fed back by the displacement sensor with the target position of the command, calculates the error, and adjusts the signal output to the servo driver in real time through the PID control algorithm to eliminate the error and achieve precise positioning.

[0040] The PLC controller sends the calculated control signals to each servo driver. Upon receiving the signals, the servo drivers drive the servo motors to rotate at precise speeds and torques. The output shaft of the servo motors is connected to a reducer via a coupling. The reducer reduces the speed and amplifies the torque to drive heavy loads. The output end of the reducer is connected to a ball screw. The nut in the ball screw converts the rotational motion into precise linear motion, thereby driving the lifting mechanism to rise or fall. The displacement sensor directly measures the actual position of the lifting rod and feeds it back to the PLC controller in real time. When the error between the actual position fed back by the displacement sensor and the target position enters a very small allowable range, the PLC controller determines that positioning is complete. The PLC controller then instructs the servo drivers to stop, and the servo motors enter a zero-speed lock state, causing the lifting rod to stop stably at the target position.

[0041] The cabling method of the flexible cabling system with automated control function described in this embodiment includes the following steps: Step 1: The cabling software generates lifting control point information files and projection information files: The cabling software drags the modular shape 4 to the wire harness drawing interface 5, modifies the corresponding parameters according to the wire harness topology diagram, completes the drawing of the wire harness body and the wire harness assembly information, and forms the cabling information parameters 6. The wire harness design file and the production BOM list are exported to form the wire harness file report and the process file report. The information in the two reports is converted into lifting control point information files and projection information files. Step 2: The control system generates control point information and transmits it to the automatic lifting mechanism 7 and the projector 2 respectively. The control system 1 transmits the lifting control point information file for the automatic lifting mechanism 7 and the projection information file for the projector 2 to the automatic lifting mechanism 7 and the projector 2 respectively. The control system 1 converts the control point information into the lifting mechanism's raising or lowering command information. Step 3: The automatic lifting mechanism 7 raises or lowers the lifting rod 8 according to the control point information. The projector 2 projects the wiring information 13 onto the dot matrix wiring board. The control point information of the control system 1 is transmitted to the PLC controller of the automatic lifting mechanism 7 through the signal transmission interface 9. The PLC controller controls the raising or lowering of the lifting rod 8 through electrical signals, forming a wiring template on the dot matrix wiring board, including the binding point control block 10, the end control block 11, and the wire harness control block 12, which is consistent with the design template. At the same time, the projector 2 receives the projection information file and projects the wiring information 13 onto the dot matrix wiring board, including connection point information, wiring relationship information, binding point information, etc. Step 4: Complete the wiring harness on the dot matrix wiring board: After the wiring template and projection information are generated, the operator identifies the processing content according to the wiring template number, and completes the wiring operation, end connection, and wiring harness binding step by step on the dot matrix wiring board according to the lifting control point information file and projection information file, and finally completes the wiring harness. Step 5: Tooling and cabling mechanism reset: After the wiring harness is completed, the operator submits the task completion on the human-machine interface of the control system 1. The control system 1 issues an instruction to the automatic lifting mechanism 7 of the cabling workbench 3 to reset the lifting rod 8 and turn off the projector 2.

[0042] The wiring method of the flexible wiring system with automated control function described in this embodiment actually adopts a dense dot matrix structure to simulate the actual wiring state. Wiring software designs the wiring scheme and generates a wiring schematic. The control system then converts the schematic into control signals and transmits them to the automatic lifting mechanism. The PLC controller of the automatic lifting mechanism controls the movement of the lifting rod, forming a wiring template on the dot matrix wiring board, thereby achieving the desired wiring pattern. Figure 1 The well-designed wiring structure makes wiring design more convenient.

[0043] Finally, it should be noted that the above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. However, any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A flexible cabling system with automated control function, characterized in that, include: The cabling software generates lifting control point information files and projection information files from the cabling plan; The control system (1) receives and processes the lifting control point information file and the projection information file, and transmits them to the tooling wiring mechanism; The tooling wiring mechanism includes a projector (2), an automatic lifting mechanism (7), and a dot matrix wiring board. The automatic lifting mechanism (7) includes a PLC controller and an array of liftable lifting rods (8). A terminal block is set on the top of the lifting rod (8), and the terminal block is integrated into a dot matrix wiring board. The PLC controller receives displacement commands from the control system (1) and controls the lifting rod (8) to move up and down. The projector (2) projects the projection information file onto the dot matrix wiring board, and finally completes the wiring of the wire harness on the wiring board on which the wiring information is projected.

2. The flexible cabling system with automated control function according to claim 1, characterized in that, The automatic lifting mechanism (7) also includes a servo driver, a servo motor, a reducer, and a ball screw. Each lifting rod (10) has a servo driver, a servo motor, a reducer, and a ball screw on its lower side. The PLC controller sends control signals to each servo driver. After receiving the signal, the servo driver drives the servo motor to rotate. The rotation output shaft of the servo motor is connected to the reducer. The output end of the reducer is connected to the ball screw. The nut in the ball screw pushes the lifting mechanism to rise or fall.

3. The flexible cabling system with automated control function according to claim 1, characterized in that, The automatic lifting mechanism (7) also includes a displacement sensor, which feeds back the real-time position of the lifting rod (8) to the PLC controller.

4. A flexible cabling system with automated control function according to claim 3, characterized in that, The displacement sensor is a grating ruler.

5. A flexible cabling system with automated control function according to claim 1, characterized in that, The cabling software supports file conversion output, which takes the collected electrical connection information, physical path information, termination processing information, component and identification information, and test and inspection information, expresses the electrical connection information, physical path information, component and identification information, and test and inspection information through a wiring harness topology diagram, transmits the termination processing information through process documents, converts the electrical connection information, component and identification information, and test and inspection information into projection information files, transmits them to the projector through the control system, and converts the physical path information into lifting control point information files, transmits them to the automatic lifting mechanism through the control system.

6. A wiring method for a flexible wiring system with automated control function according to any one of claims 1 to 5, characterized in that, Includes the following steps: Step 1: The cabling software generates lifting control point information files and projection information files; Step 2: The control system (1) generates control point information and transmits it to the automatic lifting mechanism (7) and the projector (2) respectively. Step 3: The automatic lifting mechanism (7) raises or lowers the lifting rod (8) according to the control point information, and the projector (2) projects the wiring information onto the dot matrix wiring board. Step 4: Complete the wiring on the dot matrix wiring board; Step 5: Reset the tooling wiring mechanism.

7. The cabling method for a flexible cabling system with automated control function according to claim 6, characterized in that, In step one, the wiring software generates corresponding parameters based on the wiring harness topology diagram, completes the drawing of the wiring harness body and the wiring harness assembly information, and forms wiring information parameters (6). The wiring harness design documents and production BOM list are exported to form wiring harness file reports and process file reports. The information in the two reports is converted into lifting control point information files and projection information files.

8. The cabling method for a flexible cabling system with automated control function according to claim 6, characterized in that, In step three, the motion control module in the PLC controller of the automatic lifting mechanism (7) or the motion controller connected via communication performs calculations, including: Trajectory planning generates smooth motion curves to avoid impacts when the lifting boom starts and stops; Multi-axis synchronous control: The PLC controller uses a virtual spindle or electronic gear / cam algorithm to ensure that the displacement, speed and acceleration of all lifting rods are completely synchronized, preventing the dot matrix wiring board from jamming or tilting. In closed-loop control, the PLC controller compares the actual position fed back by the displacement sensor with the target position of the command, calculates the error, and adjusts the signal output to the servo driver in real time through the PID control algorithm to eliminate the error and achieve precise positioning.

9. The cabling method for a flexible cabling system with automated control function according to claim 6, characterized in that, In step three, the displacement sensor measures the actual position of the lifting rod (8) and feeds it back to the PLC controller in real time. When the error between the actual position fed back by the displacement sensor and the target position is within the allowable range, the PLC controller determines that the positioning is complete, and the PLC controller instructs the servo driver to stop, the servo motor enters the zero-speed lock state, and the lifting rod stops stably at the target position.

Images