An ai server high-speed wire core shaping alignment device and method

Abstract

The application relates to the technical field of AI server manufacturing, and particularly discloses an AI server high-speed wire core shaping and aligning device and a method thereof, which comprises a base, a driving platform arranged on the base, an insulation positioning assembly, a shaping and aligning assembly, a visual positioning assembly and a positioning jig. The driving platform comprises a first driving element and a second driving element. The first driving element is used for driving the shaping and aligning assembly to reciprocate in a horizontal direction. The second driving element is used for driving the shaping and aligning assembly to reciprocate in a vertical direction. The positioning jig is arranged on the base, the driving platform or an external transfer mechanism. The visual positioning assembly is located above the shaping and aligning assembly and is electrically connected with the driving platform and each assembly to coordinate the cooperative work of each driving element and each assembly. The shaping and aligning assembly is driven by the first driving element and the second driving element to perform shaping and aligning on the core wire on the welding pad.

Description

Technical Field

[0001] This invention relates to the field of AI server manufacturing technology, and in particular discloses a high-speed wire core forming and alignment device and method for AI servers. Background Technology

[0002] Currently, the core wire shaping and alignment of high-speed AI server cables largely relies on manual or semi-automated equipment. Manual operation is prone to core wire misalignment and scratches due to uneven force and visual errors, making it difficult to ensure consistent spacing between multiple core wires. Furthermore, it is inefficient and has a large fluctuation in yield. Semi-automated equipment is mostly driven by a single or dual axis, and the shaping components lack flexibility in movement, making it unable to adapt to different specifications of cables. Positioning relies solely on mechanical limits, lacking visual and sensor-based collaborative calibration. After shaping, the core wire is prone to detaching from the pad bonding position due to springback stress. At the same time, the lack of insulation protection measures can easily lead to the risk of conductive short circuits. This makes it difficult to meet the high-precision and high-consistency processing requirements of high-speed AI server cables. There is an urgent need for a technical solution that can achieve automated and precise shaping and positioning to solve the above problems. Summary of the Invention

[0003] In order to overcome the shortcomings and deficiencies of the existing technology, the purpose of this invention is to provide a high-speed wire core shaping and alignment device and alignment method for AI servers.

[0004] To achieve the above objectives, the present invention provides a high-speed wire core shaping and alignment device for AI servers, comprising a base, a drive platform disposed on the base, an insulation positioning component, a shaping and alignment component, a visual positioning component, and a positioning fixture; the drive platform includes a first drive member and a second drive member, the first drive member being used to drive the shaping and alignment component to reciprocate in the horizontal direction, and the second drive member being used to drive the shaping and alignment component to reciprocate in the vertical direction; the positioning fixture is disposed on the base, the drive platform, or an external transfer mechanism, and the visual positioning component is located above the shaping and alignment component and is electrically connected to the drive platform and each component to coordinate the collaborative work of each drive member and each component; The positioning fixture has a wire-receiving groove for accommodating the wire and a pad adapted to the wire-receiving groove. After the wire is accommodated in the wire-receiving groove, the core wire of the wire is exposed on the pad. The insulating positioning component is used to abut and position the pad and the core wire of the wire. The shaping and alignment component is driven to move above the positioning fixture via a first driving member and a second driving member to shape and align the core wire of the wire on the pad. The driving platform further includes a fourth driving member, which is used to drive the shaping and alignment component to reciprocate laterally along a direction perpendicular to the driving direction of the first driving member.

[0005] This structure utilizes multiple driving components to achieve three-axis movement of the shaping and alignment assembly (horizontal, vertical, and lateral), significantly improving the spatial flexibility of the equipment and adapting to the shaping and alignment requirements of high-speed AI server cables of various specifications. The positioning fixture's accommodating slots and pads precisely match, stably fixing the cable and accurately exposing the core wire. Combined with the abutment positioning of the insulation positioning component, it effectively prevents cable displacement. The collaborative control function of the vision positioning component can coordinate the actions of each driving component and assembly in real time, achieving automated and precise operation, reducing errors caused by manual intervention, improving the consistency and efficiency of core wire shaping and alignment, and meeting the high-precision processing requirements of high-speed AI server cables.

[0006] Furthermore, the shaping and alignment assembly includes a shaping component disposed at the driving end of the second driving component. The side of the shaping component facing the positioning fixture is a shaping surface. A guide groove is recessed on the shaping surface. A guide arc is provided between the groove wall of the guide groove and the shaping surface. The guide arc is used to abut against the core wire of the wire, so that the core wire of the wire is guided into the guide groove through the guide arc, thereby making the core wire of the wire fit against the pad.

[0007] The guide arc of the forming component features an arc-shaped structure design, effectively preventing sharp edges from scratching or damaging the core wire upon contact, thus ensuring the electrical performance of the high-speed wire remains unaffected. The guide arc smoothly guides the core wire, allowing it to slide smoothly into the guide groove along the arc trajectory, achieving rapid positioning. The guide groove limits the core wire's position, ensuring precise alignment with the preset position on the solder pad, preventing welding defects caused by core wire misalignment, improving the yield rate of subsequent welding processes, simplifying the forming and alignment operation, shortening the forming time for a single wire, and improving the overall processing efficiency of the equipment.

[0008] Furthermore, the number of wires and the number of guide grooves are both multiple, and the multiple guide grooves correspond one-to-one with the core wires of the multiple wires; the pad has multiple mating portions corresponding to the multiple core wires, and there is a gap between the multiple mating portions; a positioning tooth is formed between the guide arc portions of two adjacent guide grooves, and the positioning tooth can be inserted into the gap.

[0009] Multiple sets of guide grooves correspond one-to-one with the core wires, enabling simultaneous shaping and alignment of multiple core wires. This significantly improves equipment processing efficiency and meets the batch processing needs of multi-core high-speed cables for AI servers. The precise fit between the positioning teeth and the pad contact area allows for secondary positioning of the shaped component after insertion, preventing horizontal displacement and ensuring accurate alignment between the guide grooves and the core wires. Simultaneously, the positioning teeth separate adjacent core wires, preventing entanglement or contact during shaping, ensuring insulation performance, reducing the risk of signal interference during subsequent use, and improving the transmission stability of high-speed cables.

[0010] Furthermore, the positioning fixture includes a fixture base plate, a wire-aligning plate disposed on the fixture base plate, and a wire-pressing plate; the wire-pressing plate is hinged to the wire-aligning plate or the fixture base plate, and the wire-pressing plate is rotatable and presses against the wire-aligning plate; the accommodating wire groove is disposed on the wire-aligning plate, and the wire can be accommodated in the accommodating wire groove and positioned by pressing against the wire-pressing plate; the wire-pressing plate has an opening structure or a slot structure that exposes the accommodating wire groove, and the opening structure or slot structure is used to provide operating space for the visual positioning component to detect the wire alignment and for the shaping and alignment component to abut against the wire.

[0011] The positioning fixture features a hinged wire clamping plate design, enabling rapid wire clamping, fixing, and disassembly. This convenient and efficient operation reduces operator workload. The wire accommodating groove provides initial wire positioning, and the clamping plate further prevents wire displacement during shaping, ensuring the core wire remains in the preset position on the pad. The openings or slots on the clamping plate provide a clear inspection field for the vision positioning component, allowing for accurate acquisition of wire alignment data. They also provide ample operating space for the shaping and alignment component, ensuring smooth contact between the shaping parts and core wires for shaping. This simplifies the fixture structure, reduces interference between components, and improves equipment operational stability.

[0012] Furthermore, the visual positioning component includes a visual camera, a positioning lens, and a light source adapted to the positioning lens; the visual camera is disposed on the base or the driving platform, and the positioning lens is disposed below the visual camera.

[0013] The vision positioning component is equipped with a dedicated light source, which effectively improves the clarity of image acquisition and avoids positioning errors caused by insufficient light or reflection, ensuring that the vision camera can accurately capture the position information of the solder pads and core wires. The alignment lens magnifies the detection area, further improving the accuracy of position detection, enabling the drive platform to accurately adjust the position of the shaping and alignment component based on the detection data. The flexible installation method of the vision camera adapts to different equipment layout requirements, and its electrical connection with the drive platform and other components realizes automated closed-loop control of the equipment, reducing the tedious steps of manual positioning, improving the accuracy and efficiency of shaping and alignment, and providing reliable positional assurance for subsequent welding processes.

[0014] Furthermore, the insulating positioning assembly includes a third driving member disposed on the base and an insulating member disposed on the driving end of the third driving member; the side of the insulating member facing the positioning fixture is an insulating surface, and a plurality of insulating protrusions protrude from the insulating surface; the solder pad is supported on the insulating protrusions or accommodated between two adjacent insulating protrusions.

[0015] The insulating positioning assembly uses insulating components made of insulating material, effectively preventing conductive short circuits during positioning and ensuring the safety of equipment operation and the electrical performance of high-speed wires. Multiple insulating protrusions precisely limit the pad's position, ensuring it is stably supported in the preset location and preventing pad displacement that could lead to misalignment between the core wire and the bonding part. The third drive component allows for flexible adjustment of the insulating component's position, adapting to the positioning requirements of pads of different sizes and improving the equipment's versatility. Simultaneously, the insulating component's abutting positioning action enhances the bonding stability between the wire and the pad, providing a solid foundation for subsequent shaping and alignment processes and reducing shaping errors caused by pad movement.

[0016] Furthermore, it also includes a sensor assembly, which is electrically connected to the visual positioning assembly and the driving platform; the sensor assembly includes position sensors disposed on each driving component, which are used to detect the travel position of each driving component; the travel signal of the position sensor is fed back to the visual positioning assembly, and the action parameters of the shaping and alignment assembly are adjusted in coordination with the visual detection data.

[0017] The position sensors in the sensor assembly can detect the travel position of each driving component in real time, accurately feeding back the motion status of the forming and alignment assembly, avoiding equipment damage caused by overtravel of the driving components, and improving the operational safety of the equipment. The coordinated processing of position signals and visual inspection data enables dynamic adjustment of the motion parameters of the forming and alignment assembly, effectively compensating for positioning errors caused by equipment wear or environmental factors, and further improving the accuracy of core wire forming and alignment. Simultaneously, the linkage control of the sensor assembly, visual positioning assembly, and driving platform gives the equipment adaptive adjustment capabilities, allowing it to adapt to the processing requirements of different batches of wire, enhancing the stability and reliability of the equipment, and reducing subsequent maintenance costs.

[0018] A method for shaping and aligning the core wire of a high-speed wire used in an AI server includes the following steps: S1, wire feeding and fixture positioning: The high-speed wire is placed in the receiving groove of the positioning fixture, and the wire is pressed and fixed by rotating the pressure plate, so that the core wire is exposed on the pad; the visual positioning component turns on the light source, and the initial position information of the pad and the core wire is collected through the visual camera and the alignment lens, and the third driving component of the insulation positioning component is coordinated to drive the insulation component to move, so that the pad is accurately supported on the insulation protrusion or placed between two adjacent insulation protrusions to complete the support positioning; S2, shaping component positioning: The visual positioning component collects the position data of the positioning fixture in real time, combines it with the stroke signal detected by the position sensor set on each driving component and feeds it back to the driving platform, and then... The first and second driving components work together to move the shaping and alignment component to a preset position above the positioning fixture, so that the guide groove of the shaping component initially aligns with the core wire position; S3, Core wire shaping and real-time alignment calibration: The second driving component drives the shaping component downwards towards the core wire, and the vision positioning component monitors the relative position of the core wire and the guide groove in real time, guiding the guide arc to accurately guide the core wire into the guide groove, while the positioning teeth are inserted into the gap between the pad bonding parts; Subsequently, the first driving component drives the shaping component to reciprocate in the horizontal direction, and the vision positioning component continuously collects the core wire posture information. If the core wire offset or springback is detected, it is immediately fed back to the driving platform, driving the shaping and alignment component to fine-tune the position until the core wire accurately fits the bonding part of the pad.

[0019] This method achieves fully automated control of the high-speed wire core from positioning to shaping through meticulous step-by-step operations, significantly reducing errors caused by manual operation. In step S1, the collaborative positioning of the vision positioning component and the insulation positioning component ensures accurate initial positioning of the pads and the core, laying a solid foundation for subsequent shaping. Step S2 combines visual data and sensor travel signals to achieve precise pre-positioning of the shaping component, improving shaping efficiency. The real-time alignment calibration mechanism in step S3 dynamically corrects core offset or springback issues, ensuring the core ultimately fits precisely to the pads, significantly improving the accuracy and consistency of shaping alignment. The entire method is compact and logically clear, effectively improving the processing quality and production efficiency of high-speed wires for AI servers and reducing the defect rate.

[0020] Furthermore, between S1 and S2, there is also a wire flattening step: the visual positioning component acquires the wire arrangement image in the accommodating wire groove through the opening structure or slot structure of the pressure plate, and judges whether the wire is neat; if it is judged to be uneven, the visual positioning component feeds back a signal to the driving platform, and the driving platform controls the shaping and alignment component to move down, and the shaping surface of the shaping component abuts and combs the wire in the accommodating wire groove until the visual positioning component judges that the wire arrangement spacing deviation is ≤ preset threshold.

[0021] The newly added wire leveling step pre-processes the wires within the accommodating grooves before the forming assembly's formal positioning, promptly correcting any uneven wire arrangement and preventing core wires from failing to accurately enter the guide grooves during subsequent forming due to uneven wire spacing. The vision positioning assembly acquires images through the openings or slots in the pressure plate, providing high detection accuracy and precisely determining the wire arrangement status. The forming surface of the forming component abuts against the combed wires, quickly adjusting the wire spacing to a preset range and ensuring consistent arrangement of multiple wires. This step further optimizes the forming and alignment process, reducing errors at the source, improving the overall accuracy of core wire forming and alignment, while also reducing rework rates in subsequent processes and increasing equipment production efficiency.

[0022] Furthermore, in S3, when the first driving member drives the shaping member to reciprocate in the horizontal direction, the groove wall of the guide groove and the positioning teeth synchronously abut against the outer surface of the core wire, and drive the core wire to reciprocate along the pad bonding portion to relieve the springback stress of the core wire.

[0023] This step involves driving the shaping component to reciprocate horizontally, causing the guide groove wall and positioning teeth to simultaneously abut against the core wire and roll it along the pad contact area. This effectively eliminates the springback stress caused by the core wire's material properties, preventing it from detaching from the pad contact area after shaping and ensuring the stability of the shaping effect. The reciprocating rolling of the core wire also enhances the contact tightness between the core wire and the pad contact area, providing better contact conditions for subsequent welding processes and improving welding quality. Furthermore, this operation requires no additional equipment components; stress relief is achieved solely through the reciprocating motion of the driving component, simplifying the process, reducing equipment modification costs, and further enhancing the practicality and economy of the shaping and alignment method.

[0024] The beneficial effects of this invention are as follows: The equipment achieves three-axis movement of the shaping and alignment components through multiple driving components, and coordinates with vision positioning and sensor components for precise adjustment of the shaping component's position. The positioning fixture fixes the wire and exposes the core wire, while the insulated positioning component stabilizes the pads to prevent displacement; the guide arc of the shaping component non-destructively guides the core wire into the groove, and the positioning teeth are inserted into the gaps in the pads for secondary positioning, separating the core wire to prevent entanglement interference. The alignment method adds wire flattening pretreatment, visual inspection, and combing of the wire until the spacing meets the standard; during shaping, real-time visual calibration drives the shaping component to reciprocate horizontally, causing the core wire to roll, eliminating springback stress, and ensuring that the core wire accurately fits the pads. The entire process is automated to achieve high-precision shaping and positioning, improving processing consistency and yield. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the overall structure of a high-speed wire core shaping and alignment device for AI servers according to the present invention. Figure 2 This is a schematic diagram of the structure of the present invention, which removes the positioning fixture; Figure 3This is a schematic diagram of the structure of the shaping and positioning component of the present invention; Figure 4 This is a schematic diagram of the structure of the visual positioning component of the present invention; Figure 5 This is a partial structural schematic diagram of the positioning fixture and insulating positioning assembly of the present invention; Figure 6 This is a flowchart illustrating the steps of a high-speed wire core shaping and alignment method for AI servers according to the present invention.

[0026] The reference numerals in the attached drawings include: 1. Base; 2. Drive platform; 3. Insulating positioning assembly; 4. Shaping and alignment assembly; 5. Vision positioning assembly; 6. Positioning fixture; 7. First drive component; 8. Second drive component; 9. Receiving groove; 11. Solder pad; 12. Shaping component; 13. Shaping surface; 14. Guide groove; 15. Guide arc; 16. Fitting part; 17. Positioning tooth; 18. Fixture base plate; 19. Wire straightening plate; 21. Wire pressing plate; 22. Vision camera; 23. Alignment lens; 24. Light source; 25. Third drive component; 26. Insulating component; 27. Insulating surface; 28. Insulating protrusion; 29. ​​Sensor assembly; 31. Fourth drive component. Detailed Implementation

[0027] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided below.

[0028] Please see Figures 1 to 6 As shown, a high-speed wire core shaping and alignment device for AI servers according to the present invention includes a base 1, a drive platform 2 disposed on the base 1, an insulation positioning component 3, a shaping and alignment component 4, a visual positioning component 5, and a positioning fixture 6. The drive platform 2 includes a first drive member 7 and a second drive member 8. The first drive member 7 is used to drive the shaping and alignment component 4 to reciprocate in the horizontal direction, and the second drive member 8 is used to drive the shaping and alignment component 4 to reciprocate in the vertical direction. The positioning fixture 6 is disposed on the base 1, the drive platform 2, or an external transfer mechanism. The visual positioning component 5 is located above the shaping and alignment component 4 and is electrically connected to the drive platform 2 and each component to coordinate the collaborative work of each drive member and each component. The positioning fixture 6 has a wire receiving groove 9 for accommodating the wire and a pad 11 adapted to the wire receiving groove 9. After the wire is accommodated by the wire receiving groove 9, the core wire of the wire is exposed on the pad 11. The insulating positioning component 3 is used to abut and position the pad 11 and the core wire of the wire. The shaping and alignment component 4 is driven to move above the positioning fixture 6 via the first driving component 7 and the second driving component 8 to shape and align the core wire of the wire on the pad 11. The driving platform 2 also includes a fourth driving component 31, which is used to drive the shaping and alignment component 4 to reciprocate laterally along a direction perpendicular to the driving direction of the first driving component 7.

[0029] The base 1 serves as the foundation for the equipment. The first, second, and fourth drive components 31 integrated in the drive platform 2 can preferably be servo motors paired with ball screw modules, or stepper motors paired with synchronous belt modules depending on cost requirements. The servo motor solution can control motion accuracy to the 0.01mm level, suitable for high-precision shaping scenarios, while the stepper motor solution can control accuracy to the 0.05mm level, meeting the needs of mass production with ordinary precision requirements. The positioning fixture 6 can be flexibly installed according to the production scenario. When manually loading, it can be fixed to the base 1, while in automated production lines, it can be equipped with an external transfer mechanism to achieve transfer. The transfer mechanism can be a belt conveyor or a robotic arm transfer module.

[0030] The vision positioning component 5 can be electrically connected to an industrial camera and a PLC control system. After power-on, it can first complete the origin calibration of each component. The calibration reference can be the standard positioning pin on the base 1. Then, it can collect the position coordinates of the positioning fixture 6 and the core wire in real time and feed the data back to the drive platform 2. During operation, the wire can be embedded into the receiving groove 9 so that the core wire is in contact with the solder pad 11. The insulating positioning component 3 moves to press against the solder pad 11 and the wire. The vision positioning component 5 outputs instructions according to the detection data. After receiving the instructions, the drive platform 2 can control the shaping and alignment component 4 to move along the three-axis direction to above the solder pad 11. During the movement, an S-shaped acceleration and deceleration algorithm can be used to avoid the impact when the component starts and stops, and accurately hover for subsequent shaping operations. The whole process can be completed without manual intervention.

[0031] Specifically, the shaping and alignment component 4 includes a shaping component 12 disposed at the driving end of the second driving component 8. The side of the shaping component 12 facing the positioning fixture 6 is a shaping surface 13. A guide groove 14 is recessed on the shaping surface 13. A guide arc portion 15 is provided between the groove wall of the guide groove 14 and the shaping surface 13. The guide arc portion 15 is used to abut against the core wire of the wire, so that the core wire of the wire is guided into the guide groove 14 through the guide arc portion 15, thereby making the core wire of the wire fit against the pad 11.

[0032] The shaping component 12 can be made of anti-static hard alloy or wear-resistant nylon. Hard alloy is suitable for high-frequency processing, while nylon better prevents scratches on the core wire. The shaping component 12 can be fixed to the drive end flange of the second drive component 8 by bolts or by quick-change fixtures, facilitating the replacement of different models of the shaping component 12 according to the core wire specifications and ensuring no loosening during high-speed movement. The guide arc 15 can be CNC machined into a circular arc transition structure with a radius of 0.2-0.5mm, and the surface roughness can be controlled below Ra0.8 to prevent sharp edges from scratching the core wire insulation layer.

[0033] After the vision positioning component 5 completes the core wire position calibration, the second driving component 8 can drive the shaping component 12 to move vertically downwards at a speed of 2-5 mm / s, gradually bringing the shaping surface 13 closer to the pad 11. When the guide arc 15 contacts the core wire, the core wire slides along the arc under pressure, gradually embedding itself into the guide groove 14. The width and depth of the guide groove 14 can be customized according to the core wire diameter, slightly larger than the core wire diameter by 0.05-0.1 mm, ensuring smooth entry of the core wire into the groove while achieving precise positioning. After the core wire enters the groove, the second driving component 8 can apply constant pressure, which can be adjusted to 5-10 N depending on the core wire material, ensuring the core wire fits tightly against the surface of the pad 11 and completing the initial shaping. Throughout the process, the vision positioning component 5 can monitor in real time, with a sampling frequency of 100 Hz to ensure no core wire deviation.

[0034] Specifically, the number of wires and the number of guide grooves 14 are both multiple, and the multiple guide grooves 14 correspond one-to-one with the core wires of the multiple wires; the pad 11 has multiple mating portions 16 corresponding to the multiple core wires, and there is a gap between the multiple mating portions 16; a positioning tooth 17 is formed between the guide arc portions 15 of two adjacent guide grooves 14, and the positioning tooth 17 can be inserted into the gap.

[0035] Based on the number of core wires in the high-speed AI server wiring harness, the guide grooves 14 can be processed into multiple sets of equally spaced structures. The spacing can be completely consistent with the spacing of the pad 11 contact portion 16, or it can be finely adjusted by ±0.03mm according to the insulation layer thickness of the core wires to ensure one-to-one correspondence. The positioning teeth 17 can be integrally formed from adjacent guide arc portions 15, and their thickness can match the gap width between the pad 11 contact portion 16, with a tolerance controlled within ±0.02mm. The ends of the positioning teeth 17 can be processed into a chamfered structure, with a chamfer angle of 30°-45°, to facilitate smooth insertion into the gap. When the shaping component 12 is pressed down, the positioning teeth 17 can be inserted into the gap of the pad 11 first, achieving precise alignment between the shaping component 12 and the pad 11, preventing horizontal displacement of the shaping component 12 from causing misalignment between the guide grooves 14 and the core wires.

[0036] Multiple sets of guide grooves 14 can simultaneously contact the corresponding core wires. Utilizing the guiding effect of the guide arc 15, multiple core wires are simultaneously embedded into the grooves, avoiding the cumbersome process of operating each core wire individually. After the positioning teeth 17 are inserted into the gap, they can also separate adjacent core wires. The separation distance can be controlled between 0.1-0.2mm, preventing the core wires from contacting each other during the shaping process, effectively avoiding the risk of short circuits. Simultaneously, it ensures uniform core wire spacing, meeting the impedance requirements of high-speed transmission, and is suitable for cable types with high spacing accuracy requirements, such as differential signal lines.

[0037] Specifically, the positioning fixture 6 includes a fixture base plate 18, a wire-aligning plate 19 disposed on the fixture base plate 18, and a wire-pressing plate 21; the wire-pressing plate 21 is hinged to the wire-aligning plate 19 or the fixture base plate 18, and the wire-pressing plate 21 is rotatable and presses against the wire-aligning plate 19; the accommodating groove 9 is disposed on the wire-aligning plate 19, and the wire can be accommodated in the accommodating groove 9 and pressed and positioned by the wire-pressing plate 21; The pressure plate 21 has an opening or slot structure that exposes the accommodating wire groove 9. The opening or slot structure provides operating space for the visual positioning component 5 to detect the neatness of the wire and for the shaping and alignment component 4 to abut against the wire.

[0038] The fixture base plate 18 can be made of aluminum alloy or stainless steel. Aluminum alloy is lightweight and easy to handle, while stainless steel is more wear-resistant. The wire assembly plate 19 can be fixed to the base plate by positioning pins or by magnetic connection, facilitating quick replacement of different specifications of the wire assembly plate 19. The wire receiving groove 9 can be milled according to the outer diameter of the wire. The groove depth can be 1 / 2 or 2 / 3 of the outer diameter of the wire, and the groove width can be 0.05mm larger than the outer diameter of the wire to ensure that the wire will not roll after being embedded. The wire pressing plate 21 can be hinged to one side of the wire assembly plate 19. The edge can be equipped with a buckle structure or a magnetic lock. During manual loading, the wire pressing plate 21 can be opened, and the wires can be embedded one by one into the wire receiving groove 9, so that the core wires are laid flat on the solder pads 11. Then the wire pressing plate 21 can be fastened, and the wires can be pressed tightly by the locking force of the buckles. The clamping force can be controlled by adjusting the elastic coefficient of the buckles to prevent the wires from shifting during shaping.

[0039] The width of the slotted structure on the pressure plate 21 can be slightly larger than that of the accommodating slot 9, and its length can cover the entire exposed area of ​​the core wire. The perforation structure can adopt an array of round holes, and the hole diameter can be adjusted according to the core wire diameter. This ensures that the detection field of the visual positioning component 5 is not obstructed, while also providing sufficient operating space for the shaping and alignment component 4. During operation, the visual positioning component 5 can acquire images of the core wire through the slotted structure to determine whether the arrangement is neat; the shaping and alignment component 4 can pass through the slotted structure and directly contact the core wire for shaping without disassembling the pressure plate 21, greatly improving operating efficiency.

[0040] Specifically, the visual positioning component 5 includes a visual camera 22, a positioning lens 23, and a light source 24 adapted to the positioning lens 23; the visual camera 22 is disposed on the base 1 or the driving platform 2, and the positioning lens 23 is disposed below the visual camera 22.

[0041] The vision camera 22 can preferably be a 2-megapixel industrial area array camera or a 5-megapixel camera. The high-pixel camera is suitable for inspecting ultra-fine core wires. The camera can be fixed to the crossbeam of the base 1 or the drive platform 2 via a bracket. The bracket height is adjustable, with an adjustment range of 100-200mm. The alignment lens 23 can be a telecentric lens with a focal length of 12-25mm or a macro lens. The telecentric lens provides distortion-free imaging, while the macro lens is suitable for close-range, high-precision inspection, ensuring distortion-free imaging. The light source 24 can be a ring-shaped shadowless light source or a backlight 24. The ring-shaped light source 24 is suitable for core wire edge inspection, while the backlight 24 is suitable for clear imaging of the core wire outline. The light source 24 is installed below the lens, and its brightness can be adjusted via a controller, with an adjustment range of 0-255 levels, avoiding problems such as strong light reflection or weak light blurring.

[0042] After the equipment is powered on, the vision system can first be calibrated. A conversion relationship between pixels and actual dimensions is established using a standard calibration board, achieving a calibration accuracy of 0.005 mm / pixel. The calibration board can be a checkerboard calibration board or a dot calibration board. During operation, the light source 24 can be turned on to illuminate the pads 11 and the core wire area. The vision camera 22 can acquire high-definition images through the alignment lens 23, and image processing algorithms are used to identify the edge contours of the core wire. Algorithms such as the Canny edge detection algorithm or the Sobel algorithm can be used to calculate the actual position coordinates of the core wire. The coordinate data can then be transmitted to the PLC control system, compared with the preset standard position, to obtain the offset. A control signal is then output to the drive platform 2 to adjust the position of the shaping and alignment component 4, achieving precise alignment. The entire vision inspection and data processing process takes no more than 0.5 seconds.

[0043] Specifically, the insulating positioning component 3 includes a third driving member 25 disposed on the base 1 and an insulating member 26 disposed at the driving end of the third driving member 25; the side of the insulating member 26 facing the positioning fixture 6 is an insulating surface 27, and a plurality of insulating protrusions 28 protrude from the insulating surface 27; the solder pad 11 is supported on the insulating protrusions 28 or accommodated between two adjacent insulating protrusions 28.

[0044] The third drive component 25 can preferably be driven by a cylinder or an electric actuator. Cylinder drive offers faster response, while electric actuator provides higher positioning accuracy. The insulating component 26 can be made of high-temperature resistant insulating ceramic or polytetrafluoroethylene (PTFE). Ceramic has better high-temperature resistance, while PTFE is lighter. The insulating component 26 can be fixed to the cylinder piston rod end via a threaded connection or a slotted connection. The height of the insulating protrusions 28 can be 0.5-1mm, and the spacing can match the size of the pads 11 or be adjusted according to the thickness of the pads 11 to ensure that the pads 11 can be stably placed on the protrusions or embedded between adjacent protrusions. The top of the insulating protrusions 28 can be machined with rounded corners to avoid scratching the pads 11. After the wire is fed and the pressure plate 21 is engaged, the PLC control system can send a command, and the third drive component 25 can drive the insulating component 26 to move horizontally at a speed of 3-8mm / s, approaching the area of ​​the pads 11 on the positioning fixture 6.

[0045] When the insulating component 26 reaches the preset position, the pad 11 can be precisely supported on the insulating protrusion 28, or accommodated between adjacent insulating protrusions 28. The insulating protrusions 28 can provide three-point support and positioning for the pad 11, preventing the pad 11 from shifting horizontally or vertically during the shaping process. At the same time, the insulating component 26, made of insulating ceramic material, can effectively isolate the pad 11 from the metal parts of the equipment, with an insulation resistance of over 10^12Ω, avoiding short circuits in the core wire due to static electricity or leakage, and ensuring the electrical safety of the equipment and the wire. After positioning, the insulating component 26 can remain stationary until the entire wire is shaped and reset. A delay time of 0.5 seconds can be set during reset to ensure that the shaping process is completely completed.

[0046] Specifically, it also includes a sensor assembly 29, which is electrically connected to the visual positioning assembly 5 and the drive platform 2. The sensor assembly 29 includes position sensors disposed on each drive component, which are used to detect the travel position of each drive component. The travel signal of the position sensor is fed back to the visual positioning assembly 5, and the action parameters of the shaping and alignment assembly 4 are adjusted in coordination with the visual detection data.

[0047] Sensor assembly 29 can use a grating ruler or a proximity switch as a position sensor. The grating ruler is suitable for high-precision displacement detection, while the proximity switch is more cost-effective. The sensors can be installed on the motion guide rails of the first, second, third, and fourth drive components 31, and electrically connected to the control system of the drive components. During installation, the detection distance of the sensors can be adjusted using brackets to ensure detection accuracy. The position sensors can detect the stroke position of each drive component in real time, converting the displacement signal into an electrical signal and feeding it back to the control system of the vision positioning assembly 5. Signal transmission can use RS485 or Ethernet protocol. During operation, the core wire position data collected by the vision positioning assembly 5 can be used as a "visual positioning reference," and the drive component stroke data fed back by the position sensors can be used as a "mechanical positioning reference." The control system can fuse the two sets of data. The fusion algorithm can use a weighted average algorithm to correct positioning errors caused by equipment vibration and temperature changes. The temperature compensation coefficient can be set to 0.001 mm / ℃ according to the equipment operating environment.

[0048] For example, when the visual system detects a core wire offset of 0.02mm, while the position sensor detects an actual travel deviation of 0.01mm for the drive component, the system can comprehensively adjust the motion parameters of the drive component to compensate for the total offset of 0.03mm. Simultaneously, the position sensor can also implement an overtravel protection function. When the drive component moves beyond the preset travel range, the sensor can immediately send an alarm signal, causing the drive component to stop urgently to prevent equipment collision damage. The overtravel alarm threshold can be set to ±5% of the preset travel range.

[0049] A method for shaping and aligning the core wires of high-speed cables used in AI servers includes the following steps: S1. Wire feeding and fixture positioning: The high-speed wire is placed in the accommodating groove 9 of the positioning fixture 6, and the wire pressing plate 21 is rotated to press and fix the wire, so that the core wire is exposed on the pad 11; the visual positioning component 5 turns on the light source 24, and the initial position information of the pad 11 and the core wire is collected through the visual camera 22 and the alignment lens 23. The third driving component 25 of the insulation positioning component 3 is coordinated to drive the insulating component 26 to move, so that the pad 11 is accurately supported on the insulating protrusion 28 or placed between two adjacent insulating protrusions 28 to complete the support and positioning. S2, Shaping component positioning: The visual positioning component 5 collects the position data of the positioning fixture 6 in real time, combines the stroke signal detected by the position sensor set on each driving component and feeds it back to the driving platform 2. The first driving component 7 and the second driving component 8 work together to move the shaping alignment component 4 to the preset position above the positioning fixture 6, so that the guide groove 14 of the shaping component 12 initially corresponds to the position of the core wire. S3. Core wire shaping and real-time alignment calibration: The second driving component 8 drives the shaping component 12 downward to approach the core wire. The vision positioning component 5 monitors the relative position of the core wire and the guide groove 14 in real time, and guides the guide arc 15 to accurately guide the core wire into the guide groove 14. At the same time, the positioning teeth 17 are inserted into the gap between the pad 11 and the bonding part 16. Then, the first driving component 7 drives the shaping component 12 to reciprocate in the horizontal direction. The vision positioning component 5 continuously collects the core wire posture information. If the core wire is detected to deviate or spring back, it is immediately fed back to the driving platform 2, which drives the shaping and alignment component 4 to fine-tune the position until the core wire is accurately bonded to the bonding part 16 of the pad 11.

[0050] In step S1, the high-speed wire can be embedded into the receiving slot 9 of the wire board 19 by manual labor or a robotic arm. The robotic arm can be a SCARA robotic arm or a Cartesian coordinate robotic arm. The wire clamping plate 21 is then fastened and fixed. The vision positioning component 5 can turn on the light source 24 to collect the initial image. The brightness of the light source 24 can be adjusted according to the ambient light. After identifying the position of the pad 11 and the core wire, a command can be sent to the third driving component 25 to drive the insulating component 26 to accurately position the pad 11. The positioning accuracy can be controlled within 0.02mm.

[0051] In step S2, the visual positioning component 5 can combine the travel data of the position sensor, and the data fusion frequency can be set to 50Hz to calculate the target position of the shaping and alignment component 4. The first and second driving components 8 can work together to drive the shaping component 12 to move above the pad 11. During the movement, an interpolation motion algorithm can be used to make the guide groove 14 correspond one-to-one with the core wire, thus completing the initial alignment.

[0052] In step S3, the second driving component 8 drives the shaping component 12 to press down at a speed of 1-3 mm / s. The guide arc 15 guides the core wire into the slot, and the positioning teeth 17 insert into the gap of the pad 11. Subsequently, the first driving component 7 drives the shaping component 12 to reciprocate horizontally at a frequency of 2-5 times / second. The vision positioning component 5 acquires core wire images at a frequency of 50 frames / second to monitor the core wire posture in real time. If core wire offset or springback is detected, and the offset exceeds 0.01 mm, the system can immediately calculate the compensation amount with a compensation accuracy of 0.005 mm. The system then drives the shaping and alignment component 4 to fine-tune the position until the core wire is fully attached to the pad 11 and the attachment part 16. The entire process can be controlled within 3-5 seconds to ensure that the shaping accuracy meets the process requirements. This method is suitable for shaping core wires with a diameter of 0.05-0.5 mm.

[0053] Specifically, between S1 and S2, there is also a wire flattening step: the visual positioning component 5 collects the wire arrangement image in the accommodating wire groove 9 through the opening structure or slot structure of the wire pressure plate 21, and judges whether the wire is neat; if it is judged to be uneven, the visual positioning component 5 feeds back a signal to the driving platform 2, and the driving platform 2 controls the shaping and alignment component 4 to move down, and the shaping surface 13 of the shaping component 12 abuts and combs the wire in the accommodating wire groove 9 until the visual positioning component 5 judges that the wire arrangement spacing deviation is ≤ preset threshold.

[0054] After the S1 fixture is positioned and before the S2 shaping component is positioned, the wire leveling step can be initiated. This step can be enabled or disabled according to production needs and is suitable for scenarios with strict requirements on the spacing of multi-core wires. The vision positioning component 5 can acquire images of the wire arrangement within the accommodating slot 9 through the slotted structure of the wire pressing plate 21. The image resolution can be set to 1920×1080. An algorithm is used to calculate the spacing between adjacent wires. The algorithm can be a template matching algorithm, which is compared with a preset threshold (usually ±0.05mm). The threshold can be adjusted according to the core wire specifications. If the spacing deviation exceeds the threshold, it is determined that the wire arrangement is not neat, and the vision positioning component 5 can feed back the signal to the drive platform 2. The feedback delay time can be controlled within 0.1 seconds.

[0055] The drive platform 2 controls the second drive component 8 to drive the shaping component 12 downwards, so that the shaping surface 13 contacts the wire surface. The contact pressure can be controlled between 0.1-0.2 MPa, and the pressure can be monitored in real time by a pressure sensor to avoid damaging the core wire. Subsequently, the first drive component 7 drives the shaping component 12 to slowly reciprocate along the length of the accommodating groove 9. The movement speed can be set to 0.5-2 mm / s. The shaping surface 13 abuts and combs the wire. The combing direction can be unidirectional or bidirectional, so that the wire is evenly distributed within the accommodating groove 9. During the combing process, the vision positioning component 5 can continuously collect images and judge the spacing deviation. The sampling interval can be set to 0.2 seconds until the deviation is ≤ a preset threshold. The shaping component 12 can then be reset. The reset height can be set to 5 mm, and then the process enters the S2 shaping component positioning step. This step can effectively solve the problem of uneven distribution when feeding wires, lay the foundation for subsequent accurate shaping, and reduce the shaping failure rate caused by uneven wire spacing.

[0056] Specifically, in S3, when the first driving member 7 drives the shaping member 12 to reciprocate in the horizontal direction, the groove wall of the guide groove 14 and the positioning tooth 17 simultaneously abut against the outer circular surface of the core wire, and drive the core wire to reciprocate along the bonding portion 16 of the solder pad 11 to relieve the springback stress of the core wire.

[0057] During the S3 core wire shaping stage, after the core wire is embedded in the guide groove 14 and the positioning teeth 17 are inserted into the gap of the pad 11, the first driving component 7 can drive the shaping component 12 to reciprocate along the length of the pad 11 contact portion 16. The movement speed can be controlled at 5-10 mm / s, and can also be adjusted according to the material of the core wire. For soft core wires, a lower speed can be selected, and the stroke can be 1.2 times the length of the contact portion 16 to ensure that the core wire is combed throughout. During the movement, the two side walls of the guide groove 14 and the side of the positioning teeth 17 can simultaneously abut against the outer surface of the core wire, applying a constant lateral pressure. The pressure value can be set to 3-8 N, and the pressure can be adjusted by the pressure regulating valve, driving the core wire to roll back and forth along the surface of the pad 11. The rolling trajectory can be a straight line or a slight arc. When the core wire rolls, the elastic deformation stress inside it can be gradually released, thereby eliminating the springback stress caused by bending or squeezing. The degree of stress relief can be judged by visual inspection of the straightness of the core wire. A straightness deviation of ≤0.03mm is considered qualified, thus preventing the core wire from springing back and detaching from the solder pad after shaping.

[0058] Meanwhile, the reciprocating friction between the core wire and the pad 11 enhances the tightness of their fit, keeping the gap within 0.01mm and improving the reliability of subsequent soldering. The visual positioning component 5 can monitor the core wire position throughout the process, covering the entire pad 11 contact area 16. If the core wire is found to have shifted due to rolling, and the shift exceeds 0.01mm, the shaping component 12 can be immediately driven to fine-tune its position. The fine-tuning step size can be 0.005mm to ensure that the core wire is always in contact with the pad 11 contact area 16 until the springback stress is completely dissipated. The springback stress dissipation time can be controlled within 1-2 seconds. The shaping component 12 can then stop its reciprocating motion and reset. After resetting, the process can proceed to the next step after a delay of 0.3 seconds.

[0059] The working principle of this invention: The high-speed wire core shaping and alignment equipment for AI servers uses base 1 as its supporting foundation. The drive platform 2 achieves three-axis linkage of the shaping and alignment component 4 in the horizontal, vertical, and transverse directions through the combination of multiple drive components. Servo motors or stepper motors can be selected according to processing requirements, and different transmission modules can be matched to adapt to different precision scenarios. During operation, the high-speed wire is first placed in the accommodating groove 9 of the positioning fixture 6 and pressed and fixed by the hinged wire pressing plate 21, so that the core wire is exposed on the pad 11. The drive component of the insulating positioning component 3 drives the insulating component 26 to move, and the insulating protrusion 28 forms a precise support and positioning for the pad 11, avoiding displacement and conductivity risks. The vision positioning component 5 is equipped with an industrial camera, telecentric lens, and adjustable light source 24. The core wire position is identified through image algorithm. Combined with the drive component stroke data fed back by the sensor component 29, the position of the shaping and alignment component 4 is adjusted in a coordinated manner to achieve dual calibration of mechanical positioning and vision positioning.

[0060] During the shaping and alignment stage, the guide arc 15 of the shaping component 12 smoothly guides the core wire into the guide groove 14. Multiple sets of grooves correspond one-to-one with the core wire. The positioning teeth 17 between adjacent grooves are inserted into the gaps of the pad 11 contact portion 16, which not only achieves secondary positioning of the shaping component 12, but also separates the core wire to prevent contact short circuits. The driving component drives the shaping component 12 to move horizontally back and forth, driving the core wire to roll along the pad 11 contact portion 16 to eliminate springback stress. During the process, the vision positioning component 5 monitors the core wire posture in real time. If a deviation is detected, it immediately provides feedback and adjustment to ensure that the core wire is accurately attached to the pad 11. The alignment method adds a wire flattening pre-processing step, which can sort out unevenly distributed wires through the shaping surface 13, further improving the shaping consistency. The entire process realizes automated high-precision shaping and alignment, meeting the processing requirements of high-speed wires for AI servers.

[0061] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A high-speed wire core shaping and alignment device for AI servers, characterized in that, The device includes a base (1), a drive platform (2) mounted on the base (1), an insulating positioning component (3), a shaping and alignment component (4), a visual positioning component (5), and a positioning fixture (6). The drive platform (2) includes a first drive member (7) and a second drive member (8). The first drive member (7) drives the shaping and alignment component (4) to reciprocate in the horizontal direction, and the second drive member (8) drives the shaping and alignment component (4) to reciprocate in the vertical direction. The positioning fixture (6) is mounted on the base (1), the drive platform (2), or an external transfer mechanism. The visual positioning component (5) is located above the shaping and alignment component (4) and is electrically connected to the drive platform (2) and each component to coordinate the collaborative work of each drive member and each component. The positioning fixture (6) has a wire receiving groove (9) for receiving wires and a pad (11) adapted to the wire receiving groove (9). After the wire receiving groove (9) receives the wire, the core wire of the wire is exposed on the pad (11). The insulating positioning component (3) is used to abut and position the pad (11) and the core wire of the wire. The shaping and alignment component (4) is driven to move above the positioning fixture (6) via the first driving member (7) and the second driving member (8) to shape and align the core wire of the wire on the pad (11). The shaping and alignment component (4) includes a shaping component (12) disposed at the driving end of the second driving component (8). The side of the shaping component (12) facing the positioning fixture (6) is a shaping surface (13). A guide groove (14) is recessed on the shaping surface (13). A guide arc (15) is provided between the groove wall of the guide groove (14) and the shaping surface (13). The guide arc (15) is used to abut against the core wire of the wire, so that the core wire of the wire is guided to the guide groove (14) through the guide arc (15), thereby making the core wire of the wire fit on the pad (11).

2. The high-speed wire core shaping and alignment device for AI servers according to claim 1, characterized in that, The number of wires and the number of guide grooves (14) are both set to multiple, and the multiple guide grooves (14) correspond one-to-one with the core wires of the multiple wires; the pad (11) has multiple mating parts (16) corresponding to the multiple core wires, and there is a gap between the multiple mating parts (16); a positioning tooth (17) is formed between the guide arcs (15) of two adjacent guide grooves (14), and the positioning tooth (17) can be inserted into the gap.

3. The high-speed wire core shaping and alignment device for AI servers according to claim 1, characterized in that, The positioning fixture (6) includes a fixture base plate (18), a wire straightening plate (19) disposed on the fixture base plate (18), and a wire pressing plate (21); the wire pressing plate (21) is hinged to the wire straightening plate (19) or the fixture base plate (18), and the wire pressing plate (21) is rotatable and pressed onto the wire straightening plate (19); the accommodating groove (9) is disposed on the wire straightening plate (19), and the wire can be accommodated in the accommodating groove (9) and pressed and positioned by the wire pressing plate (21); the wire pressing plate (21) has an opening structure or a slot structure that exposes the accommodating groove (9), and the opening structure or slot structure is used to provide operating space for the visual positioning component (5) to detect the neatness of the wire and for the shaping and alignment component (4) to abut against the wire.

4. The high-speed wire core shaping and alignment device for AI servers according to claim 1, characterized in that, The visual positioning component (5) includes a visual camera (22), a positioning lens (23), and a light source (24) adapted to the positioning lens (23); the visual camera (22) is disposed on the base (1) or the driving platform (2), and the positioning lens (23) is disposed below the visual camera (22).

5. The high-speed wire core shaping and alignment device for AI servers according to claim 1, characterized in that, The insulating positioning assembly (3) includes a third driving member (25) disposed on the base (1) and an insulating member (26) disposed on the driving end of the third driving member (25); the side of the insulating member (26) facing the positioning fixture (6) is an insulating surface (27), and a plurality of insulating protrusions (28) protrude from the insulating surface (27); the pad (11) is supported on the insulating protrusions (28) or accommodated between two adjacent insulating protrusions (28).

6. The high-speed wire core shaping and alignment device for AI servers according to claim 1, characterized in that, It also includes a sensor assembly (29), which is electrically connected to the visual positioning assembly (5) and the drive platform (2); the sensor assembly (29) includes a position sensor disposed on each drive component, which is used to detect the stroke position of each drive component; the stroke signal of the position sensor is fed back to the visual positioning assembly (5) and the action parameters of the shaping and alignment assembly (4) are adjusted in coordination with the visual detection data.

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