Automatic wire harness feeding equipment, method and system

Abstract

The invention relates to the technical field of wire harness processing, in particular to automatic wire harness feeding equipment, method and system. A multi-clamping jaw feeding mechanism; the wire harness transferring and distributing mechanism is used for directionally transferring the wire harnesses grabbed by the multi-clamping-jaw feeding mechanism to a wire harness inserting station and positioning the wire harnesses in corresponding wire harness mounting panel areas; the mechanical arm insertion mechanism comprises a multi-degree-of-freedom mechanical arm, a flexible end effector, an insertion force detection module and an insertion depth monitoring unit, and is used for completing insertion and real-time deviation correction of the wire harness and the Kit assembly; a process control and data tracing module; according to the invention, automatic management and control from material tray scheduling, accurate grabbing, stable transferring, high-precision insertion connection data tracing and abnormity optimization are realized, so that the technical problems of poor assembly consistency, low production efficiency, difficulty in tracing quality problems and lagging abnormity processing caused by dependence on manual operation in traditional wire harness feeding production are solved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of wiring harness processing, in particular to a wiring harness automatic feeding equipment, method and system. BACKGROUND

[0002] As the core connecting component of the vehicle electronic system, the automobile wiring harness is the key carrier for realizing signal transmission and power supply of various electronic devices, and its assembly quality is directly related to the safety, reliability and functional integrity of the whole vehicle. In the whole vehicle wiring harness production process, the post-assembly process is an important link to ensure the performance of the wiring harness. This process usually covers a series of key operations such as precise feeding of the wiring harness, insertion of the terminal and Kit component, fastening of the ribbon, and protection of the glue wrapping, etc. It is the core process of converting scattered wiring harness into functional components that meet the requirements of whole vehicle assembly. At present, the industry mainly adopts a production mode of manual operation combined with part of semi-automatic equipment. Through the operation personnel, according to the work instruction, with the help of simple tools, the positioning, grabbing, insertion and subsequent fixing of the wiring harness are completed, and a relatively mature operation process is formed in the long-term production practice.

[0003] With the development of the automobile industry towards intelligence and individualization, the specifications and models of the whole vehicle wiring harness are increasingly diversified, and the production demand of high hybridization and small batch is becoming more and more common. Under the existing production mode, the core link of wiring harness assembly relies on manual operation, and there are natural differences in the skill proficiency and operation habits of different operators, which makes it difficult to achieve complete standardization of the assembly parameters (such as insertion force, depth, direction, etc.) of the same specification wiring harness, and further affects the connection stability of the wiring harness and Kit component, which brings potential risks to the subsequent use of the whole vehicle. At the same time, the process of manual operation lacks real-time and accurate data collection and monitoring means. When quality problems occur, it is difficult to quickly trace the specific link and reason of the problem, which is not convenient for timely optimization of the process. In addition, the efficiency of manual operation is limited by factors such as physical strength and energy. When working for a long time or frequently switching between wiring harness models, the production rhythm is difficult to stabilize and guarantee, and the operating personnel need to be trained for a long time to meet the requirements of the post, which is high in labor cost and the personnel mobility has a significant impact on the stability of production capacity. SUMMARY

[0004] The main purpose of the present application is to provide a wiring harness automatic feeding equipment, method and system, which aims to solve the technical problems raised in the background.

[0005] The present application provides a wiring harness automatic feeding equipment, which comprises: An automatic tray feeding mechanism, comprising a warehouse station and a conveying device, for carrying standardized finished product trays of different models of wiring harnesses, and conveying the standardized finished product trays to a preset feeding station by the conveying device; A multi-claw feeding mechanism is set above the feeding station. The multi-claw feeding mechanism includes multiple adjustable-spacing claw mechanisms, a vision recognition component, and a 3DoF force sensing unit, which are used to identify the position and posture of the wire harness and complete the gripping. The wire harness transfer and distribution mechanism includes a guide rail assembly and a lifting drive unit, which is used to orient the wire harness gripped by the multi-claw feeding mechanism to the wire harness insertion station and position it in the corresponding wire harness mounting panel area. The robotic arm insertion mechanism includes a multi-degree-of-freedom robotic arm, a flexible end effector, an insertion force detection module, and an insertion depth monitoring unit, which is used to complete the insertion of the wire harness and the Kit component and to correct the deviation in real time. The process control and data traceability module includes a central control platform, a data storage unit, and a visual interactive interface. The central control platform is connected to the automated tray feeding mechanism, the multi-claw feeding mechanism, the wire harness transfer and distribution mechanism, and the robotic arm insertion mechanism to collect and store operation data in real time, so as to realize the visualization and traceability of the process.

[0006] Preferably, the multi-claw feeding mechanism further includes a spacing adjustment drive component, which is electrically connected to the central control platform and is used to automatically adjust the spacing between adjacent gripper mechanisms according to the wire harness specifications. The visual recognition component includes a fixed-side visual camera, a movable-side visual camera, and a point laser locator. The fixed-side visual camera is used to collect reference position information of the wire harness at the warehouse end. The movable-side visual camera and the point laser locator work together to detect the wire harness posture in real time during the grasping process. The flexible end effector has a built-in elastic buffer mechanism, the insertion force detection module is a pressure sensor, the insertion depth monitoring unit is a laser displacement sensor, and both the pressure sensor and the laser displacement sensor are linked to the 3DoF force sensing unit.

[0007] The present invention also provides an automated wire harness feeding method, comprising: Obtain the model parameters of the wire harness to be assembled and the assembly requirements of the Kit components, so as to call up the appropriate standardized finished product tray, and transport the standardized finished product tray to the preset loading station through the conveying equipment of the automated tray loading mechanism; The visual recognition component and 3DoF force sensing unit of the multi-gripper feeding mechanism work together to detect the position and posture of the wire harness, adjust the spacing of the gripper mechanism to grab the wire harness and complete the posture correction. The guide rail assembly and lifting drive unit of the wire harness transfer and distribution mechanism will directionally transfer the corrected wire harness along a preset path to the wire harness insertion station and position it in the target area of ​​the wire harness mounting panel. By using a multi-degree-of-freedom robotic arm and a flexible end effector in the robotic arm insertion mechanism, combined with real-time feedback from the insertion force detection module and the insertion depth monitoring unit, the insertion and alignment correction of the wire harness and the Kit component are completed. The process control and data traceability module collects real-time operation status data during the operation process, performs visual monitoring, and stores the data; The system monitors assembly anomalies. When an assembly anomaly occurs, it performs source tracing analysis based on stored data, generates process adjustment instructions, and feeds them back to each execution module.

[0008] Preferably, the step of obtaining the model parameters of the wire harness to be assembled and the assembly requirements information of the Kit components, so as to call up the appropriate standardized finished product tray, and transporting the standardized finished product tray to the preset loading station through the conveying equipment of the automated tray loading mechanism includes: Obtain the cross-sectional dimensions, length, terminal type, and interface specifications of the Kit components for the wire harness to be assembled, and determine the groove dimensions, spacing, and positioning reference of the standardized finished product tray; RFID tags are set on the standardized finished product trays according to the positioning reference. The conveying equipment is provided to transport the standardized finished product tray to a preset loading station; The system reads the information from the RFID tag and compares it with the production task information preset on the central control platform. If the comparison matches, the material loading preparation is completed; if the comparison does not match, an alarm signal is issued and a material tray switching command is triggered.

[0009] Preferably, the step of using the visual recognition component and 3DoF force sensing unit of the multi-claw feeding mechanism to collaboratively detect the position and orientation of the wire harness, adjusting the spacing of the gripper mechanism to grasp the wire harness and complete the orientation correction includes: The fixed-edge vision camera of the vision recognition component acquires a global image of the wire harness in the standardized finished product tray, and extracts the feature point coordinates of the wire harness terminals to obtain the preliminary position of the wire harness. Based on the initial position of the wire harness, the local detail images and height information of the wire harness are collected in collaboration between the active edge vision camera and the point laser locator of the vision recognition component, and the actual attitude parameters of the wire harness are calculated. Based on the cross-sectional dimensions of the wire harness and the actual posture parameters, the central control platform sends an adjustment command to the spacing adjustment drive component to adjust the spacing of the gripper mechanism to a value that matches the wire harness specifications. The gripper mechanism moves to the initial position of the wire harness and performs a pre-grip action. At the same time, the pre-grip force value is detected in real time by the 3DoF force sensing unit and compared with the preset safety range. If the pre-grip force value is within the preset safety range, the formal gripping is performed directly. If the pre-grip force value exceeds the preset safety range, the gripper opening degree is adjusted first, and then the pre-grip action is re-executed until the pre-grip force value is within the preset safety range. The image of the grasped wire harness is acquired by a visual recognition component. The actual position and posture parameters of the wire harness in the image are compared with the preset grasping target parameters to calculate the position deviation and posture deviation. The position and posture of the gripper mechanism are dynamically corrected based on the position deviation and posture deviation.

[0010] Preferably, the step of using the guide rail assembly and lifting drive unit of the wire harness transfer and distribution mechanism to orient the calibrated wire harness along a preset path to the wire harness insertion station and position it in the target area of ​​the wire harness mounting panel includes: The relative positions of the loading station and the insertion station, the layout parameters of the wire harness installation panel, and the restricted areas for equipment operation are obtained. The optimal path for wire harness transfer is generated through a path planning algorithm. The guide rail assembly is controlled to move along the optimal path, and the position information of the guide rail assembly is recorded. The transfer height of the wire harness is maintained synchronously through the lifting drive unit. The distance between the wire harness and the surrounding equipment is continuously detected by the laser positioning sensor, and the distance is compared with a preset safety threshold. If the distance is less than the preset safety threshold, the deceleration command of the guide rail assembly is triggered. Based on the position information of the guide rail assembly, it is determined whether the guide rail assembly has reached the insertion station. When it has reached the station, the lifting drive unit drives the wire harness to descend to the preset positioning height. The positioning of the wire harness is completed by the positioning pin on the wire harness mounting panel cooperating with the positioning hole of the wire harness terminal.

[0011] Preferably, the steps for completing the insertion and alignment correction of the wire harness and Kit assembly through the multi-degree-of-freedom robotic arm and flexible end effector of the robotic arm insertion mechanism, combined with the real-time feedback from the insertion force detection module and the insertion depth monitoring unit, include: Obtain the interface specifications of the Kit component, and obtain the insertion force threshold, insertion depth threshold, and allowable alignment deviation range based on the interface specifications; A multi-degree-of-freedom robotic arm drives a flexible end effector to fix the wire harness terminals, while the elastic buffer mechanism of the flexible end effector is used to compensate for the initial alignment deviation between the wire harness and the Kit assembly. The insertion action is performed, and the force value data during the insertion process is collected in real time by the insertion force detection module. The insertion depth monitoring unit detects the insertion depth in real time by the laser displacement sensor. The force value data is compared with the insertion force threshold, and the insertion depth is compared with the insertion depth threshold. If the force value is less than the insertion force threshold and the insertion depth has not reached the insertion depth threshold, then the remaining insertion stroke continues to be completed. If the force value data exceeds the preset force threshold or the insertion depth does not reach the insertion depth threshold, the force value data sequence and the insertion depth data sequence are obtained through the central control platform. Based on the force value fluctuation characteristics and the depth change trend, the feature vector of the current insertion process is extracted to analyze the cause of the deviation. Based on the cause of the deviation, alignment correction or re-insertion is performed. If the force value is less than the insertion force threshold and the insertion depth reaches the insertion depth threshold, the insertion is determined to be complete. The multi-degree-of-freedom robotic arm performs a reset action, and the flexible end effector releases the wiring harness, completing the insertion and alignment correction of the wiring harness and the Kit component.

[0012] Preferably, the step of collecting work status data in real time through the process control and data traceability module, performing visual monitoring, and storing the data includes: The process control and data traceability module synchronously collects operation status data at a preset sampling frequency. The operation status data is filtered and denoised, and key feature parameters are extracted. The processed key feature parameters are compared with preset standard parameters. If the key feature parameters exceed the preset standard parameters, they are marked as assembly abnormalities in real time. The system displays real-time operation status and assembly anomaly information through a visual interactive interface. Obtain the current production task order information and the assembly anomaly information, and then timestamp and store the key feature parameters, the operation status data, the assembly anomaly information, and the current production task order information.

[0013] Preferably, the steps of monitoring assembly anomaly information and, when an assembly anomaly occurs, retrieving stored data based on the assembly anomaly information for source tracing analysis to generate process adjustment instructions and feeding them back to each execution module include: Obtain information about assembly anomalies, and when an assembly anomaly occurs, retrieve the associated work status data based on the information about the assembly anomaly. The operation status data is fused and analyzed to locate the root cause of the abnormal process; Generate process adjustment instructions based on the root cause process; The process adjustment command is sent to the corresponding execution module.

[0014] The present invention also provides an automated wire harness feeding system, comprising the following modules: The tray scheduling module is used to obtain the model parameters of the wire harness to be assembled and the assembly requirements of the Kit components, so as to call up the appropriate standardized finished product tray and transport the standardized finished product tray to the preset loading station through the conveying equipment of the automated tray loading mechanism. The gripping and correction module is used to detect the position and posture of the wire harness by the visual recognition component and the 3DoF force sensing unit of the multi-gripper feeding mechanism, and then grip the wire harness and complete the posture correction after adjusting the spacing of the gripper mechanism. The transfer and positioning module is used to transfer the calibrated wire harness along a preset path to the wire harness insertion station and position it in the target area of ​​the wire harness mounting panel through the guide rail assembly and lifting drive unit of the wire harness transfer and distribution mechanism. The insertion and alignment correction module is used to complete the insertion and alignment correction of the wire harness and Kit components by combining the multi-degree-of-freedom robotic arm and flexible end effector of the robotic arm insertion mechanism with the real-time feedback of the insertion force detection module and the insertion depth monitoring unit. The monitoring and storage module is used to collect work status data in real time during the operation process through the process control and data traceability module, perform visual monitoring, and store the data; The traceability optimization module is used to monitor assembly anomaly information, and when an assembly anomaly occurs, it calls the stored data to perform traceability analysis based on the assembly anomaly information, so as to generate process adjustment instructions and feed them back to each execution module.

[0015] The beneficial effects of this invention are as follows: By setting up a multi-claw feeding mechanism in coordination with a vision recognition component and a point laser positioner, and combining the automatic adaptation function of the spacing adjustment drive component, this invention achieves standardized adjustment of gripping parameters for wire harnesses of different specifications. At the same time, by using the force detection and depth monitoring module of the robotic arm insertion mechanism, key parameters in the insertion process are controlled in real time, effectively solving the problem of inconsistent assembly parameters caused by manual operation in the prior art, and significantly improving the consistency and reliability of wire harness assembly.

[0016] This invention relies on the high-frequency data acquisition, distributed storage, and visual monitoring functions of the process control and data traceability module. It realizes real-time recording and associated storage of the entire process data of wire harness feeding, transfer, and insertion, covering key information such as force curves, insertion depth, and operation cycle. When quality abnormalities occur, the problem can be quickly traced through multi-dimensional retrieval, solving the pain points of uncontrollable processes and difficult traceability in existing technologies, and providing accurate data support for process optimization.

[0017] This invention constructs a fully automated wire harness assembly solution through the coordinated operation of an automated tray feeding mechanism, a wire harness transfer and distribution mechanism, and a robotic arm insertion mechanism. This eliminates reliance on manual operation, significantly improving work efficiency per unit time. In high-mix, small-batch production scenarios, the central control platform can quickly switch production parameters to adapt to different wire harness specifications, shortening model changeover time and stabilizing production cycle. At the same time, it eliminates the need for long-term skills training for operators, reducing labor costs and effectively avoiding the impact of personnel turnover on production capacity stability. Attached Figure Description

[0018] Figure 1 This is a three-dimensional structural diagram of an automated wire harness feeding device according to an embodiment of this application.

[0019] Figure 2 This is a plan view of an automated wire harness feeding device according to an embodiment of this application.

[0020] Figure 3 This is a schematic diagram of a method flow according to an embodiment of this application.

[0021] Figure 4 This is a schematic diagram of the system structure according to an embodiment of this application.

[0022] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0023] It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0024] like Figures 1-2 As shown, this application provides an automated wire harness feeding device, comprising: The automated tray loading mechanism 2 includes a storage station and a conveying device, which is used to carry standardized finished product trays of different types of wire harnesses, and a conveying device to transport the standardized finished product trays to a preset loading station. A multi-claw feeding mechanism 3 is disposed above the feeding station. The multi-claw feeding mechanism includes multiple adjustable-spacing claw mechanisms, a vision recognition component 1, and a 3DoF force sensing unit, which are used to identify the position and posture of the wire harness and complete the gripping. The wire harness transfer and distribution mechanism 4 includes a guide rail assembly and a lifting drive unit, which is used to directionally transfer the wire harness gripped by the multi-claw feeding mechanism to the wire harness insertion station and position it in the corresponding wire harness mounting panel area. The robotic arm insertion mechanism 5 includes a multi-degree-of-freedom robotic arm, a flexible end effector, an insertion force detection module, and an insertion depth monitoring unit, which are used to complete the insertion of the wire harness and the Kit component and to correct deviation in real time. The process control and data traceability module includes a central control platform, a data storage unit, and a visual interactive interface. The central control platform is connected to the automated tray feeding mechanism, the multi-claw feeding mechanism, the wire harness transfer and distribution mechanism, and the robotic arm insertion mechanism to collect and store operation data in real time, so as to realize the visualization and traceability of the process.

[0025] It should be noted that the core of the automated wire harness feeding equipment of this invention is to address the problems of low assembly accuracy, untraceable processes, low changeover efficiency, and delayed anomaly handling in traditional manual and semi-automated production in the highly mixed and small-batch scenarios of automotive wire harness production. It constructs a fully automated closed-loop system. In this invention, each mechanism achieves standardized interface communication through a central control platform, which facilitates individual debugging and maintenance, and can quickly switch parameters to adapt to different specifications of wire harnesses. At the same time, each mechanism integrates a high-precision detection module to avoid assembly deviations from the source and ensure that process parameters are monitorable and traceable.

[0026] In one embodiment of the present invention, the multi-claw feeding mechanism 3 further includes a spacing adjustment drive component, which is electrically connected to the central control platform and is used to automatically adjust the spacing between adjacent gripper mechanisms according to the wire harness specifications. The visual recognition component 1 includes a fixed-side visual camera 12, a movable-side visual camera 11, and a point laser locator. The fixed-side visual camera is used to collect the reference position information of the wire harness at the warehouse end. The movable-side visual camera and the point laser locator work together to detect the attitude of the wire harness in real time during the grasping process. The flexible end effector has a built-in elastic buffer mechanism, the insertion force detection module is a pressure sensor, the insertion depth monitoring unit is a laser displacement sensor, and both the pressure sensor and the laser displacement sensor are linked to the 3DoF force sensing unit.

[0027] Furthermore, the multi-claw feeding mechanism 3, as the core of the gripping process, solves the problems of poor adaptability and unstable gripping posture of traditional fixed-spacing grippers. In addition to multiple adjustable-spacing gripper mechanisms, the vision recognition component 1, and the 3DoF force sensing unit, this mechanism also includes a spacing adjustment drive component electrically connected to the central control platform. This component uses a servo motor and ball screw structure to automatically adjust the spacing between adjacent gripper mechanisms according to the wire harness specifications, avoiding wire harness compression or unstable gripping. The innovative combination of the vision recognition component 1 breaks through the limitations of single vision detection. Its fixed-side vision camera, movable-side vision camera, and point laser positioner form a dual guarantee of "global positioning + local fine detection." The fixed-side vision camera covers the entire tray area to collect reference position information, while the movable-side vision camera and point laser positioner... The system works in conjunction with other components to achieve real-time detection of the wire harness posture during the grasping process. The camera used is a 12-megapixel industrial CMOS camera, and the point laser positioner has a measurement range of 0-50mm, which can accurately acquire posture parameters such as wire harness tilt angle, terminal orientation, and suspension height. The flexible end effector in the robotic arm insertion mechanism 5 has a built-in elastic buffer mechanism. The insertion force detection module uses a pressure sensor with a measurement range of 0-50N and an accuracy of ±0.05N, and the insertion depth monitoring unit uses a laser displacement sensor with a measurement range of 0-100mm and an accuracy of ±0.02mm. Both of these components are linked to the 3DoF force sensing unit signal, which can provide real-time feedback on the force and depth changes during the insertion process, providing accurate data support for subsequent correction actions. The collaborative design of these core components is the key to solving the problems of large alignment deviation and compensation lag in the traditional insertion process.

[0028] like Figure 3 As shown, the present invention also provides an automated wire harness feeding method, comprising: S1, obtain the model parameters of the wire harness to be assembled and the assembly requirements of the Kit components, so as to call up the appropriate standardized finished product tray, and transport the standardized finished product tray to the preset loading station through the conveying equipment of the automated tray loading mechanism 2. S2, the position and posture of the wire harness are detected by the visual recognition component 1 and the 3DoF force sensing unit of the multi-claw feeding mechanism 3, the spacing of the gripper mechanism is adjusted, the wire harness is gripped and the posture correction is completed. S3, the wire harness is oriented and transported along a preset path to the wire harness insertion station by the guide rail assembly and lifting drive unit of the wire harness transfer and distribution mechanism 4, and positioned in the target area of ​​the wire harness installation panel. S4, through the multi-degree-of-freedom robotic arm and flexible end effector of the robotic arm insertion mechanism 5, combined with the real-time feedback of the insertion force detection module and the insertion depth monitoring unit, the insertion and alignment correction of the wire harness and Kit components are completed. S5 collects real-time work status data during the operation process through the process control and data traceability module, performs visual monitoring, and stores the data; S6 monitors assembly anomaly information. When an assembly anomaly occurs, it performs source tracing analysis based on stored data, generates process adjustment instructions, and feeds them back to each execution module.

[0029] As described in steps S1-S6 above, in the automotive wiring harness production process, material loading and connection are the core links connecting parts and finished components. The smoothness of the process and the accuracy of the operation directly determine product quality and production cycle. In the traditional production model, key steps such as material tray selection, wiring harness picking, transfer and positioning, and connection operations are mostly completed manually. This is not only affected by the operator's skill level and operating habits, leading to differences in assembly parameters for the same specification of wiring harness, affecting connection stability, but also results in high labor costs, large fluctuations in production cycle, and difficulty in tracing quality problems. At the same time, when assembly abnormalities occur, it is necessary to manually check each process step by step and adjust process parameters, which is not only time-consuming and labor-intensive, but may also lead to the production of batches of unqualified products. Therefore, building a fully automated material loading method with monitorable parameters and traceable abnormalities has become a core requirement for improving the intelligence level of wiring harness production and product quality stability.

[0030] The automated wire harness feeding method provided by this invention realizes automated control from tray scheduling, precise grabbing, stable transfer, high-precision insertion to data traceability and anomaly optimization. This solves the technical pain points of traditional wire harness feeding production that rely on manual operation, such as poor assembly consistency, low production efficiency, difficulty in tracing quality problems, and lagging anomaly handling. It provides an efficient, accurate, and controllable solution for automotive wire harness high-mix and small-batch production scenarios.

[0031] In one embodiment of the present invention, the step of obtaining the model parameters of the wire harness to be assembled and the assembly requirements information of the Kit components, so as to call up the appropriate standardized finished product tray, and conveying the standardized finished product tray to the preset loading station through the conveying equipment of the automated tray loading mechanism 2 includes: S11, Obtain the cross-sectional dimensions, length, terminal type, and interface specifications of the Kit component of the wire harness to be assembled, and determine the groove dimensions, spacing, and positioning reference of the standardized finished product tray; S12, RFID tags are set on the standardized finished product tray according to the positioning reference. The RFID tags store the wire harness model, the adapter kit component number and the production batch information. S13, the conveying equipment adopts a belt conveyor line driven by a servo motor. A positioning sensor and a lifting mechanism are set at the end of the belt conveyor line. The positioning sensor is used to detect the arrival signal of the finished product tray and provide the lifting mechanism to lift the standardized finished product tray to a preset height that is flush with the loading station. S14 reads the information of the RFID tag on the standardized finished product tray through the reader and compares it with the production task information preset by the central control platform. If the comparison is consistent, the material loading preparation is completed. If the comparison is inconsistent, an alarm signal is issued and the tray switching command is triggered.

[0032] As described in steps S11-S14 above, due to the differences in structural parameters and corresponding Kit component interface specifications among different models of wire harnesses in the high-mix, small-batch production scenario of automotive wiring harnesses, the standardized finished product trays carrying the wire harnesses must have a targeted structural design to ensure stable wire harness storage and facilitate subsequent automated picking. Furthermore, if problems such as mismatched tray models or inaccurate positioning occur during production, subsequent processes will be unable to proceed normally. Therefore, accurate tray adaptation, information verification, and positioning are crucial prerequisites for ensuring production continuity and accuracy. This invention achieves accurate adaptation and loading positioning of standardized finished product trays with the wire harnesses to be assembled and the production task, providing a stable and reliable pre-process guarantee for subsequent picking, transfer, and insertion processes.

[0033] Specifically, to establish the compatibility between wire harness parameters and tray specifications, the wire harness model parameters and Kit component assembly requirements required for this step can be imported through the production task management module of the central control platform or manually entered by operators through a visual interactive interface. Since the cross-sectional dimensions, length, and terminal types of different wire harness models directly determine the load-bearing capacity of the tray grooves, and the interface specifications of the Kit components affect the positioning reference of the wire harness on the tray, it is necessary to determine the groove dimensions, spacing, and positioning reference of the standardized finished product tray based on these parameters to ensure that the tray can stably support the wire harness and that the terminal orientation is consistent with the subsequent insertion direction. RFID tags are used to achieve unique identification and information storage for the tray. RFID tags are used because they have the characteristics of non-contact reading and strong anti-interference capabilities, and can stably store and transmit key information in the production environment. Based on the positioning reference determined in step S11, RFID tags are affixed to the designated positions on the standardized finished product tray. The tags store information such as the wire harness model, compatible Kit component number, and production batch. This information corresponds one-to-one with the production task information in the central control platform, providing a basis for subsequent information verification, while also preventing the tags from being damaged by the grippers during the grasping process. To achieve precise material tray delivery and positioning, the conveying equipment employs a servo motor-driven belt conveyor line, capable of meeting different production cycle requirements. Since the material tray needs to be precisely aligned with the loading station after being conveyed to the end of the belt to ensure accurate gripping by the subsequent grippers, a positioning sensor and a lifting mechanism are installed at the end of the belt conveyor line. After the positioning sensor detects the material tray's arrival signal, the central control platform stops the servo motor, and then the lifting mechanism raises the material tray to a preset height level with the loading station, ensuring that the grippers can vertically grasp the wire harness and avoid gripping deviations caused by tilted forces.

[0034] Error prevention for material trays is achieved through RFID information comparison. A reader is installed next to the loading station, and the RFID tag information read from the trays is transmitted in real time to the central control platform for comparison with preset production task information. This step is designed to avoid production accidents caused by incorrect tray scheduling. If the information matches perfectly, the central control platform sends a "loading preparation complete" signal to the multi-gripper loading mechanism, initiating the subsequent gripping process. If the information does not match, the platform issues an alarm signal and triggers a tray switching command, returning the incorrect tray to the storage station and calling upon a suitable tray for re-loading until a match is found.

[0035] In one embodiment of the present invention, the step of detecting the position and orientation of the wire harness by the visual recognition component 1 and the 3DoF force sensing unit of the multi-claw feeding mechanism 3, adjusting the spacing of the gripper mechanism, grasping the wire harness, and completing the orientation correction includes: S21, the fixed-edge vision camera 12 of the vision recognition component 1 acquires a global image of the wire harness in the standardized finished product tray, extracts the feature point coordinates of the wire harness terminals, and obtains the preliminary position of the wire harness. S22, based on the initial position of the wire harness, the visual recognition component 1 obtains local detail images and height information of the wire harness through the collaboration of the active edge visual camera 11 and the point laser locator, and calculates the actual attitude parameters of the wire harness, including tilt angle, terminal orientation and suspension height; S23, based on the cross-sectional dimensions of the wire harness and the actual posture parameters, an adjustment command is sent to the spacing adjustment drive component through the central control platform to adjust the spacing of the gripper mechanism to a value that matches the wire harness specifications. S24, the gripper mechanism moves to the initial position of the wire harness and performs a pre-grip action. At the same time, the pre-grip force value is detected in real time by the 3DoF force sensing unit and compared with the preset safety range. If the pre-grip force value is within the preset safety range, the formal gripping is performed directly. If the pre-grip force value exceeds the preset safety range, the gripper opening degree is adjusted first, and then the pre-grip action is re-executed until the pre-grip force value is within the preset safety range. S25, the image of the grasped wire harness is acquired by the visual recognition component 1, the actual position and posture parameters of the wire harness in the image of the grasped wire harness are compared with the preset grasping target parameters, the position deviation and posture deviation are calculated, and the position and posture of the gripper mechanism are dynamically corrected based on the position deviation and posture deviation.

[0036] As described in steps S21-S25 above, in the automated production of automotive wiring harnesses, the placement of the wiring harnesses in the standardized finished product trays is easily affected by factors such as transportation and placement, resulting in positional deviations and tilting. Furthermore, the differences in specifications between different wiring harness models require flexible adaptation capabilities for the gripper spacing. If the position judgment is inaccurate, the posture control is poor, or the gripper spacing is incompatible during gripping, it can lead to problems such as wiring harness damage, detachment, or difficulties in subsequent insertion. Therefore, this invention provides a method for accurately identifying the position and posture of the wiring harness, dynamically adjusting the gripper adaptation parameters, and correcting the posture after gripping, ultimately achieving stable gripping of the wiring harness.

[0037] Specifically, the first step involves global positioning of the wire harness using a fixed-edge vision camera. The standardized finished product tray position information required for this step has already been calibrated by the automated tray loading mechanism 2. The fixed-edge vision camera is mounted on a fixed bracket above the loading station, with its lens vertically downwards covering the entire tray area, capturing a global image of the wire harness within the tray. Because the wire harness terminals possess unique structural features (such as metal contacts and snap-fit ​​contours), image processing algorithms extract the coordinates of these feature points, converting the image pixel coordinates into X and Y axis coordinates in the device coordinate system, thereby obtaining the initial position of the wire harness. This step provides a clear target area for subsequent fine-grained inspection, avoiding large-scale blind searches, improving inspection efficiency, and ensuring the rapid identification of the approximate position of each wire harness, laying the foundation for batch processing.

[0038] Then, based on the initial position, refined attitude detection is performed. Both the movable edge vision camera and the point laser positioner are mounted on the moving bracket of the multi-gripper loading mechanism, moving synchronously with the grippers to the initial position of the wire harness. The movable edge vision camera acquires local detail images of the wire harness at an inclined angle. By analyzing the contour shape of the wire harness in the image, the inclined angle (rotation angle in the XY plane) and terminal orientation of the wire harness are calculated. The point laser positioner emits a laser beam focused on the top of the wire harness terminal, acquiring height information (Z-axis coordinate) in real time, i.e., the suspension height (the vertical distance between the wire harness and the surface of the tray). After the data from both are fused, complete attitude parameters including inclined angle, terminal orientation, and suspension height are formed. This dual detection method of "vision + laser" overcomes the limitation of single vision detection in acquiring three-dimensional information, ensuring the accuracy of attitude parameters and providing precise data support for adjusting the gripper spacing and adapting the gripping angle.

[0039] Next, the gripper spacing is dynamically adjusted based on the wire harness specifications and attitude parameters. The central control platform uses the wire harness cross-sectional dimensions obtained in step S11 and combines them with the attitude parameters (especially the tilt angle) obtained in step S22 to calculate the appropriate gripper spacing. Since the gripper needs to adapt to the actual projected width of the wire harness for stable clamping when it is tilted, the spacing calculation must consider the influence of the tilt angle to ensure that the gripper accurately fits the wire harness terminals, avoiding instability due to insufficient spacing causing terminal compression or excessive spacing causing unstable gripping. After receiving the adjustment command from the central control platform, the spacing adjustment drive component uses a servo motor to drive the ball screw structure to move the gripper, achieving automatic spacing adjustment. This allows for adaptation to different wire harness specifications without manual intervention, significantly improving the equipment's adaptability to different configurations.

[0040] Then, force control feedback is used to achieve safe gripping. After the gripper mechanism moves to the initial position of the wire harness, a pre-grip action is performed. At this time, the 3DoF force sensing unit detects the pre-grip force value in real time. Setting a preset safety range is to balance gripping stability and wire harness protection, avoiding damage to the wire harness terminals due to excessive force or detachment due to insufficient force. When the pre-grip force value is within the safety range, the formal gripping is performed directly; if the force value exceeds the range, the gripper opening degree is adjusted and the gripping is tried again until the force value meets the requirements. This logic of "pre-grip - force detection - adaptive adjustment" gives the gripping action feedback adjustment capability, effectively dealing with gripping deviations caused by small fluctuations in the wire harness posture, ensuring that each wire harness can be gripped stably and safely.

[0041] Finally, after post-grabbing posture correction, the vision recognition component 1 re-captures the image of the grasped wire harness, extracts the actual position and posture parameters, and compares them with the preset grasping target parameters (i.e., ideal position and posture) to calculate the position deviation and posture deviation. Based on the deviation data, the central control platform sends correction commands to the fine-tuning mechanism of the multi-gripper feeding mechanism. The micro servo motor drives the grippers to make minor adjustments in the X, Y, Z axes and rotation direction, correcting the posture deviation generated during the grasping process. This ensures that the wire harness posture meets the requirements for subsequent transfer and insertion, further improving posture accuracy.

[0042] In one embodiment of the present invention, the step of directionally transporting the corrected wire harness along a preset path to the wire harness insertion station and positioning it in the target area of ​​the wire harness mounting panel via the guide rail assembly and lifting drive unit of the wire harness transfer and distribution mechanism 4 includes: S31: Obtain the relative positions of the loading station and the insertion station, the layout parameters of the wire harness installation panel, and the restricted area for equipment operation; generate the optimal path for wire harness transfer through the path planning algorithm. S32, control the guide rail assembly to move along the optimal path, record the position information of the guide rail assembly, and simultaneously maintain the transfer height of the wire harness through the lifting drive unit; S33, continuously detect the distance between the wire harness and the surrounding equipment through the laser positioning sensor, and compare the distance with a preset safety threshold. If the distance is less than the preset safety threshold, trigger the deceleration command of the guide rail assembly. S34. Based on the position information of the guide rail assembly, determine whether the guide rail assembly has reached the insertion station. When it has reached the station, the lifting drive unit drives the wire harness to descend to the preset positioning height. The positioning of the wire harness is completed by the positioning pin on the wire harness mounting panel cooperating with the positioning hole of the wire harness terminal.

[0043] As described in steps S31-S35 above, the present invention achieves safe, efficient and precise transfer and positioning of the corrected wire harness from the current loading station to the target insertion station, providing a wire harness state with accurate position and stable posture for the subsequent robotic arm insertion process.

[0044] In the automated production process of automotive wiring harnesses, the transfer stage is the crucial link connecting gripping and insertion. Its efficiency directly affects the overall production cycle, while the safety and positioning accuracy of the transfer process directly determine the success rate of subsequent insertion processes. Due to the complex layout of equipment on the production floor, there are various obstacles such as the range of motion of robotic arms and material trays, and fixed distances and height differences between different workstations. If the transfer path is not designed properly, it can easily lead to collisions and damage between the wiring harness and surrounding equipment. At the same time, if the positioning deviation of the wiring harness after it is transferred to the insertion station is too large, it will cause misalignment between the wiring harness terminals and the Kit component interface, resulting in problems such as incomplete insertion and terminal damage. Therefore, dynamic optimization of the transfer path, safety protection during the transfer process, and accurate positioning at the end point are core requirements for ensuring continuous and smooth automated production.

[0045] This invention generates the optimal transfer path through a dynamic path planning algorithm. The required data, including the relative positions of the loading and insertion stations, the layout parameters of the wiring harness installation panel, and the restricted operating areas of the equipment, are pre-stored by the central control platform through prior equipment calibration and on-site mapping, or are collected and updated in real time by laser rangefinders. The path planning algorithm employs the A* algorithm, which constructs a cost function by comprehensively evaluating factors such as transfer distance and obstacle avoidance costs. This algorithm can quickly search for the shortest, collision-free optimal route in complex equipment layout scenarios. Compared to traditional fixed paths, it significantly shortens the transfer distance, improves production cycle time, and can flexibly adapt to minor adjustments in the on-site equipment layout. In actual operation, the central control platform automatically retrieves data on the restricted operating areas of surrounding equipment based on the coordinates of the loading and insertion stations corresponding to the current task. The algorithm quickly generates the transfer path, with a planning time of no more than 100ms, ensuring efficient connection of the transfer process.

[0046] To ensure stable transport of the wire harness along the optimal path, the guide rail assembly is driven by a linear motor. Its operating speed can be adaptively adjusted within the range of 0.1-0.5 m / s according to the production cycle, meeting different production efficiency requirements. Simultaneously, the guide rail assembly incorporates a high-precision encoder with a resolution of 0.01 mm, which records its own position information in real time and feeds it back to the central control platform, forming a closed-loop position control to ensure that the guide rail assembly moves strictly along the planned path and avoids path deviation. The lifting drive unit uses a ball screw-type lifting platform with a lifting accuracy of ±0.1 mm. During transport, its core function is to maintain the wire harness at a preset transport height. This height is pre-set according to the on-site equipment layout and is 100 mm above the equipment platform surface, preventing the wire harness from rubbing or tangling with the platform or surrounding low-profile equipment during transport, ensuring the stability of the wire harness posture.

[0047] To ensure safe transport, this invention incorporates a dynamic safety monitoring mechanism. A laser positioning sensor, mounted on the side of the guide rail assembly, emits a 650nm laser beam at a frequency of 100Hz to continuously detect the real-time distance between the cable harness and surrounding equipment. The sensor's detection range is 0-500mm, with a response time of no more than 1ms, enabling rapid detection of distance changes. A preset safety threshold, determined based on the on-site equipment layout and cable harness size, is set at 20mm. When the sensor detects a distance less than this threshold, the central control platform immediately triggers a deceleration command on the guide rail assembly, reducing its operating speed from the current maximum of 500mm / s to 100mm / s until the distance recovers above the safety threshold. If the distance continues to decrease, the system will further trigger a stop command. This dynamic obstacle avoidance method, compared to traditional fixed-stroke limit protection, can more flexibly respond to sudden interference during transport and avoid collision risks.

[0048] To achieve precise positioning of the wire harness at the splicing station, when the encoder of the guide rail assembly reports that it has reached the preset coordinates above the splicing station, the central control platform sends a descent command to the lifting drive unit. This controls the lifting platform to descend the wire harness to the preset positioning height at a stable speed of 50mm / s. This positioning height is flush with the surface of the wire harness mounting panel, ensuring precise alignment between the wire harness terminals and the positioning structure on the panel. The wire harness mounting panel is equipped with cylindrical positioning pins, and corresponding positioning holes are provided at the positions of the wire harness terminals. The positioning pins and positioning holes are fitted with a clearance fit. The guiding effect of the positioning pins further corrects for any minor positional deviations that may occur during transport, ultimately achieving precise positioning of the wire harness. This ensures accurate alignment between the wire harness terminals and the Kit component interface, providing a crucial guarantee for the smooth progress of subsequent splicing processes.

[0049] In one embodiment of the present invention, the step of completing the insertion and alignment correction of the wire harness and Kit assembly by means of the multi-degree-of-freedom robotic arm and flexible end effector of the robotic arm insertion mechanism 5, combined with the real-time feedback of the insertion force detection module and the insertion depth monitoring unit, includes: S41, obtain the interface specifications of the Kit component, and obtain the insertion force threshold, insertion depth threshold and alignment deviation allowable range according to the interface specifications; S42, the multi-degree-of-freedom robotic arm drives the flexible end effector to fix the wire harness terminal, and at the same time uses the elastic buffer mechanism of the flexible end effector to compensate for the initial alignment deviation between the wire harness and the Kit assembly; S43, execute the insertion action, collect the force value data in real time during the insertion process through the insertion force detection module, and the insertion depth monitoring unit detects the insertion depth in real time through the laser displacement sensor; S44, compare the force value data with the insertion force threshold, and compare the insertion depth with the insertion depth threshold: S441, if the force value data is less than the insertion force threshold and the insertion depth has not reached the insertion depth threshold, then continue to complete the remaining insertion stroke. S442, if the force value data exceeds a preset force threshold or the insertion depth does not reach the insertion depth threshold, the force value data sequence and insertion depth data sequence are obtained through the central control platform. Based on the force value fluctuation characteristics and depth change trend, the feature vector of the current insertion process is extracted to analyze the cause of the deviation. Based on the cause of the deviation, alignment correction or re-insertion is performed. Specifically: The force value data sequence and the insertion depth data sequence are divided into three stages according to the insertion process: initial contact, smooth insertion, and end locking. The mean force value, standard deviation of force value, mean force value gradient, force-depth correlation coefficient, and abnormal peak count are extracted for each stage (initial contact, smooth insertion, and end locking) to construct the feature vector of the current insertion process. The feature vector of the current insertion process is matched with a pre-stored deviation cause library for similarity. The deviation cause library includes alignment offset mode, component interference mode, terminal deformation mode and loose connection mode. By calculating the fusion similarity measure of weighted Mahalanobis distance value and dynamic time warping distance, the deviation cause of the current anomaly and its confidence level are identified. The formula for calculating the weighted Mahalanobis distance is: ; In the formula, This represents the weighted Mahalanobis distance value (calculated by distributing the current feature vector to each cause of deviation). The feature vector representing the current insertion process includes the mean force value, standard deviation of force value, mean force gradient, force-depth correlation coefficient, and abnormal peak count for each stage (initial contact, smooth insertion, end locking). Indicates the first The mean eigenvector of the cause of class bias (during the training phase, by calculating all values ​​belonging to the class bias) The arithmetic mean of the eigenvectors of historical samples representing the causes of this type of bias is used to obtain the canonical feature centers that characterize the causes of this type of bias. The feature weight diagonal matrix (a diagonal matrix determined based on the importance of each feature in the feature vector of the current insertion process for classifying the causes of deviations, obtained through feature selection algorithms (such as linear discriminant analysis) during the training phase, or directly set by domain experts based on process knowledge). The inverse matrix of the covariance matrix (the covariance matrix is ​​calculated during the training phase). The covariance of the feature vectors of historical samples representing the cause of a bias is obtained, which characterizes the correlation and dispersion among the features within that bias cause. The inverse covariance matrix is ​​used to eliminate the influence of the correlation between features and standardize the scale of each feature in the distance calculation. This indicates transpose.

[0050] Based on the identified causes of deviation, confidence levels, and the current insertion stage, historical successful correction cases are retrieved from a pre-built strategy library (stored in a graph structure, where nodes represent causes of deviation, edges represent state transitions (i.e., correction actions), and the weight of the edge represents the success rate of the transition; correction strategy generation is to find the optimal path from the current state to the target state (successful insertion) in this graph). At least one recommended correction strategy is generated using a case-based reasoning algorithm. The algorithm calculates the similarity between the current state features and the state features of historical cases, and prioritizes historical strategies with high similarity and high correction success rates as recommended strategies. S443, if the force value data is less than the insertion force threshold and the insertion depth reaches the insertion depth threshold, the insertion is determined to be completed, the multi-degree-of-freedom robotic arm performs a reset action, the flexible end effector releases the harness, and the harness and Kit component are connected and aligned.

[0051] As described in steps S41-S44 above, in the automated production of automotive wiring harnesses, the splicing process is the core link determining the stability of the connection between the wiring harness and the kit components. Its accuracy directly affects the signal transmission and power supply reliability of the entire vehicle's electronic system. Because the wiring harness may have slight posture deviations after transportation, and different kit components have different interface specifications (such as pin diameter, depth, and spacing), if there is a lack of real-time monitoring and dynamic correction mechanisms for force and depth during the splicing process, problems such as misalignment, incomplete insertion, or over-insertion leading to terminal deformation and component damage are very likely to occur. Therefore, accurately setting splicing process parameters, real-time monitoring of the splicing status, intelligent identification of deviation causes, and targeted correction are the core requirements for achieving high-precision splicing. This invention addresses this problem specifically through parameter presetting, flexible compensation, real-time monitoring, and intelligent correction processes, achieving automation, precision, and intelligence in the splicing process.

[0052] Specifically, the first step is to establish precise process parameter benchmarks for the mating process. The interface specifications of the Kit components are retrieved from the process database of the central control platform. This database pre-stores parameters such as the pin diameter, depth, and spacing of different Kit component models, which are associated with the model parameters of the wire harness to be assembled. The central control platform automatically matches the corresponding mating force threshold, mating depth threshold, and allowable alignment deviation range according to the interface specifications. The mating force threshold must be adapted to the terminal material and interface tightness to avoid damaging the terminals due to excessive force or causing an insecure connection due to insufficient force. The mating depth threshold is consistent with the pin depth of the Kit component to ensure proper mating. The allowable alignment deviation range sets reasonable boundaries for subsequent flexible compensation and dynamic correction. The precise matching of these parameters provides a foundation for the standardization and consistency of the mating process, avoiding assembly quality problems caused by manual setting deviations.

[0053] Then, the flexible end effector's elastic buffer mechanism compensates for initial alignment deviations, a key innovation for improving plug-in adaptability. After the multi-degree-of-freedom robotic arm moves the flexible end effector to the wiring harness positioning position, the end effector clamps the wiring harness terminals. The flexible end effector's built-in elastic buffer mechanism uses a spring-damped structure with a compensation stroke of 0-5mm, and its stiffness coefficient can be adjusted according to the compatibility requirements of the wiring harness and kit components. When there is a slight initial alignment deviation between the wiring harness terminals and the kit component interface, the buffer mechanism can absorb the deviation through elastic deformation, avoiding damage to the terminals or kit components caused by hard contact. It also provides a buffer margin for subsequent precise plug-in. The multi-degree-of-freedom robotic arm's repeatability accuracy can reach ±0.05mm, and it can flexibly adjust the posture of the wiring harness terminals to ensure initial alignment with the kit component interface.

[0054] Further, real-time data acquisition in two dimensions is performed during the insertion process. The insertion force detection module uses a pressure sensor, installed on the clamping mechanism of the flexible end effector, to acquire force data in real time at a frequency of 100Hz. This sensor has a range of 0-50N and an accuracy of ±0.05N, accurately capturing minute changes in force. The insertion depth monitoring unit uses a laser displacement sensor with a measurement range of 0-50mm and an accuracy of ±0.02mm, focusing on the top of the wire harness terminal and simultaneously acquiring insertion depth data. Both sets of data are transmitted to the central control platform in real time, forming a force-depth dual-dimensional monitoring system.

[0055] Next, through refined feature extraction, accurate similarity matching, and intelligent strategy generation, detection, analysis, and correction are achieved. When the force value data is less than the insertion force threshold and the insertion depth has not reached the threshold, it indicates that the insertion process is smooth but not in place. The central control platform controls the robotic arm to continue advancing to complete the remaining insertion stroke. Intelligent processing is performed for abnormal situations. First, the force value data sequence and the insertion depth data sequence are divided into three stages according to the insertion process: initial contact, smooth insertion, and end-locking. The mean force value, standard deviation of force value, mean force gradient, force-depth correlation coefficient, and abnormal peak count are extracted for each stage to construct a feature vector of the current insertion process containing 15 feature dimensions. This comprehensively captures the state changes of the insertion process. For example, an excessively large standard deviation of force value in the initial contact stage may indicate alignment misalignment, and abnormal peaks in the smooth insertion stage may indicate component interference.

[0056] The current feature vector is then matched with a pre-stored database of deviation causes. The database contains patterns such as alignment shift, component interference, terminal deformation, and loose connection, all trained using extensive historical anomaly data. Each pattern corresponds to a set of mean feature vectors, a feature weight diagonal matrix, and the inverse of the covariance matrix. By calculating a fusion similarity measure of weighted Mahalanobis distance and dynamic time warping distance, the deviation cause and its confidence level of the current anomaly can be accurately identified. This fusion measure considers both the overall distribution differences of the feature vectors and the temporal characteristics of the data sequence, resulting in high accuracy. Based on the identified cause of deviation, confidence level, and current insertion stage, historical successful correction cases are retrieved from a pre-built strategy library. The strategy library is stored in a graph structure, where nodes represent the cause of deviation, edges represent state transitions (i.e., correction actions), and the weight of the edge represents the success rate of the transition. The case-based reasoning algorithm prioritizes historical strategies with high similarity and high correction success rates as recommended strategies. For example, when the deviation is identified as an alignment offset mode, the algorithm outputs micron-level correction parameters for the robot arm's X, Y, and Z axes; when the deviation is identified as a terminal jamming mode, the algorithm outputs a command to reverse fine-tune and re-insert the device, ensuring the targeted and effective nature of the correction actions.

[0057] Finally, the plugging loop is completed. When the force value data is stable within the plugging force threshold range and the plugging depth reaches the preset threshold, the central control platform determines that the plugging is complete, sends a command to control the multi-degree-of-freedom robotic arm to reset, and the flexible end effector releases the wiring harness. The entire plugging process is automated.

[0058] In one embodiment of the present invention, the step of collecting work status data in real time through the process control and data traceability module, performing visual monitoring, and storing the data includes: S51, during the corresponding operations of the automated tray feeding mechanism 2, the multi-claw feeding mechanism 3, the wire harness transfer and distribution mechanism 4, and the robotic arm insertion mechanism 5, the operation status data is synchronously collected by the process control and data traceability module at a preset sampling frequency. The operation status data includes the pre-gripping force value of the gripper mechanism, the force value data of the robotic arm insertion mechanism 5 during the insertion process, the insertion depth of the insertion depth monitoring unit, the position and speed data of each drive component (including the guide rail assembly, the lifting drive unit, the multi-degree-of-freedom robotic arm, the drive part of the conveying equipment, and the spacing adjustment drive assembly), and the timestamps of each operation stage, and the operation status data is constructed. S52, the operation status data is filtered and noise reduced, and key feature parameters are extracted. The key feature parameters include the maximum pre-grabbing force value, the average gripping force value, the maximum insertion force value during the insertion process, the stable insertion force value when the insertion is completed, the insertion depth achieved, and the total operation cycle from gripping to insertion completion. S53, compare the processed key feature parameters with preset standard parameters. If the key feature parameters exceed the preset standard parameters, mark it as an assembly abnormality in real time. S54 displays real-time work status and assembly anomaly information through a visual interactive interface; S55, obtain the current production task order information and the assembly abnormality information, and timestamp-associate and store the key feature parameters, the operation status data, the assembly abnormality information and the current production task order information.

[0059] As described in steps S51-S55 above, the operation status data is collected synchronously across all dimensions. The trigger signals for each mechanism required in this step are uniformly coordinated by the central control platform to ensure the synchronization of data collection. The process control and data traceability module synchronously collects the operation status data of the automated tray loading mechanism 2, the multi-gripper loading mechanism 3, the wire harness transfer and distribution mechanism 4, and the robotic arm insertion mechanism 5 at a preset sampling frequency (consistent with the sampling frequency of each detection module, which is 100Hz). The collected data dimensions comprehensively cover each key process: the pre-gripping force value of the gripper mechanism reflects the stability of the gripping process; the force value data and insertion depth of the robotic arm insertion mechanism 5 reflect the insertion accuracy; the position and speed data of each drive component (including the guide rail assembly, lifting drive unit, multi-degree-of-freedom robotic arm, drive part of the conveying equipment, and spacing adjustment drive component) ensure the accuracy of transfer and action execution; the timestamps of each operation stage (such as tray arrival time, gripping completion time, insertion start / end time) provide a basis for process time analysis and process optimization. By collecting this data synchronously, a complete dataset of job status is built, avoiding the one-sidedness of monitoring caused by single-dimensional data.

[0060] Processing and extracting key features from the collected operational status data is the core step in improving data usability. Since the raw data may contain irrelevant information such as sensor noise and signal interference, a Kalman filter algorithm is used for noise reduction to effectively remove interference signals and retain true data characteristics. After data processing, key feature parameters are extracted. These parameters are core indicators reflecting operational quality and efficiency, including the maximum pre-grabbing force, average gripping force (assessing gripping stability), maximum insertion force during the insertion process, stable insertion force upon completion (determining insertion reliability), achieved insertion depth (verifying insertion accuracy), and the total operational cycle from gripping to insertion completion (measuring production efficiency). Through feature extraction, massive amounts of raw data are transformed into key parameters with clear physical meaning.

[0061] Real-time identification of assembly anomalies is achieved through parameter comparison. The central control platform compares the key feature parameters extracted in step S52 with preset standard parameters one by one. The preset standard parameters are stored in the process database of the central control platform based on different wire harness models and production process requirements, and correspond one-to-one with the production task information. During the comparison process, if a key feature parameter exceeds the preset standard range (such as the maximum insertion force value being greater than the insertion force threshold, or the insertion depth value being less than the insertion depth threshold), the system marks the operation as an assembly anomaly in real time and records the specific value of the abnormal parameter and the time of occurrence to ensure that no anomaly is missed.

[0062] Real-time monitoring of the work status is achieved through a visual interactive interface. The process control and data traceability module displays the real-time work status (including the operating parameters of each mechanism and key characteristic parameters) and assembly anomaly information on the visual interactive interface in the form of graphs, parameter lists, and anomaly warning signs. The interface design is simple and intuitive, allowing operators to clearly view the real-time operation of each process. When an assembly anomaly occurs, the interface will highlight the anomaly information with a flashing red indicator and trigger an audible and visual alarm to ensure that operators can promptly detect and handle the anomaly, avoiding production losses caused by the escalation of the anomaly.

[0063] Ultimately, standardized and correlated data storage is achieved, laying the foundation for quality traceability and process optimization. The central control platform acquires current production task information (including production batch, harness model, equipment number, operator information, etc.), and timestamps the key feature parameters extracted in step S52, the raw work status data collected in step S51, and the assembly anomaly information marked in step S53 with the production task information, ensuring that each set of data accurately corresponds to a specific production task and work process. Data storage adopts a distributed storage architecture, which features large storage capacity, fast read and write speed, and high data security, meeting the long-term storage needs of large amounts of production data. It also supports data retrieval and export based on multiple dimensions such as production batch, time range, harness model, and equipment number, providing complete data support for quality problem tracing, production efficiency analysis, and process parameter optimization.

[0064] In one embodiment of the present invention, the step of monitoring assembly anomaly information and, when an assembly anomaly occurs, calling stored data based on the assembly anomaly information for source tracing analysis to generate process adjustment instructions and feeding them back to each execution module includes: S61, Obtain assembly abnormality information; when an assembly abnormality occurs, retrieve associated work status data based on the assembly abnormality information. S62, perform fusion analysis on the work status data to locate the root cause of the abnormal process; S63, Generate process adjustment instructions based on the root cause process; S64, the process adjustment command is sent to the corresponding execution module.

[0065] As described in steps S61-S64 above, the required assembly anomaly information for retrieving associated work status data after an assembly anomaly is generated in real time by step S53. This information includes the anomaly type (e.g., abnormal gripping force, insufficient insertion depth, excessive force), the anomaly occurrence timestamp, and the corresponding production task sheet information. When the central control platform detects an assembly anomaly, it immediately retrieves the complete work status data corresponding to that operation from the data storage unit based on the timestamp and production task sheet information in the anomaly information. This data includes the operating parameters of each mechanism, force and depth data, and timestamps of each process collected in step S51. This ensures that the retrieved data is accurately correlated with the anomaly event, providing comprehensive and complete raw data support for subsequent traceability analysis and avoiding traceability deviations caused by missing data.

[0066] By integrating and analyzing multi-dimensional data, the root cause of anomalies can be identified. Specifically, the central control platform performs layered decomposition and cross-analysis of the retrieved operational status data, dividing the data into dimensions according to processes such as feeding, gripping, transfer, and insertion. The deviations of key characteristic parameters of each process from preset standard parameters are compared one by one. For example, if the anomaly is insufficient insertion depth, the analysis will focus on the posture correction data of the gripping stage (to determine if posture deviation is causing inaccurate insertion alignment), the positioning data of the transfer stage (to verify if transfer positioning deviation is causing subsequent insertion problems), and the force and depth change curves of the insertion stage (to investigate whether abnormal insertion force or component interference is causing insufficient depth). Simultaneously, by combining the timestamps of each process with the temporal relationship of parameter changes, a data correlation graph is constructed. By analyzing the correlation strength between abnormal parameters and each process, the root cause of the anomaly can be identified. For example, if the posture deviation during the gripping stage exceeds a preset threshold, and the parameters in the subsequent transfer and insertion stages show a regular abnormality around this deviation, then the root cause of the abnormality is determined to be inadequate posture correction in the gripping process; if the parameters in the gripping and transfer stages are normal, but the force value suddenly spikes and the depth stops during the insertion stage, then the root cause is component interference or terminal jamming in the insertion process.

[0067] Generating quantified process adjustment instructions based on the root cause of the problem avoids the subjectivity and uncertainty of traditional manual adjustments. The central control platform generates targeted adjustment instructions based on the positioning results of the root cause process, combined with the process parameter range and historical optimization data. If the root cause is inadequate posture correction in the gripping process, it generates instructions to adjust the gripper mechanism's posture compensation parameters (such as X-axis offset compensation value and rotation angle correction value) and the detection parameters of the vision recognition component (such as increasing the sampling frequency of the moving-side vision camera and optimizing the threshold of the feature point extraction algorithm). If the root cause is alignment misalignment in the insertion process, it generates micron-level correction parameters for the robotic arm's X, Y, and Z axes and fine-tuning instructions for the insertion force threshold. If the root cause is a tray positioning deviation in the loading process, it generates height compensation values ​​for the lifting mechanism and detection sensitivity adjustment parameters for the positioning sensor. These adjustment instructions are all quantified parameters, directly corresponding to the controllable parameters of each execution module, ensuring the accuracy and operability of process adjustments.

[0068] Finally, the process adjustment instructions are sent to the corresponding execution modules. Specifically, the central control platform sends the process adjustment instructions to the corresponding automated tray loading mechanism 2, multi-gripper loading mechanism 3, wire harness transfer and distribution mechanism 4, or robotic arm insertion mechanism 5 through a standardized communication interface, based on the execution mechanism to which the root process belongs. After receiving the instructions, each execution module updates its own operating parameters in real time to ensure that subsequent operations are performed according to the optimized process parameters. For example, after receiving the posture correction compensation instruction, the multi-gripper loading mechanism 3 will automatically adjust the position and posture of the grippers in the next gripping operation; after receiving the correction parameters, the robotic arm insertion mechanism 5 will perform alignment adjustments according to the new parameters in subsequent insertion actions. At the same time, the central control platform records the parameter changes and operation data before and after the adjustment to verify the adjustment effect. If the anomaly is not eliminated after the adjustment, the source tracing analysis process will be triggered again to optimize the adjustment instructions until the anomaly is resolved.

[0069] like Figure 4 As shown, the present invention also provides an automated wire harness feeding system, comprising the following modules: The tray scheduling module is used to obtain the model parameters of the wire harness to be assembled and the assembly requirements of the Kit components, so as to call up the appropriate standardized finished product tray and transport the standardized finished product tray to the preset loading station through the conveying equipment of the automated tray loading mechanism 2. The gripping and correction module is used to detect the position and posture of the wire harness by the visual recognition component 1 and the 3DoF force sensing unit of the multi-gripper feeding mechanism 3, and to grip the wire harness and complete the posture correction after adjusting the spacing of the gripper mechanism. The transfer and positioning module is used to transfer the corrected wire harness along a preset path to the wire harness insertion station via the guide rail assembly and lifting drive unit of the wire harness transfer and distribution mechanism 4, and to position it in the target area of ​​the wire harness installation panel. The insertion and alignment correction module is used to complete the insertion and alignment correction of the wire harness and Kit components by combining the multi-degree-of-freedom robotic arm and flexible end effector of the robotic arm insertion mechanism 5 with the real-time feedback of the insertion force detection module and the insertion depth monitoring unit. The monitoring and storage module is used to collect work status data in real time during the operation process through the process control and data traceability module, perform visual monitoring, and store the data; The traceability optimization module is used to monitor assembly anomaly information, and when an assembly anomaly occurs, it calls the stored data to perform traceability analysis based on the assembly anomaly information, so as to generate process adjustment instructions and feed them back to each execution module.

[0070] It should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, apparatus, article, or method that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, apparatus, article, or method. Unless otherwise specified, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, apparatus, article, or method that includes that element.

[0071] The above description is merely a preferred embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A harness automated feeding apparatus characterized by comprising: Comprise: An automated tray feeding mechanism, comprising a warehouse station and a conveying device, for carrying standardized finished product trays of different types of wire harnesses and conveying the standardized finished product trays to a preset feeding station by the conveying device; A multi-jaw feeding mechanism arranged above the feeding station, comprising a plurality of adjustable spacing jaw mechanisms, a visual recognition component, and a 3DoF force perception unit, for recognizing the position and posture of the wire harness and completing the grabbing; A wire harness transfer and distribution mechanism, comprising a guide rail assembly and a lifting drive unit, for directing the wire harness grabbed by the multi-jaw feeding mechanism to the wire harness insertion station and positioning it in the corresponding wire harness mounting panel area; A mechanical arm insertion mechanism, comprising a multi-degree-of-freedom mechanical arm, a flexible end effector, an insertion force detection module, and an insertion depth monitoring unit, for completing the insertion of the wire harness and Kit components and real-time correction; A process control and data traceability module, comprising a central control platform, a data storage unit, and a visual interactive interface, the central control platform is communicatively connected with the automated tray feeding mechanism, the multi-jaw feeding mechanism, the wire harness transfer and distribution mechanism, and the mechanical arm insertion mechanism, for real-time acquisition and storage of operation data to realize process visualization and traceability.

2. The wire harness automated feeding equipment according to claim 1, wherein: The multi-jaw feeding mechanism further comprises a spacing adjustment drive assembly electrically connected with the central control platform for automatically adjusting the spacing of adjacent jaw mechanisms according to the wire harness specifications; The visual recognition component comprises a fixed edge visual camera, a movable edge visual camera, and a point laser positioner, the fixed edge visual camera is used to collect wire harness reference position information at the warehouse end, the movable edge visual camera and the point laser positioner are used for real-time detection of wire harness posture during the grabbing process; The flexible end effector has a built-in elastic buffer mechanism, the insertion force detection module is a pressure sensor, and the insertion depth monitoring unit is a laser displacement sensor, both the pressure sensor and the laser displacement sensor are signal linked with the 3DoF force perception unit.

3. A harness automated feeding method characterized by, Comprise: Obtain the model parameters and Kit component assembly requirement information of the wire harness to be assembled to call the appropriate standardized finished product tray, and convey the standardized finished product tray to the preset feeding station by the conveying device of the automated tray feeding mechanism; Detect the position and posture of the wire harness by the visual recognition component and the 3DoF force perception unit of the multi-jaw feeding mechanism, adjust the spacing of the jaw mechanisms, grab the wire harness, and complete the posture correction; Direct the corrected wire harness along the preset path to the wire harness insertion station by the guide rail assembly and lifting drive unit of the wire harness transfer and distribution mechanism, and position it in the target area of the wire harness mounting panel; Complete the insertion of the wire harness and Kit components and the alignment correction by the multi-degree-of-freedom mechanical arm and flexible end effector of the mechanical arm insertion mechanism, combined with the real-time feedback of the insertion force detection module and the insertion depth monitoring unit; Real-time acquisition of job status data during the job process, visual monitoring, and data storage by the process control and data traceability module; The information of assembly exception is monitored, when the assembly exception occurs, traceability analysis is performed based on the stored data, process adjustment instructions are generated and fed back to each execution module.

4. The method of claim 3, wherein, The step of obtaining the model parameters of the wire harness to be assembled and the Kit assembly requirement information, calling the adaptive standardized product tray, and conveying the standardized product tray to the preset feeding station through the conveying equipment of the automatic tray feeding mechanism includes: Obtaining the cross-sectional size, length, terminal type of the wire harness to be assembled and the interface specification of the Kit component, determining the groove size, spacing and positioning reference of the standardized product tray; According to the positioning reference, an RFID tag is arranged on the standardized product tray; The conveying equipment is provided to convey the standardized product tray to the preset feeding station; The information of the RFID tag is read and compared with the production task information preset by the central control platform, if the comparison is consistent, the feeding preparation is completed, if the comparison is inconsistent, an alarm signal is sent and a tray switching instruction is triggered.

5. The method of claim 3, wherein, The step of detecting the position and posture of the wire harness through the visual recognition component of the multi-claw feeding mechanism and the 3DoF force sensing unit, adjusting the spacing of the claw mechanism, grabbing the wire harness and completing the posture correction includes: The global image of the wire harness in the standardized product tray is collected by the fixed edge visual camera of the visual recognition component, the feature point coordinates of the wire harness terminal are extracted to obtain the preliminary position of the wire harness; Based on the preliminary position of the wire harness, the local detail image and height information of the wire harness are collected by the movable edge visual camera and the point laser positioner of the visual recognition component, and the actual posture parameters of the wire harness are calculated; According to the cross-sectional size of the wire harness and the actual posture parameters, the central control platform sends an adjustment instruction to the spacing adjustment driving component to adjust the spacing of the claw mechanism to a value suitable for the specification of the wire harness. The claw mechanism moves to the preliminary position of the wire harness, performs a pre-grabbing action, and simultaneously detects the pre-grabbing force value in real time through the 3DoF force sensing unit, and compares the pre-grabbing force value with the preset safe range, if the pre-grabbing force value is within the preset safe range, the formal grabbing is directly performed, if the pre-grabbing force value exceeds the preset safe range, the opening and closing degree of the claw is adjusted, and the pre-grabbing action is re-executed until the pre-grabbing force value is within the preset safe range. The image of the grabbed wire harness is collected by the visual recognition component, the actual position and posture parameters of the wire harness in the grabbed wire harness image are compared with the preset grabbing target parameters, the position deviation and posture deviation are calculated, and the position and posture of the claw mechanism are dynamically corrected based on the position deviation and posture deviation.

6. The method of claim 3, wherein, The step of directing the corrected wire harness to the wire harness insertion station along the preset path through the guide rail assembly and lifting driving unit of the wire harness transfer and distribution mechanism, and positioning the target area of the wire harness mounting panel includes: The relative position of the feeding station and the insertion station, the layout parameters of the wire harness mounting panel and the forbidden range of equipment operation are obtained, and the optimal path of the wire harness transfer is generated through a path planning algorithm; Controlling the guide rail assembly to move along the optimal path and recording position information of the guide rail assembly, and maintaining the transfer height of the wire harness by the lifting driving unit in synchronization; Continuously detecting the distance between the wire harness and the surrounding equipment by the laser positioning sensor, and comparing the distance with a preset safety threshold, if the distance is less than the preset safety threshold, triggering the deceleration instruction of the guide rail assembly; According to the position information of the guide rail assembly, it is judged whether the guide rail assembly reaches above the plug-in station, when reaching, the lifting driving unit drives the wire harness to drop to a preset positioning height, and the positioning of the wire harness is completed through the cooperation of the positioning pin on the wire harness mounting panel and the positioning hole of the wire harness terminal.

7. The method of claim 3, wherein, The steps of completing the plug-in and alignment and deviation correction of the wire harness and the Kit assembly by the multi-degree-of-freedom mechanical arm and the flexible end effector of the mechanical arm plug-in mechanism, combined with the real-time feedback of the plug-in force detection module and the plug-in depth monitoring unit, include: Obtaining the interface specification of the Kit assembly, and obtaining the plug-in force threshold, the plug-in depth threshold and the alignment deviation allowable range according to the interface specification; The multi-degree-of-freedom mechanical arm drives the flexible end effector to fix the wire harness terminal, and at the same time, the elastic buffer mechanism of the flexible end effector compensates the initial alignment deviation between the wire harness and the Kit assembly; Performing plug-in action, real-time collecting force value data in the plug-in process by the plug-in force detection module, and real-time detecting plug-in depth by the laser displacement sensor of the plug-in depth monitoring unit; Comparing the force value data with the plug-in force threshold, and comparing the plug-in depth with the plug-in depth threshold: If the force value data is less than the plug-in force threshold, and the plug-in depth does not reach the plug-in depth threshold, the remaining plug-in stroke is continuously completed; If the force value data exceeds the preset force threshold or the plug-in depth does not reach the plug-in depth threshold, the force value data sequence and the plug-in depth data sequence are obtained through the central control platform, the feature vector of the current plug-in process is extracted based on the force value fluctuation characteristics and the depth change trend, to analyze the deviation reason, and alignment correction or re-plug-in is performed based on the deviation reason; If the force value data is less than the plug-in force threshold, and the plug-in depth reaches the plug-in depth threshold, it is determined that the plug-in is completed, the multi-degree-of-freedom mechanical arm performs reset action, the flexible end effector releases the wire harness, and the plug-in and alignment correction of the wire harness and the Kit assembly are completed.

8. The method of claim 3, wherein, The steps of real-time collecting work state data in the work process by the process control and data traceability module, visual monitoring, and storing data include: Synchronously collecting work state data by the process control and data traceability module according to a preset sampling frequency; Filtering and denoising the work state data, and extracting key characteristic parameters; Comparing the processed key characteristic parameters with preset standard parameters, if the key characteristic parameters exceed the preset standard parameters, real-time marking as assembly abnormality; Displaying real-time work state and assembly abnormality information through a visual interactive interface; Obtain current production task sheet information and the information of the assembly exception, timestamp-associate store the key feature parameters, the job state data, and the information of the assembly exception with the current production task sheet information.

9. The method of claim 8, wherein, The step of monitoring the information of the assembly exception, and when the assembly exception occurs, calling the stored data according to the information of the assembly exception to perform traceability analysis, to generate a process adjustment instruction and feedback to each execution module comprises: Obtain the information of the assembly exception, and when the assembly exception occurs, call the associated job state data according to the information of the assembly exception; Fuse and analyze the job state data to locate the root cause process; Generate a process adjustment instruction according to the root cause process; Issue the process adjustment instruction to the corresponding execution module.

10. A harness automated feeding system characterized by, Comprise the following modules: Tray scheduling module, for obtaining the model parameters of the wire harness to be assembled and the Kit assembly requirement information, calling the adaptive standardized finished product tray, and conveying the standardized finished product tray to the preset feeding station through the conveying equipment of the automatic tray feeding mechanism; Grabbing correction module, for detecting the position and posture of the wire harness through the visual recognition component and 3DoF force perception unit of the multi-gripper feeding mechanism, adjusting the distance of the gripper mechanism, grabbing the wire harness and completing the posture correction; Transfer positioning module, for transferring the corrected wire harness to the wire harness insertion work station along the preset path through the guide rail assembly and lifting drive unit of the wire harness transfer and distribution mechanism, and positioning the target area of the wire harness mounting panel; Insertion correction module, for completing the insertion and alignment correction of the wire harness and Kit assembly through the multi-degree-of-freedom mechanical arm and flexible end effector of the mechanical arm insertion mechanism, combining the real-time feedback of the insertion force detection module and insertion depth monitoring unit; Monitoring and storage module, for real-time acquisition of job state data during the job process through the process control and data traceability module, visual monitoring, and data storage; Traceability optimization module, for monitoring the information of the assembly exception, and when the assembly exception occurs, calling the stored data according to the information of the assembly exception to perform traceability analysis, to generate a process adjustment instruction and feedback to each execution module.

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