High speed wire harness low resistance welding method and system based on local microenvironment control

Abstract

The present application relates to the technical field of wire harness ultrasonic welding, and is a high-speed wire harness low-resistance welding method and system based on local micro-environment control, comprising: obtaining a plurality of reference wire harness raw material sets, performing vibration friction testing on the reference wire harness raw material sets to obtain a friction reaction index, performing pressure deformation testing on the reference wire harness raw material sets to obtain a deformation response index, performing heat conduction testing on the reference wire harness raw material sets to obtain a heat storage index, and collecting corresponding training sample groups of the reference wire harness raw material sets to obtain a plurality of training sample groups; training a pre-constructed deep learning model based on the plurality of training sample groups to obtain a wire harness welding model; obtaining a current property parameter group based on a formal wire harness set; and performing welding prediction on the current property parameter group by using the wire harness welding model to obtain a target welding parameter group. The present application can shorten the welding parameter debugging cycle, improve the production efficiency and ultrasonic welding quality.

Description

Technical Field

[0001] This invention relates to the field of ultrasonic welding technology for wire harnesses, and in particular to a high-speed low-resistance welding method and system for wire harnesses based on local microenvironment control. Background Technology

[0002] Wire harnesses, as crucial electrical connection components in modern electronic devices and in the automotive and aerospace industries, play a vital role in power transmission. With the increasing complexity of electronic products and vehicles, higher demands are placed on the conductivity, welding reliability, and mechanical stability of wire harnesses. Ultrasonic welding technology is widely used in wire harness welding processes due to its high welding speed, high weld density, and the fact that it requires no additional solder.

[0003] Currently, existing ultrasonic welding methods typically use fixed welding parameters to perform welding operations on wire harnesses of different models and types. In order to ensure the consistency and reliability of the welding, some factories manually adjust the welding parameters or conduct parameter tests on a small number of samples in order to find applicable welding conditions.

[0004] However, different wire harnesses exhibit significant differences in physical properties such as material type, stranding method, and single filament diameter. Using uniform welding parameters can easily lead to insufficient weld density, increased contact resistance, or unstable mechanical properties in some wire harnesses. Therefore, there is an urgent need for a technical solution that can combine the multi-dimensional physical characteristics of wire harnesses and achieve intelligent control of welding parameters through model prediction and fine-tuning to improve the stability and reliability of ultrasonic welding quality of wire harnesses and shorten the parameter adjustment cycle. Summary of the Invention

[0005] This invention provides a high-speed wire harness low-resistance welding method based on local microenvironment control and a computer-readable storage medium. Its main purpose is to shorten the welding parameter debugging cycle and improve production efficiency and ultrasonic welding quality.

[0006] To achieve the above objectives, the present invention provides a high-speed wire harness low-resistance welding method based on local microenvironment control, comprising:

[0007] Obtain multiple reference wire harness material sets, wherein the reference wire harness material sets include: multiple reference wire harness materials;

[0008] For each of the multiple reference harness material sets, perform the following operation:

[0009] Vibration and friction tests were conducted on the reference wire harness material set to obtain the friction response index; pressure deformation tests were conducted on the reference wire harness material set to obtain the deformation response index; and heat conduction tests were conducted on the reference wire harness material set to obtain the heat storage index.

[0010] Obtain the welding frequency range, welding pressure range, and welding time range;

[0011] Low-resistance welding evaluation was performed on a reference wire harness material set based on a pre-constructed ultrasonic welder, welding frequency range, welding pressure range, and welding time range to obtain the optimal test parameter set and optimal environmental parameters.

[0012] Confirm the reference wire diameter and the number of reference wire cores in the reference wire harness material set;

[0013] By summarizing the friction response index, deformation response index, heat storage index, optimal environmental parameters, reference wire harness diameter, and reference wire core quantity, a set of reference property parameters is obtained. The set of reference property parameters and the set of optimal test parameters are combined to obtain a training sample set.

[0014] The training sample sets corresponding to the reference wire harness material set are summarized to obtain multiple training sample sets. The pre-built deep learning model is trained based on the multiple training sample sets to obtain the wire harness welding model.

[0015] Obtain the formal welding wire harness set, obtain the current property parameter set based on the formal welding wire harness set, and use the wire harness welding model to perform welding prediction on the current property parameter set to obtain the target welding parameter set;

[0016] Welding is performed on the formal welding wire bundle set based on the target welding parameter set and ultrasonic welder to obtain the target welding wire bundle set.

[0017] Optionally, the vibration and friction test on the reference wire harness material set to obtain the friction response index includes:

[0018] The first vibration test wire harness and the second vibration test wire harness were extracted from the reference wire harness raw material collection;

[0019] Confirm the first vibration welding end of the first vibration test harness, and confirm the second vibration welding end of the second vibration test harness.

[0020] The vibration testing device was identified, which includes: an indenter clamp, a tensile testing machine, and a vibration testing machine. The tensile testing machine includes: a fixing clamp, a tension rod, and a tension sensor. The vibration testing machine includes: a vibration table.

[0021] The first vibration welding end of the first vibration test wire harness and the second vibration welding end of the second vibration test wire harness are placed in opposite directions and overlapped in the pressure head clamp. Based on the preset initial pressure and the pressure head clamp, pressure is applied to the first vibration welding end and the second vibration welding end placed in opposite directions to obtain the pressure and vibration test piece.

[0022] The compression and vibration test specimen is placed on the vibration table of the vibration testing machine to obtain the prepared vibration test specimen;

[0023] Based on the preset vibration amplitude, preset vibration frequency, preset vibration time, and vibration testing machine, the prepared vibration test piece is vibrated to obtain the completed vibration test piece;

[0024] The first vibration test harness in the completed vibration test piece is fixed in the fixing fixture of the tensile testing machine, and the second vibration test harness in the completed vibration test piece is fixed on the tension rod of the tensile testing machine to obtain the tensile test piece;

[0025] Based on the preset tensile gradient timing and the tension rod of the tensile testing machine, a parallel tensile force is applied to the second vibration test bundle in the tensile test piece. The tensile force value of the parallel tensile force applied to the second vibration test bundle in the tensile test piece by the tension rod of the tensile testing machine is monitored in real time by a tensile sensor until the second vibration test bundle in the tensile test piece is completely separated from the first vibration test bundle in the tensile test piece. The tensile force value monitored by the tensile sensor when the second vibration test bundle in the tensile test piece is completely separated from the first vibration test bundle in the tensile test piece is taken as the ultimate friction tensile force. The second vibration test bundle in the tensile test piece that is completely separated from the first vibration test bundle is recorded as the second separated bundle, and the first vibration test bundle in the tensile test piece that is completely separated from the second vibration test bundle is recorded as the first separated bundle.

[0026] The first average port temperature of the first vibrating welding end in the first separation wire harness and the second average port temperature of the second vibrating welding end in the second separation wire harness were read using a pre-built infrared thermometer.

[0027] The friction response index is calculated based on the initial pressure, vibration amplitude, vibration frequency, vibration time, ultimate friction tension, first average port temperature, and second average port temperature.

[0028] Optionally, the formula for calculating the friction response index is as follows:

[0029]

[0030] in, The frictional response index, This is the ultimate frictional tension. As the initial pressure, and These are the first average port temperature and the second average port temperature, respectively. It is a natural constant. The amplitude of vibration. The vibration frequency, The vibration time.

[0031] Optionally, the step of performing a pressure deformation test on the reference wire harness material set to obtain the deformation response index includes:

[0032] Deformation test wire harnesses were extracted from the reference wire harness raw material collection, and the deformation welding ends of the deformation test wire harnesses were confirmed.

[0033] The pressure testing device was identified, which includes: a pressure testing platform, a pressure head, and a displacement sensor;

[0034] The deformation welding end of the deformation test harness is fixed on the pressure test bench to obtain a fixed deformation harness;

[0035] The fixed deformation wire harness is pressurized based on the preset first pressure and the pressure head, and the first pressure distance when the pressure head presses the fixed deformation wire harness is read by the displacement sensor.

[0036] The second pressure distance is obtained based on the preset second pressure, pressure head, displacement sensor and fixed deformation wire harness;

[0037] The deformation response index is calculated based on the first applied pressure, the second applied pressure, the first applied pressure distance, and the second applied pressure distance.

[0038] Optionally, the step of performing a heat conduction test on the reference wire harness material set to obtain a heat storage index includes:

[0039] The heat test wire harness was extracted from the reference wire harness raw material collection, and the heat welding end of the heat test wire harness was identified. The heat welding end includes: the starting end and the ending end.

[0040] Obtain a miniature heating element and fix it to the starting end of the heat test harness to obtain the prepared heat harness;

[0041] The heat-generating wire harness is heated based on a preset heating temperature, a preset heating time, and a miniature heating element to obtain a heated wire harness.

[0042] The initial average port temperature at the upper end of the heating element harness was read using an infrared thermometer.

[0043] The heating wire bundle is placed into a pre-constructed constant test chamber to obtain the waiting heat wire bundle. The time for obtaining the waiting heat wire bundle is taken as the starting point and the time is recorded in real time to obtain the heat dissipation time. The heat dissipation time continues until the heat dissipation time reaches the preset heat dissipation threshold. Then the waiting heat wire bundle is taken out from the constant test chamber to obtain the heat dissipation wire bundle.

[0044] Use an infrared thermometer to read the average end port temperature of the heat dissipation harness.

[0045] The heat storage index is calculated based on the initial average port temperature, heating temperature, heating time, final average port temperature, and heat dissipation threshold.

[0046] Optionally, the low-resistance welding evaluation of the reference wire harness material set based on the pre-constructed ultrasonic welder, welding frequency range, welding pressure range, and welding time range is used to obtain the optimal test parameter set and optimal environmental parameters, including:

[0047] Multiple test parameter sets were obtained by combining the welding frequency range, welding pressure range, and welding time range. These test parameter sets included: test welding frequency, test welding pressure, and test welding time.

[0048] Perform the following operation for each of the multiple test parameter groups:

[0049] The ultrasonic welder was set using the test welding frequency, test welding pressure, and test welding time in the test parameter group to obtain the test welder;

[0050] The test environment temperature and humidity of the test welder are read using pre-built temperature and humidity sensors, and the test environment parameters are obtained by summarizing the test environment temperature and humidity.

[0051] The first and second wire harnesses awaiting welding were extracted from the reference wire harness raw material set. The first waiting welding end of the first waiting welding end of the first waiting welding end of the first waiting welding end of the second waiting welding end of the second waiting welding end of the second waiting welding end were identified.

[0052] The first waiting-to-weld end of the first waiting-to-weld wire harness and the second waiting-to-weld end of the second waiting-to-weld wire harness were ultrasonically welded using a test welder to obtain a test welded wire harness.

[0053] A low-resistance electrical evaluation was performed on the tested welded wire harness to obtain an electrical score for the wire harness.

[0054] The electrical scores and test environment parameters of the wire harness were summarized separately to obtain multiple electrical scores and multiple test environment parameters for the wire harness;

[0055] The optimal electrical score was determined based on multiple electrical scores of the wiring harness. The optimal electrical score is the largest electrical score among the multiple electrical scores of the wiring harness.

[0056] Based on the optimal electrical score, the optimal test parameter group and optimal environmental parameters were identified from multiple test parameter groups and multiple test environment parameters, respectively. The optimal test parameter group and optimal environmental parameters are the test parameter groups and test environment parameters corresponding to the optimal electrical score in the multiple test parameter groups and the multiple test environment parameters, respectively.

[0057] Optionally, the test parameters for the welding frequency range, welding pressure range, and welding time range are combined to obtain multiple test parameter sets, including:

[0058] Based on the preset frequency sampling interval, the welding frequency range is sampled at equal intervals to obtain a test welding frequencies;

[0059] b test welding pressures are obtained based on the preset pressure sampling interval and welding pressure range, and c test welding times are obtained based on the preset time sampling interval and welding time range.

[0060] By combining a test welding frequency, b test welding pressure, and c test welding time, multiple test parameter sets are obtained. The number of test parameter sets in the multiple test parameter sets is P, and P = a × b × c.

[0061] Optionally, the low-resistance electrical evaluation of the tested welded wire harness to obtain a wire harness electrical score includes:

[0062] Confirm the welding head, welding start point, and welding end point of the test welding harness;

[0063] The welding image is obtained by taking pictures of the weld head using a pre-built industrial camera;

[0064] The welding image is converted to grayscale to obtain a grayscale welding image, wherein the grayscale welding image includes: multiple grayscale pixels, wherein the grayscale pixels include: pixel grayscale values;

[0065] For each grayscale pixel in a grayscale welding image, perform the following operation:

[0066] Compare the pixel grayscale value of grayscale pixels with the preset bad pixel grayscale threshold;

[0067] If the pixel grayscale value is greater than the bad pixel grayscale threshold, then the grayscale pixel corresponding to the pixel grayscale value is recorded as a bad pixel.

[0068] Summarize the bad pixel counts to obtain multiple bad pixel counts;

[0069] Confirm the number of bad pixels and the original number of multiple bad pixels and multiple grayscale pixels respectively;

[0070] The resistance between the welding start and welding end points of the test welding harness is read using a pre-built ohmmeter.

[0071] The initial heating temperature of the welding start point on the test welding wire harness was read using an infrared thermometer.

[0072] The test welding wire harness is tested based on the preset energizing current and preset energizing time to obtain the energized test wire harness.

[0073] Use an infrared thermometer to read the end-of-heat temperature of the soldering start point on the energized test harness;

[0074] The electrical score of the wire harness is calculated based on the energizing current, energizing time, test resistance, initial heating temperature, final heating temperature, number of defective points, and original number.

[0075] Optionally, the formula for calculating the electrical score of the wire harness is as follows:

[0076]

[0077] in, Evaluate the electrical performance of the wire harness. and These are the end heating temperature and the initial heating temperature, respectively. For the current flowing through, For the power-on time, and These represent the number of defective pixels and the original number, respectively. To test the resistance value, It is the natural logarithm.

[0078] To achieve the above objectives, the present invention also provides a high-speed wire harness low-resistance welding system based on local microenvironment control, comprising:

[0079] The wire harness feature extraction module is used to acquire multiple reference wire harness material sets, wherein the reference wire harness material sets include multiple reference wire harness materials. For each reference wire harness material set, the following operations are performed: vibration friction test is performed on the reference wire harness material set to obtain the friction response index; pressure deformation test is performed on the reference wire harness material set to obtain the deformation response index; and heat conduction test is performed on the reference wire harness material set to obtain the heat storage index.

[0080] The wire harness welding test module is used to obtain the welding frequency range, welding pressure range, and welding time range. Based on the pre-built ultrasonic welder, welding frequency range, welding pressure range, and welding time range, it performs low-resistance welding evaluation on the reference wire harness material set to obtain the optimal test parameter set and optimal environmental parameters.

[0081] The welding model training module is used to confirm the reference wire harness diameter and the number of reference wire cores in the reference wire harness material set, summarize the friction response index, deformation response index, heat storage index, optimal environmental parameters, reference wire harness diameter and the number of reference wire cores to obtain a reference property parameter set, combine the reference property parameter set and the optimal test parameter set to obtain a training sample set, summarize the training sample sets corresponding to the reference wire harness material set to obtain multiple training sample sets, and train the pre-built deep learning model based on multiple training sample sets to obtain the wire harness welding model;

[0082] The formal welding control module is used to acquire the formal welding wire harness set, acquire the current property parameter set based on the formal welding wire harness set, use the wire harness welding model to perform welding prediction on the current property parameter set to obtain the target welding parameter set, and weld the formal welding wire harness set based on the target welding parameter set and the ultrasonic welder to obtain the target welding wire harness set.

[0083] To address the above problems, the present invention also provides an electronic device, the electronic device comprising:

[0084] Memory, storing at least one instruction;

[0085] The processor executes the instructions stored in the memory to implement the high-speed wire harness low-resistance welding method based on local microenvironment control described above.

[0086] To address the aforementioned problems, the present invention also provides a computer-readable storage medium storing at least one instruction, which is executed by a processor in an electronic device to implement the high-speed wire harness low-resistance welding method based on local microenvironment control described above.

[0087] To address the problems described in the background art, this invention obtains multiple reference wire harness material sets. These reference wire harness material sets include various types and physical properties of reference wire harness materials, covering potential differences in materials, stranding methods, wire diameters, and the number of wire cores. This provides a comprehensive physical feature sample basis for subsequent welding parameter optimization, ensuring the representativeness and broad applicability of the model training data. Furthermore, the following operations are performed on each reference wire harness material set: vibration and friction testing is conducted to obtain the friction response index; pressure deformation testing is conducted to obtain the deformation response index; and further... By conducting heat conduction tests and obtaining the heat storage index, it can be seen that the embodiments of the present invention, through systematic physical performance testing, can quantify the physical properties of the wire harness under ultrasonic welding conditions, providing a basis for subsequent welding parameter prediction. Welding frequency range, welding pressure range, and welding time range are obtained. Based on the pre-constructed ultrasonic welder, welding frequency range, welding pressure range, and welding time range, low-resistance welding evaluation is performed on the reference wire harness material set to obtain the optimal test parameter set and optimal environmental parameters. It is evident that the embodiments of the present invention, through welding tests, select the most suitable welding parameter combination for each reference wire harness, achieving matching between welding parameters and wire harness physical properties. This provides a reliable and matched training sample set for subsequent model training, improving subsequent welding... Based on the predicted accuracy, the reference wire harness diameter and the number of reference wire cores in the reference wire harness material set are confirmed. The friction response index, deformation response index, heat storage index, optimal environmental parameters, reference wire harness diameter, and the number of reference wire cores are summarized to obtain a reference property parameter set. This reference property parameter set is then combined with the optimal test parameter set to obtain a training sample set. It can be seen that this embodiment of the invention constructs a mapping relationship between wire harness physical properties and welding process parameters by mapping physical feature parameters to welding target parameters, providing systematic input and output data for the deep learning model. Multiple training sample sets are obtained by summarizing the training sample sets corresponding to the reference wire harness material set. The pre-constructed deep learning model is then trained based on these multiple training sample sets to obtain... The wire harness welding model, as seen in this embodiment of the invention, trains a deep learning model using diverse training samples, enabling it to learn the influence of wire harness physical properties on welding parameters. This allows for the prediction and intelligent control of welding parameters for different wire harnesses in actual welding, improving welding consistency and quality. The process involves obtaining a formal welding wire harness set, acquiring a current property parameter set based on this set, using the wire harness welding model to predict the welding performance of this parameter set, obtaining a target welding parameter set, and then welding the formal welding wire harness set using the target welding parameter set and an ultrasonic welder to obtain the target welding wire harness set. Thus, this embodiment of the invention predicts ideal welding parameters suitable for the formal welding wire harness set through the model, thereby reducing weld contact resistance and improving welding quality.Therefore, the present invention can shorten the welding parameter adjustment cycle and improve production efficiency and ultrasonic welding quality. Attached Figure Description

[0088] Figure 1 This is a schematic flowchart of a high-speed wire harness low-resistance welding method based on local microenvironment control provided in an embodiment of the present invention.

[0089] Figure 2 This is a functional block diagram of a high-speed wire harness low-resistance welding system based on local microenvironment control, provided in an embodiment of the present invention.

[0090] Figure 3 This is a schematic diagram of the structure of an electronic device that implements the high-speed wire harness low-resistance welding method based on local microenvironment control, according to an embodiment of the present invention.

[0091] Explanation of reference numerals in the attached figures:

[0092] 10. Electronic device; 11. Processor; 12. Memory; 13. Bus.

[0093] 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

[0094] It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0095] This application provides a high-speed wire harness low-resistance welding method based on local microenvironment control. The executing entity of this high-speed wire harness low-resistance welding method based on local microenvironment control includes, but is not limited to, at least one of the following electronic devices that can be configured to execute the method provided in this application: a server, a terminal, etc. In other words, the high-speed wire harness low-resistance welding method based on local microenvironment control can be executed by software or hardware installed on a terminal device or a server device, and the software can be a blockchain platform. The server includes, but is not limited to, a single server, a server cluster, a cloud server, or a cloud server cluster.

[0096] Reference Figure 1 The diagram shown is a flowchart illustrating a high-speed wire harness low-resistance welding method based on local microenvironment control according to an embodiment of the present invention. In this embodiment, the high-speed wire harness low-resistance welding method based on local microenvironment control includes:

[0097] S1. Obtain multiple reference wire harness material sets, wherein the reference wire harness material sets include: multiple reference wire harness materials.

[0098] It should be understood that due to differences in material type, stranding method, and single filament diameter, different wire harnesses exhibit significantly different sensitivities to process parameters such as ultrasonic frequency, pressure, and welding time during ultrasonic welding. Using uniform welding parameters in actual welding processes can easily lead to problems such as insufficient weld density, increased resistance, or unstable mechanical properties in some wire harnesses. Therefore, this invention pre-acquires numerous different types of wire harnesses, extracts features of their physical properties, and conducts welding tests to find welding parameters suitable for different physical characteristics. The deep learning model is then trained using the correspondence between multiple sets of physical features and welding parameters. This trained deep learning model is used to perform targeted micro-adjustments of the welding parameters during the subsequent formal welding process, ensuring that the welding parameters match the physical characteristics of the wire harness itself. This reduces the contact resistance between weld points of different wire harnesses and improves the stability and reliability of ultrasonic welding quality.

[0099] For example, a wire harness processing factory needs to extract features of the physical properties of different types of wire harnesses as described above. Therefore, it collects multiple sets of wire harnesses of different types produced or purchased in the factory. These multiple sets of wire harnesses are multiple sets of reference wire harness materials. Within a single set, all wire harnesses have the same model number, while wire harnesses in different sets have different models. That is, all reference wire harness materials in a single set are of the same model, but the model number of any one set of reference wire harness materials is different from the wire harnesses in other sets within the multiple sets. A wire harness set refers to a collection of multiple wire harnesses, and the reference wire harness material is a type of wire harness.

[0100] S2. Perform the following operations on each of the multiple reference wire harness material sets: conduct vibration friction test on the reference wire harness material set to obtain the friction response index; conduct pressure deformation test on the reference wire harness material set to obtain the deformation response index; and conduct heat conduction test on the reference wire harness material set to obtain the heat storage index.

[0101] Specifically, the vibration and friction test performed on the reference wire harness material set to obtain the friction response index includes:

[0102] The first vibration test wire harness and the second vibration test wire harness were extracted from the reference wire harness raw material collection;

[0103] Confirm the first vibration welding end of the first vibration test harness, and confirm the second vibration welding end of the second vibration test harness.

[0104] The vibration testing device was identified, which includes: an indenter clamp, a tensile testing machine, and a vibration testing machine. The tensile testing machine includes: a fixing clamp, a tension rod, and a tension sensor. The vibration testing machine includes: a vibration table.

[0105] The first vibration welding end of the first vibration test wire harness and the second vibration welding end of the second vibration test wire harness are placed in opposite directions and overlapped in the pressure head clamp. Based on the preset initial pressure and the pressure head clamp, pressure is applied to the first vibration welding end and the second vibration welding end placed in opposite directions to obtain the pressure and vibration test piece.

[0106] The compression and vibration test specimen is placed on the vibration table of the vibration testing machine to obtain the prepared vibration test specimen;

[0107] Based on the preset vibration amplitude, preset vibration frequency, preset vibration time, and vibration testing machine, the prepared vibration test piece is vibrated to obtain the completed vibration test piece;

[0108] The first vibration test harness in the completed vibration test piece is fixed in the fixing fixture of the tensile testing machine, and the second vibration test harness in the completed vibration test piece is fixed on the tension rod of the tensile testing machine to obtain the tensile test piece;

[0109] Based on the preset tensile gradient timing and the tension rod of the tensile testing machine, a parallel tensile force is applied to the second vibration test bundle in the tensile test piece. The tensile force value of the parallel tensile force applied to the second vibration test bundle in the tensile test piece by the tension rod of the tensile testing machine is monitored in real time by a tensile sensor until the second vibration test bundle in the tensile test piece is completely separated from the first vibration test bundle in the tensile test piece. The tensile force value monitored by the tensile sensor when the second vibration test bundle in the tensile test piece is completely separated from the first vibration test bundle in the tensile test piece is taken as the ultimate friction tensile force. The second vibration test bundle in the tensile test piece that is completely separated from the first vibration test bundle is recorded as the second separated bundle, and the first vibration test bundle in the tensile test piece that is completely separated from the second vibration test bundle is recorded as the first separated bundle.

[0110] The first average port temperature of the first vibrating welding end in the first separation wire harness and the second average port temperature of the second vibrating welding end in the second separation wire harness were read using a pre-built infrared thermometer.

[0111] The friction response index is calculated based on the initial pressure, vibration amplitude, vibration frequency, vibration time, ultimate friction tension, first average port temperature, and second average port temperature.

[0112] For example, two reference wire harness materials are randomly extracted from a set of reference wire harness materials. One of the reference wire harness materials is used as the first vibration test wire harness, and the other reference wire harness material is used as the second vibration wire harness. The first vibration welding end is a pre-designed area on the first vibration test wire harness for ultrasonic welding, and the second vibration welding end is a pre-designed area on the second vibration test wire harness for ultrasonic welding. Specifically, both the first and second vibration welding ends are formed by pre-processing the insulation layer of their corresponding wire harnesses. The pre-processing includes, but is not limited to, stripping the wire harness ends to expose the conductor portion and form a welding area suitable for ultrasonic welding. The stripping length, stripping method, and stripping position are manually set by the technicians at the wire harness processing plant based on the wire diameter, stranding method, and actual welding requirements.

[0113] It should be explained that the vibration testing device is an integrated unit comprising an indenter clamp, a tensile testing machine, and a vibration testing machine. The indenter clamp is a clamp capable of applying a specific clamping force. The tensile testing machine is a tensile testing machine, comprising a fixing clamp, a tension rod, and a tension sensor. The fixing clamp is used to fix the object to be tested within the tensile testing machine. The tension rod is a mechanical rod used to apply tensile force to the object to be tested. The tension sensor monitors the magnitude of the tensile force applied by the tension rod to the object to be tested. The vibration testing machine is a piezoelectric vibration table, comprising a vibration table, which is a platform on the vibration testing machine used to place the object to be tested.

[0114] It is understood that placing the first vibration welding end of the first vibration test wire harness and the second vibration welding end of the second vibration test wire harness in reverse overlap in the pressure head clamp means that the first vibration welding end and the second vibration welding end are arranged opposite to each other in the axial direction of the pressure head clamp, so that the exposed conductor areas of the two welding ends overlap and contact each other in the pressure head clamp, and the orientation of the first vibration welding end in the first vibration test wire harness is opposite to the wire harness orientation of the second vibration welding end in the second vibration test wire harness.

[0115] For example, if the preset initial pressure is 50N, the pressure head clamp applies a clamping force of 50N to the first and second vibration welding ends. At this time, the pressure head clamp, the clamped and pressed first and second vibration test wire harnesses together constitute the compressed vibration test piece. If the preset vibration amplitude is 50 micrometers, the preset vibration frequency is 20 kHz, and the preset vibration time is 2 seconds, the vibration testing machine applies vibration to the prepared vibration test piece on the vibration table for 2 seconds at a vibration amplitude of 50 micrometers and a vibration frequency of 20 kHz. The prepared vibration test piece after vibration is completed is the completed vibration test piece.

[0116] It should be explained that fixing the first vibration test harness in the completed vibration test piece to the fixing fixture of the tensile testing machine and fixing the second vibration test harness in the completed vibration test piece to the tension rod of the tensile testing machine means: fixing the end of the first vibration test harness in the completed vibration test piece away from the pressure head fixture to the fixing fixture of the tensile testing machine, and fixing the end of the second vibration test harness in the completed vibration test piece away from the pressure head fixture to the tension rod of the tensile testing machine. The completed vibration test piece after fixing is the tensile test piece.

[0117] For example, if the preset tension gradient timing sequence is (0N-0s, 5N-1s, 10N-2s, ..., 1000N-200s), then at 0 seconds, the tension rod of the tensile testing machine applies a parallel tension of 0N to the second vibration test wire in the tensile test piece; at 1 second, the tension rod of the tensile testing machine applies a parallel tension of 5N to the second vibration test wire in the tensile test piece, and so on. The application of parallel tension means that the tension rod applies a tension parallel to the axial direction of the wire to the second vibration test wire. The tension value is the magnitude of the parallel tension applied by the tension rod of the tensile testing machine to the second vibration test wire in the tensile test piece. Until the second vibration test wire is completely pulled out of the tensile test piece by the tension rod under the action of the tension rod, that is, completely separated from the first vibration test wire, the second vibration test wire at this time is regarded as the second separated wire, and the first vibration test wire at this time is regarded as the first separated wire.

[0118] It should be explained that the infrared thermometer is an infrared thermometer. Reading the first average port temperature of the first vibrating welded end in the first separation harness refers to: using an infrared thermometer to sample the temperature of the first vibrating welded end at multiple points, and averaging the collected temperature values ​​to obtain an average temperature value, which is the first average port temperature. The method for reading the second average port temperature of the second vibrating welded end in the second separation harness is the same as the method for reading the first average port temperature of the first vibrating welded end in the first separation harness, and will not be repeated here.

[0119] In detail, the formula for calculating the friction response index is as follows:

[0120]

[0121] in, The frictional response index, This is the ultimate frictional tension. As the initial pressure, and These are the first average port temperature and the second average port temperature, respectively. It is a natural constant. The amplitude of vibration. The vibration frequency, The vibration time.

[0122] It should be understood that the friction response index reflects the frictional intensity between conductors within the reference wire harness material under high-frequency vibration conditions. A higher friction response index indicates higher frictional intensity between conductors within the reference wire harness material under high-frequency vibration conditions, resulting in higher frictional force and heat release between the wire harness conductors. Since ultrasonic vibration causes high-frequency friction and heat release at the conductor interfaces of the wire harness during ultrasonic welding, this friction response index characterizes the internal frictional intensity and vibration thermal response characteristics of the wire harness, providing a reference for adjusting welding parameters during ultrasonic welding.

[0123] It should be explained that in the embodiments of the present invention, all formulas are calculated by simply substituting their numerical values, without considering their dimensions.

[0124] Specifically, the pressure deformation test on the reference wire harness material set to obtain the deformation response index includes:

[0125] Deformation test wire harnesses were extracted from the reference wire harness raw material collection, and the deformation welding ends of the deformation test wire harnesses were confirmed.

[0126] The pressure testing device was identified, which includes: a pressure testing platform, a pressure head, and a displacement sensor;

[0127] The deformation welding end of the deformation test harness is fixed on the pressure test bench to obtain a fixed deformation harness;

[0128] The fixed deformation wire harness is pressurized based on the preset first pressure and the pressure head, and the first pressure distance when the pressure head presses the fixed deformation wire harness is read by the displacement sensor.

[0129] The second pressure distance is obtained based on the preset second pressure, pressure head, displacement sensor and fixed deformation wire harness;

[0130] The deformation response index is calculated based on the first applied pressure, the second applied pressure, the first applied pressure distance, and the second applied pressure distance, using the following formula:

[0131]

[0132] in, The deformation response index. and These are the first and second applied pressures, respectively. and These are the first pressure distance and the second pressure distance, respectively.

[0133] It is understood that the method for extracting the deformation test wire bundle from the reference wire bundle material set is the same as the method for extracting the first vibration test wire bundle from the reference wire bundle material set, and the method for confirming the deformation weld end of the deformation test wire bundle is the same as the method for confirming the first vibration weld end of the first vibration test wire bundle; therefore, these methods will not be repeated here. Furthermore, this deformation test wire bundle is the reference wire bundle material used for subsequent pressure testing.

[0134] It should be explained that the pressure testing device is a pressure testing machine, and the pressure testing device includes: a pressure testing platform, a pressure head, and a pressure sensor. The pressure testing platform is a platform used to place and fix the deformation test wire harness. The pressure head is a device in the pressure testing device used to apply pressure to the fixed deformation wire harness, thereby compressing the welded ends of the wire harness. The displacement sensor is used to read the displacement from the initial position when the pressure head applies pressure to the fixed deformation wire harness.

[0135] For example, if the preset first pressure is 80N, the pressure head is made to apply a force of 80N downward to the fixed deformation wire harness on the pressure test bench, and the displacement sensor is used to read the distance that the pressure head is displaced downward under the condition of applying a force of 80N, thus obtaining the first pressure distance.

[0136] It is understood that the method for obtaining the second pressure distance based on the preset second pressure, pressure head, displacement sensor and fixed deformation wire harness is the same as the method for obtaining the first pressure distance using the preset first pressure, pressure head, pressure sensor and fixed deformation wire harness, and will not be described again here.

[0137] It should be understood that the deformation response index reflects the stiffness of the reference wire harness material. Since the wire harness is compressed by a preset welding pressure during ultrasonic welding, the deformation response index characterizes the compressive deformation capability of the wire harness under the compressed state during welding. The degree of compression deformation affects the effect of ultrasonic vibration transmission to the contact interface. Therefore, by extracting the physical characteristics of the wire harness from the deformation response index, a reference can be provided for the control of welding parameters during ultrasonic welding.

[0138] Specifically, the heat conduction test on the reference wire harness material set to obtain the heat storage index includes:

[0139] The heat test wire harness was extracted from the reference wire harness raw material collection, and the heat welding end of the heat test wire harness was identified. The heat welding end includes: the starting end and the ending end.

[0140] Obtain a miniature heating element and fix it to the starting end of the heat test harness to obtain the prepared heat harness;

[0141] The heat-generating wire harness is heated based on a preset heating temperature, a preset heating time, and a miniature heating element to obtain a heated wire harness.

[0142] The initial average port temperature at the upper end of the heating element harness was read using an infrared thermometer.

[0143] The heating wire bundle is placed into a pre-constructed constant test chamber to obtain the waiting heat wire bundle. The time for obtaining the waiting heat wire bundle is taken as the starting point and the time is recorded in real time to obtain the heat dissipation time. The heat dissipation time continues until the heat dissipation time reaches the preset heat dissipation threshold. Then the waiting heat wire bundle is taken out from the constant test chamber to obtain the heat dissipation wire bundle.

[0144] Use an infrared thermometer to read the average end port temperature of the heat dissipation harness.

[0145] The heat storage index is calculated based on the initial average port temperature, heating temperature, heating time, final average port temperature, and heat dissipation threshold. The calculation formula is shown below:

[0146]

[0147] in, The heat storage index, and These are the initial average port temperature and the final average port temperature, respectively. and These are heating time and heat dissipation threshold, respectively. This refers to the heating temperature.

[0148] It should be explained that the method for extracting the heat test wire bundle from the reference wire bundle material set is the same as the method for extracting the first vibration test wire bundle from the reference wire bundle material set, and the method for confirming the heat welding end of the heat test wire bundle is the same as the method for confirming the first vibration welding end of the first vibration test wire bundle. These will not be repeated here. The heat test wire bundle is the reference wire bundle material used for subsequent heating tests.

[0149] For example, if the heat welding end is divided into two equal parts in the axial direction, the starting end refers to the area on the heat welding end that is close to the unstripped reference wire harness material, and the ending end refers to the area on the other side of the heat welding end. This division is only used for area identification and does not mean that the heat welding end is actually cut or physically separated in reality.

[0150] It should be explained that the micro heating element is an electric heating element with a volume of less than 5 cubic centimeters.

[0151] For example, a miniature heating element is bound to the starting end of a heat test harness. The bound heat test harness is the heat preparation harness. If the preset heating temperature is 100 degrees Celsius and the heating time is 10 seconds, the miniature heating element heats the starting end of the heat preparation harness at 100 degrees Celsius for 10 seconds. The heated heat preparation harness is the heated heat harness.

[0152] It is understood that the method of reading the initial average port temperature of the upper end of the heating wire harness using an infrared thermometer and the method of reading the final average port temperature of the upper end of the heat dissipation wire harness using an infrared thermometer are the same as the method of reading the first average port temperature of the first vibration welding end in the first separation wire harness, and will not be described again here.

[0153] It should be explained that the constant temperature and humidity test chamber is a constant temperature and humidity test chamber, and the temperature and humidity of the constant temperature and humidity test chamber are manually set by the technicians of the wire harness processing factory.

[0154] For example, the heating wire harness is placed in a pre-constructed constant test chamber for heat dissipation. The heating wire harness placed in the constant test chamber is the waiting heat wire harness. If the waiting heat wire harness time is 8:00:00, then 8:00:00 is taken as the starting point and the time is recorded in real time. When 8:00:02, the heat dissipation time is 2 seconds. If the heat dissipation threshold is 20 seconds, then at 8:00:20, the heat dissipation time reaches the preset heat dissipation threshold, and the waiting heat wire harness is taken out of the constant test chamber. The waiting heat wire harness after being taken out is the heat dissipation wire harness.

[0155] It should be understood that the heat storage index reflects the utilization rate of external heat by the reference wire harness material when heated. The higher the heat storage index, the higher the utilization rate of external heat by the reference wire harness material when heated, and the easier it is to absorb, conduct, and retain heat. During ultrasonic welding, the wire harness undergoes relative friction and generates heat under high-frequency vibration. This heat needs to be effectively absorbed by the wire harness and conducted to the welding area to promote plastic flow of the metal material and achieve reliable welding. Therefore, the heat storage index, representing the utilization rate of heat by the wire harness when heated, directly affects the temperature rise rate, plastic flow degree, and final welding quality of the welding area. Thus, extracting the physical characteristics of the wire harness based on this heat storage index provides a reference for the control of welding parameters during ultrasonic welding.

[0156] S3. Obtain the welding frequency range, welding pressure range, and welding time range.

[0157] For example, by querying the minimum and maximum welding frequencies among all welding frequencies used by the wire harness processing factory in ultrasonic welding in history, the minimum welding frequency is used as the minimum value and the maximum welding frequency is used as the maximum value to construct a welding frequency range. Similarly, by querying the minimum and maximum welding pressures among all welding pressures used by the wire harness processing factory in ultrasonic welding in history, as well as the shortest and longest welding times among all welding times, the minimum welding pressure is used as the minimum value and the maximum welding pressure is used as the maximum value to construct a welding pressure range. Finally, by using the shortest welding time as the minimum value and the longest welding time as the maximum value, a welding time range is constructed.

[0158] It should be explained that ultrasonic welding refers to ultrasonic welding, and ultrasonic welding is existing technology, so it will not be described in detail here. Welding frequency refers to the frequency of the ultrasonic waves used in ultrasonic welding, and welding pressure refers to the normal clamping force applied to the wire harness to be welded by the welding head or pressure head through the clamp during ultrasonic welding. Welding time refers to the duration of ultrasonic vibration during a single ultrasonic welding process.

[0159] S4. Based on the pre-constructed ultrasonic welder, welding frequency range, welding pressure range, and welding time range, low-resistance welding evaluation is performed on the reference wire harness material set to obtain the optimal test parameter set and optimal environmental parameters.

[0160] It should be explained that an ultrasonic welder is a wire harness welding machine that uses ultrasonic metal welding technology.

[0161] In detail, the low-resistance welding evaluation of the reference wire harness material set based on the pre-constructed ultrasonic welder, welding frequency range, welding pressure range, and welding time range yields the optimal test parameter set and optimal environmental parameters, including:

[0162] Multiple test parameter sets were obtained by combining the welding frequency range, welding pressure range, and welding time range. These test parameter sets included: test welding frequency, test welding pressure, and test welding time.

[0163] Perform the following operation for each of the multiple test parameter groups:

[0164] The ultrasonic welder was set using the test welding frequency, test welding pressure, and test welding time in the test parameter group to obtain the test welder;

[0165] The test environment temperature and humidity of the test welder are read using pre-built temperature and humidity sensors, and the test environment parameters are obtained by summarizing the test environment temperature and humidity.

[0166] The first and second wire harnesses awaiting welding were extracted from the reference wire harness raw material set. The first waiting welding end of the first waiting welding end of the first waiting welding end of the first waiting welding end of the second waiting welding end of the second waiting welding end of the second waiting welding end were identified.

[0167] The first waiting-to-weld end of the first waiting-to-weld wire harness and the second waiting-to-weld end of the second waiting-to-weld wire harness were ultrasonically welded using a test welder to obtain a test welded wire harness.

[0168] A low-resistance electrical evaluation was performed on the tested welded wire harness to obtain an electrical score for the wire harness.

[0169] The electrical scores and test environment parameters of the wire harness were summarized separately to obtain multiple electrical scores and multiple test environment parameters for the wire harness;

[0170] The optimal electrical score was determined based on multiple electrical scores of the wiring harness. The optimal electrical score is the largest electrical score among the multiple electrical scores of the wiring harness.

[0171] Based on the optimal electrical score, the optimal test parameter group and optimal environmental parameters were identified from multiple test parameter groups and multiple test environment parameters, respectively. The optimal test parameter group and optimal environmental parameters are the test parameter groups and test environment parameters corresponding to the optimal electrical score in the multiple test parameter groups and the multiple test environment parameters, respectively.

[0172] It should be explained that setting the ultrasonic welder using the test welding frequency, test welding pressure, and test welding time in the test parameter set to obtain the test welder means: setting the ultrasonic welder to use the test welding frequency, test welding pressure, and test welding time for subsequent ultrasonic welding; the ultrasonic welder after setting is the test welder. A humidity sensor is a sensor that can determine ambient humidity, and a temperature sensor is a sensor that can determine ambient temperature. Reading the test ambient temperature and humidity of the test welder using a pre-built temperature sensor and a pre-built humidity sensor means: installing the temperature sensor and humidity sensor on the outer surface of the test welder, and then reading the temperature and humidity at the outer surface of the test welder; the temperature at the outer surface of the test welder is the test ambient temperature, and the humidity at the outer surface of the test welder is the test ambient humidity.

[0173] It is understood that the method for extracting the first and second waiting-to-be-welded wire bundles from the reference wire bundle material set is the same as the method for extracting the first and second vibration test wire bundles from the reference wire bundle material set, and will not be repeated here. Furthermore, both the first and second waiting-to-be-welded wire bundles are reference wire bundle materials subsequently used for ultrasonic welding. The method for confirming the first waiting-to-be-welded end of the first waiting-to-be-welded wire bundle and the method for confirming the second waiting-to-be-welded end of the second waiting-to-be-welded wire bundle are the same as the method for confirming the first vibration welded end of the first vibration test wire bundle, and will not be repeated here.

[0174] It should be explained that the ultrasonic welding of the first waiting-to-weld end of the first waiting-to-weld wire bundle and the second waiting-to-weld end of the second waiting-to-weld wire bundle using a test welder to obtain the test welded wire bundle refers to: placing the first waiting-to-weld end of the first waiting-to-weld wire bundle and the second waiting-to-weld end of the second waiting-to-weld wire bundle in reverse overlap in the test welder, and performing ultrasonic welding on the reverse-overlapping first waiting-to-weld end of the first waiting-to-weld wire bundle and the second waiting-to-weld end of the second waiting-to-weld wire bundle under test welding frequency, test welding pressure, and test welding time. The finally welded first waiting-to-weld wire bundle and the second waiting-to-weld wire bundle together constitute the test welded wire bundle. The method of placing the first waiting-to-weld end of the first waiting-to-weld wire bundle and the second waiting-to-weld end of the second waiting-to-weld wire bundle in reverse overlap in the test welder is the same as the method of placing the first vibration welding end of the first vibration test wire bundle and the second vibration welding end of the second vibration test wire bundle in reverse overlap in the pressure head clamp, and will not be repeated here.

[0175] In detail, the test parameters for the welding frequency range, welding pressure range, and welding time range are combined to obtain multiple test parameter sets, including:

[0176] Based on the preset frequency sampling interval, the welding frequency range is sampled at equal intervals to obtain a test welding frequencies;

[0177] b test welding pressures are obtained based on the preset pressure sampling interval and welding pressure range, and c test welding times are obtained based on the preset time sampling interval and welding time range.

[0178] By combining a test welding frequency, b test welding pressure, and c test welding time, multiple test parameter sets are obtained. The number of test parameter sets in the multiple test parameter sets is P, and P = a × b × c.

[0179] For example, if the frequency sampling interval is 5 kHz and the welding frequency range is [20 kHz, 40 kHz], where kHz refers to kilohertz, then the welding frequency range is sampled at equal intervals based on the preset frequency sampling interval to obtain 5 test welding frequencies: 20 kHz, 25 kHz, 30 kHz, 35 kHz and 40 kHz.

[0180] It is understood that the method for obtaining b test welding pressures based on a preset pressure sampling interval and welding pressure range, and the method for obtaining c test welding times based on a preset time sampling interval and welding time range, are the same as the method for obtaining a test welding frequencies by equidistant sampling of the welding frequency range based on a preset frequency sampling interval, and will not be elaborated here. Furthermore, the frequency sampling interval, pressure sampling interval, and time sampling interval are all manually set by the technicians at the wire harness processing factory. Optionally, the frequency sampling interval is 5 kHz, the pressure sampling interval is 1 MPa, and the time sampling interval is 0.1 seconds.

[0181] For example, if there are 5 test welding frequencies, 5 test welding pressures, and 5 test welding times, then the Cartesian product of the 5 test welding frequencies, 5 test welding pressures, and 5 test welding times is performed to iterate through all possible combinations (a combination contains one test welding frequency, one test welding pressure, and one test welding time). Each combination is a test parameter group, resulting in 75 test parameter groups.

[0182] In detail, the low-resistance electrical evaluation of the tested welded wire harness to obtain a wire harness electrical score includes:

[0183] Confirm the welding head, welding start point, and welding end point of the test welding harness;

[0184] The welding image is obtained by taking pictures of the weld head using a pre-built industrial camera;

[0185] The welding image is converted to grayscale to obtain a grayscale welding image, wherein the grayscale welding image includes: multiple grayscale pixels, wherein the grayscale pixels include: pixel grayscale values;

[0186] For each grayscale pixel in a grayscale welding image, perform the following operation:

[0187] Compare the pixel grayscale value of grayscale pixels with the preset bad pixel grayscale threshold;

[0188] If the pixel grayscale value is greater than the bad pixel grayscale threshold, then the grayscale pixel corresponding to the pixel grayscale value is recorded as a bad pixel.

[0189] Summarize the bad pixel counts to obtain multiple bad pixel counts;

[0190] Confirm the number of bad pixels and the original number of multiple bad pixels and multiple grayscale pixels respectively;

[0191] The resistance between the welding start and welding end points of the test welding harness is read using a pre-built ohmmeter.

[0192] The initial heating temperature of the welding start point on the test welding wire harness was read using an infrared thermometer.

[0193] The test welding wire harness is tested based on the preset energizing current and preset energizing time to obtain the energized test wire harness.

[0194] Use an infrared thermometer to read the end-of-heat temperature of the soldering start point on the energized test harness;

[0195] The electrical score of the wire harness is calculated based on the energizing current, energizing time, test resistance, initial heating temperature, final heating temperature, number of defective points, and original number.

[0196] It should be explained that the welding end refers to the overall area where the first welding end of the first waiting welding wire bundle and the second welding end of the second waiting welding wire bundle overlap each other in the axial direction and form a welding connection. The welding start point is located at the boundary between the welding end and the first waiting welding wire bundle, and the welding end point is located at the boundary between the welding end and the second waiting welding wire bundle.

[0197] It is understood that the industrial camera is an industrial video camera. The welding image refers to an image of the welded end captured by the industrial camera. Converting the welding image to grayscale means converting each pixel in the welding image to grayscale; the resulting grayscale welding image is the grayscale-converted welding image. Grayscale pixels are the pixels in the grayscale welding image, and pixel grayscale value refers to the grayscale value of a grayscale pixel. The defective pixel grayscale threshold is set by the technicians at the wire harness processing plant based on historical ultrasonic welding data. For example, the technicians at the wire harness processing plant acquire images of welded ends that have historically exhibited welding defects such as scorching or overheating during ultrasonic welding, convert the acquired images to grayscale, average the grayscale values ​​of all pixels in the grayscale-converted image, and use the averaged grayscale value as the defective pixel grayscale threshold.

[0198] It should be explained that the number of bad pixels refers to the total number of bad pixels out of multiple bad pixels, while the original number refers to the total number of grayscale pixels out of multiple grayscale pixels. A ohmmeter is a multimeter used to measure resistance. The phrase "using a pre-built ohmmeter to read the test resistance value between the welding start and end points of the test welding harness" means: using the ohmmeter to read the resistance value between the welding start and end points of the welding harness; this resistance value is the test resistance value. The initial heating temperature refers to the temperature at the welding start point on the test welding harness. The final heating temperature refers to the temperature at the welding start point on the energized test welding harness.

[0199] For example, if the current is 5 amps and the energizing time is 30 seconds, a rated current of 5 amps is applied to the test welding wire harness through a programmable constant current power supply and the energizing is continued for 30 seconds, so that the current flows stably at the welding terminal. The test welding wire harness after energizing is the energized test wire harness.

[0200] In detail, the calculation formula for the electrical rating of the wire harness is as follows:

[0201]

[0202] in, Evaluate the electrical performance of the wire harness. and These are the end heating temperature and the initial heating temperature, respectively. For the current flowing through, For the power-on time, and These represent the number of defective pixels and the original number, respectively. To test the resistance value, It is the natural logarithm.

[0203] It should be explained that the electrical rating of the wire harness reflects the electrical performance stability and welding quality level of the tested and welded wire harness. The higher the electrical rating of the wire harness, the higher the electrical performance stability of the tested and welded wire harness and the better the welding quality.

[0204] S5. Summarize the friction response index, deformation response index, heat storage index, optimal environmental parameters, reference harness diameter, and reference core quantity to obtain a reference property parameter set. Combine the reference property parameter set and the optimal test parameter set to obtain a training sample set.

[0205] It should be explained that, since all reference wire harness materials in a single reference wire harness material set have the same model, the reference wire harness diameter refers to the wire diameter of any one reference wire harness material in the reference wire harness material set, and the number of reference wire cores refers to the number of conductive wire cores contained in a single reference wire harness material.

[0206] For example, the training sample set is: [{reference property parameter set}, {optimal test parameter set}].

[0207] S6. Summarize the training sample groups corresponding to the reference wire harness material set to obtain multiple training sample groups. Train the pre-built deep learning model based on the multiple training sample groups to obtain the wire harness welding model.

[0208] It should be explained that the deep learning model includes, but is not limited to, multilayer perceptrons, convolutional neural networks, and graph neural networks. The process of training a pre-constructed deep learning model based on multiple training sample sets to obtain a wire harness welding model refers to using the friction response index, deformation response index, heat storage index, optimal environmental parameters, reference wire harness diameter, and reference wire core quantity from the reference property parameter set in the training sample set as input data for training the deep learning model. The test welding frequency, test welding pressure, and test welding time from the optimal test parameter set in the training sample set are used as output data for the deep learning model. Then, the deep learning model is iteratively trained using multiple training sample sets. The deep learning model gradually adjusts the network parameters by optimizing the loss function (e.g., mean squared error, weighted error, etc.), enabling the deep learning model to learn the mapping relationship between the input data (friction response index, deformation response index, heat storage index, optimal environmental parameters, reference wire harness diameter, and reference wire core quantity) and the output data (test welding frequency, test welding pressure, and test welding time). The trained deep learning model is the wire harness welding model. When the current property parameter set of the formally welded wire harness is subsequently collected, and the current friction response index, current deformation response index, current heat storage index, current environmental parameters, current wire harness diameter, and current number of reference wire cores in the current property parameter set are input into the wire harness welding model as the friction response index, deformation response index, heat storage index, optimal environmental parameters, reference wire harness diameter, and reference number of reference wire cores, respectively, the wire harness welding model can automatically output the predicted target welding parameter set (optimal welding frequency, optimal welding pressure, and optimal welding time). Furthermore, the training process of the above deep learning model is all publicly available prior art, and will not be described in detail here.

[0209] It should be understood that, in the embodiments of the present invention, when training a deep learning model, all input data is pre-normalized before being input into the model, and the output data of the model is also restored using inverse normalization. Optionally, max-min normalization is used as the normalization method.

[0210] S7. Obtain the formal welding wire harness set, obtain the current property parameter set based on the formal welding wire harness set, and use the wire harness welding model to perform welding prediction on the current property parameter set to obtain the target welding parameter set.

[0211] It should be explained that the formally welded wire harness set refers to the collection of multiple wire harnesses that the wire harness processing plant currently needs to formally carry out welding production.

[0212] It is understood that the method for obtaining the current property parameter set based on the formal welding wire harness set is the same as the method for obtaining the reference property parameter set using the reference wire harness material set, and will not be repeated here. The current property parameter set includes: current friction response index, current deformation response index, current heat storage index, current environmental parameters, current wire harness diameter, and current reference wire core quantity, which correspond to the friction response index, deformation response index, heat storage index, optimal environmental parameters, reference wire harness diameter, and reference wire core quantity in the reference property parameter set, respectively.

[0213] It should be understood that the aforementioned method of using a wire harness welding model to predict welding based on the current set of property parameters and obtain the target welding parameter set refers to the following: when the current friction response index, current deformation response index, current heat storage index, current environmental parameters, current wire harness diameter, and current number of reference wire cores in the current set of property parameters are input into the wire harness welding model as the friction response index, deformation response index, heat storage index, optimal environmental parameters, reference wire harness diameter, and reference number of reference wire cores, respectively, the test welding frequency, test welding pressure, and test welding time output by the wire harness welding model are used as the optimal welding frequency, optimal welding pressure, and optimal welding time, respectively, and the optimal welding frequency, optimal welding pressure, and optimal welding time are summarized to obtain the target welding parameter set.

[0214] S8. Based on the target welding parameter set and the ultrasonic welder, the formal welding wire bundle set is welded to obtain the target welding wire bundle set.

[0215] It should be explained that the process of welding the formal welding wire bundle set based on the target welding parameter set and the ultrasonic welder to obtain the target welding wire bundle set means: setting the welding frequency, welding pressure and welding time of the ultrasonic welder to the optimal welding frequency, optimal welding pressure and optimal welding time in the target welding parameter set, then extracting two formal welding wire bundles from the formal welding wire bundle set in sequence, and using the set ultrasonic welder to perform ultrasonic welding on the two formal welding wire bundles to obtain the target welding wire bundle, until all formal welding wire bundles in the formal welding wire bundle set have been welded, and summing up the target welding wire bundles to obtain the target welding wire bundle set, thus completing the welding of the high-speed wire bundle.

[0216] Understandably, after the wire harness welding model is trained in this embodiment of the invention, whenever a wire harness processing plant needs to perform ultrasonic welding on a new model or different type of wire harness, the wire harness welding model can be used to predict the ideal target welding parameter set for the wire harness, including key parameters such as welding frequency, welding pressure, and welding time. Subsequently, with fine-tuning and confirmation by technicians, ultrasonic welding is performed on the corresponding wire harness welding ends, thereby achieving a high-quality, low-resistance wire harness welding process with good welding consistency, significantly shortening the parameter debugging cycle, and improving production efficiency and welding reliability.

[0217] To address the problems described in the background art, this invention obtains multiple reference wire harness material sets. These reference wire harness material sets include various types and physical properties of reference wire harness materials, covering potential differences in materials, stranding methods, wire diameters, and the number of wire cores. This provides a comprehensive physical feature sample basis for subsequent welding parameter optimization, ensuring the representativeness and broad applicability of the model training data. Furthermore, the following operations are performed on each reference wire harness material set: vibration and friction testing is conducted to obtain the friction response index; pressure deformation testing is conducted to obtain the deformation response index; and further... By conducting heat conduction tests and obtaining the heat storage index, it can be seen that the embodiments of the present invention, through systematic physical performance testing, can quantify the physical properties of the wire harness under ultrasonic welding conditions, providing a basis for subsequent welding parameter prediction. Welding frequency range, welding pressure range, and welding time range are obtained. Based on the pre-constructed ultrasonic welder, welding frequency range, welding pressure range, and welding time range, low-resistance welding evaluation is performed on the reference wire harness material set to obtain the optimal test parameter set and optimal environmental parameters. It is evident that the embodiments of the present invention, through welding tests, select the most suitable welding parameter combination for each reference wire harness, achieving matching between welding parameters and wire harness physical properties. This provides a reliable and matched training sample set for subsequent model training, improving subsequent welding... Based on the predicted accuracy, the reference wire harness diameter and the number of reference wire cores in the reference wire harness material set are confirmed. The friction response index, deformation response index, heat storage index, optimal environmental parameters, reference wire harness diameter, and the number of reference wire cores are summarized to obtain a reference property parameter set. This reference property parameter set is then combined with the optimal test parameter set to obtain a training sample set. It can be seen that this embodiment of the invention constructs a mapping relationship between wire harness physical properties and welding process parameters by mapping physical feature parameters to welding target parameters, providing systematic input and output data for the deep learning model. Multiple training sample sets are obtained by summarizing the training sample sets corresponding to the reference wire harness material set. The pre-constructed deep learning model is then trained based on these multiple training sample sets to obtain... The wire harness welding model, as seen in this embodiment of the invention, trains a deep learning model using diverse training samples, enabling it to learn the influence of wire harness physical properties on welding parameters. This allows for the prediction and intelligent control of welding parameters for different wire harnesses in actual welding, improving welding consistency and quality. The process involves obtaining a formal welding wire harness set, acquiring a current property parameter set based on this set, using the wire harness welding model to predict the welding performance of this parameter set, obtaining a target welding parameter set, and then welding the formal welding wire harness set using the target welding parameter set and an ultrasonic welder to obtain the target welding wire harness set. Thus, this embodiment of the invention predicts ideal welding parameters suitable for the formal welding wire harness set through the model, thereby reducing weld contact resistance and improving welding quality.Therefore, the present invention can shorten the welding parameter adjustment cycle and improve production efficiency and ultrasonic welding quality.

[0218] like Figure 2 The diagram shown is a functional block diagram of a high-speed wire harness low-resistance welding system based on local microenvironment control provided in an embodiment of the present invention.

[0219] The high-speed wire harness low-resistance welding system 100 based on local microenvironment control described in this invention can be installed in electronic devices. Depending on the functions implemented, the high-speed wire harness low-resistance welding system 100 may include a wire harness feature extraction module 101, a wire harness welding test module 102, a welding model training module 103, and a formal welding control module 104. The module described in this invention can also be called a unit, referring to a series of computer program segments that can be executed by the processor of an electronic device and perform a fixed function, stored in the memory of the electronic device.

[0220] The wire harness feature extraction module 101 is used to acquire multiple reference wire harness material sets, wherein the reference wire harness material sets include multiple reference wire harness materials. For each reference wire harness material set in the multiple reference wire harness material sets, the following operations are performed: vibration friction test is performed on the reference wire harness material set to obtain the friction response index; pressure deformation test is performed on the reference wire harness material set to obtain the deformation response index; and heat conduction test is performed on the reference wire harness material set to obtain the heat storage index.

[0221] The wire harness welding test module 102 is used to obtain the welding frequency range, welding pressure range, and welding time range. Based on the pre-constructed ultrasonic welder, welding frequency range, welding pressure range, and welding time range, it performs low-resistance welding evaluation on the reference wire harness material set to obtain the optimal test parameter set and optimal environmental parameters.

[0222] The welding model training module 103 is used to confirm the reference wire harness diameter and the number of reference wire cores in the reference wire harness material set, summarize the friction response index, deformation response index, heat storage index, optimal environmental parameters, reference wire harness diameter and the number of reference wire cores to obtain a reference property parameter set, combine the reference property parameter set and the optimal test parameter set to obtain a training sample set, summarize the training sample sets corresponding to the reference wire harness material set to obtain multiple training sample sets, and train the pre-constructed deep learning model based on the multiple training sample sets to obtain the wire harness welding model;

[0223] The formal welding control module 104 is used to acquire a formal welding wire harness set, acquire a current property parameter set based on the formal welding wire harness set, perform welding prediction on the current property parameter set using a wire harness welding model to obtain a target welding parameter set, and perform welding on the formal welding wire harness set based on the target welding parameter set and an ultrasonic welder to obtain the target welding wire harness set.

[0224] In detail, the modules in the high-speed wire harness low-resistance welding system 100 based on local microenvironment control described in this embodiment of the invention employ the same methods as described above during use. Figure 1 The method described herein is the same as the high-speed wire harness low-resistance welding method based on local microenvironment control, and can produce the same technical effect, so it will not be repeated here.

[0225] like Figure 3 The diagram shown is a structural schematic of an electronic device that implements a high-speed wire harness low-resistance welding method based on local microenvironment control, according to an embodiment of the present invention.

[0226] The electronic device 1 may include a processor 10, a memory 11 and a bus 12, and may also include a computer program stored in the memory 11 and executable on the processor 10, such as a high-speed wire harness low-resistance welding method program based on local microenvironment control.

[0227] The memory 11 includes at least one type of readable storage medium, such as flash memory, portable hard drive, multimedia card, card-type memory (e.g., SD or DX memory), magnetic memory, magnetic disk, optical disk, etc. In some embodiments, the memory 11 can be an internal storage unit of the electronic device 1, such as a portable hard drive. In other embodiments, the memory 11 can be an external storage device of the electronic device 1, such as a plug-in portable hard drive, smart media card (SMC), secure digital card (SD), flash card, etc., equipped on the electronic device 1. Furthermore, the memory 11 includes both internal storage units and external storage devices of the electronic device 1. The memory 11 can be used not only to store application software and various types of data installed on the electronic device 1, such as the code of a high-speed wire harness low-resistance welding method program based on local microenvironment control, but also to temporarily store data that has been output or will be output.

[0228] In some embodiments, the processor 10 may be composed of integrated circuits, such as a single packaged integrated circuit or multiple integrated circuits with the same or different functions, including combinations of one or more central processing units (CPUs), microprocessors, digital processing chips, graphics processors, and various control chips. The processor 10 is the control unit of the electronic device, connecting various components of the entire electronic device through various interfaces and lines. It executes programs or modules stored in the memory 11 (e.g., a high-speed wire harness low-resistance welding method program based on local microenvironment control) and calls data stored in the memory 11 to perform various functions of the electronic device 1 and process data.

[0229] The bus 12 can be a peripheral component interconnect (PCI) bus or an extended industry standard architecture (EISA) bus, etc. The bus 12 can be divided into an address bus, a data bus, a control bus, etc. The bus 12 is configured to realize the connection and communication between the memory 11 and at least one processor 10, etc.

[0230] Figure 3 Only electronic devices with components are shown; it will be understood by those skilled in the art that... Figure 3 The structure shown does not constitute a limitation on the electronic device 1, and may include fewer or more components than shown, or combine certain components, or have different component arrangements.

[0231] For example, although not shown, the electronic device 1 may also include a power supply (such as a battery) to power the various components. Preferably, the power supply can be logically connected to the at least one processor 10 through a power management device, thereby enabling functions such as charging management, discharging management, and power consumption management. The power supply may also include one or more DC or AC power supplies, recharging devices, power fault detection circuits, power converters or inverters, power status indicators, and other arbitrary components. The electronic device 1 may also include various sensors, Bluetooth modules, Wi-Fi modules, etc., which will not be described in detail here.

[0232] Furthermore, the electronic device 1 may also include a network interface. Optionally, the network interface may include a wired interface and / or a wireless interface (such as a Wi-Fi interface, a Bluetooth interface, etc.), which is typically used to establish communication connections between the electronic device 1 and other electronic devices.

[0233] Optionally, the electronic device 1 may further include a user interface, which may be a display, an input unit (such as a keyboard), and optionally, a standard wired interface or a wireless interface. Optionally, in some embodiments, the display may be an LED display, a liquid crystal display, a touch-sensitive liquid crystal display, or an OLED (Organic Light-Emitting Diode) touchscreen, etc. The display may also be appropriately referred to as a screen or display unit, used to display information processed in the electronic device 1 and to display a visual user interface.

[0234] The high-speed wire harness low-resistance welding method program based on local microenvironment control stored in the memory 11 of the electronic device 1 is a combination of multiple instructions. When run in the processor 10, it can achieve the following:

[0235] Obtain multiple reference wire harness material sets, wherein the reference wire harness material sets include: multiple reference wire harness materials;

[0236] For each of the multiple reference harness material sets, perform the following operation:

[0237] Vibration and friction tests were conducted on the reference wire harness material set to obtain the friction response index; pressure deformation tests were conducted on the reference wire harness material set to obtain the deformation response index; and heat conduction tests were conducted on the reference wire harness material set to obtain the heat storage index.

[0238] Obtain the welding frequency range, welding pressure range, and welding time range;

[0239] Low-resistance welding evaluation was performed on a reference wire harness material set based on a pre-constructed ultrasonic welder, welding frequency range, welding pressure range, and welding time range to obtain the optimal test parameter set and optimal environmental parameters.

[0240] Confirm the reference wire diameter and the number of reference wire cores in the reference wire harness material set;

[0241] By summarizing the friction response index, deformation response index, heat storage index, optimal environmental parameters, reference wire harness diameter, and reference wire core quantity, a set of reference property parameters is obtained. The set of reference property parameters and the set of optimal test parameters are combined to obtain a training sample set.

[0242] The training sample sets corresponding to the reference wire harness material set are summarized to obtain multiple training sample sets. The pre-built deep learning model is trained based on the multiple training sample sets to obtain the wire harness welding model.

[0243] Obtain the formal welding wire harness set, obtain the current property parameter set based on the formal welding wire harness set, and use the wire harness welding model to perform welding prediction on the current property parameter set to obtain the target welding parameter set;

[0244] Welding is performed on the formal welding wire bundle set based on the target welding parameter set and ultrasonic welder to obtain the target welding wire bundle set.

[0245] Specifically, the processor 10's implementation method for the above instructions can be found in [reference needed]. Figures 1 to 3 The descriptions of the relevant steps in the corresponding embodiments are not repeated here.

[0246] Furthermore, if the modules / units integrated in the electronic device 1 are implemented as software functional units and sold or used as independent products, they can be stored in a computer-readable storage medium. The computer-readable storage medium can be volatile or non-volatile. For example, the computer-readable medium may include: any entity or device capable of carrying the computer program code, a recording medium, a USB flash drive, a portable hard drive, a magnetic disk, an optical disk, a computer memory, or a read-only memory (ROM).

[0247] The present invention also provides a computer-readable storage medium storing a computer program, which, when executed by a processor of an electronic device, can perform the following:

[0248] Obtain multiple reference wire harness material sets, wherein the reference wire harness material sets include: multiple reference wire harness materials;

[0249] For each of the multiple reference harness material sets, perform the following operation:

[0250] Vibration and friction tests were conducted on the reference wire harness material set to obtain the friction response index; pressure deformation tests were conducted on the reference wire harness material set to obtain the deformation response index; and heat conduction tests were conducted on the reference wire harness material set to obtain the heat storage index.

[0251] Obtain the welding frequency range, welding pressure range, and welding time range;

[0252] Low-resistance welding evaluation was performed on a reference wire harness material set based on a pre-constructed ultrasonic welder, welding frequency range, welding pressure range, and welding time range to obtain the optimal test parameter set and optimal environmental parameters.

[0253] Confirm the reference wire diameter and the number of reference wire cores in the reference wire harness material set;

[0254] By summarizing the friction response index, deformation response index, heat storage index, optimal environmental parameters, reference wire harness diameter, and reference wire core quantity, a set of reference property parameters is obtained. The set of reference property parameters and the set of optimal test parameters are combined to obtain a training sample set.

[0255] The training sample sets corresponding to the reference wire harness material set are summarized to obtain multiple training sample sets. The pre-built deep learning model is trained based on the multiple training sample sets to obtain the wire harness welding model.

[0256] Obtain the formal welding wire harness set, obtain the current property parameter set based on the formal welding wire harness set, and use the wire harness welding model to perform welding prediction on the current property parameter set to obtain the target welding parameter set;

[0257] Welding is performed on the formal welding wire bundle set based on the target welding parameter set and ultrasonic welder to obtain the target welding wire bundle set.

[0258] In the embodiments provided by this invention, it should be understood that the disclosed devices, systems, and methods can be implemented in other ways. For example, the system embodiments described above are merely illustrative, and actual implementations may have other classification methods.

[0259] The modules described as separate components may or may not be physically separate. The components shown as modules may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs.

[0260] Furthermore, the functional modules in the various embodiments of the present invention can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or in the form of hardware plus software functional modules.

[0261] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the present invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the present invention.

[0262] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. A high-speed wire harness low-resistance welding method based on local microenvironment control, characterized in that, The method includes: Obtain multiple reference wire harness material sets, wherein the reference wire harness material sets include: multiple reference wire harness materials; For each of the multiple reference harness material sets, perform the following operation: Vibration and friction tests were conducted on the reference wire harness material set to obtain the friction response index; pressure deformation tests were conducted on the reference wire harness material set to obtain the deformation response index; and heat conduction tests were conducted on the reference wire harness material set to obtain the heat storage index. Obtain the welding frequency range, welding pressure range, and welding time range; Low-resistance welding evaluation of a reference wire harness material set was performed based on a pre-constructed ultrasonic welder, welding frequency range, welding pressure range, and welding time range to obtain the optimal test parameter set and optimal environmental parameters. The evaluation included: Multiple test parameter sets were obtained by combining the welding frequency range, welding pressure range, and welding time range. These test parameter sets included: test welding frequency, test welding pressure, and test welding time. Perform the following operation for each of the multiple test parameter groups: The ultrasonic welder was set using the test welding frequency, test welding pressure, and test welding time in the test parameter group to obtain the test welder; The test environment temperature and humidity of the test welder are read using pre-built temperature and humidity sensors, and the test environment parameters are obtained by summarizing the test environment temperature and humidity. The first and second wire harnesses awaiting welding were extracted from the reference wire harness raw material set. The first waiting welding end of the first waiting welding end of the first waiting welding end of the first waiting welding end of the second waiting welding end of the second waiting welding end of the second waiting welding end were identified. The first waiting-to-weld end of the first waiting-to-weld wire harness and the second waiting-to-weld end of the second waiting-to-weld wire harness were ultrasonically welded using a test welder to obtain a test welded wire harness. A low-resistance electrical evaluation was performed on the tested welded wire harness to obtain an electrical score for the wire harness. The electrical scores and test environment parameters of the wire harness were summarized separately to obtain multiple electrical scores and multiple test environment parameters for the wire harness; The optimal electrical score was determined based on multiple electrical scores of the wiring harness. The optimal electrical score is the largest electrical score among the multiple electrical scores of the wiring harness. Based on the best electrical score, the best test parameter group and the best environmental parameter were identified in multiple test parameter groups and multiple test environment parameters, respectively. The best test parameter group and the best environmental parameter are the test parameter group and the test environment parameter corresponding to the best electrical score in multiple test parameter groups and multiple test environment parameters, respectively. Confirm the reference wire diameter and the number of reference wire cores in the reference wire harness material set; By summarizing the friction response index, deformation response index, heat storage index, optimal environmental parameters, reference wire harness diameter, and reference wire core quantity, a set of reference property parameters is obtained. The set of reference property parameters and the set of optimal test parameters are combined to obtain a training sample set. The training sample sets corresponding to the reference wire harness material set are summarized to obtain multiple training sample sets. The pre-built deep learning model is trained based on the multiple training sample sets to obtain the wire harness welding model. Obtain the formal welding wire harness set, obtain the current property parameter set based on the formal welding wire harness set, and use the wire harness welding model to perform welding prediction on the current property parameter set to obtain the target welding parameter set; Welding is performed on the formal welding wire bundle set based on the target welding parameter set and ultrasonic welder to obtain the target welding wire bundle set.

2. The high-speed wire harness low-resistance welding method based on local microenvironment control as described in claim 1, characterized in that, The vibration and friction test performed on the reference wire harness material set to obtain the friction response index includes: The first vibration test wire harness and the second vibration test wire harness were extracted from the reference wire harness raw material collection; Confirm the first vibration welding end of the first vibration test harness, and confirm the second vibration welding end of the second vibration test harness. The vibration testing device was identified, which includes: an indenter clamp, a tensile testing machine, and a vibration testing machine. The tensile testing machine includes: a fixing clamp, a tension rod, and a tension sensor. The vibration testing machine includes: a vibration table. The first vibration welding end of the first vibration test wire harness and the second vibration welding end of the second vibration test wire harness are placed in opposite directions and overlapped in the pressure head clamp. Based on the preset initial pressure and the pressure head clamp, pressure is applied to the first vibration welding end and the second vibration welding end placed in opposite directions to obtain the pressure and vibration test piece. The compression and vibration test specimen is placed on the vibration table of the vibration testing machine to obtain the prepared vibration test specimen; Based on the preset vibration amplitude, preset vibration frequency, preset vibration time, and vibration testing machine, the prepared vibration test piece is vibrated to obtain the completed vibration test piece; The first vibration test harness in the completed vibration test piece is fixed in the fixing fixture of the tensile testing machine, and the second vibration test harness in the completed vibration test piece is fixed on the tension rod of the tensile testing machine to obtain the tensile test piece; Based on the preset tensile gradient timing and the tension rod of the tensile testing machine, a parallel tensile force is applied to the second vibration test bundle in the tensile test piece. The tensile force value of the parallel tensile force applied to the second vibration test bundle in the tensile test piece by the tension rod of the tensile testing machine is monitored in real time by a tensile sensor until the second vibration test bundle in the tensile test piece is completely separated from the first vibration test bundle in the tensile test piece. The tensile force value monitored by the tensile sensor when the second vibration test bundle in the tensile test piece is completely separated from the first vibration test bundle in the tensile test piece is taken as the ultimate friction tensile force. The second vibration test bundle in the tensile test piece that is completely separated from the first vibration test bundle is recorded as the second separated bundle, and the first vibration test bundle in the tensile test piece that is completely separated from the second vibration test bundle is recorded as the first separated bundle. The first average port temperature of the first vibrating welding end in the first separation wire harness and the second average port temperature of the second vibrating welding end in the second separation wire harness were read using a pre-built infrared thermometer. The friction response index is calculated based on the initial pressure, vibration amplitude, vibration frequency, vibration time, ultimate friction tension, first average port temperature, and second average port temperature.

3. The high-speed wire harness low-resistance welding method based on local microenvironment control as described in claim 2, characterized in that, The formula for calculating the friction response index is as follows: in, The frictional response index, This is the ultimate frictional tension. As the initial pressure, and These are the first average port temperature and the second average port temperature, respectively. It is a natural constant. The amplitude of vibration. The vibration frequency, The vibration time.

4. The high-speed wire harness low-resistance welding method based on local microenvironment control as described in claim 3, characterized in that, The process of performing pressure deformation testing on the reference wire harness material set to obtain the deformation response index includes: Deformation test wire harnesses were extracted from the reference wire harness raw material collection, and the deformation welding ends of the deformation test wire harnesses were confirmed. The pressure testing device was identified, which includes: a pressure testing platform, a pressure head, and a displacement sensor; The deformation welding end of the deformation test harness is fixed on the pressure test bench to obtain a fixed deformation harness; The fixed deformation wire harness is pressurized based on the preset first pressure and the pressure head, and the first pressure distance when the pressure head presses the fixed deformation wire harness is read by the displacement sensor. The second pressure distance is obtained based on the preset second pressure, pressure head, displacement sensor and fixed deformation wire harness; The deformation response index is calculated based on the first applied pressure, the second applied pressure, the first applied pressure distance, and the second applied pressure distance.

5. The high-speed wire harness low-resistance welding method based on local microenvironment control as described in claim 4, characterized in that, The heat conduction test on the reference wire harness material set to obtain the heat storage index includes: The heat test wire harness was extracted from the reference wire harness raw material collection, and the heat welding end of the heat test wire harness was identified. The heat welding end includes: the starting end and the ending end. Obtain a miniature heating element and fix it to the starting end of the heat test harness to obtain the prepared heat harness; The heat-generating wire harness is heated based on a preset heating temperature, a preset heating time, and a miniature heating element to obtain a heated wire harness. The initial average port temperature at the upper end of the heating element harness was read using an infrared thermometer. The heating wire bundle is placed into a pre-constructed constant test chamber to obtain the waiting heat wire bundle. The time for obtaining the waiting heat wire bundle is taken as the starting point and the time is recorded in real time to obtain the heat dissipation time. The heat dissipation time continues until the heat dissipation time reaches the preset heat dissipation threshold. Then the waiting heat wire bundle is taken out from the constant test chamber to obtain the heat dissipation wire bundle. Use an infrared thermometer to read the average end port temperature of the heat dissipation harness. The heat storage index is calculated based on the initial average port temperature, heating temperature, heating time, final average port temperature, and heat dissipation threshold.

6. The high-speed wire harness low-resistance welding method based on local microenvironment control as described in claim 5, characterized in that, The test parameters for the welding frequency range, welding pressure range, and welding time range are combined to obtain multiple test parameter sets, including: Based on the preset frequency sampling interval, the welding frequency range is sampled at equal intervals to obtain a test welding frequencies; b test welding pressures are obtained based on the preset pressure sampling interval and welding pressure range, and c test welding times are obtained based on the preset time sampling interval and welding time range. By combining a test welding frequency, b test welding pressure, and c test welding time, multiple test parameter sets are obtained. The number of test parameter sets in the multiple test parameter sets is P, and P = a × b × c.

7. The high-speed wire harness low-resistance welding method based on local microenvironment control as described in claim 6, characterized in that, The low-resistance electrical evaluation of the tested welded wire harness, resulting in a wire harness electrical score, includes: Confirm the welding head, welding start point, and welding end point of the test welding harness; The welding image is obtained by taking pictures of the weld head using a pre-built industrial camera; The welding image is converted to grayscale to obtain a grayscale welding image, wherein the grayscale welding image includes: multiple grayscale pixels, wherein the grayscale pixels include: pixel grayscale values; For each grayscale pixel in a grayscale welding image, perform the following operation: Compare the pixel grayscale value of grayscale pixels with the preset bad pixel grayscale threshold; If the pixel grayscale value is greater than the bad pixel grayscale threshold, then the grayscale pixel corresponding to the pixel grayscale value is recorded as a bad pixel. Summarize the bad pixel counts to obtain multiple bad pixel counts; Confirm the number of bad pixels and the original number of multiple bad pixels and multiple grayscale pixels respectively; The resistance between the welding start and welding end points of the test welding harness is read using a pre-built ohmmeter. The initial heating temperature of the welding start point on the test welding wire harness was read using an infrared thermometer. The test welding wire harness is tested based on the preset energizing current and preset energizing time to obtain the energized test wire harness. Use an infrared thermometer to read the end-of-heat temperature of the soldering start point on the energized test harness; The electrical score of the wire harness is calculated based on the energizing current, energizing time, test resistance, initial heating temperature, final heating temperature, number of defective points, and original number.

8. The high-speed wire harness low-resistance welding method based on local microenvironment control as described in claim 7, characterized in that, The formula for calculating the electrical rating of the wire harness is as follows: in, Evaluate the electrical performance of the wire harness. and These are the end heating temperature and the initial heating temperature, respectively. For the current flowing through, For the power-on time, and These represent the number of defective pixels and the original number, respectively. To test the resistance value, It is the natural logarithm.

9. A high-speed wire harness low-resistance welding system based on local microenvironment control, characterized in that, The system includes: The wire harness feature extraction module is used to acquire multiple reference wire harness material sets, wherein the reference wire harness material sets include multiple reference wire harness materials. For each reference wire harness material set, the following operations are performed: vibration friction test is performed on the reference wire harness material set to obtain the friction response index; pressure deformation test is performed on the reference wire harness material set to obtain the deformation response index; and heat conduction test is performed on the reference wire harness material set to obtain the heat storage index. A wire harness welding test module is used to acquire welding frequency range, welding pressure range, and welding time range. Based on a pre-constructed ultrasonic welder, welding frequency range, welding pressure range, and welding time range, it performs low-resistance welding evaluation on a reference wire harness material set to obtain the optimal test parameter set and optimal environmental parameters. The step of performing low-resistance welding evaluation on the reference wire harness material set based on the pre-constructed ultrasonic welder, welding frequency range, welding pressure range, and welding time range to obtain the optimal test parameter set and optimal environmental parameters includes: Multiple test parameter sets were obtained by combining the welding frequency range, welding pressure range, and welding time range. These test parameter sets included: test welding frequency, test welding pressure, and test welding time. Perform the following operation for each of the multiple test parameter groups: The ultrasonic welder was set using the test welding frequency, test welding pressure, and test welding time in the test parameter group to obtain the test welder; The test environment temperature and humidity of the test welder are read using pre-built temperature and humidity sensors, and the test environment parameters are obtained by summarizing the test environment temperature and humidity. The first and second wire harnesses awaiting welding were extracted from the reference wire harness raw material set. The first waiting welding end of the first waiting welding end of the first waiting welding end of the first waiting welding end of the second waiting welding end of the second waiting welding end of the second waiting welding end were identified. The first waiting-to-weld end of the first waiting-to-weld wire harness and the second waiting-to-weld end of the second waiting-to-weld wire harness were ultrasonically welded using a test welder to obtain a test welded wire harness. A low-resistance electrical evaluation was performed on the tested welded wire harness to obtain an electrical score for the wire harness. The electrical scores and test environment parameters of the wire harness were summarized separately to obtain multiple electrical scores and multiple test environment parameters for the wire harness; The optimal electrical score was determined based on multiple electrical scores of the wiring harness. The optimal electrical score is the largest electrical score among the multiple electrical scores of the wiring harness. Based on the best electrical score, the best test parameter group and the best environmental parameter were identified in multiple test parameter groups and multiple test environment parameters, respectively. The best test parameter group and the best environmental parameter are the test parameter group and the test environment parameter corresponding to the best electrical score in multiple test parameter groups and multiple test environment parameters, respectively. The welding model training module is used to confirm the reference wire harness diameter and the number of reference wire cores in the reference wire harness material set, summarize the friction response index, deformation response index, heat storage index, optimal environmental parameters, reference wire harness diameter and the number of reference wire cores to obtain a reference property parameter set, combine the reference property parameter set and the optimal test parameter set to obtain a training sample set, summarize the training sample sets corresponding to the reference wire harness material set to obtain multiple training sample sets, and train the pre-built deep learning model based on multiple training sample sets to obtain the wire harness welding model; The formal welding control module is used to acquire the formal welding wire harness set, acquire the current property parameter set based on the formal welding wire harness set, use the wire harness welding model to perform welding prediction on the current property parameter set to obtain the target welding parameter set, and weld the formal welding wire harness set based on the target welding parameter set and the ultrasonic welder to obtain the target welding wire harness set.

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