High-speed wire harness self-adaptive shaping method and system based on stress analysis

Abstract

The invention relates to the technical field of stress analysis wire harness shaping, in particular to a high-speed wire harness self-adaptive shaping method and system based on stress analysis, and the method comprises the steps: obtaining the wire harness tensile strength of a to-be-shaped high-speed wire harness, carrying out the preliminary shaping path construction operation of the to-be-shaped high-speed wire harness, and obtaining a preliminary shaping path; sequentially extracting shaping line segments from the preliminary shaping path, if the extracted shaping line segments are linear path segments, determining qualified linear wire harness segments, and if the extracted shaping line segments are curve path segments, performing curve segment shaping on the curve wire harness segments to obtain curve wire harness segments; and the bending outer side tensile stress and the bending inner side tensile stress of the curve wire harness sections subjected to curve section shaping are monitored in real time, self-adaptive shaping operation is performed on the curve wire harness sections to obtain qualified curve wire harness sections, qualified straight wire harness sections and the qualified curve wire harness sections are gathered, and a qualified straight wire harness section set and a qualified curve wire harness section set are obtained. According to the invention, the automation level and stress controllability of high-speed wire harness shaping can be improved.

Description

Technical Field

[0001] This invention relates to the field of stress analysis and wire harness shaping technology, and in particular to a high-speed wire harness adaptive shaping method and system based on stress analysis. Background Technology

[0002] Stress analysis is the process of studying the internal stress state of a material or structure under stress. High-speed wiring harnesses refer to wiring harnesses used to transmit high-speed signals, commonly used in electronic devices, communication systems, automotive electronics, and other fields. Adaptive shaping is a technique that automatically adjusts shaping parameters based on system input / output data or feedback signals to achieve optimized control effects.

[0003] Traditional high-speed wire harness shaping methods largely rely on manual operation or fixed mechanical structures. Manual shaping is not only inefficient but also struggles to guarantee shaping accuracy and consistency. Furthermore, existing technologies generally neglect the crucial role of stress analysis, failing to delve into the stress distribution patterns of wire harnesses under different operating conditions and unable to accurately predict and control deformation trends. Therefore, improving the automation level and stress controllability of high-speed wire harness shaping is an urgent technical challenge. Summary of the Invention

[0004] This invention provides a high-speed wire harness adaptive shaping method based on stress analysis and a computer-readable storage medium. Its main purpose is to improve the automation level and stress controllability of high-speed wire harness shaping.

[0005] To achieve the above objectives, this invention provides a high-speed harness adaptive shaping method based on stress analysis, comprising: The high-speed wire harness and distributed stress sensor that need to be shaped are identified. The stress analysis command is received, and the tensile strength of the high-speed wire harness that needs to be shaped is obtained according to the stress analysis command. Based on the distributed stress sensor, a preliminary shaping path is constructed for the high-speed wire harness that needs to be shaped, and a preliminary shaping path is obtained. The preliminary shaping path includes multiple shaping line segments, which are either straight line path segments or curved line path segments. The curved line path segments include circular arc path segments and spline curve segments. The shaping line segments are extracted sequentially from the initial shaping path. If the extracted shaping line segment is a straight path segment, the extracted shaping line segment is taken as a straight line bundle segment. The qualified straight line bundle segment is confirmed based on the straight line bundle segment and the tensile strength of the bundle. If the extracted shaping segment is a curved path segment, then the extracted shaping segment is taken as a curved line bundle segment. According to the preset target bending angle, the pre-constructed robotic arm is used to shape the curved line bundle segment, and the tensile stress on the outer side and the tensile stress on the inner side of the curved line bundle segment being shaped are monitored in real time. Based on the tensile stress on the outer side and the tensile stress on the inner side of the bend, an adaptive shaping operation is performed on the curved wire harness segment to obtain a qualified curved wire harness segment. By summarizing qualified straight wire harness segments and qualified curved wire harness segments, a set of qualified straight wire harness segments and a set of qualified curved wire harness segments are obtained. Based on the set of qualified straight wire harness segments and the set of qualified curved wire harness segments, high-speed wire harness adaptive shaping based on stress analysis is completed.

[0006] Optionally, the preliminary shaping path construction operation based on distributed stress sensors for the high-speed harness requiring shaping, to obtain the preliminary shaping path, includes: A sensor array is constructed based on a distributed stress sensor and a preset installation interval. The extracted high-speed wire harness that needs to be shaped is placed in the sensor array to obtain the high-speed wire harness to be analyzed. Key features of the high-speed harness to be analyzed are identified to obtain a sequence of key feature coordinate points of the harness, which includes multiple key feature coordinate points of the harness. A preliminary shaping path is generated based on the sequence of key feature coordinate points of the harness.

[0007] Optionally, generating the preliminary shaping path based on the sequence of key feature coordinate points of the wire harness includes: Obtain the starting point coordinates and ending point coordinates of the high-speed harness to be analyzed, extract the key feature coordinate points of the harness sequentially from the key feature coordinate point sequence, and use the extracted key feature coordinate points of the harness as the current key feature coordinate points. The initial straight line path segment is obtained based on the starting point coordinates of the harness and the current key feature coordinates. The adjacent key feature coordinates are identified from the key feature coordinates sequence of the harness based on the current key feature coordinates. The adjacent key feature coordinates are adjacent and lag behind the current key feature coordinates. Obtain straight path segments, circular path parameters, or spline curve segments based on the current key feature coordinate points and adjacent key feature coordinate points; Take the adjacent key feature coordinate points as the current key feature coordinate points, and return to the step of extracting key feature coordinate points of the wire harness sequentially from the sequence of key feature coordinate points of the wire harness, until the current key feature coordinate point is equal to the end point coordinates of the wire harness. The parameters of straight path segments, circular path segments, and spline curve segments are summarized separately to obtain the set of straight path segments, the set of circular path parameters, and the set of spline curve segments. The set of circular path parameters includes the set of circular path segments and the set of radii of multiple path coordinate points. According to the order of extracting the key feature coordinate points of the wire harness, the initial straight path segment, the set of straight path segments, the set of circular arc path segments, and the set of spline curve segments are spliced ​​end to end to obtain the spliced ​​path, and the total length of the spliced ​​path is calculated. A preliminary reshaping path is generated based on the total length of the spliced ​​path and the radius set of multiple path coordinate points.

[0008] Optionally, obtaining the straight path segment, circular path parameter, or spline curve segment based on the current key feature coordinate point and adjacent key feature coordinate points includes: Identify the feature coordinate point type of the current key feature coordinate point, where the feature coordinate point type is either an inflection point type or a joint type; If the feature coordinate point type is an inflection point type, then calculate the entry point direction vector based on the starting point coordinates of the line bundle and the current key feature coordinate point, calculate the exit point direction vector based on the current key feature coordinate point and adjacent key feature coordinate points, and calculate the vector angle based on the entry point direction vector and the exit point direction vector. If the angle between the vectors is greater than the preset direction change threshold, then a curved segment is generated based on the current key feature coordinates and adjacent key feature coordinates to obtain the arc path parameters. The arc path parameters include: the arc path segment and the set of radii of the path coordinates. If the angle between the vectors is not greater than the direction change threshold, then a straight path segment is generated based on the current key feature coordinates and adjacent key feature coordinates. If the feature coordinate point type is a joint type, then the flexible transition interval segment is determined based on the current key feature coordinate point. Based on the flexible transition interval segment, the current key feature coordinate point, the starting point coordinate of the wire harness, and the adjacent key feature coordinate points are interpolated to obtain the spline curve segment.

[0009] Optionally, the step of generating curved segments based on the current key feature coordinates and adjacent key feature coordinates to obtain arc path parameters includes: Calculate the angle bisector vector and the plane normal vector based on the in-point direction vector and the out-point direction vector. Perform a cross product operation on the angle bisector vector and the plane normal vector to obtain the perpendicular direction vector. Calculate the coordinates of the arc's center based on the vertical direction vector and the current key feature coordinates. The coordinates of the starting point of the arc are calculated based on the coordinates of the arc center, the preset initial bending radius, and the entry point direction vector. Calculate the coordinates of the arc's endpoint based on the arc's center coordinates, initial bending radius, and exit point direction vector. Based on the preset arc discretization precision, arc start coordinates, arc end coordinates, and arc center coordinates, a set of arc path coordinate points is generated. Based on the set of arc path coordinate points, adjacent key feature coordinate points, and arc center coordinates, the set of path coordinate point radii and the arc path segment are determined. The parameters of the circular path are determined based on the set of radius points of the path coordinates and the circular path segment.

[0010] Optionally, the formula for calculating the coordinates of the center of the arc is as follows: in, Represents the coordinates of the center of the arc. Indicates the coordinates of the current key feature point. Indicates the initial bending radius. Indicates the bending angle of the target. Represents the tangent function. This represents the vertical direction vector.

[0011] Optionally, the formula for calculating the coordinates of the starting point of the arc is as follows: in, Indicates the coordinates of the starting point of the arc. This represents the direction vector of the entry point.

[0012] Optionally, the step of generating a preliminary shaped path based on the total length of the spliced ​​path and the radius set of multiple path coordinate points includes: The difference between the total length of the splicing path and the preset total installation length of the wire harness is calculated to obtain the path length difference. If the path length difference is greater than the preset zero value, the longest straight path segment is identified from the set of straight path segments. The longest straight path segment is lengthened to obtain the adjusted straight path segment. The updated total path length is calculated based on the adjusted straight path segment. The updated total path length is used as the splicing path total length. The process returns to the step of calculating the difference between the splicing path total length and the preset wire harness target installation total length until the path length difference is equal to zero. If the path length difference is less than zero, the optimal arc length is determined from the arc path segment set based on the radius set of multiple path coordinate points. The radius of the optimal arc length is increased to obtain the adjusted arc length. The total length of the adjusted path is calculated based on the adjusted arc length. The total length of the adjusted path is used as the total length of the splicing path. The process returns to the step of calculating the difference between the total length of the splicing path and the preset total length of the wire harness target installation until the path length difference is equal to zero. If the path length difference is zero, the spliced ​​path will be used as the initial shaping path.

[0013] Optionally, the step of identifying qualified straight wire harness segments based on the straight wire harness segments and the tensile strength of the wire harness includes: An axial tensile force is applied to a straight wire harness segment using a robotic arm, and the average stress value of the straight wire harness segment to which the axial tensile force is applied is monitored in real time. Obtain the stress value range, and determine the upper and lower limits of the stress value based on the stress value range; If the average stress value is greater than the upper limit of the stress value, the tension of the straight wire harness segment is reduced by using the preset adjustment step size and wire harness tensile strength to obtain the adjusted straight wire harness segment. The adjusted straight wire harness segment is then used as the straight wire harness segment, and the process returns to the step of applying axial tension to the straight wire harness segment using the robotic arm until the average stress value is within the stress value range. If the average stress value is less than the lower limit of the stress value, the tension of the straight wire harness segment is increased by adjusting the step size to obtain an updated straight wire harness segment. The updated straight wire harness segment is used as the straight wire harness segment, and the process returns to the step of applying axial tension to the straight wire harness segment using the robotic arm until the average stress value is within the stress value range. If the average stress value is within the stress value range, then the straight wire harness segment is considered a qualified straight wire harness segment.

[0014] To achieve the above objectives, the present invention also provides a high-speed harness adaptive shaping system based on stress analysis, comprising: The preliminary shaping path construction module is used to identify the high-speed wire harness to be shaped and the distributed stress sensor, receive stress analysis instructions, obtain the tensile strength of the high-speed wire harness to be shaped according to the stress analysis instructions, and perform preliminary shaping path construction operation on the high-speed wire harness to be shaped based on the distributed stress sensor to obtain the preliminary shaping path. The preliminary shaping path includes multiple shaping line segments, which are straight line path segments or curved line path segments. The curved line path segments include circular arc path segments and spline curve segments. The straight line harness segment processing module is used to extract shaping line segments sequentially from the initial shaping path. If the extracted shaping line segment is a straight path segment, the extracted shaping line segment is used as a straight line harness segment. The qualified straight line harness segment is confirmed based on the straight line harness segment and the tensile strength of the harness. The curve harness segment processing module is used to treat the extracted shaping segment as a curve path segment if the extracted shaping segment is a curve path segment. Based on the preset target bending angle, the module uses a pre-constructed robotic arm to shape the curve harness segment and monitors the tensile stress on the outer and inner sides of the curve harness segment in real time. Based on the tensile stress on the outer and inner sides of the curve harness segment, the module performs adaptive shaping operation on the curve harness segment to obtain a qualified curve harness segment. The harness shaping module is used to summarize qualified straight harness segments and qualified curved harness segments to obtain a set of qualified straight harness segments and a set of qualified curved harness segments. Based on the set of qualified straight harness segments and the set of qualified curved harness segments, it completes high-speed harness adaptive shaping based on stress analysis.

[0015] To address the above problems, the present invention also provides an electronic device, the electronic device comprising: Memory, storing at least one instruction; The processor executes the instructions stored in the memory to implement the stress analysis-based high-speed harness adaptive shaping method described above.

[0016] 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 stress analysis-based high-speed harness adaptive shaping method described above.

[0017] To address the problems described in the background art, this invention identifies the high-speed wire harness requiring shaping and uses a distributed stress sensor. It receives stress analysis commands and, based on these commands, obtains the tensile strength of the high-speed wire harness. Then, using the distributed stress sensor, it performs a preliminary shaping path construction operation on the high-speed wire harness, resulting in a preliminary shaping path. This preliminary shaping path includes multiple shaping segments, which can be straight or curved. The curved path segments include circular arc segments and spline curve segments. This invention leverages the precise sensing capabilities of the distributed stress sensor to generate a preliminary shaping path containing straight, circular, and spline curve segments. The path not only conforms to the key morphological characteristics of the harness but also avoids the risk of stress concentration in advance, providing scientific path guidance for subsequent segmented shaping. Shaping segments are extracted sequentially from the initial shaping path. If the extracted shaping segment is a straight path segment, it is considered a straight harness segment. Based on the straight harness segment and its tensile strength, qualified straight harness segments are confirmed. This invention conducts directional shaping and stress verification targeting the characteristics of straight segments to ensure that the stress state of the straight harness segment is within a safe range. This avoids both excessive tension causing tensile damage to the harness and insufficient tension causing harness slack, ensuring the structural stability and transmission reliability of the straight segment. If the extracted shaping segment is a curved path segment, then the extracted shaping segment is taken as a curved wire harness segment. Based on a preset target bending angle, a pre-constructed robotic arm is used to shape the curved wire harness segment, and the tensile stress on the outer and inner sides of the curved wire harness segment being shaped is monitored in real time. This invention achieves precise shaping of the curved segment through a robotic arm, while simultaneously monitoring the tensile stress on the outer and inner sides of the bend in real time. This allows for a direct understanding of the stress distribution at different parts of the curved segment. Based on the tensile stress on the outer and inner sides of the bend, an adaptive shaping operation is performed on the curved wire harness segment to obtain a qualified curved wire harness segment. This invention is based on real-time monitoring... By specifically adjusting stress data, the bending shape of curve segments can be dynamically optimized to ensure that the stress on both the inner and outer sides of the bend does not exceed the material's tolerance threshold. This avoids problems such as cracking and deformation caused by uneven stress distribution in the curve segments. Qualified straight and curved wire harness segments are collected to obtain sets of qualified straight and curved wire harness segments. Based on these sets, adaptive shaping of high-speed wire harnesses based on stress analysis is completed. This invention integrates all qualified segments to form a complete shaping scheme, achieving dual compliance in both the overall shape and stress state of the wire harness. This satisfies the spatial installation requirements of high-speed wire harnesses while improving their long-term stability. Therefore, this invention can improve the automation level and stress controllability of high-speed wire harness shaping. Attached Figure Description

[0018] Figure 1 This is a flowchart illustrating a high-speed harness adaptive shaping method based on stress analysis provided in an embodiment of the present invention. Figure 2A functional block diagram of a high-speed wire harness adaptive shaping system based on stress analysis provided in an embodiment of the present invention; Figure 3 This is a schematic diagram of an electronic device that implements the stress analysis-based high-speed harness adaptive shaping method according to an embodiment of the present invention.

[0019] Explanation of reference numerals in the attached figures: 10. Electronic device; 11. Processor; 12. Memory; 13. Bus.

[0020] 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

[0021] It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0022] This application provides a high-speed wire harness adaptive shaping method based on stress analysis. The executing entity of the stress analysis-based high-speed wire harness adaptive shaping method 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 stress analysis-based high-speed wire harness adaptive shaping method 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.

[0023] Reference Figure 1 The diagram shown is a flowchart illustrating a high-speed wire harness adaptive shaping method based on stress analysis according to an embodiment of the present invention. In this embodiment, the high-speed wire harness adaptive shaping method based on stress analysis includes: S1. Identify the high-speed wire harness and distributed stress sensor that need to be shaped, receive the stress analysis command, and obtain the tensile strength of the high-speed wire harness that needs to be shaped according to the stress analysis command.

[0024] It should be explained that high-speed wire harnesses requiring shaping are high-speed transmission wire harnesses that need to undergo shaping processes such as morphological adjustment and structural optimization. These high-speed transmission wire harnesses are mainly used in high-frequency, high-speed signal or power transmission scenarios (such as aerospace equipment wiring, high-voltage wire harnesses in new energy vehicles, and internal connection wires in precision instruments). Due to installation space limitations, transmission performance attenuation, stress concentration, and other issues, the routing and bending radius of high-speed transmission wire harnesses need to be shaped to meet usage requirements. A distributed stress sensor is a sensor capable of continuously and multi-point monitoring the stress distribution of the measured object. The tensile strength of a wire harness reflects the maximum stress value that prevents the wire harness from breaking under tensile force. The stress analysis command is issued by the operator to initiate stress analysis on the high-speed wire harness requiring shaping.

[0025] S2. Based on the distributed stress sensor, a preliminary shaping path is constructed for the high-speed wire harness that needs to be shaped, and a preliminary shaping path is obtained. The preliminary shaping path includes multiple shaping segments, which are either straight path segments or curved path segments. The curved path segments include circular arc path segments and spline curve segments.

[0026] In detail, the preliminary shaping path construction operation based on distributed stress sensors for the high-speed wire harness requiring shaping, to obtain the preliminary shaping path, includes: A sensor array is constructed based on a distributed stress sensor and a preset installation interval. The extracted high-speed wire harness that needs to be shaped is placed in the sensor array to obtain the high-speed wire harness to be analyzed. Key features of the high-speed harness to be analyzed are identified to obtain a sequence of key feature coordinate points of the harness, which includes multiple key feature coordinate points of the harness. A preliminary shaping path is generated based on the sequence of key feature coordinate points of the harness.

[0027] It should be explained that the installation interval is the distance between two adjacent sensors in a distributed stress sensor array. The sensor array is an array formed by arranging multiple distributed stress sensors according to the installation interval. The high-speed wire harness to be analyzed is a high-speed wire harness that needs shaping and is placed in the sensor array, awaiting key feature identification and stress analysis. The steps for key feature identification of the high-speed wire harness to be analyzed are as follows: taking a picture of the high-speed wire harness to obtain an image of the high-speed wire harness; extracting multiple feature points from the image of the high-speed wire harness; and matching each of the multiple feature points with a pre-built wire harness feature point database. The extraction of multiple feature points from the image of the high-speed wire harness is done using SIFT. The matching of each of the multiple feature points with the pre-built wire harness feature point database uses the k-nearest neighbor search algorithm, and the Euclidean distance between the multiple feature points is calculated to measure the similarity. Scale-Invariant Feature Transform (SIFT) and the k-nearest neighbor search algorithm are both existing technologies and will not be elaborated upon here. The key feature coordinates of the wire harness are the spatial coordinates of the feature points on the high-speed wire harness to be analyzed, which play a guiding role in the design of the shaping path. The spatial coordinates are established in a spatial rectangular coordinate system with the geometric center of the high-speed wire harness to be analyzed as the origin.

[0028] It should be noted that, in order to balance monitoring accuracy and data processing load, and to avoid missing stress concentration points due to excessively large installation intervals and increasing data processing pressure due to excessively small intervals, this invention sets an installation interval. At the same time, in order to ensure that the high-speed harness to be shaped is within the accurate sensing range of the sensors and to provide a reliable data acquisition carrier for subsequent feature identification, the high-speed harness to be shaped is placed in the sensor array. Since the key feature coordinate points of the harness are the core data reflecting the geometric shape and stress state of the harness, only by accurately extracting the spatial coordinates of these points can a quantitative basis be provided for the initial shaping path generation. Therefore, key feature identification is performed on the high-speed harness to be analyzed to obtain the sequence of key feature coordinate points of the harness. Finally, the discrete feature points are transformed into a continuous path scheme to ensure that the shaped high-speed harness meets the spatial installation requirements, avoids the risk of stress concentration, and improves transmission stability.

[0029] Specifically, the step of generating a preliminary shaping path based on the sequence of key feature coordinate points of the wire harness includes: Obtain the starting point coordinates and ending point coordinates of the high-speed harness to be analyzed, extract the key feature coordinate points of the harness sequentially from the key feature coordinate point sequence, and use the extracted key feature coordinate points of the harness as the current key feature coordinate points. The initial straight line path segment is obtained based on the starting point coordinates of the harness and the current key feature coordinates. The adjacent key feature coordinates are identified from the key feature coordinates sequence of the harness based on the current key feature coordinates. The adjacent key feature coordinates are adjacent and lag behind the current key feature coordinates. Obtain straight path segments, circular path parameters, or spline curve segments based on the current key feature coordinate points and adjacent key feature coordinate points; Take the adjacent key feature coordinate points as the current key feature coordinate points, and return to the step of extracting key feature coordinate points of the wire harness sequentially from the sequence of key feature coordinate points of the wire harness, until the current key feature coordinate point is equal to the end point coordinates of the wire harness. The parameters of straight path segments, circular path segments, and spline curve segments are summarized separately to obtain the set of straight path segments, the set of circular path parameters, and the set of spline curve segments. The set of circular path parameters includes the set of circular path segments and the set of radii of multiple path coordinate points. According to the order of extracting the key feature coordinate points of the wire harness, the initial straight path segment, the set of straight path segments, the set of circular arc path segments, and the set of spline curve segments are spliced ​​end to end to obtain the spliced ​​path, and the total length of the spliced ​​path is calculated. A preliminary reshaping path is generated based on the total length of the spliced ​​path and the radius set of multiple path coordinate points.

[0030] It should be explained that the harness start-point coordinates are the three-dimensional spatial coordinates of the starting end of the high-speed harness to be analyzed. The harness end-point coordinates are the three-dimensional spatial coordinates of the ending end of the high-speed harness to be analyzed. The current key feature coordinate points are the key feature coordinate points extracted from the harness key feature coordinate point sequence during the path generation process. The initial straight path segment is the path segment formed by directly connecting the harness start-point coordinates and the first current key feature coordinate point. The straight path segment set, the circular arc path segment set, and the spline curve segment set are sets composed of straight path segments, circular arc path segments, and spline curve segments, respectively. Head-to-tail splicing is the operation of sequentially connecting the path units in the initial straight path segment, straight path segment set, circular arc path segment set, and spline curve segment set according to the extraction order of the harness key feature coordinate points, with the end point of the previous segment serving as the starting point of the next segment. The spliced ​​path is a continuous harness path formed by integrating the initial straight path segment, straight path segment set, circular arc path segment set, and spline curve segment set through head-to-tail splicing. The steps for calculating the total length of the splicing path are as follows: obtain the length of the initial straight path segment, the length of each straight path segment in the straight path segment set, the length of each arc path segment in the arc path segment set, and the length of each spline curve segment in the spline curve segment set. The total length of the splicing path is obtained by adding these lengths together.

[0031] For example, the starting coordinates of the high-speed harness to be analyzed are: and the coordinates of the endpoint are The points extracted from the key feature coordinate point sequence are as follows: (Inflection point type) (Connector type) (Inflection point type), the calculated set of path segments is: the initial straight path segment is → (A straight line of length 300mm), the set of straight line path segments includes → (A straight line of length 300mm), the set of arc path segments includes → The spline curve segment set contains → (A cubic spline curve generated based on the joint's flexible transition requirements, adapted to the stress buffer at the joint). The specific operation of the first and last splicing is performed according to the order of key feature point extraction: the first step is to extract the endpoint of the initial straight path segment. Starting point of the circular path segment Overlap, achieve → and → The seamless connection, the second step is to connect the endpoint of the arc path segment The starting point of the spline curve segment Overlap, complete → arrive → The transition, the third step is to end the spline curve segment The starting point of the straight path segment Overlap, achieve → arrive → The connections ultimately form a continuous splicing path. → → → → The starting point of each path segment is the ending point of the previous path segment.

[0032] It should be explained that in the above steps of the present invention, by fitting the continuous path of discrete feature points, the path is ensured to fit the key morphological features of the high-speed wire harness to be analyzed, thereby flexibly adapting to different shaping requirements, ensuring the continuity and accuracy of the path, and at the same time, by constraining the path length and the radius of curvature, the risk of stress concentration in subsequent shaping operations is avoided, and the feasibility of the shaping scheme is improved.

[0033] Specifically, obtaining straight path segments, circular path parameters, or spline curve segments based on the current key feature coordinate points and adjacent key feature coordinate points includes: Identify the feature coordinate point type of the current key feature coordinate point, where the feature coordinate point type is either an inflection point type or a joint type; If the feature coordinate point type is an inflection point type, then calculate the entry point direction vector based on the starting point coordinates of the line bundle and the current key feature coordinate point, calculate the exit point direction vector based on the current key feature coordinate point and adjacent key feature coordinate points, and calculate the vector angle based on the entry point direction vector and the exit point direction vector. If the angle between the vectors is greater than the preset direction change threshold, then a curved segment is generated based on the current key feature coordinates and adjacent key feature coordinates to obtain the arc path parameters. The arc path parameters include: the arc path segment and the set of radii of the path coordinates. If the angle between the vectors is not greater than the direction change threshold, then a straight path segment is generated based on the current key feature coordinates and adjacent key feature coordinates. If the feature coordinate point type is a joint type, then the flexible transition interval segment is determined based on the current key feature coordinate point. Based on the flexible transition interval segment, the current key feature coordinate point, the starting point coordinate of the wire harness, and the adjacent key feature coordinate points are interpolated to obtain the spline curve segment.

[0034] It should be explained that the inflection point type represents the point type where the wire harness bends in its direction among the key feature coordinate points. The connector type represents the point type where the wire harness connects to other components or branches. If the feature coordinate point type is an inflection point type, it means that the key feature coordinate point of the wire harness is a bending node in the wire harness geometry, and there is a significant difference in the extension direction of the wire harness on both sides. A corresponding path segment needs to be designed based on the degree of direction change. The entry point direction vector is the vector obtained by subtracting the current key feature coordinate point from the wire harness starting point coordinates. The exit point direction vector is the vector obtained by subtracting the adjacent key feature coordinate point from the current key feature coordinate point. The vector angle is the angle between the entry point direction vector and the exit point direction vector, used to quantify the magnitude of the direction change of the wire harness at the inflection point. It should be noted that the vector angle in this invention is calculated using the vector dot product formula. If the vector angle is greater than the direction change threshold, it indicates that the bending degree of the high-speed wire harness to be analyzed at the inflection point is large. Directly using a straight path will lead to stress concentration, and it is necessary to generate an arc path segment and the corresponding set of path coordinate point radii to achieve a smooth transition.

[0035] Understandably, the direction change threshold is a pre-set value. For example, the direction change threshold is 5 degrees. If the vector angle is not greater than the direction change threshold, it indicates that the direction change of the high-speed harness to be analyzed at the inflection point is small, and a straight path can meet the morphological and stress requirements. The straight path segment is a path segment formed by connecting the current key feature coordinate point with adjacent key feature coordinate points. If the feature coordinate point type is a joint type, it means that the point is the connection or branch position of the high-speed harness to be analyzed, and a flexible transition path needs to be designed to adapt to the installation and stress buffering requirements at the joint. The flexible transition interval segment is determined based on the current key feature coordinate point. This is done by combining the process requirements of the joint type (such as the connection length and flexible deformation range of the joint) and the spatial coordinates of the point to define the interval range that needs to be interpolated by spline curves, providing a boundary basis for the subsequent generation of spline curve segments.

[0036] In detail, the step of generating curved segments based on the current key feature coordinates and adjacent key feature coordinates to obtain arc path parameters includes: Calculate the angle bisector vector and the plane normal vector based on the in-point direction vector and the out-point direction vector. Perform a cross product operation on the angle bisector vector and the plane normal vector to obtain the perpendicular direction vector. Calculate the coordinates of the arc's center based on the vertical direction vector and the current key feature coordinates. The coordinates of the starting point of the arc are calculated based on the coordinates of the arc center, the preset initial bending radius, and the entry point direction vector. Calculate the coordinates of the arc's endpoint based on the arc's center coordinates, initial bending radius, and exit point direction vector. Based on the preset arc discretization precision, arc start coordinates, arc end coordinates, and arc center coordinates, a set of arc path coordinate points is generated. Based on the set of arc path coordinate points, adjacent key feature coordinate points, and arc center coordinates, the set of path coordinate point radii and the arc path segment are determined. The parameters of the circular path are determined based on the set of radius points of the path coordinates and the circular path segment.

[0037] It should be explained that the detailed steps for calculating the arc center coordinates based on the vertical direction vector and the current key feature coordinates will be given later. The calculation methods for the angle bisector vector and plane normal vector in the step of calculating the angle bisector vector and plane normal vector based on the entry point direction vector and exit point direction vector are existing technologies and will not be elaborated here. The angle bisector vector is a vector along the bisector of the angle between the entry point direction vector and the exit point direction vector, used to determine the symmetrical direction of the arc bending. The plane normal vector is a vector perpendicular to the plane formed by the entry point direction vector and the exit point direction vector. The vertical direction vector is obtained by performing a cross product operation on the angle bisector vector and the plane normal vector. The calculation formula for the arc endpoint coordinates in the step of calculating the arc endpoint coordinates based on the arc center coordinates, the initial bending radius, and the exit point direction vector is as follows: in, Indicates the coordinates of the endpoint of the arc. Represent the direction vector of the point.

[0038] Understandably, the arc discretization precision is a numerical value indicating the fineness of decomposing the arc path into a number of discrete coordinate points. Higher discretization precision results in a larger number of discrete coordinate points and a smoother arc path. For example, an arc discretization precision of 1 degree. The arc path coordinate point set is a collection of arc path coordinate points. The steps for generating the arc path coordinate point set based on the preset arc discretization precision, arc start coordinates, arc end coordinates, and arc center coordinates are as follows: starting from the arc start coordinates, divide the arc path according to the arc discretization precision and arc center coordinates to obtain arc path coordinate points, until the arc path coordinate points equal the arc end coordinates, thus obtaining the arc path coordinate point set. The steps for determining the path coordinate point radius set and the arc path segment based on the arc path coordinate point set and arc center coordinates are as follows: calculate the distance from each arc path coordinate point in the arc path coordinate point set to the center coordinates, summarize these distance values ​​to form the path coordinate point radius set, and connect these arc path coordinate points sequentially to fit and form a continuous arc path segment.

[0039] In detail, the formula for calculating the coordinates of the center of the arc is as follows: in, Represents the coordinates of the center of the arc. Indicates the coordinates of the current key feature point. Indicates the initial bending radius. Indicates the bending angle of the target. Represents the tangent function. This represents the vertical direction vector.

[0040] It should be explained that the initial bending radius is a pre-set base curvature radius for generating the arc path segment. For example, the initial bending radius is 50mm. The target bending angle is the directional deflection angle that the line bundle needs to complete when passing the current inflection point. For example, the target bending angle is 90°. In the above-mentioned calculation formula for the arc center coordinates of this invention, taking the current key feature coordinate point as the reference point, extending a length along the direction of the vertical vector is: The distance is determined, and the final spatial coordinates are the coordinates of the center of the arc. Mathematical calculations are used to precisely locate the spatial position of the arc's center, ensuring that the generated arc path accurately matches the directional deflection requirements of the line harness at the inflection point, while also guaranteeing that the bending radius meets mechanical constraints.

[0041] In detail, the formula for calculating the coordinates of the starting point of the arc is as follows: in, Indicates the coordinates of the starting point of the arc. This represents the direction vector of the entry point.

[0042] It should be noted that the calculation formula for the starting point coordinates of the arc in this invention is based on the coordinates of the arc center. The distance is extended along the opposite direction of the entry point direction vector by a distance equal to the initial bending radius. The final determined spatial coordinates are the starting point coordinates of the arc. The entry point direction vector represents the direction of the wire harness when it enters the inflection point. Taking its opposite direction is to ensure that the starting point of the arc is on the side of the center facing the entry point of the wire harness, ensuring seamless connection between the arc and the wire harness segment in the entry point direction. The initial bending radius ensures that the distance from the starting point of the arc to the center conforms to the geometric definition of the arc.

[0043] Specifically, the process of generating a preliminary shaped path based on the total length of the spliced ​​path and the radius set of multiple path coordinate points includes: The difference between the total length of the splicing path and the preset total installation length of the wire harness is calculated to obtain the path length difference. If the path length difference is greater than the preset zero value, the longest straight path segment is identified from the set of straight path segments. The longest straight path segment is lengthened to obtain the adjusted straight path segment. The updated total path length is calculated based on the adjusted straight path segment. The updated total path length is used as the splicing path total length. The process returns to the step of calculating the difference between the splicing path total length and the preset wire harness target installation total length until the path length difference is equal to zero. If the path length difference is less than zero, the optimal arc length is determined from the arc path segment set based on the radius set of multiple path coordinate points. The radius of the optimal arc length is increased to obtain the adjusted arc length. The total length of the adjusted path is calculated based on the adjusted arc length. The total length of the adjusted path is used as the total length of the splicing path. The process returns to the step of calculating the difference between the total length of the splicing path and the preset total length of the wire harness target installation until the path length difference is equal to zero. If the path length difference is zero, the spliced ​​path will be used as the initial shaping path.

[0044] It should be explained that the target total installation length of the wire harness is the total length standard that the high-speed wire harness to be analyzed needs to meet in the actual installation scenario. For example, the target total installation length of the wire harness is 1.3 meters. The path length difference is the value obtained by subtracting the total splicing path length from the target total installation length of the wire harness. If the path length difference is greater than zero, it means that the total splicing path length exceeds the target total installation length of the wire harness. The longest straight path segment is the longest straight path segment selected from the set of straight path segments. The steps for lengthening the longest straight path segment are as follows: divide the path length difference by a preset number of straight segments (e.g., 3) to obtain the increment step, and use the increment step to lengthen the longest straight path segment. The adjusted straight path segment is the straight path segment after the length growth operation. The updated total path length is the total splicing path length recalculated based on the adjusted straight path segments. If the path length difference is less than zero, it means that the total splicing path length has not reached the target total installation length of the wire harness. The step of determining the optimal arc length from the set of arc path segments based on the set of radii of multiple path coordinate points is as follows: The largest path coordinate point radius is determined from the set of multiple path coordinate point radii; from the set of arc path segments, the length of the arc path segment corresponding to the largest path coordinate point radius is taken as the optimal arc length. The step of increasing the radius of the optimal arc length is as follows: The length obtained by dividing the path length difference by the target bending angle is added to the length of the optimal arc length. This invention increases the arc length of the arc path segment by expanding the radius of curvature of the arc, thereby adjusting the total length of the spliced ​​path. The adjusted arc length is the arc length corresponding to the arc path after the radius increase operation. The adjusted total path length is the total spliced ​​path length recalculated based on the adjusted arc length. The initial shaped path is the spliced ​​path where the path length difference is equal to zero. In this invention, zero is 0.

[0045] Importantly, because quantifying the length deviation clarifies the direction of path adjustment and allows for precise judgment of the degree and trend of deviation between the total length of the spliced ​​path and the target total installation length, the above steps of this invention first calculate the path length difference between the total length of the spliced ​​path and the target total installation length of the wire harness. This allows for precise location of the gap between the path length and the target requirement. Simultaneously, because straight-line segment adjustments have minimal impact on path shape and stress distribution, when the path length difference is greater than zero (i.e., the total length of the spliced ​​path has not reached the target length), the longest straight-line path segment is selected for adjustment. This ensures that the length requirement is met while avoiding new stress concentration problems. Furthermore, because increasing the arc radius can shorten the arc length, and arc segment adjustments are easier to control stress changes, when the path length difference is less than zero (i.e., the total length of the spliced ​​path exceeds the target length), the optimal arc length adjustment radius is selected. This ensures that the bending stress of the high-speed wire harness under analysis does not exceed the tolerance threshold while reducing the length. The tolerance threshold is the maximum mechanical stress critical value that the high-speed wire harness and its insulation layer material can withstand. If this value is exceeded, the high-speed wire harness or its insulation layer will suffer irreversible damage (such as breakage, cracking, plastic deformation, etc.).

[0046] S3. Extract shaping line segments sequentially from the initial shaping path. If the extracted shaping line segment is a straight path segment, then the extracted shaping line segment is taken as a straight line bundle segment. Based on the straight line bundle segment and the tensile strength of the bundle, the qualified straight line bundle segment is confirmed.

[0047] It should be explained that the straight wire harness segment is the shaping segment corresponding to the straight path segment extracted from the initial shaping path. The robotic arm is an automated execution device used to perform the wire harness shaping operation. The axial tension application operation is the operation of applying tension to the straight wire harness segment along its axial direction using the robotic arm. The step of real-time monitoring of the average stress value of the straight wire harness segment undergoing the axial tension application operation is as follows: when the axial tension application operation is performed, the average stress value is the average value of the stress values ​​at all sensor locations on the straight wire harness segment.

[0048] Specifically, the process of identifying qualified straight wire harness segments based on the straight wire harness segments and their tensile strength includes: An axial tensile force is applied to a straight wire harness segment using a robotic arm, and the average stress value of the straight wire harness segment to which the axial tensile force is applied is monitored in real time. Obtain the stress value range, and determine the upper and lower limits of the stress value based on the stress value range; If the average stress value is greater than the upper limit of the stress value, the tension of the straight wire harness segment is reduced by using the preset adjustment step size and wire harness tensile strength to obtain the adjusted straight wire harness segment. The adjusted straight wire harness segment is then used as the straight wire harness segment, and the process returns to the step of applying axial tension to the straight wire harness segment using the robotic arm until the average stress value is within the stress value range. If the average stress value is less than the lower limit of the stress value, the tension of the straight wire harness segment is increased by adjusting the step size to obtain an updated straight wire harness segment. The updated straight wire harness segment is used as the straight wire harness segment, and the process returns to the step of applying axial tension to the straight wire harness segment using the robotic arm until the average stress value is within the stress value range. If the average stress value is within the stress value range, then the straight wire harness segment is considered a qualified straight wire harness segment.

[0049] It should be explained that the stress range refers to a pre-defined range of stress that a straight wire harness segment can withstand under axial tensile force. It serves as the basis for judging whether the mechanical properties of the straight wire harness segment are up to standard. The upper limit of the stress value is the maximum value within the stress range. The lower limit of the stress value is the minimum value within the stress range, used to ensure the wire harness has sufficient tension to prevent slack. The adjustment step size is a fixed amount of change when adjusting the tension, used to precisely control the adjustment range. For example, the adjustment step size is 0.5% of the wire harness tensile strength. The wire harness tensile strength is the critical value of the maximum tensile stress that a high-speed wire harness (including the conductor core and outer insulation material) can withstand. The adjusted straight wire harness segment is the straight wire harness segment obtained after reducing the tension by adjusting the step size when the average stress value is greater than the upper limit of the stress value. If the average stress value is greater than the upper limit of the stress value, it indicates that the straight wire harness segment is subjected to excessive tension, exceeding the safe range, and there is a risk of tensile damage. If the average stress value is less than the lower limit of the stress value, it indicates that the straight wire harness segment is not under sufficient tension, and the stress is below the required standard, which can easily lead to problems such as loosening and tangling. Updating the straight wire harness segment involves increasing the tension of the segment by adjusting the step size. If the average stress value is within the stress value range, it means that the straight wire harness segment will neither be damaged by excessive tension nor loosen due to insufficient tension. A qualified straight wire harness segment is one whose average stress value is within the stress value range.

[0050] It should be noted that, in order to ensure the consistency of the tension adjustment process and avoid excessively large or small tension correction ranges due to inconsistent adjustment step sizes (excessive ranges may cause stress to repeatedly exceed the range and damage the wire harness material, while insufficient ranges will prolong the adjustment iteration cycle and reduce shaping efficiency), the same adjustment step size is used to increase or decrease the tension of the straight wire harness segment. Ultimately, this can efficiently and stably control the average stress value within the stress value range, ensuring the accuracy of the determination of qualified straight wire harness segments.

[0051] S4. If the extracted shaping line segment is a curved path segment, then the extracted shaping line segment is taken as a curved line harness segment. According to the preset target bending angle, the pre-constructed robotic arm is used to shape the curved line harness segment, and the tensile stress on the outer side and the tensile stress on the inner side of the curved line harness segment being shaped are monitored in real time.

[0052] It should be explained that the curved wire harness segment is the shaping segment corresponding to the arc path segment extracted from the initial shaping path. The tensile stress on the outer side of the bend is the tensile stress generated on the outer arc surface of the curved wire harness segment during shaping and bending due to stretching. This stress value must be controlled within the tolerance threshold of the insulation layer and the wire harness material to avoid cracking of the outer material. The tensile stress on the inner side of the bend is the tensile stress generated on the inner arc surface of the curved wire harness segment during shaping and bending due to compression and slight stretching. Excessive stress must be prevented to avoid plastic deformation or damage to the inner material.

[0053] S5. Based on the tensile stress on the outer side and the tensile stress on the inner side of the bend, perform adaptive shaping operation on the curved wire harness segment to obtain a qualified curved wire harness segment.

[0054] In detail, the adaptive shaping operation of the curved wire harness segment based on the tensile stress on the outer side and the tensile stress on the inner side of the bend to obtain a qualified curved wire harness segment includes: If the tensile stress on the outer side of the bend is greater than the preset tensile stress threshold of the conductor area or the tensile stress on the inner side of the bend is greater than the preset compressive stress threshold of the insulation layer, then the instantaneous radius of curvature and the instantaneous arc center are obtained according to the curve bundle segment, the instantaneous radius of curvature and the preset radius adjustment coefficient are multiplied to obtain the updated target radius, and the difference between the updated target radius and the instantaneous radius of curvature is calculated to obtain the radial offset distance. The updated center coordinates are calculated based on the radial offset distance and the instantaneous arc center, and the updated arc harness path is constructed based on the updated center coordinates and the updated target radius. The curved wire harness segment is subjected to bidirectional synchronous operation based on the updated arc wire harness path to obtain a qualified curved wire harness segment.

[0055] It should be explained that the conductor tensile stress threshold is the maximum permissible tensile stress value set to protect the conductor material of the wire harness, used to prevent the conductor from undergoing plastic deformation or breakage due to excessive tensile stress. For example, the conductor tensile stress threshold is 160 MPa. The insulation layer compressive stress threshold is the maximum permissible compressive stress value set to protect the insulation layer material of the wire harness, used to prevent the insulation layer from being damaged due to excessive compressive stress. For example, the insulation layer compressive stress threshold is 35 MPa. If the tensile stress on the outer side of the bend is greater than the preset conductor tensile stress threshold or the tensile stress on the inner side of the bend is greater than the preset insulation layer compressive stress threshold, it indicates that the current bending action may cause damage to the wire harness, and adjustment must be made immediately. The instantaneous radius of curvature refers to the radius corresponding to the curved wire harness segment at the moment of the current bend. The radius adjustment coefficient is a preset value used to determine the proportion of radius increase. For example, the radius adjustment coefficient is 1.2. The updated target radius is the product of the instantaneous radius of curvature and the radius adjustment coefficient. The radial offset distance is the distance obtained by subtracting the instantaneous radius of curvature from the updated target radius. The radial offset distance represents the straight-line distance that the center of the curve segment needs to move outward to increase the bending radius from the instantaneous radius of curvature to the updated target radius. The step of calculating the updated center based on the radial offset distance and the instantaneous arc center is as follows: obtain the current coordinates of the robotic arm's end effector, and calculate the updated center based on the radial offset distance, the instantaneous arc center, and the current coordinates of the robotic arm's end effector. The calculation formula is as follows: in, This indicates updating the center coordinates of the circle. Indicates the instantaneous center of the arc. Indicates the radial offset distance. This indicates the current coordinates of the robotic arm's end effector. The construction of the updated arc harness path based on the updated center coordinates and the updated target radius involves maintaining the current tangent direction (i.e., first-order continuity with the original path at the switching point) while constructing the updated arc harness path. The step of performing bidirectional synchronous operation on the curved harness segment based on the updated arc harness path is as follows: While controlling the robotic arm to continue bending motion according to the updated arc harness path, stress changes are monitored in real time to ensure that the tensile stress on the outer side and the tensile stress on the inner side of the bend gradually decreases and stabilizes below the tensile stress threshold in the conductor region and the compressive stress threshold in the insulation layer. During this process, auxiliary measures such as local heating are simultaneously activated to collaboratively reduce the bending resistance of the harness. When the bending angle reaches the preset target angle and the stress data remains consistently below the threshold, the curved harness segment is determined to be a qualified curved harness segment.

[0056] S6. Summarize the qualified straight wire harness segments and qualified curved wire harness segments to obtain the qualified straight wire harness segment set and the qualified curved wire harness segment set. Based on the qualified straight wire harness segment set and the qualified curved wire harness segment set, complete the high-speed wire harness adaptive shaping based on stress analysis.

[0057] It should be explained that the set of qualified straight wire harness segments and the set of qualified curved wire harness segments are respectively the sets composed of qualified straight wire harness segments and the sets composed of qualified curved wire harness segments. This invention integrates all qualified segments to form a complete shaping scheme, achieving dual compliance in both the overall shape and stress state of the wire harness. This satisfies the spatial installation requirements of high-speed wire harnesses while improving their long-term stability.

[0058] To address the problems described in the background art, this invention identifies the high-speed wire harness requiring shaping and uses a distributed stress sensor. It receives stress analysis commands and, based on these commands, obtains the tensile strength of the high-speed wire harness. Then, using the distributed stress sensor, it performs a preliminary shaping path construction operation on the high-speed wire harness, resulting in a preliminary shaping path. This preliminary shaping path includes multiple shaping segments, which can be straight or curved. The curved path segments include circular arc segments and spline curve segments. This invention leverages the precise sensing capabilities of the distributed stress sensor to generate a preliminary shaping path containing straight, circular, and spline curve segments. The path not only conforms to the key morphological characteristics of the harness but also avoids the risk of stress concentration in advance, providing scientific path guidance for subsequent segmented shaping. Shaping segments are extracted sequentially from the initial shaping path. If the extracted shaping segment is a straight path segment, it is considered a straight harness segment. Based on the straight harness segment and its tensile strength, qualified straight harness segments are confirmed. This invention conducts directional shaping and stress verification targeting the characteristics of straight segments to ensure that the stress state of the straight harness segment is within a safe range. This avoids both excessive tension causing tensile damage to the harness and insufficient tension causing harness slack, ensuring the structural stability and transmission reliability of the straight segment. If the extracted shaping segment is a curved path segment, then the extracted shaping segment is taken as a curved wire harness segment. Based on a preset target bending angle, a pre-constructed robotic arm is used to shape the curved wire harness segment, and the tensile stress on the outer and inner sides of the curved wire harness segment being shaped is monitored in real time. This invention achieves precise shaping of the curved segment through a robotic arm, while simultaneously monitoring the tensile stress on the outer and inner sides of the bend in real time. This allows for a direct understanding of the stress distribution at different parts of the curved segment. Based on the tensile stress on the outer and inner sides of the bend, an adaptive shaping operation is performed on the curved wire harness segment to obtain a qualified curved wire harness segment. This invention is based on real-time monitoring... By specifically adjusting stress data, the bending shape of curve segments can be dynamically optimized to ensure that the stress on both the inner and outer sides of the bend does not exceed the material's tolerance threshold. This avoids problems such as cracking and deformation caused by uneven stress distribution in the curve segments. Qualified straight and curved wire harness segments are collected to obtain sets of qualified straight and curved wire harness segments. Based on these sets, adaptive shaping of high-speed wire harnesses based on stress analysis is completed. This invention integrates all qualified segments to form a complete shaping scheme, achieving dual compliance in both the overall shape and stress state of the wire harness. This satisfies the spatial installation requirements of high-speed wire harnesses while improving their long-term stability. Therefore, this invention can improve the automation level and stress controllability of high-speed wire harness shaping.

[0059] like Figure 2 The diagram shown is a functional block diagram of a high-speed wire harness adaptive shaping system based on stress analysis provided in an embodiment of the present invention.

[0060] The high-speed wire harness adaptive shaping system 100 based on stress analysis described in this invention can be installed in an electronic device. Depending on the functions implemented, the high-speed wire harness adaptive shaping system 100 based on stress analysis may include a preliminary shaping path construction module 101, a straight wire harness segment processing module 102, a curved wire harness segment processing module 103, and a wire harness shaping completion module 104. The module described in this invention can also be called a unit, which refers to a series of computer program segments that can be executed by the processor of an electronic device and can perform a fixed function, and which are stored in the memory of the electronic device. The preliminary shaping path construction module 101 is used to identify the high-speed wire harness to be shaped and the distributed stress sensor, receive stress analysis instructions, obtain the tensile strength of the high-speed wire harness to be shaped according to the stress analysis instructions, and perform a preliminary shaping path construction operation on the high-speed wire harness to be shaped based on the distributed stress sensor to obtain a preliminary shaping path. The preliminary shaping path includes multiple shaping line segments, which are straight line path segments or curved path segments. The curved path segments include circular arc path segments and spline curve segments. The straight wire harness segment processing module 102 is used to extract shaping wire segments sequentially from the preliminary shaping path. If the extracted shaping wire segment is a straight path segment, the extracted shaping wire segment is used as a straight wire harness segment. The qualified straight wire harness segment is confirmed based on the straight wire harness segment and the tensile strength of the wire harness. The curve harness segment processing module 103 is used to treat the extracted shaping segment as a curve harness segment if the extracted shaping segment is a curve path segment. According to the preset target bending angle, the module uses a pre-constructed robotic arm to shape the curve harness segment and monitors the bending outer tensile stress and bending inner tensile stress of the curve harness segment being shaped in real time. Based on the bending outer tensile stress and bending inner tensile stress, the module performs adaptive shaping operation on the curve harness segment to obtain a qualified curve harness segment. The harness shaping module 104 is used to summarize qualified straight harness segments and qualified curved harness segments to obtain a set of qualified straight harness segments and a set of qualified curved harness segments, and to complete high-speed harness adaptive shaping based on stress analysis based on the set of qualified straight harness segments and the set of qualified curved harness segments.

[0061] In detail, the modules in the high-speed harness adaptive shaping system 100 based on stress analysis described in this embodiment of the invention employ the same methods as described above during use. Figure 1 The method uses the same techniques as the stress analysis-based adaptive shaping method for high-speed wire harnesses described above, and can produce the same technical effects, so it will not be repeated here.

[0062] like Figure 3 The diagram shown is a structural schematic of an electronic device that implements a high-speed wire harness adaptive shaping method based on stress analysis, according to an embodiment of the present invention.

[0063] 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 adaptive shaping method program based on stress analysis.

[0064] The memory 11 includes at least one type of readable storage medium, including 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 the portable hard drive of the electronic device 1. 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 adaptive shaping method program based on stress analysis, but also to temporarily store data that has been output or will be output.

[0065] 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 adaptive shaping method program based on stress analysis) and calls data stored in the memory 11 to perform various functions of the electronic device 1 and process data.

[0066] 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.

[0067] 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.

[0068] 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.

[0069] 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.

[0070] 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.

[0071] The high-speed wire harness adaptive shaping method program based on stress analysis 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: The high-speed wire harness and distributed stress sensor that need to be shaped are identified. The stress analysis command is received, and the tensile strength of the high-speed wire harness that needs to be shaped is obtained according to the stress analysis command. Based on the distributed stress sensor, a preliminary shaping path is constructed for the high-speed wire harness that needs to be shaped, and a preliminary shaping path is obtained. The preliminary shaping path includes multiple shaping line segments, which are either straight line path segments or curved line path segments. The curved line path segments include circular arc path segments and spline curve segments. The shaping line segments are extracted sequentially from the initial shaping path. If the extracted shaping line segment is a straight path segment, the extracted shaping line segment is taken as a straight line bundle segment. The qualified straight line bundle segment is confirmed based on the straight line bundle segment and the tensile strength of the bundle. If the extracted shaping segment is a curved path segment, then the extracted shaping segment is taken as a curved line bundle segment. According to the preset target bending angle, the pre-constructed robotic arm is used to shape the curved line bundle segment, and the tensile stress on the outer side and the tensile stress on the inner side of the curved line bundle segment being shaped are monitored in real time. Based on the tensile stress on the outer side and the tensile stress on the inner side of the bend, an adaptive shaping operation is performed on the curved wire harness segment to obtain a qualified curved wire harness segment. By summarizing qualified straight wire harness segments and qualified curved wire harness segments, a set of qualified straight wire harness segments and a set of qualified curved wire harness segments are obtained. Based on the set of qualified straight wire harness segments and the set of qualified curved wire harness segments, high-speed wire harness adaptive shaping based on stress analysis is completed.

[0072] 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.

[0073] 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).

[0074] 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: The high-speed wire harness and distributed stress sensor that need to be shaped are identified. The stress analysis command is received, and the tensile strength of the high-speed wire harness that needs to be shaped is obtained according to the stress analysis command. Based on the distributed stress sensor, a preliminary shaping path is constructed for the high-speed wire harness that needs to be shaped, and a preliminary shaping path is obtained. The preliminary shaping path includes multiple shaping line segments, which are either straight line path segments or curved line path segments. The curved line path segments include circular arc path segments and spline curve segments. The shaping line segments are extracted sequentially from the initial shaping path. If the extracted shaping line segment is a straight path segment, the extracted shaping line segment is taken as a straight line bundle segment. The qualified straight line bundle segment is confirmed based on the straight line bundle segment and the tensile strength of the bundle. If the extracted shaping segment is a curved path segment, then the extracted shaping segment is taken as a curved line bundle segment. According to the preset target bending angle, the pre-constructed robotic arm is used to shape the curved line bundle segment, and the tensile stress on the outer side and the tensile stress on the inner side of the curved line bundle segment being shaped are monitored in real time. Based on the tensile stress on the outer side and the tensile stress on the inner side of the bend, an adaptive shaping operation is performed on the curved wire harness segment to obtain a qualified curved wire harness segment. By summarizing qualified straight wire harness segments and qualified curved wire harness segments, a set of qualified straight wire harness segments and a set of qualified curved wire harness segments are obtained. Based on the set of qualified straight wire harness segments and the set of qualified curved wire harness segments, high-speed wire harness adaptive shaping based on stress analysis is completed.

[0075] 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.

[0076] 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.

[0077] 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.

[0078] 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.

[0079] 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 adaptive shaping method based on stress analysis, characterized in that, The method includes: The high-speed wire harness and distributed stress sensor that need to be shaped are identified. The stress analysis command is received, and the tensile strength of the high-speed wire harness that needs to be shaped is obtained according to the stress analysis command. Based on the distributed stress sensor, a preliminary shaping path is constructed for the high-speed wire harness that needs to be shaped, and a preliminary shaping path is obtained. The preliminary shaping path includes multiple shaping line segments, which are either straight line path segments or curved line path segments. The curved line path segments include circular arc path segments and spline curve segments. The shaping line segments are extracted sequentially from the initial shaping path. If the extracted shaping line segment is a straight path segment, the extracted shaping line segment is taken as a straight line bundle segment. The qualified straight line bundle segment is confirmed based on the straight line bundle segment and the tensile strength of the bundle. If the extracted shaping segment is a curved path segment, then the extracted shaping segment is taken as a curved line bundle segment. According to the preset target bending angle, the pre-constructed robotic arm is used to shape the curved line bundle segment, and the tensile stress on the outer side and the tensile stress on the inner side of the curved line bundle segment being shaped are monitored in real time. Based on the tensile stress on the outer side and the tensile stress on the inner side of the bend, an adaptive shaping operation is performed on the curved wire harness segment to obtain a qualified curved wire harness segment. By summarizing qualified straight wire harness segments and qualified curved wire harness segments, a set of qualified straight wire harness segments and a set of qualified curved wire harness segments are obtained. Based on the set of qualified straight wire harness segments and the set of qualified curved wire harness segments, high-speed wire harness adaptive shaping based on stress analysis is completed.

2. The high-speed harness adaptive shaping method based on stress analysis as described in claim 1, characterized in that, The preliminary shaping path construction operation based on distributed stress sensors for high-speed wire harnesses requiring shaping, resulting in a preliminary shaping path, includes: A sensor array is constructed based on a distributed stress sensor and a preset installation interval. The extracted high-speed wire harness that needs to be shaped is placed in the sensor array to obtain the high-speed wire harness to be analyzed. Key features of the high-speed harness to be analyzed are identified to obtain a sequence of key feature coordinate points of the harness, which includes multiple key feature coordinate points of the harness. A preliminary shaping path is generated based on the sequence of key feature coordinate points of the harness.

3. The high-speed harness adaptive shaping method based on stress analysis as described in claim 2, characterized in that, The process of generating a preliminary shaping path based on the sequence of key feature coordinate points of the wire harness includes: Obtain the starting point coordinates and ending point coordinates of the high-speed harness to be analyzed, extract the key feature coordinate points of the harness sequentially from the key feature coordinate point sequence, and use the extracted key feature coordinate points of the harness as the current key feature coordinate points. The initial straight line path segment is obtained based on the starting point coordinates of the harness and the current key feature coordinates. The adjacent key feature coordinates are identified from the key feature coordinates sequence of the harness based on the current key feature coordinates. The adjacent key feature coordinates are adjacent and lag behind the current key feature coordinates. Obtain straight path segments, circular path parameters, or spline curve segments based on the current key feature coordinate points and adjacent key feature coordinate points; Take the adjacent key feature coordinate points as the current key feature coordinate points, and return to the step of extracting key feature coordinate points of the wire harness sequentially from the sequence of key feature coordinate points of the wire harness, until the current key feature coordinate point is equal to the end point coordinates of the wire harness. The parameters of straight path segments, circular path segments, and spline curve segments are summarized separately to obtain the set of straight path segments, the set of circular path parameters, and the set of spline curve segments. The set of circular path parameters includes the set of circular path segments and the set of radii of multiple path coordinate points. According to the order of extracting the key feature coordinate points of the wire harness, the initial straight path segment, the set of straight path segments, the set of circular arc path segments, and the set of spline curve segments are spliced ​​end to end to obtain the spliced ​​path, and the total length of the spliced ​​path is calculated. A preliminary reshaping path is generated based on the total length of the spliced ​​path and the radius set of multiple path coordinate points.

4. The high-speed harness adaptive shaping method based on stress analysis as described in claim 3, characterized in that, The step of obtaining straight path segments, circular path parameters, or spline curve segments based on the current key feature coordinate points and adjacent key feature coordinate points includes: Identify the feature coordinate point type of the current key feature coordinate point, where the feature coordinate point type is either an inflection point type or a joint type; If the feature coordinate point type is an inflection point type, then calculate the entry point direction vector based on the starting point coordinates of the line bundle and the current key feature coordinate point, calculate the exit point direction vector based on the current key feature coordinate point and adjacent key feature coordinate points, and calculate the vector angle based on the entry point direction vector and the exit point direction vector. If the angle between the vectors is greater than the preset direction change threshold, then a curved segment is generated based on the current key feature coordinates and adjacent key feature coordinates to obtain the arc path parameters. The arc path parameters include: the arc path segment and the set of radii of the path coordinates. If the angle between the vectors is not greater than the direction change threshold, then a straight path segment is generated based on the current key feature coordinates and adjacent key feature coordinates. If the feature coordinate point type is a joint type, then the flexible transition interval segment is determined based on the current key feature coordinate point. Based on the flexible transition interval segment, the current key feature coordinate point, the starting point coordinate of the wire harness, and the adjacent key feature coordinate points are interpolated to obtain the spline curve segment.

5. The high-speed harness adaptive shaping method based on stress analysis as described in claim 4, characterized in that, The process of generating curved segments based on the current key feature coordinates and adjacent key feature coordinates to obtain arc path parameters includes: Calculate the angle bisector vector and the plane normal vector based on the in-point direction vector and the out-point direction vector. Perform a cross product operation on the angle bisector vector and the plane normal vector to obtain the perpendicular direction vector. Calculate the coordinates of the arc's center based on the vertical direction vector and the current key feature coordinates. The coordinates of the starting point of the arc are calculated based on the coordinates of the arc center, the preset initial bending radius, and the entry point direction vector. Calculate the coordinates of the arc's endpoint based on the arc's center coordinates, initial bending radius, and exit point direction vector. Based on the preset arc discretization precision, arc start coordinates, arc end coordinates, and arc center coordinates, a set of arc path coordinate points is generated. Based on the set of arc path coordinate points, adjacent key feature coordinate points, and arc center coordinates, the set of path coordinate point radii and the arc path segment are determined. The parameters of the circular path are determined based on the set of radius points of the path coordinates and the circular path segment.

6. The high-speed harness adaptive shaping method based on stress analysis as described in claim 5, characterized in that, The formula for calculating the coordinates of the center of the arc is as follows: in, Represents the coordinates of the center of the arc. Indicates the coordinates of the current key feature point. Indicates the initial bending radius. Indicates the bending angle of the target. Represents the tangent function. This represents the vertical direction vector.

7. The high-speed harness adaptive shaping method based on stress analysis as described in claim 6, characterized in that, The formula for calculating the coordinates of the starting point of the arc is as follows: in, Indicates the coordinates of the starting point of the arc. This represents the direction vector of the entry point.

8. The high-speed harness adaptive shaping method based on stress analysis as described in claim 7, characterized in that, The process of generating a preliminary shaped path based on the total length of the spliced ​​path and the radius set of multiple path coordinate points includes: The difference between the total length of the splicing path and the preset total installation length of the wire harness is calculated to obtain the path length difference. If the path length difference is greater than the preset zero value, the longest straight path segment is identified from the set of straight path segments. The longest straight path segment is lengthened to obtain the adjusted straight path segment. The updated total path length is calculated based on the adjusted straight path segment. The updated total path length is used as the splicing path total length. The process returns to the step of calculating the difference between the splicing path total length and the preset wire harness target installation total length until the path length difference is equal to zero. If the path length difference is less than zero, the optimal arc length is determined from the arc path segment set based on the radius set of multiple path coordinate points. The radius of the optimal arc length is increased to obtain the adjusted arc length. The total length of the adjusted path is calculated based on the adjusted arc length. The total length of the adjusted path is used as the total length of the splicing path. The process returns to the step of calculating the difference between the total length of the splicing path and the preset total length of the wire harness target installation until the path length difference is equal to zero. If the path length difference is zero, the spliced ​​path will be used as the initial shaping path.

9. The high-speed wire harness adaptive shaping method based on stress analysis as described in claim 8, characterized in that, The process of identifying qualified straight wire harness segments based on their straight wire harness segments and tensile strength includes: An axial tensile force is applied to a straight wire harness segment using a robotic arm, and the average stress value of the straight wire harness segment to which the axial tensile force is applied is monitored in real time. Obtain the stress value range, and determine the upper and lower limits of the stress value based on the stress value range; If the average stress value is greater than the upper limit of the stress value, the tension of the straight wire harness segment is reduced by using the preset adjustment step size and wire harness tensile strength to obtain the adjusted straight wire harness segment. The adjusted straight wire harness segment is then used as the straight wire harness segment, and the process returns to the step of applying axial tension to the straight wire harness segment using the robotic arm until the average stress value is within the stress value range. If the average stress value is less than the lower limit of the stress value, the tension of the straight wire harness segment is increased by adjusting the step size to obtain an updated straight wire harness segment. The updated straight wire harness segment is used as the straight wire harness segment, and the process returns to the step of applying axial tension to the straight wire harness segment using the robotic arm until the average stress value is within the stress value range. If the average stress value is within the stress value range, then the straight wire harness segment is considered a qualified straight wire harness segment.

10. A high-speed wire harness adaptive shaping system based on stress analysis, characterized in that, The system includes: The preliminary shaping path construction module is used to identify the high-speed wire harness to be shaped and the distributed stress sensor, receive stress analysis instructions, obtain the tensile strength of the high-speed wire harness to be shaped according to the stress analysis instructions, and perform preliminary shaping path construction operation on the high-speed wire harness to be shaped based on the distributed stress sensor to obtain the preliminary shaping path. The preliminary shaping path includes multiple shaping line segments, which are straight line path segments or curved line path segments. The curved line path segments include circular arc path segments and spline curve segments. The straight line harness segment processing module is used to extract shaping line segments sequentially from the initial shaping path. If the extracted shaping line segment is a straight path segment, the extracted shaping line segment is used as a straight line harness segment. The qualified straight line harness segment is confirmed based on the straight line harness segment and the tensile strength of the harness. The curve harness segment processing module is used to treat the extracted shaping segment as a curve path segment if the extracted shaping segment is a curve path segment. Based on the preset target bending angle, the module uses a pre-constructed robotic arm to shape the curve harness segment and monitors the tensile stress on the outer and inner sides of the curve harness segment in real time. Based on the tensile stress on the outer and inner sides of the curve harness segment, the module performs adaptive shaping operation on the curve harness segment to obtain a qualified curve harness segment. The harness shaping module is used to summarize qualified straight harness segments and qualified curved harness segments to obtain a set of qualified straight harness segments and a set of qualified curved harness segments. Based on the set of qualified straight harness segments and the set of qualified curved harness segments, it completes high-speed harness adaptive shaping based on stress analysis.

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