Automatic control method for harness cutting and tinning integration

Abstract

The application discloses a wire harness cutting and tin coating integrated automatic control method, relates to the technical field of industrial automation control, and is used for solving the problems of easy wire core cutting, uneven tin coating and end tin ice column in traditional wire harness processing. The wire harness cutting and tin coating integrated automatic control method first analyzes the wire dynamic hardness impedance by collecting the current characteristics of the feed and the tool holder motor, and adaptively compensates the peeling micro-feeding amount; then, the exposed wire core micro-distance image is acquired, affine transformation correction is performed based on the wire core deflection angle, and the filament dispersion coefficient is accurately calculated; next, the tin furnace real-time power attenuation and liquid level height data are fused, the optimal pressing depth and wetting time are dynamically solved, and a nonlinear pulling speed curve is generated; finally, the wire harness is controlled to be immersed in tin and pulled according to the planning, the current attenuation slope is monitored synchronously, the reverse pulse transient back pulling is issued when the surface tension fracture threshold is triggered, the liquid tin connection is physically cut off, and a flexible and precise integrated closed-loop control system is constructed.

Description

Technical Field

[0001] This invention relates to the field of industrial automation control technology, specifically to an integrated automated control method for wire harness cutting and tinning. Background Technology

[0002] With the continuous evolution of industries such as electronics manufacturing, communication equipment, and new energy vehicles, the market demand for wire harnesses, as a fundamental component for electrical signal transmission within equipment, is growing exponentially. Modern electronic equipment is constantly evolving towards miniaturization and high precision, placing extremely stringent requirements on wire harness processing quality, electrical connection stability, and batch yield. Traditional wire harness processing largely relies on labor-intensive production methods, heavily dependent on manual operation and experience-based judgment. Its processing pace struggles to keep up with the high-efficiency workflow of modern industry, and manual operation is highly susceptible to human error, making it difficult to meet the high-precision and high-consistency production demands of modern high-end manufacturing. Therefore, promoting the automation upgrade of wire harness cutting, stripping, and tinning processes has become a key direction for the manufacturing industry to improve production efficiency and reduce manufacturing costs.

[0003] Existing automated wire harness processing equipment typically employs multiple machines operating in segments or a single machine executing in an open-loop, fixed sequence, which presents significant physical defects in actual production. During the stripping stage, the equipment uses fixed parameters to control the cutter's descent. Due to physical differences in the hardness of the insulation layer between different batches of wire, a fixed cutting depth easily cuts through the internal copper wires or results in incomplete stripping of the outer insulation layer. In the soldering process, existing equipment uses fixed immersion times and pull-out speeds, ignoring the differences in the degree of wire strand dispersion after stripping and the slight fluctuations in the molten solder temperature. This frequently leads to false soldering, internal voids, or localized solder thickening during the immersion process. Furthermore, when pulling the wire harness out of the molten solder pot, the surface tension of the molten solder easily forms residual solder icicles at the wire harness end, resulting in an uneven soldered end face, severely affecting the mechanical bonding force and electrical connection stability of subsequent terminal crimping processes. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides an automated control method for integrated wire harness cutting and tinning, which solves the problems mentioned above.

[0005] To achieve the above objectives, the present invention is implemented through the following technical solution: an integrated automated control method for wire harness cutting and tinning, comprising the following steps: S1, during the wire feeding and stripping stages, the torque current sequence of the feed servo motor and the current gradient change rate of the tool holder motor at the instant it cuts into the insulation layer are simultaneously acquired. Based on the torque current sequence and current gradient change rate, the dynamic hardness impedance value and the wire core deflection angle of the wire are analyzed. Micro-feed compensation parameters are set based on the dynamic hardness impedance value, and the tool is controlled to perform the stripping action according to the micro-feed compensation parameters; S2, a micro-morphological image of the exposed wire core after the stripping action is acquired, the wire core deflection angle is extracted to construct a rotation correction matrix, and an affine transformation horizontal correction is performed on the micro-morphological image. The outer edge coordinates of the copper wire ends in the corrected image are extracted, and the fraying coefficient is calculated based on the outer edge coordinates; S 3. Collect real-time power attenuation characteristics and liquid level data of the tin bath at the tin-coating station. Input the filament divergence coefficient, real-time power attenuation characteristics, and liquid level data into the preset thermodynamic wetting mapping relationship to solve for the initial downward pressure depth and target capillary wetting time of immersion in the liquid tin pool. Generate a nonlinear lifting speed curve with the initial downward pressure depth and target capillary wetting time as constraints. S4. Control the wire harness to descend to the initial downward pressure depth and enter the liquid tin pool and activate the dwell timer. When the dwell timer accumulates to the target capillary wetting time, control the lifting servo motor to lift the wire harness according to the nonlinear lifting speed curve. Simultaneously calculate the attenuation slope of the motor load current. When the attenuation slope triggers the surface tension fracture threshold, send a reverse pulse command to drive the lifting servo motor to perform an instantaneous retraction action to cut off the liquid tin connection at the end of the wire harness.

[0006] Furthermore, during the wire feeding and stripping stages, the torque current sequence of the feed servo motor and the rate of change of the current gradient at the instant the tool holder motor cuts into the insulation layer are simultaneously acquired. The specific process of analyzing the dynamic hardness resistance value and the core deflection angle of the wire based on the torque current sequence and the rate of change of the current gradient is as follows: The sliding window mean filtering algorithm is applied to the torque current sequence to filter out high-frequency interference features, and the steady-state friction torque baseline is extracted as the steady-state feed resistance feature. The steady-state feed resistance feature is input into a pre-calibrated material mechanical impedance lookup table for interpolation comparison, and the dynamic hardness resistance value is output. The extreme value of the rate of change of the current gradient at the instant the tool holder motor cuts into the insulation layer is extracted. The extreme value of the rate of change of the current gradient and the dynamic hardness resistance value are used as input components and substituted into the multi-degree-of-freedom kinematic decoupling matrix to perform forward kinematic deduction, and the feature vector of the lateral displacement of the wire under stripping force is separated, and the core deflection angle is output.

[0007] Furthermore, the specific process of setting micro-feed compensation parameters based on dynamic hardness resistance values ​​and controlling the tool to perform peeling actions according to micro-feed compensation parameters is as follows: The dynamic hardness resistance value is input into the spline nonlinear interpolator, which outputs the corresponding dynamic depth of cut deviation vector. The dynamic depth of cut deviation vector is fused with the standard depth of cut baseline of the current gauge to generate micro-feed compensation parameters. According to the electronic gear ratio configuration of the tool post motor, the micro-feed compensation parameters are converted into a target position pulse sequence. The target position pulse sequence is sent down to the underlying fieldbus controller to drive the tool post servo motor to perform peeling actions under the set position loop tracking and torque upper limit clamping dual closed-loop constraint state.

[0008] Further, the specific process of acquiring a macroscopic topographic image of the exposed wire core after the stripping action, extracting the wire core deflection angle to construct a rotation correction matrix, and performing affine transformation horizontal correction on the macroscopic topographic image is as follows: extract the sine and cosine components of the wire core deflection angle to construct a two-dimensional affine rotation correction matrix, perform grayscale binarization processing on the macroscopic topographic image, and identify the transition boundary contour between the insulation layer and the exposed wire core; extract the geometric centroid coordinates of the connected domain of the transition boundary contour and designate them as rotation anchor points; perform spatial mapping on the global pixel coordinate system of the macroscopic topographic image around the rotation anchor points according to the two-dimensional affine rotation correction matrix, and apply the bilinear interpolation algorithm to resample and fill the pixel gaps after spatial mapping, outputting a corrected image aligned with the horizontal reference.

[0009] Further, the specific process of extracting the outer edge coordinates of the copper wire ends in the corrected image and calculating the filament divergence coefficient based on the outer edge coordinates is as follows: Apply the edge gradient operator to the corrected image to extract the continuous line edge gradient map, scan the line edge gradient map along the axial direction of the wire core, extract the outer edge coordinates of the ends of multiple exposed copper wires and construct an edge pixel cluster; perform a bounding box fitting algorithm on the edge pixel cluster to generate the minimum bounding rectangle, extract the pixel span size of the minimum bounding rectangle perpendicular to the axial direction of the wire core as the horizontal width parameter, input the horizontal width parameter and the preset theoretical standard diameter of the wire core into the structural deviation analysis logic to perform discreteness mapping solution, and output the filament divergence coefficient.

[0010] Furthermore, the real-time power attenuation characteristics and liquid level height data of the tin bath at the tin-filling station are collected. The filament divergence coefficient, real-time power attenuation characteristics, and liquid level height data are input into a preset thermodynamic wetting mapping relationship to solve for the initial immersion depth and target capillary wetting time in the liquid tin pool. The specific process is as follows: The duty cycle disturbance of the tin bath heating rod during the isothermal maintenance cycle is extracted as the real-time power attenuation characteristic. The liquid level echo signal fed back by the ultrasonic ranging sensor is extracted and analyzed into liquid level height data in the absolute physical coordinate system. The filament divergence coefficient, real-time power attenuation characteristics, and liquid level height data are used as input nodes and substituted into the multi-dimensional fuzzy inference control matrix to perform thermodynamic wetting mapping fusion, and the initial immersion depth and target capillary wetting time in the liquid tin pool are output.

[0011] Furthermore, the specific process of generating a nonlinear lifting speed curve with the initial pressing depth and the target capillary wetting time as constraints is as follows: The initial pressing depth is set as the total displacement constraint boundary of the lifting motion, and the end point of the target capillary wetting time is set as the zero point of the starting time of the lifting motion; a cubic spline interpolation algorithm is introduced to plan feature nodes in the lifting motion trajectory, including an initial slow separation segment, a middle uniform acceleration lifting segment, and a final high-speed shearing segment; and a smooth transition fitting is performed on the feature nodes according to the total displacement constraint boundary and the zero point of the starting time to generate a nonlinear lifting speed curve.

[0012] Furthermore, the control harness descends to the initial pressing depth to enter the liquid tin pool and activates the dwell timer. When the dwell timer accumulates to the target capillary wetting time, the specific process of controlling the lifting servo motor to lift the harness according to the nonlinear lifting speed curve is as follows: Based on the liquid level height data and the initial pressing depth, the absolute coordinates for descent are planned, and a position feedforward control command is issued to drive the lifting servo motor to move the harness down to the absolute coordinates for descent. When the end of the harness reaches the physical position corresponding to the liquid level height data, the dwell timer inside the controller is activated to start clock step accumulation. When the dwell timer accumulates to the target capillary wetting time, a hardware interrupt signal is generated, the discrete speed matrix sequence corresponding to the nonlinear lifting speed curve is extracted, the discrete speed matrix sequence is converted into a frequency conversion pulse sequence and sent to the driver of the lifting servo motor to control the lifting servo motor to lift the harness.

[0013] Furthermore, the attenuation slope of the motor load current is calculated synchronously. When the attenuation slope triggers the surface tension fracture threshold, a reverse pulse command is issued to drive the lifting servo motor to perform an instantaneous retraction action to cut off the liquid solder connection at the end of the wire harness. The specific process is as follows: During the lifting of the wire harness, the active load current sequence of the lifting servo motor is collected in real time through the bottom current loop of the servo driver. The first-order differential operator is applied to the active load current sequence to perform differentiation operation and output the attenuation slope of the motor load current. The attenuation slope is continuously input into the hysteresis comparator and compared with the surface tension fracture threshold execution state. During the control cycle when the attenuation slope exceeds the surface tension fracture threshold, a reverse pulse command containing negative gain characteristics is forcibly injected into the speed loop of the lifting servo motor to trigger the rotor of the lifting servo motor to perform an instantaneous retraction action to cut off the liquid solder connection at the end of the wire harness.

[0014] The present invention has the following beneficial effects:

[0015] (1) The integrated automated control method for wire harness cutting and tinning, by synchronously acquiring the torque current sequence of the feed servo motor and the rate of change of the current gradient at the moment of cutting into the insulation layer during the wire feeding and stripping stages, can accurately analyze the dynamic hardness and impedance value of the wire, and then dynamically adjust the micro-feed amount of the tool, fundamentally overcoming the processing defect that the internal wire core is easily damaged when the tool is used with fixed parameters. At the same time, the wire core deflection angle is extracted and the micro-morphology image is horizontally corrected by affine transformation, accurately extracting the outer edge coordinates of the copper wire end and calculating the filament divergence coefficient, realizing the quantitative evaluation of the micro-physical morphology of the exposed wire core, avoiding the defect of blindly pressing the tinning without being able to sense the wire core state of the existing equipment, and greatly improving the yield and processing consistency of the stripping process.

[0016] (2) The integrated automated control method for wire harness cutting and tinning, by collecting real-time power attenuation characteristics and liquid level data of the tin furnace, and combining the filament divergence coefficient with the thermodynamic wetting mapping relationship, can solve the customized initial pressing depth and target capillary wetting time for the current molten pool heat capacity state and the discrete morphology of the wire core. This effectively solves the problem of uneven tinning or cold solder joints caused by the combined effects of differences in the physical state of the wire and temperature fluctuations in the tin furnace. During the lifting and detachment stage, the lifting action is controlled by the generated nonlinear lifting speed curve, and the attenuation slope of the load current of the lifting servo motor is monitored in real time. When the surface tension fracture threshold is triggered, a reverse pulse command is instantly sent to drive the servo motor to perform an instantaneous retraction action, forcibly cutting off the liquid tin connection, completely eliminating the phenomenon of wire end sharpening and residual tin icicles, and completing high-quality closed-loop flexible automated control.

[0017] Of course, any product implementing this invention does not necessarily need to achieve all of the advantages described above at the same time. Attached Figure Description

[0018] Figure 1 This is a flowchart of the automated control method for integrated wire harness cutting and tinning of the present invention.

[0019] Figure 2 This is a flowchart of dynamic hardness impedance analysis and feed compensation control.

[0020] Figure 3 Flowchart for visual correction and filament feature calculation of exposed wire cores.

[0021] Figure 4 A flowchart for thermodynamic wetting mapping and pull-up trajectory planning.

[0022] Figure 5 This is a flowchart of surface tension fracture adaptive monitoring and pullback control. Detailed Implementation

[0023] This application embodiment solves the problems of wire core damage, uneven soldering, and solder icicle formation during lifting caused by the integrated automated control method for wire harness cutting and soldering in existing wire harness processing equipment when faced with fluctuations in wire material.

[0024] The overall concept of the solution in this application embodiment is as follows:

[0025] Abandoning the traditional mechanical loop and visual post-processing inspection model, this method directly transforms the physical execution results of preceding actions into dynamic control input parameters for subsequent actions, forming a coherent closed loop at the physical quantity level. First, by capturing the microscopic characteristics of the underlying servo current during the feeding and cutting processes, impedance changes are analyzed to achieve adaptive compensation for stripping depth. Next, affine transformation correction technology is used to precisely quantify the geometric filament state of the wire core after stripping. Then, the acquired filament divergence coefficient is mapped and fused with the thermodynamic characteristics of the solder pot to dynamically plan the immersion depth and dwell time for each soldering step. Finally, in the lifting stage, a load current attenuation slope monitoring and a reverse micro-pulse pull mechanism are introduced to actively sense and cut off the surface tension pull of the molten solder. The data chains between each processing step are tightly interlocked, forming a flexible adaptive control system from impedance sensing, visual correction, thermodynamic mapping to tension countermeasures, ultimately achieving efficient, precise, and stable automated wire harness processing.

[0026] Please see Figure 1This invention provides a technical solution: an integrated automated control method for wire harness cutting and tinning, comprising the following steps: S1, during the wire feeding and stripping stage, synchronously acquiring the torque current sequence of the feed servo motor and the current gradient change rate of the tool holder motor at the instant it cuts into the insulation layer, analyzing the dynamic hardness impedance value and core deflection angle of the wire based on the torque current sequence and current gradient change rate, setting micro-feed compensation parameters based on the dynamic hardness impedance value, and controlling the tool to perform the stripping action according to the micro-feed compensation parameters; S2, acquiring a micro-morphological image of the exposed core after the stripping action, extracting the core deflection angle to construct a rotation correction matrix and performing affine transformation level correction on the micro-morphological image, extracting the outer edge coordinates of the copper wire ends in the corrected image, and calculating the filament divergence coefficient based on the outer edge coordinates; S3, acquiring... The real-time power attenuation characteristics and liquid level data of the tin bath at the tin-coating station are used to input the filament divergence coefficient, real-time power attenuation characteristics, and liquid level data into a preset thermodynamic wetting mapping relationship to solve for the initial downward pressure depth and target capillary wetting time when immersed in the liquid tin pool. A nonlinear lifting speed curve is generated with the initial downward pressure depth and target capillary wetting time as constraints. S4: The control wire harness descends to the initial downward pressure depth and enters the liquid tin pool and activates the dwell timer. When the dwell timer accumulates to the target capillary wetting time, the lifting servo motor is controlled to lift the wire harness according to the nonlinear lifting speed curve. The attenuation slope of the motor load current is calculated synchronously. When the attenuation slope triggers the surface tension fracture threshold, a reverse pulse command is sent to drive the lifting servo motor to perform an instantaneous retraction action to cut off the liquid tin connection at the end of the wire harness.

[0027] In this implementation scheme, step S1 is mainly used to achieve flexible adaptive control of the feed depth during the stripping stage. During wire feeding and cutting, the system synchronously monitors the motor's torque-current sequence and current gradient rate of change. The torque-current sequence reflects the overall friction and resistance during wire travel; the current gradient rate of change refers to the rapid change in current over time at the moment the tool contacts the insulation layer; the dynamic hardness resistance value refers to the comprehensive physical resistance exhibited by the material under dynamic cutting; and the wire core deflection angle refers to the physical angle by which the internal copper wire deviates from the central axis due to tool compression. By analyzing these parameters, the system can obtain real-time information on the hardness and softness of the insulation layer of the current wire segment and its internal stress deformation state, thereby adaptively setting micro-feed compensation parameters and controlling tool cutting. This step effectively solves the technical defects of traditional equipment where varying insulation layer hardness due to different batches of wire leads to easy cutting of internal copper wires or incomplete stripping at a fixed feed depth, ensuring the physical execution accuracy of non-destructive stripping.

[0028] Step S2 is primarily used to accurately quantify the microscopic divergence morphology of the exposed wire core after stripping. After stripping, the system acquires a microscopic topographic image of the wire end area and uses the wire core deflection angle obtained in the previous stage to construct a rotation correction matrix to perform affine transformation level correction. Affine transformation level correction is an image processing technique designed to pull the wire core tilted by force back to a standard horizontal baseline through linear spatial mapping, eliminating visual errors caused by physical pose. The filament divergence coefficient is a quantitative indicator used to characterize the degree of loose outward expansion at the ends of multi-strand copper wires. Based on the corrected image, the coordinates of the outer edge of the copper wire end are extracted and the filament divergence coefficient is calculated, enabling the control system to accurately grasp the current physical divergence state of the wire core. This step provides a reliable geometric topographic input for the subsequent tinning process, overcoming the technical problem of traditional equipment blindly applying downward pressure for tinning due to its inability to perceive the filament state of the wire core, resulting in molten solder splashing or excessive solder coating.

[0029] Step S3 is primarily used to dynamically plan the spatiotemporal trajectory of tin immersion based on the molten pool's thermal capacity and the discrete morphology of the wire core. The system collects real-time power attenuation characteristics and liquid level data from the tin furnace, and combines this with the wire dispersion coefficient to solve the thermodynamic wetting mapping relationship. The real-time power attenuation characteristics reflect the fluctuations in electrical energy consumed by the tin furnace while maintaining a constant temperature; essentially, they represent the transient thermal energy consumption within the current molten tin pool. The thermodynamic wetting mapping relationship refers to the multi-dimensional control operation logic that corresponds the physical morphology of the wire bundle, the thermodynamic state of the molten tin, and the tin immersion time and depth. The target capillary wetting time refers to the optimal physical residence time required for the copper wires inside the wire to completely absorb an appropriate amount of molten tin through capillary action. After solving for the initial pressing depth and the target duration, these are used as constraints to generate a nonlinear pulling speed curve. This step enables the tin immersion action to adaptively adjust according to small fluctuations in the molten tin temperature and the degree of wire dispersion, effectively solving the problems of uneven tinning or cold solder joints caused by fixed residence time and pulling speed.

[0030] Step S4 is primarily used to forcibly sever the surface tension connection of the molten solder during the lifting and detachment phase through bottom-layer current feedback. The control system first drives the wire harness to immerse in the solder at the planned depth and precisely anchor it. Then, it lifts the wire harness according to a non-linear curve, calculating the attenuation slope of the motor load current in real time during the lifting process. The attenuation slope of the motor load current refers to the rate of change of the load current of the lifting motor over time as it drags the molten solder downwards against the surface tension of the molten solder. The surface tension breakage threshold is a specific current attenuation slope value that characterizes the molten solder droplet as it is about to stretch to its limit and break at the critical state. The reverse pulse command is an extremely short-duration reverse motion electrical signal directly injected into the bottom layer of the servo driver. When the current attenuation slope is detected to trigger the breakage threshold, the system instantly sends a reverse pulse command to cause the motor to perform an instantaneous retraction action. This step actively blocks the stretching and extension of the molten solder through a physical countermeasure mechanism, completely eliminating the residual solder icicle phenomenon that easily forms at the end of the wire in traditional lifting methods, ensuring that the solder-coated end face presents a perfectly rounded hemispherical shape.

[0031] Please see Figure 2 Specifically, during the wire feeding and stripping stages, the torque and current sequence of the feed servo motor and the rate of change of the current gradient at the instant the tool holder motor cuts into the insulation layer are simultaneously acquired. The specific process of analyzing the dynamic hardness resistance value and the core deflection angle of the wire based on the torque and current sequence and the rate of change of the current gradient is as follows: The sliding window mean filtering algorithm is applied to the torque and current sequence to filter out high-frequency interference features, and the steady-state friction torque baseline is extracted as the steady-state feed resistance feature. The steady-state feed resistance feature is input into a pre-calibrated material mechanical impedance lookup table to perform interpolation comparison and output the dynamic hardness resistance value; the extreme value of the rate of change of the current gradient at the instant the tool holder motor cuts into the insulation layer is extracted, and the extreme value of the rate of change of the current gradient and the dynamic hardness resistance value are used as input components and substituted into the multi-degree-of-freedom kinematic decoupling matrix to perform forward kinematic deduction, separating the feature vector of the wire's lateral displacement under stripping force state and outputting the core deflection angle.

[0032] In this implementation scheme, the current data of the feed motor is first smoothed using a sliding window mean filtering algorithm to eliminate current ripple caused by the inverter switching frequency. The core lies in the mathematical reconstruction of the physical force state through a multi-degree-of-freedom kinematic decoupling matrix. Since the coupling effect of shear force and extrusion force on the wire at the moment of stripping causes a small displacement of the wire core, this scheme constructs a kinematic decoupling formula: ,in : Core deflection angle; : Multi-degree-of-freedom kinematic decoupling matrix, used to map electrical signals in the current domain into displacement vectors in physical space; : Extreme value of the rate of change of current gradient; : Dynamic stiffness resistance value. During this process, the multi-degree-of-freedom kinematic decoupling matrix... By discretizing and fitting the experimental data of standard specimens under different eccentric loads, the nonlinear electromagnetic feedback is transformed into a linear geometric deviation through matrix operations. This enables the control system to accurately predict the instantaneous position fluctuation of the wire core when the stripping tool cuts in, providing accurate physical prior data for subsequent visual correction.

[0033] Specifically, the process of setting micro-feed compensation parameters based on dynamic hardness resistance values ​​and controlling the tool to perform peeling actions according to the micro-feed compensation parameters is as follows: The dynamic hardness resistance value is input into the spline nonlinear interpolator, which outputs the corresponding dynamic depth of cut deviation vector. The dynamic depth of cut deviation vector is fused with the standard depth of cut baseline of the current gauge to generate micro-feed compensation parameters. According to the electronic gear ratio configuration of the tool post motor, the micro-feed compensation parameters are converted into a target position pulse sequence. The target position pulse sequence is sent to the underlying fieldbus controller to drive the tool post servo motor to perform peeling actions under the set position loop tracking and torque upper limit clamping dual closed-loop constraint state.

[0034] In this implementation scheme, the specific process of setting micro-feed compensation parameters based on dynamic hardness impedance values ​​and controlling the tool to perform peeling actions according to these parameters is as follows: The dynamic hardness impedance value is input into the spline nonlinear interpolator, which outputs the corresponding dynamic depth-of-cut deviation vector. The dynamic depth-of-cut deviation vector is then fused with the current gauge's standard depth-of-cut baseline to generate micro-feed compensation parameters. These parameters are converted into a target position pulse sequence according to the electronic gear ratio configuration of the tool post motor. This target position pulse sequence is then sent to the underlying fieldbus controller, driving the tool post servo motor to perform the peeling action under the set position loop tracking and torque upper limit clamping dual closed-loop constraint state. In this implementation scheme, the spline nonlinear interpolator serves to establish a smooth transition curve between hardness changes and cutting depth compensation, preventing mechanical oscillations in the servo system caused by sudden parameter changes. Its calculation compensation logic is expressed as follows: ,in Micro-feed compensation parameters; : Spline interpolation function, used to calculate the feed displacement under nonlinear hardness response; Hardness sensitivity weighting coefficient; The standard cutting depth baseline for the current wire gauge. Hardness sensitivity weighting coefficient. The determination method is as follows: by pre-testing the Young's modulus and peel integrity of insulation layers of different materials, a regression analysis equation is established, and the regression coefficients are extracted as fixed weights to ensure that the compensation amount can cut through the insulation layer without damaging the internal wire core. At the execution level, the torque upper limit clamping dual closed-loop constraint refers to the real-time monitoring of the output torque of the servo drive based on the position control loop. Once the tool comes into contact with an obstacle of extremely high hardness (such as accidentally touching the wire core) causing the torque to exceed the set clamping threshold, the system will forcibly limit the feed, playing a dual role of physical protection and precision control.

[0035] Please see Figure 3 Specifically, the process of acquiring a macroscopic image of the exposed wire core after the stripping process, extracting the wire core deflection angle to construct a rotation correction matrix, and performing affine transformation horizontal correction on the macroscopic image is as follows: The sine and cosine components of the wire core deflection angle are extracted to construct a two-dimensional affine rotation correction matrix. The macroscopic image is then subjected to grayscale binarization to identify the transition boundary contour between the insulation layer and the exposed wire core. The geometric centroid coordinates of the connected domains of the transition boundary contour are extracted and designated as rotation anchor points. Spatial mapping is performed on the global pixel coordinate system of the macroscopic image around the rotation anchor points according to the two-dimensional affine rotation correction matrix. Finally, bilinear interpolation is applied to resample and fill the pixel gaps after spatial mapping, outputting a corrected image aligned with the horizontal reference.

[0036] In this implementation, the system first performs grayscale binarization on the macroscopic image to remove complex background interference and accurately identify the transition boundary contour at the junction of the insulation layer and the exposed wire core. To eliminate visual errors caused by the physical tilt of the wire core due to the previous stripping stress, the system needs to pull the tilted wire image back to a standard horizontal baseline. The system extracts the geometric centroid coordinates of the connected domain of this transition boundary contour and designates them as rotation anchor points. Combined with the wire core deflection angle obtained in the previous steps, a two-dimensional affine rotation correction matrix is ​​constructed and global spatial mapping is performed. The core spatial mapping calculation logic is expressed as follows: ,in : Target pixel coordinates after spatial mapping; : Core deflection angle; : Source pixel coordinates in the original macro topography image; : Geometric centroid coordinates of the connected component. Since the coordinate system after rotation mapping often has non-integer sub-pixel positions, direct rounding will cause jagged breaks at the image edges. Therefore, the system further applies a bilinear interpolation algorithm, which performs a weighted average of the gray values ​​of the four neighboring pixels around the target pixel, and performs resampling to fill the gaps between spatially mapped pixels, thereby outputting a corrected image with smooth edges and perfectly horizontal physical alignment.

[0037] Specifically, the process of extracting the outer edge coordinates of the copper wire ends in the corrected image and calculating the filament divergence coefficient based on the outer edge coordinates is as follows: Apply the edge gradient operator to the corrected image to extract the continuous line edge gradient map, scan the line edge gradient map along the axial direction of the wire core, extract the outer edge coordinates of the ends of multiple exposed copper wires and construct an edge pixel cluster; perform a bounding box fitting algorithm on the edge pixel cluster to generate the minimum bounding rectangle, extract the pixel span size of the minimum bounding rectangle perpendicular to the axial direction of the wire core as the horizontal width parameter, input the horizontal width parameter and the preset theoretical standard diameter of the wire core into the structural deviation analysis logic to perform discreteness mapping solution, and output the filament divergence coefficient.

[0038] In this implementation scheme, the system applies an edge gradient operator to perform high-pass filtering on the corrected image to highlight the wire bundle boundary contour and extract continuous wire edge gradient maps. Scanning this gradient map line by line along the axial direction of the wire core quickly removes overlapping, cluttered pixels and accurately captures the outermost boundary pixel cluster at the ends of the exposed copper wires. To transform the irregular physical filament shape into quantifiable geometric features, the system performs a bounding box fitting algorithm on this outer boundary pixel cluster to generate a minimum bounding rectangle, and extracts the pixel span dimension of this rectangle perpendicular to the wire core axis as the lateral width parameter. Based on this, the system performs structural deviation analysis between the actual outward expansion width and the theoretical standard; the discreteness mapping solution logic is expressed as follows: ;in, : Coefficient of filament divergence; Morphological scaling weighting coefficient; : The horizontal width parameter of the minimum bounding rectangle; : The preset theoretical standard diameter of the wire core; Optical distortion compensation threshold. By constructing this exponential nonlinear mapping relationship, the system significantly amplifies the numerical magnitude of severe fraying defects, providing a highly sensitive evaluation basis for the dynamic adjustment of subsequent solder bath immersion depth. The morphological scaling weight coefficient... The determination method is as follows: Multiple sets of standard good-quality wire harness filament morphology sample data are collected in advance; the correlation curve between ideal divergence and actual width is nonlinearly fitted using the least squares method; the tangent slope feature of the fitted curve is extracted for calibration; the optical distortion compensation threshold is... The determination method is as follows: In a darkroom reference environment without external light source interference, measure the physical drift of the edge pixels of the standard calibration block at a specific focal length of the current macro industrial camera, and take the arithmetic mean of multiple drift values ​​for fixed compensation settings.

[0039] Please see Figure 4Specifically, the real-time power attenuation characteristics and liquid level height data of the tin bath at the tin-filling station are collected. The filament divergence coefficient, real-time power attenuation characteristics, and liquid level height data are input into a preset thermodynamic wetting mapping relationship to solve for the initial immersion depth and target capillary wetting time in the liquid tin pool. The specific process is as follows: The duty cycle disturbance of the tin bath heating rod during the constant temperature maintenance period is extracted as the real-time power attenuation characteristic. The liquid level echo signal fed back by the ultrasonic ranging sensor is extracted and parsed into liquid level height data in the absolute physical coordinate system. The filament divergence coefficient, real-time power attenuation characteristics, and liquid level height data are used as input nodes and substituted into the multi-dimensional fuzzy inference control matrix to perform thermodynamic wetting mapping fusion, and the initial immersion depth and target capillary wetting time in the liquid tin pool are output.

[0040] In this implementation scheme, the duty cycle disturbance of the tin furnace heating rod is first monitored. This disturbance essentially reflects the degree of decrease in the transient heat capacity of the molten pool caused by the heat absorption when a relatively cold room-temperature wire is inserted into the high-temperature molten solder. Simultaneously, the system uses an ultrasonic sensor to acquire liquid level height data in an absolute physical coordinate system, providing a precise spatial reference for the downward pressing action. To completely solve the problem of uneven soldering or cold solder joints caused by the combined effects of differences in wire physical state and tin furnace temperature fluctuations, the system uses the previously acquired wire divergence coefficient, real-time power attenuation characteristics, and liquid level height data as input nodes, substituting them into a multi-dimensional fuzzy inference control matrix to perform thermodynamic wetting mapping fusion. Its core thermodynamic calculation logic is expressed as follows: ,as well as ,in Initial compression depth; Liquid level data; : Permeability compensation coefficient; : Coefficient of filament divergence; Real-time power attenuation characteristics; Physical wetting safety margin; Target capillary wetting duration; : Basic wetting time constant; : Capillary rheological index weights; : Heat capacity compensation coefficient. Through the above multi-dimensional mapping, the system can make dynamic responses according to specific situations. For example, when it is identified that the filament divergence coefficient is large and carries away a lot of heat, i.e., the power attenuation characteristic value is large, the algorithm will automatically increase the penetration depth and exponentially extend the residence time to ensure that the molten solder has sufficient time to completely penetrate into the loose copper wire gaps through capillary action. In this calculation step, the physical wetting safety margin... The method for determining this is to set a fixed value by measuring the critical thermal shrinkage distance of the insulation layer end under the thermal radiation of high-temperature molten tin, in order to prevent excessive pressing and damage to the insulation layer; capillary rheological index weighting. The determination method is to calibrate the dynamic permeability of lead-free liquid tin of a specific grade flowing through the gaps between multiple fine copper wire meshes at the standard melting point through a fluid dynamics experiment.

[0041] Specifically, the process of generating a nonlinear lifting speed curve with the initial pressing depth and the target capillary wetting time as constraints is as follows: The initial pressing depth is set as the total displacement constraint boundary of the lifting motion, and the end point of the target capillary wetting time is set as the zero point of the starting time of the lifting motion; a cubic spline interpolation algorithm is introduced to plan feature nodes in the lifting motion trajectory, including an initial slow separation segment, a middle uniform acceleration lifting segment, and a final high-speed shearing segment; and a smooth transition fitting is performed on the feature nodes according to the total displacement constraint boundary and the zero point of the starting time to generate a nonlinear lifting speed curve.

[0042] In this implementation scheme, after completing the precise downward pressure and dwell, the system enters the lifting and detachment trajectory planning stage. To avoid the formation of residual tin icicles at the end of the wire bundle due to the surface tension of liquid tin caused by traditional constant-speed lifting, the system sets the calculated initial downward pressure depth as the total displacement constraint boundary of the lifting motion, and sets the trigger time of the end of wetting as the zero point of the lifting motion's start time. The system introduces a cubic spline interpolation algorithm to plan feature nodes including an initial slow detachment segment, a mid-section uniformly accelerated lifting segment, and a final high-speed shearing segment, and performs smooth transition fitting to generate a nonlinear lifting speed curve. The transient speed control model of its lifting trajectory is expressed as: ,in Transient lifting speed; : accelerometer spline control parameters; : Constant acceleration spline control parameters; Initial escape velocity slope; Initial velocity at the zero point of the initial time; The time variable of the lifting motion. The purpose of this nonlinear trajectory planning is to allow excess liquid tin to overcome viscosity and flow back into the tin pool under its own gravity during the initial slow separation phase, effectively preventing tin thickening. During the high-speed shearing process from the middle to the end, the velocity and acceleration increase sharply, using strong shear inertia to physically sever the droplet connection. In this model, the acceleration spline control parameter... The method for determining this is to extract the maximum rated torque current derivative allowed by the lifting servo drive, scale it to the safe physical bearing boundary of the mechanical screw drive mechanism as the upper limit of the extreme value, thereby ensuring that the servo motor will not cause mechanical overshoot and destructive oscillation when performing a high-speed cutting action at the end.

[0043] Please see Figure 5Specifically, the control wire harness descends to the initial pressing depth to enter the liquid tin pool and activates the dwell timer. When the dwell timer accumulates to the target capillary wetting time, the lifting servo motor is controlled to lift the wire harness according to the nonlinear lifting speed curve. The specific process is as follows: Based on the liquid level height data and the initial pressing depth, the absolute coordinates for descent are planned. A position feedforward control command is issued to drive the lifting servo motor to move the wire harness down to the absolute coordinates for descent. When the end of the wire harness reaches the physical position corresponding to the liquid level height data, the dwell timer inside the controller is activated to start clock step accumulation. When the dwell timer accumulates to the target capillary wetting time, a hardware interrupt signal is generated. The discrete speed matrix sequence corresponding to the nonlinear lifting speed curve is extracted, and the discrete speed matrix sequence is converted into a frequency conversion pulse sequence and sent to the driver of the lifting servo motor to control the lifting servo motor to lift the wire harness.

[0044] In this implementation scheme, the system first translates the spatial requirements for immersion depth into the execution language of the underlying hardware. Based on the liquid level data and the initial downward pressure depth, it plans the absolute coordinates for the downward movement. The purpose of using absolute coordinates for positioning is to eliminate the cumulative displacement error that may be caused by multiple up-and-down reciprocating movements of the mechanical structure. Subsequently, a position feedforward control command is issued, enabling the lifting servo motor to directly drive the wire harness to the target depth with extremely low follow-up error. At the instant the end of the wire harness reaches the physical position of the liquid surface, the system uses a hardware interrupt mechanism to activate the dwell timer inside the controller to start clock step accumulation. The hardware-level clock ensures that the dwell time execution accuracy of capillary wetting reaches the micro-control cycle level. When the dwell timer accumulates to the target capillary wetting duration, the system extracts the discrete velocity matrix sequence corresponding to the previously planned nonlinear lifting speed curve. To enable the servo driver to accurately execute this nonlinear physical disengagement movement, the system converts the discrete velocity matrix sequence into a frequency-modulated pulse sequence and issues it. Its pulse frequency mapping model is expressed as: ,in : The discrete frequency value of the frequency conversion pulse sequence in the nth control cycle; : The transient physical linear velocity corresponding to the nth sampling point in the discrete velocity lattice sequence; The absolute encoder resolution of the lifting servo motor; The physical lead of the lifting mechanism lead screw; The reference clock execution cycle of the underlying driver. Through this step, the system accurately translates the macroscopic speed planning curve into a high-frequency electronic pulse signal that can be directly driven by the underlying motor controller. This controls the lifting servo motor to accurately lift the wire harness, ensuring that the physical trajectory of the wire leaving the molten pool perfectly matches the ideal thermodynamic separation state.

[0045] Specifically, the attenuation slope of the motor load current is calculated synchronously. When the attenuation slope triggers the surface tension fracture threshold, a reverse pulse command is issued to drive the lifting servo motor to perform an instantaneous retraction action to cut off the liquid solder connection at the end of the wire harness. The specific process is as follows: During the lifting of the wire harness, the active load current sequence of the lifting servo motor is collected in real time through the bottom current loop of the servo driver. The first-order differential operator is applied to the active load current sequence to perform differentiation operation and output the attenuation slope of the motor load current. The attenuation slope is continuously input into the hysteresis comparator and compared with the surface tension fracture threshold execution state. During the control cycle when the attenuation slope exceeds the surface tension fracture threshold, a reverse pulse command containing negative gain characteristics is forcibly injected into the speed loop of the lifting servo motor to trigger the rotor of the lifting servo motor to perform an instantaneous retraction action to cut off the liquid solder connection at the end of the wire harness.

[0046] In this implementation scheme, during the process of lifting the wire harness from the liquid solder bath, the system must overcome the downward pulling force generated by the surface tension of the liquid solder. This pulling force is the root cause of residual sharpening at the wire end. The system collects the active load current sequence of the lifting servo motor in real time through the underlying current loop of the servo driver. The active load current is essentially an electrical representation of the motor's output torque, which can be directly equivalent to the physical drag resistance of the liquid surface tension currently acting on the wire harness. To accurately capture the extreme transient characteristics of the impending breakage of the surface tension, the system applies a first-order differential operator to perform differentiation on the active load current sequence, outputting the motor load current decay slope representing the rate of change of drag resistance. Its discrete difference calculation logic is expressed as follows: ,in : The discrete derivative of the decay slope of the motor load current at the m-th sampling time; : The real-time amplitude of the active load current sequence at the m-th sampling time; The lag amplitude of the active load current sequence at the previous sampling time; : Fixed differential sampling time interval of the bottom current loop; Differential smoothing gain coefficient. The calculated attenuation slope is continuously input into the hysteresis comparator and compared with the surface tension fracture threshold at high frequency. Once the attenuation slope exceeds the surface tension fracture threshold, it indicates that the stretching and necking phenomenon of liquid tin has reached the critical point of imminent separation. At this time, the system forcibly injects a reverse pulse command containing negative gain characteristics into the speed loop of the lifting servo motor, triggering the rotor of the servo motor to produce a very short instantaneous retraction action. This action uses strong mechanical shear inertia to instantly and actively sever the residual liquid tin connection, thereby ensuring the roundness and flatness of the tin-coated end face. The differential smoothing gain coefficient mentioned in this step The determination method is to collect the white noise current differential variance of the servo system under mechanical no-load uniform speed state, take its reciprocal and normalize it, and then use it as a fixed gain input to filter out microscopic false triggers caused by high-frequency electromagnetic interference; the determination method of the surface tension fracture threshold is to stretch a standard lead-free solder droplet in a constant temperature molten state using a high-frequency electronic tensiometer, measure the critical tensile drop change rate of the droplet from stretching to necking fracture, and combine it with the torque constant of the servo motor of this model to linearly and equivalently convert it into the corresponding current derivative limit value and write it into the setting.

[0047] In summary, this application has at least the following effects:

[0048] The integrated automated control method for wire harness cutting and tinning abandons the open-loop processing mode of traditional equipment that relies on mechanical dead loops and blind execution of fixed parameters, and establishes a flexible closed-loop control system based on physical situation perception and process cascade feedback. During the stripping stage, adaptive compensation for the micro-feed amount is achieved by analyzing the impedance mapping between the underlying motor torque and current gradient, effectively eliminating the hidden danger of cutting the internal wire core due to fluctuations in wire hardness. In the vision stage, affine transformation level correction technology is used to accurately extract the filament divergence coefficient, transforming the irregular micro-morphology of the wire core into a reliable geometric feature input for subsequent processes. Subsequently, multi-dimensional thermodynamic wetting mapping is performed by combining the real-time power attenuation of the solder pot and the liquid level height. The pressing depth and nonlinear lifting trajectory are dynamically planned for the instantaneous discrete state of each wire bundle and the heat capacity of the molten pool, effectively overcoming the uneven soldering and cold solder joint defects caused by the traditional fixed dwell time. Finally, in the detachment stage, the attenuation slope of the lifting motor load current is monitored by first-order differential high-frequency monitoring, accurately capturing the critical point when the surface tension is about to break and instantly triggering a reverse pulse to perform rapid retraction, actively and physically cutting off the stretching and extension of the liquid solder, and completely eliminating the phenomenon of residual solder icicles at the wire end. This method enables tight data command interlocking between processing steps in the entire production line, achieving real-time adaptive collaborative control at the underlying physical parameter level, and significantly improving the yield, end-face flatness, and batch consistency of modern precision wire harness automated processing.

[0049] Those skilled in the art will understand that embodiments of the present invention can be provided as methods, systems, or computer program products. Therefore, the present invention can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the present invention can take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0050] This invention is described with reference to flowchart illustrations and / or block diagrams of systems, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart illustrations and / or block diagrams. Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0051] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0052] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0053] Although preferred embodiments of the invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including both the preferred embodiments and all changes and modifications falling within the scope of the invention.

[0054] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. An automated control method for integrated wire harness cutting and soldering, characterized in that, Includes the following steps: S1. During the wire feeding and stripping stage, the torque current sequence of the feed servo motor and the current gradient change rate of the tool holder motor when cutting into the insulation layer are collected simultaneously. The dynamic hardness resistance value and core deflection angle of the wire are analyzed based on the torque current sequence and current gradient change rate. The micro-feed compensation parameter is set according to the dynamic hardness resistance value, and the tool is controlled to perform the stripping action according to the micro-feed compensation parameter. S2. Collect a micro-morphological image of the exposed wire core after the stripping action, extract the wire core deflection angle to construct a rotation correction matrix, and perform affine transformation level correction on the micro-morphological image. Extract the outer edge coordinates of the copper wire end in the corrected image, and calculate the filament divergence coefficient based on the outer edge coordinates. S3. Collect the real-time power attenuation characteristics and liquid level data of the tin furnace at the tin plating station. Input the filament divergence coefficient, real-time power attenuation characteristics and liquid level data into the preset thermodynamic wetting mapping relationship, solve the initial pressure depth and target capillary wetting time of immersion in the liquid tin pool, and generate a nonlinear lifting speed curve with the initial pressure depth and target capillary wetting time as constraints. S4. Control the wire harness to descend to the initial pressing depth and enter the liquid solder pool and activate the dwell timer. When the dwell timer accumulates to the target capillary wetting time, control the lifting servo motor to lift the wire harness according to the nonlinear lifting speed curve. Simultaneously calculate the attenuation slope of the motor load current. When the attenuation slope triggers the surface tension fracture threshold, send a reverse pulse command to drive the lifting servo motor to perform an instantaneous retraction action to cut off the liquid solder connection at the end of the wire harness.

2. The integrated automated control method for wire harness cutting and tinning as described in claim 1, characterized in that: During the wire feeding and stripping stages, the torque and current sequence of the feed servo motor and the rate of change of the current gradient at the instant the tool holder motor cuts into the insulation layer are simultaneously acquired. The specific process of analyzing the dynamic hardness impedance value and core deflection angle of the wire based on the torque and current sequence and the rate of change of the current gradient is as follows: The sliding window mean filtering algorithm is applied to the torque current sequence to filter out high-frequency interference features, and the steady-state friction torque baseline is extracted as the steady-state feed resistance feature. The steady-state feed resistance feature is input into a pre-calibrated material mechanical impedance lookup table to perform interpolation comparison and output the dynamic hardness impedance value. Extract the extreme value of the rate of change of the current gradient at the instant the tool holder motor cuts into the insulation layer. Use the extreme value of the rate of change of the current gradient and the dynamic hardness impedance value as input components, substitute them into the multi-degree-of-freedom kinematic decoupling matrix to perform forward kinematic deduction, separate the characteristic vector of the wire's lateral displacement under the stripping force state, and output the wire core deflection angle.

3. The integrated automated control method for wire harness cutting and tinning as described in claim 1, characterized in that: The specific process of setting the micro-feed compensation parameters based on the dynamic hardness resistance value and controlling the tool to perform the peeling action according to the micro-feed compensation parameters is as follows: The dynamic hardness impedance value is input into the spline nonlinear interpolator, which outputs the corresponding dynamic cutting depth deviation vector. The dynamic cutting depth deviation vector is then fused with the standard cutting depth baseline of the current gauge to generate micro-feed compensation parameters. Based on the electronic gear ratio configuration of the tool turret motor, the micro-feed compensation parameters are converted into a target position pulse sequence. The target position pulse sequence is then sent to the underlying fieldbus controller to drive the tool turret servo motor to perform the peeling action under the set position loop tracking and torque upper limit clamping dual closed loop constraint state.

4. The integrated automated control method for wire harness cutting and tinning according to claim 1, characterized in that: The specific process of acquiring macroscopic topographic images of the exposed wire core after the stripping process, extracting the wire core deflection angle to construct a rotation correction matrix, and performing affine transformation level correction on the macroscopic topographic images is as follows: The sinusoidal and cosine components of the core deflection angle are extracted to construct a two-dimensional affine rotation correction matrix. Grayscale binarization is performed on the micro-topography image to identify the transition boundary contour between the insulation layer and the exposed core. Extract the geometric centroid coordinates of the connected domain of the transition boundary contour and designate them as rotation anchor points. Perform spatial mapping on the global pixel coordinate system of the macro topography image around the rotation anchor points according to the two-dimensional affine rotation correction matrix. Then, apply the bilinear interpolation algorithm to resample and fill the pixel gaps after spatial mapping, and output a corrected image aligned with the horizontal reference.

5. The integrated automated control method for wire harness cutting and tinning according to claim 4, characterized in that: The specific process of extracting the outer edge coordinates of the copper wire ends in the corrected image and calculating the wire divergence coefficient based on the outer edge coordinates is as follows: The edge gradient operator is applied to the corrected image to extract the continuous line edge gradient map. The line edge gradient map is scanned along the axial direction of the wire core to extract the outer edge coordinates of the ends of the exposed copper wires and construct the edge pixel cluster. A bounding box fitting algorithm is performed on the edge pixel clusters to generate the minimum bounding rectangle. The pixel span dimension of the minimum bounding rectangle perpendicular to the axial direction of the wire core is extracted as the horizontal width parameter. The horizontal width parameter and the preset theoretical standard diameter of the wire core are input into the structural deviation analysis logic to perform discreteness mapping solution, and the filament divergence coefficient is output.

6. The integrated automated control method for wire harness cutting and tinning according to claim 1, characterized in that: The real-time power attenuation characteristics and liquid level data of the tin bath at the tin-filling station are collected. The filament divergence coefficient, real-time power attenuation characteristics, and liquid level data are input into a preset thermodynamic wetting mapping relationship. The specific process of solving the initial immersion depth and target capillary wetting time in the liquid tin bath is as follows: The duty cycle disturbance of the tin furnace heating rod during the constant temperature maintenance period is extracted as the real-time power attenuation feature. The liquid level echo signal fed back by the ultrasonic ranging sensor is extracted and analyzed into liquid level height data in the absolute physical coordinate system. The filament divergence coefficient, real-time power attenuation characteristics, and liquid level height data are used as input nodes and substituted into the multidimensional fuzzy inference control matrix to perform thermodynamic wetting mapping fusion, outputting the initial downward pressure depth of immersion in the liquid tin pool and the target capillary wetting time.

7. The integrated automated control method for wire harness cutting and tinning according to claim 1, characterized in that: The specific process for generating a nonlinear lifting speed curve with initial compression depth and target capillary wetting time as constraints is as follows: The initial pressing depth is set as the total displacement constraint boundary of the lifting motion, and the end point of the target capillary wetting time is set as the zero point of the start time of the lifting motion. A cubic spline interpolation algorithm is introduced to plan feature nodes in the lifting motion trajectory, including an initial slow separation segment, a middle uniform acceleration lifting segment, and a final high-speed shearing segment. Based on the total displacement constraint boundary and the zero point of the starting time, a smooth transition fitting is performed on the feature nodes to generate a nonlinear lifting speed curve.

8. The integrated automated control method for wire harness cutting and tinning according to claim 1, characterized in that: The control wire harness descends to the initial pressing depth and enters the liquid solder pool, activating the dwell timer. When the dwell timer accumulates to the target capillary wetting time, the specific process of controlling the lifting servo motor to lift the wire harness according to the nonlinear lifting speed curve is as follows: Based on the liquid level data and the initial pressure depth, the absolute coordinates for the downward movement are planned. The position feedforward control command is issued to drive the lifting servo motor to move the harness down to the absolute coordinates for the downward movement. When the end of the harness reaches the physical position corresponding to the liquid level data, the dwell timer inside the controller is activated to start the clock step accumulation. When the dwell timer reaches the target capillary wetting time, a hardware interrupt signal is generated. The discrete speed matrix sequence corresponding to the nonlinear lifting speed curve is extracted, and the discrete speed matrix sequence is converted into a frequency conversion pulse sequence and sent to the driver of the lifting servo motor to control the lifting servo motor to lift the wire harness.

9. The integrated automated control method for wire harness cutting and tinning according to claim 8, characterized in that: The process of synchronously calculating the attenuation slope of the motor load current, and issuing a reverse pulse command to drive the lifting servo motor to perform an instantaneous retraction action to cut off the liquid solder connection at the end of the wire harness when the attenuation slope triggers the surface tension fracture threshold, is as follows: During the lifting process, the active load current sequence of the lifting servo motor is collected in real time through the underlying current loop of the servo driver. The first-order differential operator is applied to the active load current sequence to perform differentiation operation and output the attenuation slope of the motor load current. The attenuation slope is continuously input into the hysteresis comparator and compared with the surface tension fracture threshold execution state. During the control cycle when the attenuation slope exceeds the surface tension fracture threshold, a reverse pulse command containing negative gain characteristics is forcibly injected into the speed loop of the lifting servo motor, triggering the rotor of the lifting servo motor to generate an instantaneous retraction action to cut off the liquid solder connection at the end of the wire harness.

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