High-speed wire harness core wire quality on-line detection device

Abstract

The invention relates to the technical field of high-speed cable production and detection, and particularly discloses a high-speed wire harness core wire quality online detection device which comprises a rack, a detection assembly arranged along a wire harness path and a marking assembly located at the downstream. The detection assembly is provided with an air floatation guide mechanism and comprises breathable sliding blocks and an adjusting assembly which are arranged in a circumferential array; the adjusting assembly adopts the principle similar to a chuck to drive sliding blocks to move synchronously in the radial direction, the sliding blocks form a high-rigidity air cushion constraint field around the high-speed core wire through micropores, and non-contact guiding is achieved. The marking assembly comprises a driving rotary arm, a marking head and a connecting rod, the driving rotary arm drives the marking head to do circular motion, the lowest point of the track is synchronous with the core wire in speed, and the technical problems that under the high-speed working condition, the guide wheel vibrates to damage the wire rod, and marking is fuzzy due to airflow interference are solved through cooperation with a specially-made wind breaking cover. According to the invention, nondestructive testing and high-definition fixed-point marking of the high-speed wire harness are realized.

Description

Technical Field

[0001] This invention relates to the field of high-speed cable production and testing technology, specifically to an online testing device for the core wire quality of high-speed wire harnesses. Background Technology

[0002] With the rapid development of new energy vehicles, aerospace, and 5G communication technologies, the quality requirements for transmission harnesses are becoming increasingly stringent. In modern cable manufacturing, production speeds are often extremely high (typically between 300 meters / minute and 1000 meters / minute). Under such high-speed operating conditions, online detection and marking of damage, protrusions, dents, and color rings on the insulation layer of the core wires present significant technical challenges.

[0003] Chinese patent application CN102297867A discloses a wire harness assembly quality inspection system, including: a wire harness image acquisition module for acquiring one or more frames of wire harness images; and a judgment and detection module for extracting partial images of each type of wire in the wire harness images and comparing the partial images of each type of wire with a standard wire harness image. If the partial images of each type of wire in a wire harness are consistent with the standard wire harness image, the inspection is qualified; otherwise, the inspection is unqualified.

[0004] However, this existing technology has significant drawbacks in high-speed scenarios: First, there is physical contact and intense friction between the mechanical pressure roller and the cable surface. At high speeds, the radial runout of the mechanical roller is directly transmitted to the cable, resulting in unstable imaging focus and blurred images. At the same time, the pressure of the mechanical roller can easily leave indentations or scratches on the surface of precision cables (such as foam-insulated cables), causing secondary damage.

[0005] Secondly, existing defect marking typically uses stationary inkjet printers. At high line speeds, the boundary layer airflow on the cable surface is very strong, directly blowing away the ejected ink droplets, resulting in blurry and misaligned markings. The significant relative speed between the stationary printhead and the high-speed moving cable causes severe stretching and deformation of the printed marking pattern (Doppler effect and geometric stretching), making it impossible to form clear and readable markings.

[0006] In conclusion, the development of a detection device that can adapt to high-speed operating conditions, achieve non-contact stable guidance, and overcome airflow interference for high-definition marking is an urgent need in the industry. Summary of the Invention

[0007] This invention provides an online detection device for the core wire quality of high-speed wire harnesses, aiming to solve the problems of large guiding vibration and easy surface damage in high-speed cables, as well as the problems of large interference from airflow and severe pattern deformation of high-speed markings in related technologies.

[0008] A high-speed wire harness core wire quality online inspection device includes: a frame, an inspection component, and a marking component; the inspection component is arranged along the wire harness transmission path, and the marking component is located downstream of the inspection component; the inspection component is equipped with an air-bearing guide mechanism, which includes: a ventilated slider and an adjustment component; the ventilated sliders are arranged in a circumferential array, and the adjustment component drives several ventilated sliders to move synchronously in the radial direction; the ventilated sliders are provided with multiple vent holes on the side near the wire core, and an air supply component is connected to the ventilated sliders; the ventilated sliders are used to form an air cushion constraint field around the high-speed moving core wire; the marking component includes a drive arm and a marking head; the drive arm drives the marking head to perform a circular motion, so that the tangential velocity of the marking head when passing through the lowest point of the trajectory is the same as the velocity of the core wire, and the drive arm ensures that the marking head remains perpendicular to the core wire throughout the entire movement.

[0009] Its effect is as follows: the air cushion constraint field constructed by the breathable slider eliminates the need for traditional mechanical wheel contact guidance. During high-speed transmission, the core wire is suspended and fixed at the center of the flow field by a high-pressure air film. The air cushion not only acts as a lubricant, preventing mechanical scratches, but also functions as a high-frequency air spring, effectively absorbing the high-frequency vibrations of the core wire. This ensures the straightness and stability of the core wire in the detection area, thereby significantly improving the imaging clarity of visual inspection.

[0010] The marking component employs a rotary tangential tracking method driven by a rotating arm, ensuring that the tangential linear velocity of the marking head matches the cable's transmission speed at the instant of contact (the lowest point of the trajectory), achieving relative stillness. This zero-relative-velocity marking method completely eliminates marking stretching and distortion caused by speed differences.

[0011] Meanwhile, by maintaining a consistently vertical posture control, the nozzle is always directly facing the cable surface, avoiding trapezoidal distortion of the pattern caused by tilted spray angle. This device achieves non-destructive testing and high-precision marking while ensuring extremely high production efficiency (high speed), meeting the stringent standards of high-end cable manufacturing.

[0012] Preferably, the adjustment assembly includes: a fixed plate and a jaw; the fixed plate is disposed on the frame, the jaw is slidably disposed on the fixed plate in the radial direction, the ventilated slider is fixedly disposed on the jaw, and the ventilated slider moves radially with the jaw.

[0013] The advantages of this invention are as follows: It employs a fixed disc and jaw adjustment method (similar to the principle of a three-jaw chuck). This structure achieves absolute synchronous concentric adjustment of multiple sliders. When changing core wires of different diameters, simply rotating the drive disc causes all the jaws to move the air-bearing sliders equidistantly towards or away from the center. This not only ensures that the air-bearing center always coincides with the core wire axis (self-centering characteristic), but also results in a compact and rigid structure capable of withstanding the reaction force of high-speed airflow, significantly reducing changeover and debugging time.

[0014] Preferably, the side of the ventilated slider facing the core wire is a concave arc surface, which is made of porous sintered metal or microporous ceramic material; the density of the ventilated holes on the concave arc surface is distributed in a gradient distribution with high density at both ends and low density in the middle, so that the air cushion constraint field forms a high-pressure air curtain at both ends of the axial direction.

[0015] Its effects are as follows: the use of porous sintered metal or microporous ceramic in the venting slider ensures the uniformity of the vent diameter, resulting in a good laminar flow effect in the formed air film without turbulent vibration. More importantly, it is designed with a gradient distribution of vent density, high at both ends and low in the middle. This design forms a high-pressure air curtain at both ends of the slider. In fluid dynamics, this is equivalent to adding two end caps to the air cushion field, greatly reducing the rapid leakage of high-pressure gas along the axial direction, resulting in higher bearing pressure and stronger stiffness at the center of the air cushion, while reducing the overall energy consumption of the air source and improving the ability to suppress core wire bounce.

[0016] Preferably, the detection component is mounted on the frame via a floating damping base, which is equipped with an elastic damping element that can filter low-frequency mechanical vibrations transmitted from the outside to the air-bearing guide mechanism.

[0017] The effect is as follows: the floating damping base isolates mechanical vibrations. Industrial environments are complex, and the frame often transmits low-frequency, high-amplitude vibrations from the ground, motors, or winding equipment. A low-pass filter composed of elastic damping elements effectively blocks these low-frequency interferences from reaching the air-bearing mechanism. The air-bearing mechanism itself primarily addresses the high-frequency micro-vibrations of the core wire. This strategy of segmented management of high and low frequencies ensures that the detection components have extremely high image stabilization performance, enabling the camera to capture surface defects.

[0018] Preferably, the drive arm includes multiple connecting rods arranged radially, with the marking head located at the end of the connecting rod away from the rotation axis, and the connecting rods are engaged with the drive arm.

[0019] Its effect is that the radially arranged connecting rods solve the posture problem in rotary marking. By setting the connecting rods, the marking head is ensured to be at the bottom during marking. At the same time, setting multiple connecting rods allows for rapid and continuous marking.

[0020] Preferably, a windbreak shroud is provided on the outer periphery of the marking head; the front windward surface of the windbreak shroud is designed as an acute-angled V-shape, and the windbreak shroud is in the same direction as the tangential velocity of the drive arm rotation; when the marking head cuts into the core wire trajectory at high speed, the windbreak shroud splits the airflow on the surface of the core wire to both sides, so that the marking head nozzle located inside the windbreak shroud is in the airflow stagnant zone, preventing the high-speed airflow from blowing away the ink droplets.

[0021] Its effectiveness lies in the introduction of aerodynamic design to address the strong boundary layer airflow associated with high-speed cables. The acute-angled V-shaped wind deflector physically cuts and diverts the high-speed airflow, significantly reducing air resistance on the windward side of the marking head. More importantly, it artificially creates an airflow stagnant zone inside the deflector. Within this zone, the air velocity is extremely low, preventing the tiny ink droplets ejected from the nozzle from being dispersed by external wind. This ensures that the ink droplets fly in a straight line and adhere precisely to the cable surface, solving the problems of ink splatter and blurring during high-speed marking.

[0022] Preferably, a flexible ring is provided on the end face of the windbreak near the cable. The flexible ring is snapped onto the windbreak, and a clearance notch adapted to the cross-sectional shape of the cable is opened at the end of the flexible sealing ring near the core.

[0023] Its effect is that the flexible sealing ring and its clearance notch design constitute the last physical line of defense for the vent. It seals the bottom opening of the vent to the maximum extent without contacting or only slightly contacting the cable. At the same time, the flexible material (such as silicone or bristles) allows for a certain degree of radial runout of the cable without damaging its surface, achieving a balance between sealing and safety.

[0024] Preferably, a pneumatic slip ring is integrated at the rotation axis of the drive arm; the control signal line and ink supply line required by the marking head pass through the central hole of the pneumatic slip ring and are connected to the rotating marking head.

[0025] Its advantages lie in the fact that the integrated electric slip ring solves the problem of media transmission in rotating mechanisms. It allows the marking head to rotate continuously an unlimited number of times, making it suitable for high-frequency continuous defect marking without concerns about cable tangling or breakage. This enables the device to perform not only reciprocating marking but also continuous, intensive marking, greatly expanding its application scenarios.

[0026] Preferably, the detection assembly includes two sets of air-bearing guide mechanisms arranged at intervals along the transmission direction of the core wire; a detection zone is formed between the two sets of air-bearing guide mechanisms, and a ring light source and an industrial camera are arranged in the detection zone. The core wire is kept in the detection state within the detection zone under the pneumatic clamping of the two sets of air-bearing guide mechanisms.

[0027] The effect is that by setting two sets of spaced-apart air-bearing mechanisms, a suspended detection zone is created in the middle. The cable in this area is in a non-contact tensioned state. Compared with single-point support, the cable straightness under this dual-point support structure is better, and it is completely suspended, which facilitates all-angle illumination by the ring light source, avoids background interference, and greatly improves the signal-to-noise ratio of optical imaging.

[0028] Preferably, the adjustment assembly further includes a drive motor, a controller, and a transmission gear; the drive motor drives the chuck to move closer to or further away from the fixed disk via the transmission gear, and the controller controls the drive motor to automatically adjust the guide hole diameter formed by the air-permeable slider according to the diameter specification of the core wire to be tested.

[0029] Its effectiveness lies in the fact that by introducing a motor, controller, and transmission gears, the aperture adjustment is digitized and automated. The controller can automatically adjust the air flotation gap in milliseconds based on the wire diameter parameters in the production order. This not only eliminates errors from manual adjustment but also enables rapid mold changeover on the production line, aligning with the development trend of intelligent manufacturing in industry.

[0030] By adopting the above technical solution, the beneficial effects of the present invention are as follows:

[0031] 1. This invention achieves non-contact, image-stabilized inspection under high-speed operating conditions, eliminating the risk of mechanical damage. Existing technologies generally use mechanical guide wheels to compress and guide high-speed moving cables. This not only easily introduces high-frequency vibrations due to wheel bounce, leading to unstable visual imaging focus and blurred images, but also easily leaves indentations or scratches on the surface of precision cables (such as foamed insulation layers and special optical fibers). This application constructs an air cushion constraint field based on a breathable slider. Utilizing a high-pressure air film ejected from a porous medium, the core wire is suspended at the center of the flow field, achieving completely zero-contact guidance. The air cushion layer physically acts as a high-rigidity, frictionless air bearing, effectively lubricating the wire and preventing surface damage, while also absorbing high-frequency micro-vibrations like an air spring, ensuring that the radial runout of the wire in the inspection area is controlled at the micrometer level. This stability provides perfect imaging conditions for high-frame-rate industrial cameras, significantly improving the detection rate of minute defects.

[0032] 2. At linear speeds exceeding 500 m / min, the boundary layer airflow on the cable surface is extremely strong, often causing ink scattering and blurred markings. By utilizing aerodynamic principles through a V-shaped air breaker, the boundary layer airflow is cut like a cleaver, creating a relatively enclosed airflow stagnant zone around the marking head. Within this windless microenvironment, ink droplets maintain a straight flight trajectory and accurately adhere to the cable. Simultaneously, combined with a kinematic design for rotational tangential tracking, the marking head maintains zero relative velocity with the cable at the moment of contact. This not only eliminates pattern stretching and distortion caused by speed differences but also allows ink droplets to land vertically and smoothly on defect points, enabling the printing of clearly readable characters or color rings even at extremely high linear speeds.

[0033] 3. Given the current production situation where cable specifications vary widely (diameters ranging from 1mm to 10mm), traditional equipment often requires downtime to replace guide rollers of different sizes, which is time-consuming and labor-intensive. The air-bearing guiding mechanism in this application adopts a planar threaded synchronous adjustment structure similar to a three-jaw chuck. A motor is all that's needed to synchronously and equidistantly move the air-bearing slider centripetally or centrifugally, achieving stepless adjustment of the aperture. This design not only ensures that the air-bearing center always coincides with the equipment axis regardless of changes in cable diameter (self-centering characteristic), but also achieves millisecond-level automated mold changing, significantly reducing production line downtime for debugging.

[0034] 4. The design of the ventilated slider employs a gradient porosity process, resulting in a large airflow at both ends and a small airflow in the middle, thus forming a high-pressure air curtain sealing zone at both axial ends. This design effectively prevents rapid axial leakage of high-pressure gas, significantly improving the load-bearing stiffness and centering recovery force of the air cushion, while reducing air source energy consumption. Furthermore, the entire detection assembly is mounted on a floating damping base, utilizing elastic damping elements to construct a mechanical low-pass filter. This effectively isolates low-frequency, high-amplitude vibrations from the foundation, motor, and other external environments, ensuring that the air flotation system only needs to handle the high-frequency vibrations of the wire itself, thereby guaranteeing long-term stable operation in harsh industrial environments.

[0035] 5. The flexible sealing ring and clearance notch at the lower end of the V-shaped vent form the last line of physical protection for the vent. It seals the bottom opening of the vent to the maximum extent without contacting or only slightly contacting the cable. At the same time, the flexible material (such as silicone or bristles) allows for a certain degree of radial movement of the cable without damaging its surface, achieving a balance between sealing and safety. Attached Figure Description

[0036] Figure 1 This is a schematic diagram of the overall structure of the present invention.

[0037] Figure 2 This is a schematic diagram of the air-floating guide mechanism in the detection component of the present invention.

[0038] Figure 3 This is a schematic diagram of the structure of the air flotation guide mechanism and the marking assembly of the present invention.

[0039] Figure 4 This is a schematic diagram of the installation structure of the adjustment component of the present invention.

[0040] Figure 5 This is a schematic diagram of the structure of the breathable slider of the present invention.

[0041] Figure 6 This is a schematic diagram of the structure of the vent hole and the concave arc surface of the present invention.

[0042] Figure 7Here is a schematic diagram of the structure of the marking component of this invention: Reference numerals: 1. Frame; 2. Detection component; 21. Air-bearing guide mechanism; 211. Air-permeable slider; 212. Air supply component; 213. Air vent; 214. Concave arc surface; 22. Adjustment component; 221. Fixed plate; 222. Claw; 23. Floating shock-absorbing base; 24. Ring light source; 25. Industrial camera; 26. Drive motor; 3. Marking component; 31. Drive arm; 32. Marking head; 33. Connecting rod; 34. Air breaker; 35. Flexible sealing ring; 351. Clearance notch; 4. Core wire. Detailed Implementation

[0043] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0044] like Figures 1 to 7 As shown, a high-speed wire harness core wire quality online inspection device mainly includes: a frame 1, an upstream inspection component 2, and a downstream marking component 3; the core wire 4, driven by the production line traction equipment, passes through the device from left to right along the wire harness transmission path at high speed (e.g., 500m / min to 800m / min). The core wire 4 is inspected by the upstream inspection component 2 on the device. After the inspection is completed, the unqualified signal is transmitted to the downstream marking component 3, and the marking component 3 marks the core wire 4.

[0045] The air cushion constraint field constructed by the breathable slider 211 eliminates the need for traditional mechanical wheel contact guidance. During high-speed transmission, the core wire 4 is suspended and fixed at the center of the flow field by a high-pressure air film. The air cushion not only acts as a lubricant to prevent mechanical scratches, but also functions as a high-frequency air spring, effectively absorbing the high-frequency micro-vibrations of the core wire 4. This ensures the straightness and stability of the core wire 4 in the detection area, thereby significantly improving the imaging clarity of visual inspection.

[0046] The marking component 3 employs a rotary tangential tracking method driven by the drive arm 31, ensuring that the tangential linear velocity of the marking head 32 matches the transmission speed of the cable at the instant of contact (the lowest point of the trajectory), achieving relative stillness. This zero-relative-velocity marking method completely eliminates marking stretching and distortion caused by speed differences.

[0047] Meanwhile, by maintaining a consistently vertical posture control, the nozzle is always directly facing the cable surface, avoiding trapezoidal distortion of the pattern caused by tilted spray angle. This device achieves non-destructive testing and high-precision marking while ensuring extremely high production efficiency (high speed), meeting the stringent standards of high-end cable manufacturing.

[0048] like Figures 1 to 7As shown, the detection component 2 is arranged along the wire harness transmission path, and its core function is to provide an extremely stable shooting window for visual inspection. During high-speed movement, cables often generate severe vibrations. Traditional mechanical pressure rollers not only fail to eliminate these vibrations but also introduce new high-frequency vibrations.

[0049] The detection component 2 is equipped with two sets of air-bearing guide mechanisms 21 spaced apart along the transmission direction of the core wire 4. A suspended detection area with a length of approximately 50mm to 100mm is formed between the two sets of air-bearing guide mechanisms 21. Within this area, a ring light source 24 and a high-frame-rate industrial camera 25 are arranged. Because the core wire 4 is strongly constrained by the air-bearing mechanisms at both ends, the suspended section in the middle exhibits good straightness and stability, with a clean background, which is highly beneficial for defect identification.

[0050] The air-bearing guide mechanism 21 employs an innovative variable-diameter pneumatic chuck structure. It includes permeable sliders 211 arranged in a circumferential array (e.g., 3 or 4, evenly distributed). These sliders do not directly contact the core wire 4, but rather suspend the core wire 4 at the center by ejected high-pressure gas.

[0051] An adjustment assembly 22 is designed to accommodate cables of different specifications (e.g., diameters from 1mm to 10mm). The adjustment assembly 22 includes a fixed plate 221 fixed to the frame 1, a rotary drive plate rotatably mounted on the fixed plate 221, and sliding jaws 222. The fixed plate 221 has radially arranged T-shaped guide grooves, restricting the jaws 222 to move only radially. The end face of the rotary drive plate is machined with helical grooves, while the bottom surface of the jaws 222 has transmission teeth that mesh with the helical grooves.

[0052] like Figures 1 to 7 As shown, the adjustment system also achieves automation. The drive motor 26 meshes with gears on the outer circumference of the rotating drive disc via transmission gears. When the controller receives a changeover command, it controls the drive motor 26 to rotate by a specific angle. The rotating drive disc rotates, and through the wedge effect of the planar thread, it powerfully pushes all the jaws 222, causing the air-bearing slider 211 to move synchronously centrifugally or centrifugally. This structure ensures that regardless of the aperture change, the geometric center of the air flotation field always coincides with the centerline of the equipment, eliminating the need for secondary calibration.

[0053] The slider facing the core wire 4 is machined into a concave arc surface 214 that conforms to the shape of the cable. This part is made of porous sintered metal (such as tin bronze powder sintering) or microporous ceramic, with micron-sized venting pores 213. The air supply assembly 212 (compressed air source) is connected to the side of the venting slider 211. In order to improve the air buoyancy stiffness and reduce air leakage, this application specifically adopts a gradient porosity process. The density is lower at both ends of the slider, the venting pores 213 are densely distributed, the air outlet resistance is low, and the flow rate is high; the density is higher in the middle area, and the venting pores 213 are sparse. In this way, two high-pressure "air curtains" or "air dams" are formed at both ends of the slider, which effectively block the high-pressure gas inside the air cushion field, making it difficult for it to escape axially, thereby greatly improving the air cushion's ability to restore the radial runout of the core wire 4.

[0054] In addition, such as Figures 1 to 7 As shown, to further isolate low-frequency vibrations (such as vibrations from other motor rotations) from the production line foundation and frame 1, the detection component 2 is not rigidly connected to the frame 1, but is installed via a floating damping base 23. The suspended inner frame supports the air flotation mechanism and is connected to the frame 1 via elastic damping elements (such as wire rope shock absorbers or damping springs) arranged around it. This constitutes a mechanical low-pass filter, effectively cutting off external interference sources.

[0055] The floating damping base 23 isolates mechanical vibrations. Industrial environments are complex, and the frame often transmits low-frequency, high-amplitude vibrations from the ground, motors, or winding equipment. A low-pass filter composed of elastic damping elements effectively blocks these low-frequency interferences from reaching the air-bearing mechanism. The air-bearing mechanism itself primarily addresses the high-frequency micro-vibrations of the core wire. This high- and low-frequency segmented management strategy ensures that the detection component 2 has extremely high image stabilization performance, enabling the camera to capture surface defects.

[0056] The radially arranged connecting rod 33 solves the posture problem in rotary marking. The connecting rod 33 ensures that the marking head 32 is at its lowest position during marking. Furthermore, multiple connecting rods 33 allow for rapid, continuous marking. like Figures 1 to 7 As shown, when the industrial camera 25 detects a defect (such as skin damage) on the surface of the core wire 4, the system needs to accurately mark the defect location with inkjet ink. The marking component 3 is located downstream and undertakes this task.

[0057] Traditional fixed printheads not only spray inaccurately at high speeds, but also cause ink to be blown away due to high wind resistance. This embodiment adopts a flying shear rotary marking strategy. The marking assembly 3 includes a drive arm 31 (main arm) and a marking head 32.

[0058] Driven by a servo motor, the rotating arm 31 performs circular motion. Based on the real-time linear velocity feedback from the encoder, the system calculates the optimal rotational angular velocity, ensuring that when the marking head 32 rotates to the lowest point of its circular trajectory (i.e., the position closest to the core wire 4), its tangential linear velocity vector is exactly equal to the transmission velocity vector of the core wire 4 (equal in magnitude and direction). At this point, the marking head 32 and the core wire 4 are relatively stationary, and the inkjet printing is no longer affected by the speed difference, resulting in clear and rounded marking patterns with better marking effects.

[0059] The marking head 32 is positioned at the end of the connecting rod 33 furthest from the rotation axis via multiple radially arranged connecting rods 33, which are then engaged with the drive cantilever. During marking, the drive arm 31 rotates, causing all the marking heads 32 to rotate. The marking heads 32 maintain the same speed as the core wire 4, allowing them to quickly complete the marking. The radially arranged connecting rods 33 solve the posture problem during rotary marking. The connecting rods 33 ensure that the marking head 32 is in the lowest position during marking, and the length of the connecting rods 33 can be adjusted according to the working environment. Furthermore, the use of multiple connecting rods 33 allows for rapid and continuous marking.

[0060] like Figures 1 to 7 As shown, at speeds above 500 m / min, the surface of core wire 4 carries a boundary layer of airflow moving at the same speed as it, which acts as a barrier to block ink droplets.

[0061] By incorporating a windbreak shroud 34 on the marking head 32, with its front end designed in a sharp V-shape facing the tangential velocity direction, the V-shape splits the boundary layer airflow to the left and right when the marking head 32 cuts into the cable at high speed. This creates a relatively enclosed low-pressure cavity, or airflow stagnant zone, inside the shroud. The nozzle is hidden within this stagnant zone, allowing ink droplets to reach the cable surface in an environment free from wind interference.

[0062] To further optimize the flow field, a flexible sealing ring 35 (such as a Teflon soft brush or silicone skirt) is snapped into the bottom opening of the windbreak 34. The flexible sealing ring 35 has a clearance notch 351 that matches the cross-section of the wire core. It physically seals the bottom of the shroud, allowing only the cable to pass through.

[0063] Furthermore, to address the power and ink supply issues of the rotating components, a pneumatic-electric slip ring is integrated at the rotation axis of the drive arm 31. This is a precision component that transmits signals and fluid between the stator and rotor through sliding contact. Control signal lines and ink tubes pass through the center of the slip ring and connect to the high-speed rotating marking head 32, enabling unlimited rotational operation. Meanwhile, the drive method of the adjustment component 22 is not limited to motor gears; a cylinder connecting rod 33 can also be used. The windbreak shroud 34 can be made of carbon fiber to reduce weight, etc.

[0064] To address the strong boundary layer airflow on the surface of high-speed cables, an aerodynamic design was introduced. A sharp-angled V-shaped wind deflector physically cuts and diverts the high-speed airflow, significantly reducing air resistance on the windward side of the marking head 32. More importantly, it artificially creates an airflow stagnant zone inside the deflector. Within this zone, the air velocity is extremely low, preventing the tiny ink droplets ejected from the nozzle from being dispersed by external wind. This ensures that the ink droplets fly in a straight line and adhere precisely to the cable surface, solving the problems of ink splatter and blurring during high-speed marking.

[0065] The flexible sealing ring 35 and its clearance notch 351 form the final physical line of defense for the vent 34. It maximally seals the bottom opening of the vent 34 without contacting or only slightly contacting the cable. Simultaneously, the flexible material (such as silicone or bristles) allows for a certain degree of radial runout of the cable without damaging its surface, achieving a balance between sealing and safety. Working Principle: When the device is working, the core wire 4 passes through at high speed. The controller of the detection component 2, based on the set wire diameter, drives the motor 26 to adjust the adjustment component 22, causing the air-permeable slider 211 to move centripetally to a position approximately 0.05 mm from the surface of the core wire 4. Compressed air enters the air-permeable slider 211 through the air supply component 212 and is ejected through the gradient-distributed air holes 213, forming a high-rigidity air cushion that stably suspends the core wire 4 at the detection center and absorbs vibration. The industrial camera 25 continuously acquires images. Once the algorithm identifies a defect, the system immediately locks onto the location of the defect on the core wire 4 and calculates the time it takes for the defect to reach the marking component 3.

[0066] The servo motor of marking component 3 drives the rotary arm 31 to accelerate its rotation. At the instant the defect point reaches the marking station, the marking head 32 rotates to its lowest point, its speed synchronized with the core wire 4. The air breaker 34 cuts through the airflow, the connecting rod 33 keeps the nozzle vertical, and the nozzle sprays ink within the stagnant zone, completing precise marking. The rotary arm then continues to rotate, and the marking head 32 enters the next cycle.

[0067] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A high-speed wire harness core wire quality online detection device, characterized in that, include: The device comprises a frame (1), a detection component (2), and a marking component (3); the detection component (2) is arranged along the wire harness transmission path, and the marking component (3) is located downstream of the detection component (2); the detection component (2) is equipped with an air-bearing guide mechanism (21), which includes: a breathable slider (211) and an adjustment component (22); the breathable sliders (211) are arranged in a circumferential array, and the adjustment component (22) drives several breathable sliders (211) to move synchronously in the radial direction; the breathable sliders (211) have multiple air holes on the side near the wire core. (213) The air-permeable slider (211) is connected to an air supply component (212). The air-permeable slider (211) is used to form an air cushion constraint field around the high-speed moving core wire (4). The marking component (3) includes a drive arm (31) and a marking head (32). The drive arm (31) drives the marking head (32) to make a circular motion, so that the tangential velocity of the marking head (32) when it passes the lowest point of the trajectory is the same as the velocity of the core wire (4). The drive arm (31) makes the marking head (32) always remain perpendicular to the core wire (4) throughout the entire motion.

2. The online detection device for high-speed wire harness core quality according to claim 1, characterized in that: The adjustment component (22) includes: a fixed disk (221) and a claw (222); the fixed disk (221) is mounted on the frame (1), the claw (222) is slidably mounted on the fixed disk (221) in the radial direction, the air-permeable slider (211) is fixedly mounted on the claw (222), and the air-permeable slider (211) moves radially with the claw (222).

3. The online detection device for high-speed wire harness core quality according to claim 1, characterized in that: The side of the breathable slider (211) facing the core wire (4) is a concave arc surface (214), which is made of porous sintered metal or microporous ceramic material; the density of the breathable holes (213) on the concave arc surface (214) is distributed in a gradient distribution with high density at both ends and low density in the middle, so that the air cushion constraint field forms a high-pressure air curtain at both ends of the axial direction.

4. The online detection device for high-speed wire harness core quality according to claim 1, characterized in that: The detection component (2) is mounted on the frame (1) via a floating damping base (23), which is equipped with an elastic damping element that can filter out low-frequency mechanical vibrations transmitted from the outside to the air-bearing guide mechanism (21).

5. The online detection device for high-speed wire harness core wire quality according to claim 1, characterized in that: The drive arm (31) includes multiple connecting rods (33) arranged radially. The marking head (32) is located at the end of the connecting rod (33) away from the axis of rotation. The connecting rod (33) is snapped onto the drive arm.

6. The online detection device for high-speed wire harness core quality according to claim 1, characterized in that: The outer periphery of the marking head (32) is provided with a windbreak shroud (34); the front windward surface of the windbreak shroud (34) is designed as an acute-angled V-shape, and the tangential speed direction of the windbreak shroud (34) is consistent with that of the drive arm (31); when the marking head (32) cuts into the trajectory of the core wire (4) at high speed, the windbreak shroud (34) splits the airflow on the surface of the core wire (4) to both sides, so that the nozzle of the marking head (32) located inside the windbreak shroud (34) is in the airflow stagnant zone, preventing the high-speed airflow from blowing away the ink droplets.

7. The online detection device for high-speed wire harness core quality according to claim 6, characterized in that: A flexible ring is provided on the end face of the windbreak (34) near the cable. The flexible ring is snapped onto the windbreak (34). The flexible sealing ring (35) has a clearance notch (351) at one end near the wire core that matches the cross-sectional shape of the wire core.

8. The online detection device for high-speed wire harness core wire quality according to claim 1, characterized in that: The drive arm (31) has an integrated pneumatic slip ring at its rotation axis; the control signal line and ink supply line required by the marking head (32) pass through the central hole of the pneumatic slip ring and are connected to the rotating marking head (32).

9. The online detection device for high-speed wire harness core wire quality according to claim 1, characterized in that: The detection component (2) includes two sets of air-bearing guide mechanisms (21) arranged at intervals along the transmission direction of the core wire (4); a detection zone is formed between the two sets of air-bearing guide mechanisms (21), and a ring light source (24) and an industrial camera (25) are arranged in the detection zone. The core wire (4) is kept in the detection state in the detection zone under the pneumatic clamping of the two sets of air-bearing guide mechanisms (21).

10. The online detection device for high-speed wire harness core wire quality according to claim 2, characterized in that: The adjustment assembly (22) also includes a drive motor (26), a controller and a transmission gear; the drive motor (26) drives the claw (222) to move closer to or further away from the fixed disk (221) through the transmission gear; the controller controls the drive motor (26) to drive the claw (222) to automatically adjust the guide hole diameter formed by the air-permeable slider (211) according to the diameter specification of the core wire (4) to be tested.

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