Intelligent detection control method for wire harness crimping

Abstract

The invention provides an intelligent detection control method for wire harness crimping, and belongs to the technical field of detection control, real-time full detection of each wire harness is realized by acquiring dynamic parameters in a crimping process in real time through a preset sensor, manual visual inspection and off-line sampling test are not needed, and the intelligent detection control method can adapt to large-batch and high-speed production requirements of the wire harnesses, and is high in practicability. The detection efficiency is greatly improved; meanwhile, the detection of the crimping efficiency is considered, the production rhythm of the wire harness can be synchronously optimized, and the productivity of the wire harness is further improved; the detection process completely depends on objective dynamic data collected by the sensor and a fixed mathematical model, manual subjective judgment is not needed, and the detection standard is unified; and meanwhile, the mechanical performance, the electrical performance and the crimping efficiency are comprehensively covered, the detection sensitivity is improved by applying correction terms, comprehensive and high-precision detection is realized, and the omission ratio is greatly reduced.

Description

Technical Field

[0001] This invention belongs to the field of detection and control technology, and specifically relates to an intelligent detection and control method for wire harness crimping. Background Technology

[0002] As a crucial connecting component in electronic equipment, automotive, aerospace, and other systems, the crimping quality of wire harnesses directly determines the electrical performance, mechanical reliability, and service life of the entire system. Currently, the inspection and control of wire harness crimping quality mainly relies on manual visual inspection combined with offline sampling tensile testing. This method has several drawbacks. Manual visual inspection requires workers to observe the crimping area of ​​each wire harness one by one to determine for defects such as terminal deformation, exposed conductors, and damaged insulation. The inspection speed is limited by the operator's skill level and cannot meet the demands of large-scale and high-speed wire harness production. The offline sampling tensile testing requires taking a small number of sample wire harnesses for destructive testing after crimping, which is cumbersome and time-consuming, and cannot achieve full inspection of every wire harness. Furthermore, the judgment criteria for manual visual inspection depend on the experience of the workers. Different workers have subjective differences in the threshold for judging defects, which can easily lead to different judgments for the same sample, resulting in poor inspection consistency and preventing the formation of a standardized inspection system.

[0003] To address the issues of low detection efficiency and high subjectivity in current wire harness crimping quality inspection and control, and to achieve real-time, comprehensive, and accurate inspection and control of wire harness crimping quality, it is urgently necessary to propose an intelligent inspection and control method for wire harness crimping. This method eliminates the need for manual visual inspection, collects key physical parameters during the crimping process in real time, and combines accurate mathematical models and control rules to achieve full inspection and real-time adjustment of the crimping quality of each wire harness, ensuring the stability and consistency of crimping quality. Summary of the Invention

[0004] The purpose of this section is to outline some aspects of the embodiments of the present invention and to briefly introduce some preferred embodiments. Some simplifications or omissions may be made in this section, as well as in the specification abstract and the title of the invention, to avoid obscuring the purpose of this section, the specification abstract, and the title of the invention. Such simplifications or omissions shall not be used to limit the scope of the invention.

[0005] In view of the aforementioned existing problems, the present invention is proposed.

[0006] To solve the above-mentioned technical problems, the present invention provides the following technical solution: This invention provides an intelligent detection and control method for wire harness crimping, comprising: Initialize the crimping parameters for wire harness crimping, that is, set the reference parameters for wire harness crimping during the crimping process; During the crimping process of each wire harness to be tested, the actual dynamic parameters of the entire crimping process are collected in real time. Based on the collected actual dynamic parameters and benchmark parameters, the crimping quality assessment value is calculated. According to the crimping quality assessment value The value determines whether the crimping quality of the wire harness to be inspected is qualified; If the crimping quality of the current wire harness to be tested is determined to be qualified, the parameter deviation is calculated by comparing its actual dynamic parameters with the reference parameters. The crimping reference parameters and quality qualification threshold of the next wire harness are then adjusted accordingly to achieve dynamic control.

[0007] Preferably, the method for setting reference parameters for wire harness crimping during the crimping process specifically includes: According to the wire harness specifications, reference parameters are set for the crimping process. These reference parameters are characteristic reference values ​​of the wire harness throughout the entire crimping process, specifically including the reference crimping force characteristic value. , reference pressing displacement characteristic value Reference contact resistance and reference crimping time Simultaneously set the reference crimping energy. and reference crimping power , , .

[0008] Preferably, the wire harness crimping is performed using a crimping machine, which is equipped with a pressure sensor, a displacement sensor, and a contact resistance sensor that are connected to the controller of the crimping machine. A timer is also installed in the controller of the crimping machine. The pressure sensor is located at the connection between the pressure head and the drive component of the crimping machine used for wire harness crimping; The displacement sensor is installed on the side of the pressing head of the crimping machine; The contact resistance sensor is installed in the terminal positioning part of the crimping machine.

[0009] Preferably, the actual dynamic parameters of the entire crimping process include: The actual crimping force dynamic sequence is the instantaneous crimping force that is collected in real time by a pressure sensor and transmitted to the controller throughout the entire crimping process of the wire harness. The controller will apply instantaneous pressure. Arranging them according to the order of their collection times forms the actual pressure relay dynamic sequence; The actual pressing displacement dynamic sequence is the instantaneous pressing displacement that is collected in real time by a displacement sensor and transmitted to the controller throughout the entire wire harness pressing process. The controller will instantly press the displacement. Arranging them according to the order of their collection times forms the actual pressing displacement dynamic sequence; Actual crimping time It is a timer that records the total time from when the crimping machine starts contacting the terminal to when the crimping is completed; Actual contact resistance The contact resistance value is collected by the contact resistance sensor and transmitted to the controller after the wire harness to be tested has been crimped for 3-5 seconds. Actual crimping energy ; Actual crimping power .

[0010] Preferred actual crimping energy This is the integral value of the instantaneous crimping force and the corresponding instantaneous crimping displacement of the wire harness under test during the entire crimping process, i.e. ; Actual crimping power ; The specific implementation methods include: Based on the dynamic sequence of actual pressure force generated by synchronous data acquisition and the actual pressing displacement dynamic sequence Calculate , in This refers to the instantaneous crimping force or instantaneous crimping displacement during the entire wire harness crimping process. For the first time collected A momentary pressure relay, For the first time collected A momentary pressing displacement , Set to 0.

[0011] Preferably, the crimping quality assessment value is calculated based on the collected actual dynamic parameters and benchmark parameters. The mathematical expression is: ; In this mathematical expression, This is the assessment value for the crimping quality; This refers to the actual crimping energy. As a reference crimping energy; This refers to the actual crimping power; The reference crimping power; This represents the actual contact resistance. This is the reference contact resistance.

[0012] Preferably, based on the crimping quality assessment value The method for determining whether the crimping quality of the wire harness to be inspected is qualified by the value includes: when ≥ When the crimping quality of the wire harness to be inspected is deemed acceptable, it is determined that the crimping quality is acceptable. < If the controller determines that the crimping quality of the wire harness to be inspected is unqualified, it will trigger an alarm signal in real time and hand over the unqualified wire harness to on-site personnel for scrapping or rework. This is the quality pass threshold for the wire harness.

[0013] Preferably, the quality pass threshold for the wire harness The methods for setting initial values ​​include: Select sample wire harnesses with specifications consistent with the wire harness to be tested in advance, and crimp each sample wire harness according to the crimping process requirements specified in the industry standard. After all sample wire harnesses have been crimped, each sample wire harness is subjected to offline destructive testing to screen out all qualified sample wire harnesses. Application of crimping quality assessment value The mathematical expression is combined with the actual dynamic parameters of each qualified sample wire harness to calculate the crimping quality assessment value of all qualified sample wire harnesses. The minimum value of the crimping quality assessment value of all qualified sample wire harnesses is taken as the quality qualification threshold of the wire harness. The initial value.

[0014] Preferably, if the crimping quality of the wire harness to be tested is determined to be qualified, the mathematical expression for calculating the parameter deviation by comparing its actual dynamic parameters with the reference parameters is as follows: Deviation of actual pressing force characteristic value ; actual crimping displacement characteristic value deviation ; Actual crimping time deviation ; Actual contact resistance deviation ; In the mathematical expression for parameter deviation, This represents the characteristic value of the actual pressing force. The value is the average of all instantaneous pressure forces in the actual pressure force dynamic sequence; This represents the characteristic value of the actual pressing displacement. The value is the average of all instantaneous pressing displacements in the actual pressing displacement dynamic sequence; The method for adjusting the crimping reference parameters of the next wire harness specifically includes: Adjustment value of the reference crimping force characteristic value of the next wire harness ; Adjustment value of the reference crimping displacement characteristic value of the next wire harness ; Reference crimping time adjustment value for the next wire harness ; Reference contact resistance adjustment value for the next wire harness ; The reference crimping energy adjustment value for the next wire harness is updated synchronously. and reference crimping power adjustment amount Adjust the reference crimping force characteristic value of the next wire harness. Adjustment value of the reference crimping displacement characteristic value of the next wire harness The reference crimping time adjustment value for the next wire harness The reference contact resistance adjustment value for the next wire harness The reference crimping energy adjustment value for the next wire harness Reference crimping power adjustment for the next wire harness These values ​​will serve as the reference crimping force characteristic values ​​for the next wire harness throughout the entire crimping process. , reference pressing displacement characteristic value Reference crimping time Reference contact resistance Reference crimping energy With reference crimp power .

[0015] Preferably, the method for adjusting the quality pass threshold of the next wire harness specifically includes: crimping quality assessment value In mathematical expressions , and The reference contact resistance value of each wire harness is adjusted accordingly. The reference crimping energy adjustment value for the next wire harness Reference crimping power adjustment for the next wire harness The new crimping quality assessment value is formed by replacing the previous one. The mathematical expression for applying this new crimping quality assessment value. The mathematical expression is combined with the actual dynamic parameters of the entire crimping process of each qualified sample wire harness, which are collected in real time, to update and calculate the crimping quality assessment value of all qualified sample wire harnesses. The minimum value of the updated crimping quality assessment value of all qualified sample wire harnesses is taken as the quality qualification threshold of the wire harness. The adjustment value is the quality qualification threshold for this wire harness. The adjustment value is the quality qualification threshold for the next wire harness.

[0016] The beneficial effects of the present invention are as follows, compared with the prior art: This invention achieves real-time full inspection of each wire harness by using preset sensors to collect dynamic parameters during the crimping process. This eliminates the need for manual visual inspection and offline sampling tests, adapting to the demands of high-volume and high-speed wire harness production and significantly improving inspection efficiency. Simultaneously, it considers crimping efficiency, allowing for optimized production rhythm and further increasing wire harness capacity. The inspection process relies entirely on objective dynamic data collected by sensors and a fixed mathematical model, eliminating subjective human judgment and ensuring standardized inspection, effectively avoiding subjective biases inherent in manual inspection. Furthermore, it comprehensively covers mechanical performance, electrical performance, and crimping efficiency, using integral values ​​to capture the cumulative effect of dynamic crimping and applying correction terms to enhance detection sensitivity, achieving comprehensive and high-precision inspection and significantly reducing the false negative rate. Attached Figure Description

[0017] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. Wherein: Figure 1 This is an overall flowchart of the intelligent detection and control method for wire harness crimping described in this invention; Figure 2 The quality qualification threshold of the wire harness described in this invention The flowchart shows the method for setting the initial value. Detailed Implementation

[0018] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0019] Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without inventive effort should fall within the scope of protection of this invention.

[0020] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and those skilled in the art can make similar extensions without departing from the spirit of the invention. Therefore, the invention is not limited to the specific embodiments disclosed below.

[0021] According to an embodiment of the present invention, in combination Figure 1 The flowchart shown illustrates an intelligent detection and control method for wire harness crimping according to the present invention, comprising: S1. Initialize the crimping parameters for the wire harness, i.e., set the reference parameters for the wire harness crimping process. Note the following in this step: In a preferred embodiment, the method for setting reference parameters for wire harness crimping during the crimping process specifically includes: According to the wire harness specifications, reference parameters are set for the crimping process. These reference parameters are characteristic reference values ​​of the wire harness throughout the entire crimping process, specifically including the reference crimping force characteristic value. , reference pressing displacement characteristic value Reference contact resistance and reference crimping time Simultaneously set the reference crimping energy. and reference crimping power , , .

[0022] It should be noted that crimping energy is essentially the cumulative work done by crimping force and displacement, which conforms to the crimping mechanics of wire harness crimping; reference crimping energy and reference crimping power These can be used as benchmarks for the mechanical strength and crimping efficiency of wire harness crimping, respectively.

[0023] In a preferred embodiment, the wire harness is crimped using a crimping machine. The crimping machine is equipped with a pressure sensor, a displacement sensor, and a contact resistance sensor that are connected to the controller of the crimping machine. A timer is installed in the controller of the crimping machine. A pressure sensor is installed at the connection between the pressure head and the drive component of the crimping machine used for wire harness crimping. The pressure sensor is used to collect the crimping force and transmit it to the controller. The displacement sensor is installed on the side of the pressing head of the crimping machine and moves synchronously with the pressing head. It is used to track the distance the pressing head moves from the initial position to the crimping end position in real time, thereby collecting the crimping displacement and transmitting it to the controller. The contact resistance sensor is installed in the terminal positioning part of the crimping machine. After crimping is completed, the contact resistance sensor is used to collect the contact resistance between the wire and the terminal in real time and transmit it to the controller. The timer is used to collect the entire duration of the wire harness crimping process.

[0024] For example, the connection between the crimping head and the driving component of the crimping machine can be the connection between the crimping head and the cylinder or servo motor of the crimping machine, which serves as the driving component; the specific location of the contact resistance sensor in the terminal positioning part of the crimping machine can be the contact point between the positioning part and the non-crimping part of the terminal, such as the tail or side of the terminal; the reference crimping force characteristic value The method for obtaining the data is as follows: Select sample wire harnesses that are exactly the same as the wire harness to be tested, with ≥50 sample wire harnesses to ensure the representativeness of the data. Then, crimp the sample wire harnesses using a crimping machine. The pressure sensor collects the instantaneous crimping force of each sample wire harness in real time during the entire crimping process and transmits it to the controller. The controller arranges the instantaneous crimping force of each sample wire harness according to the order of its collection time to form the instantaneous crimping force. The dynamic sequence; offline destructive testing is performed on each sample wire harness to screen out all qualified sample wire harnesses that meet industry standards. Offline destructive testing includes pull-out force testing, contact resistance stability testing, and terminal microstructure testing; instantaneous crimping force is applied to each qualified sample wire harness. The arithmetic mean of the instantaneous clamping force in the dynamic sequence is calculated. Then, the quartile method is applied to remove outliers from the arithmetic mean of all qualified sample wire harnesses. The mean of the arithmetic mean of all qualified sample wire harnesses after removing outliers is calculated, and this mean is used as the benchmark clamping force characteristic value. ; Reference crimping displacement characteristic value The method for obtaining the displacement can be as follows: When the sample wire harness is crimped using a crimping machine, the displacement sensor also collects the instantaneous crimping displacement of each sample wire harness in real time during the entire crimping process and transmits it to the controller. The controller arranges the instantaneous crimping displacement of each sample wire harness in the order of its collection time to form the instantaneous crimping displacement. The dynamic sequence; the instantaneous crimping displacement of each qualified sample wire harness. The arithmetic mean of the instantaneous crimping displacement in the dynamic sequence is obtained. Then, the quartile method is applied to remove outliers from the arithmetic mean of all qualified sample wire harnesses. The mean of the arithmetic mean of all qualified sample wire harnesses after removing outliers is obtained, and this mean is used as the reference crimping displacement characteristic value. Reference contact resistance The method for obtaining the stable contact resistance value is as follows: After the sample wire harness is crimped, a contact resistance sensor is used to collect the stable contact resistance value of each sample wire harness. That is, 3-5 seconds after crimping is completed, the contact resistance value collected by the contact resistance sensor after the contact resistance value has stabilized is the stable contact resistance value. Then, the quartile method is applied to remove outliers from the stable contact resistance values ​​of all qualified sample wire harnesses. The maximum value among the stable contact resistance values ​​of all qualified sample wire harnesses after removing all outliers is taken as the reference contact resistance. Reference crimping time The method for obtaining the time can be as follows: A timer records the total time for each sample wire harness from the moment the crimping machine contacts the terminal until crimping is complete. Then, the quartile method is applied to remove outliers from the total time for each sample of all qualified sample wire harnesses. Finally, the arithmetic mean of the total time for all qualified sample wire harnesses after removing outliers is calculated, and this arithmetic mean is used as the baseline crimping time. The entire wire harness crimping process is the entire process from when the crimping machine starts contacting the terminals to when the crimping is completed.

[0025] S2. During the crimping process of each wire harness to be tested, the actual dynamic parameters of the entire crimping process are collected in real time. It should be noted that the following points are important in this step: In a preferred embodiment, the actual dynamic parameters of the entire crimping process specifically include: The actual crimping force dynamic sequence is the instantaneous crimping force that is collected in real time by a pressure sensor and transmitted to the controller throughout the entire crimping process of the wire harness. The controller will apply instantaneous pressure. Arranging them according to the order of their collection times forms the actual pressure relay dynamic sequence; The actual pressing displacement dynamic sequence is the instantaneous pressing displacement that is collected in real time by a displacement sensor and transmitted to the controller throughout the entire wire harness pressing process. The controller will instantly press the displacement. Arranging them according to the order of their collection times forms the actual pressing displacement dynamic sequence; Actual crimping time It is a timer that records the total time from when the crimping machine starts contacting the terminal to when the crimping is completed for the wire harness to be tested. , The moment when the crimping is completed. The moment when the crimping machine begins to contact the terminal; Actual contact resistance The contact resistance value is collected by the contact resistance sensor and transmitted to the controller after the wire harness to be tested has been crimped for 3-5 seconds. Actual crimping energy ; Actual crimping power .

[0026] It should be noted that the actual crimping energy and actual crimping power These sensors respectively reflect the actual degree of compression and crimping efficiency of the wire harness under test throughout the crimping process; the pressure sensor and displacement sensor are collected synchronously, and both have the same acquisition frequency.

[0027] In a preferred embodiment, the actual crimping energy This is the integral value of the instantaneous crimping force and the corresponding instantaneous crimping displacement of the wire harness under test during the entire crimping process, i.e. ; Actual crimping power ; The specific implementation methods include: Based on the dynamic sequence of actual pressure force generated by synchronous data acquisition and the actual pressing displacement dynamic sequence Calculate , in This refers to the instantaneous crimping force or instantaneous crimping displacement during the entire wire harness crimping process. For the first time collected A momentary pressure relay, For the first time collected A momentary pressing displacement , Set to 0.

[0028] It should be noted that the actual crimping energy This is the integral value of the instantaneous crimping force and corresponding instantaneous crimping displacement of the wire harness under test throughout the entire crimping process. This integral value is essentially the cumulative work done by the crimping force on the crimping displacement. Thus, each tiny interval... This can reflect the essence of the integral value throughout the entire pressing process, and then for each tiny interval... Summing yields the actual compression energy. .

[0029] S3. Based on the collected actual dynamic parameters and benchmark parameters, calculate the crimping quality assessment value. According to the crimping quality assessment value The value determines whether the crimping quality of the wire harness to be inspected is qualified. It should be noted that the following points should be noted in this step:

[0030] In a preferred embodiment, the crimping quality assessment value is calculated based on the collected actual dynamic parameters and reference parameters. The mathematical expression is: ; In this mathematical expression, This is the assessment value for the crimping quality; This refers to the actual crimping energy. As a reference crimping energy; This refers to the actual crimping power; The reference crimping power; This represents the actual contact resistance. This is the reference contact resistance.

[0031] It should be noted that the crimping quality assessment value It is a parameter that comprehensively reflects the crimping mechanical properties, electrical properties, and crimping efficiency of the wire harness to be tested; it is a crimping quality assessment value. The larger the value, the better the crimping quality and the higher the efficiency of the wire harness being tested; actual crimping energy It accurately reflects the cumulative compression effect throughout the entire crimping process of the wire harness under test, directly determining the mechanical strength of the crimped wire harness, such as pull-out force. It is a crucial mechanical parameter for the crimping quality of the wire harness under test, and it is matched to the dynamic changes in the crimping force and displacement of the wire harness under test; reference crimping energy. This is the benchmark value to ensure that the mechanical strength of the crimping meets the standard; the actual crimping power From actual pressing energy Compared with actual pressing time The ratio is calculated to obtain, Actual crimping power This reflects the efficiency and stability of the crimping process of the wire harness under test, and the actual crimping power. Excessive pressure can easily lead to overheating and deformation of the terminals, affecting the actual crimping power. If the value is too low, the crimping of the wire harness under test will be insufficient. It is an important efficiency parameter for crimping quality and can be matched to different dynamic crimping rhythms of the wire harness under test; reference crimping power. Based on the reference crimping energy Compacting time with reference The ratio is calculated to obtain, This is the benchmark value that ensures a balance between crimping efficiency and quality, and matches the rhythm of the dynamic crimping process of the wire harness; actual contact resistance The stable value of the contact resistance collected by the contact resistance sensor after the crimping of the wire harness under test reflects the actual electrical contact effect between the wire and the terminal after the crimping of the wire harness under test. The smaller the value, the better the contact effect and the higher the electrical transmission efficiency; it is an important electrical parameter for crimping quality; reference contact resistance. It is the maximum permissible contact resistance threshold to ensure stable electrical performance, and serves as an important criterion for judging electrical performance; For crimping quality assessment value The correction term in the mathematical expression is used to enhance the synergistic matching of mechanical and electrical properties. By amplifying the effect of parameter deviation on the crimping quality of the wire harness to be tested through square root operation, the detection sensitivity is improved and minor defects are avoided from being missed.

[0032] Furthermore, the actual pressing energy By using the integral value of the wire harness under test throughout the crimping process, the cumulative work effect of the dynamic changes in crimping force and crimping displacement is accurately captured, avoiding the defect that a single instantaneous value cannot reflect the degree of compression of the wire harness under test throughout the crimping process; reference crimping energy. Based on the benchmark crimping force characteristic value of the wire harness throughout the crimping process and reference pressing displacement characteristic value The calculations perfectly match the actual crimping conditions of the wire harness and the actual crimping energy. Establishing a ratio relationship can offset the differences in wire harness specifications and ensure... The value is universal and directly reflects the degree of matching between the actual crimping mechanical properties of the wire harness under test and the benchmark requirements; actual crimping power Actual pressing energy obtained by integration Compared with actual pressing time The calculation reflects the overall efficiency of the dynamic crimping process of the wire harness under test; the actual crimping power. With reference crimp power The ratio ensures that the wire harness crimping process meets both quality requirements and production rhythm needs, avoiding both low crimping efficiency affecting production capacity and excessively high crimping efficiency leading to quality defects. It is matched to the dynamic crimping rhythm changes of the wire harness; actual contact resistance. This is a stable value of the contact resistance after the wire harness under test has been crimped, unaffected by the dynamic process of crimping, and can accurately reflect the electrical contact effect; reference contact resistance. As a reference threshold, compared with the actual contact resistance By establishing a ratio, the difference between the actual electrical performance of the wire harness under test and the standard requirements can be intuitively reflected. ≤ When the ratio is ≥1, it helps in evaluating the crimping quality. The value has been improved, meeting the electrical performance standards for wire harnesses; crimping quality assessment value Correction terms of mathematical expressions By calculating the square root of the parameter ratio, the synergistic effect between mechanical and electrical properties is enhanced. When the value is too small, it indicates that the clamping performance of the wire harness under test is insufficient. Regardless of the fluctuations during the dynamic process, the cumulative effect will not meet the standard. A value that is too high indicates poor contact between the wires and terminals of the wire harness being tested, resulting in a lower crimping quality assessment value. Correction terms of mathematical expressions It will simultaneously decrease and increase the crimping quality assessment value. The decrease in the rate of change improves the sensitivity to detect minute defects and avoids missed detections; crimping quality assessment value The mathematical expression selects three important parameters: crimping energy, which is key to mechanics; crimping power, which is key to efficiency; and contact resistance, which is key to electrical performance. This improves the detection dimensions of intelligent detection and control for wire harness crimping, fully meets the dual requirements of quality and efficiency in wire harness crimping processes, and matches the dynamic working conditions of wire harness crimping.

[0033] Furthermore, the crimping quality assessment value Simultaneously considering the mechanical, electrical, and crimping performance of wire harnesses, this system not only reflects quality defects such as latent cracks and insufficient contact at the terminals, but also identifies quality problems caused by abnormally fast or slow crimping efficiency. This enables comprehensive and multi-scenario inspection, further reducing the false negative rate. (Crimping quality assessment value) The square root correction term can amplify the impact of minute parameter deviations on the crimping quality assessment value. The system can accurately reflect hidden defects that are difficult to detect, such as slight insufficient compression and slight poor contact in the wire harness. At the same time, it can capture the cumulative defects caused by parameter fluctuations during the dynamic crimping process of the wire harness, improve the detection accuracy, and meet the high-precision wire harness crimping requirements.

[0034] In a preferred embodiment, based on the crimping quality assessment value The method for determining whether the crimping quality of the wire harness to be inspected is qualified by the value includes: when ≥ When the crimping quality of the wire harness to be inspected is deemed acceptable, it is determined that the crimping quality is acceptable. < If the controller determines that the crimping quality of the wire harness to be inspected is unqualified, it will immediately trigger an alarm signal and hand over the unqualified wire harness to on-site personnel for scrapping or rework. This is the set quality pass threshold for the wire harness.

[0035] In a preferred embodiment, the quality qualification threshold of the wire harness The value is dynamically adjusted, with its initial value set based on qualified sample harness tests, and subsequent quality qualification thresholds for harnesses. The system updates synchronously with the baseline parameters to ensure that the judgment criteria always match the current crimping conditions; for example... Figure 2 As shown, the quality pass threshold for the wire harness The methods for setting initial values ​​include: Pre-select sample wire harnesses with specifications consistent with the wire harness to be tested, with a minimum of 500 sample wire harnesses. Crimpe each sample wire harness according to the crimping process requirements specified in industry standards, ensuring that the crimping process meets the industry standard requirements and preventing the wire harness from failing the quality acceptance threshold. The initial values ​​may be non-standard, leading to deviations in the crimping quality of the sample wire harness; After all sample wire harnesses have been crimped, each sample wire harness undergoes offline destructive testing, including pull-out force testing, contact resistance stability testing, and terminal microstructure testing, to screen out all qualified sample wire harnesses that meet industry standards. Application of crimping quality assessment value The mathematical expression is combined with the actual dynamic parameters of the entire crimping process of each qualified sample wire harness to calculate the crimping quality assessment value of all qualified sample wire harnesses. The minimum value of the crimping quality assessment value of all qualified sample wire harnesses is taken as the quality qualification threshold of the wire harness. The initial value is used. After each execution of step S4 to adjust the reference parameters, the crimping quality assessment value of all qualified sample harnesses is recalculated based on the adjusted new reference parameters. Take the crimping quality assessment value of all qualified sample wire harnesses after recalculation. The updated crimping quality assessment value is used as the basis for this assessment. The value of .

[0036] It should be noted that the industry standards for crimping each sample wire harness according to the crimping process requirements specified in the industry standards include the wire harness terminal crimping specification standard; the controller can immediately trigger an alarm signal in real time by controlling a buzzer connected to it to sound an alarm.

[0037] S4. If the crimping quality of the current wire harness to be tested is determined to be qualified, the parameter deviation is calculated by comparing its actual dynamic parameters with the reference parameters. The crimping reference parameters and quality qualification threshold of the next wire harness are then adjusted accordingly to achieve dynamic control. It should be noted that the following points are important in this step: In a preferred embodiment, if the crimping quality of the wire harness to be tested is determined to be qualified, the mathematical expression for calculating the parameter deviation by comparing its actual dynamic parameters with the reference parameters is as follows: Deviation of actual pressing force characteristic value ; actual crimping displacement characteristic value deviation ; Actual crimping time deviation ; Actual contact resistance deviation ; In the mathematical expression for parameter deviation, This represents the characteristic value of the actual pressing force. The value is the average of all instantaneous pressure forces in the actual pressure force dynamic sequence; This represents the characteristic value of the actual pressing displacement. The value is the average of all instantaneous pressing displacements in the actual pressing displacement dynamic sequence; The method for adjusting the crimping reference parameters of the next wire harness specifically includes: Adjustment value of the reference crimping force characteristic value of the next wire harness ; Adjustment value of the reference crimping displacement characteristic value of the next wire harness ; Reference crimping time adjustment value for the next wire harness ; Reference contact resistance adjustment value for the next wire harness ; The reference crimping energy adjustment value for the next wire harness is updated synchronously. and reference crimping power adjustment amount Adjust the reference crimping force characteristic value of the next wire harness. Adjustment value of the reference crimping displacement characteristic value of the next wire harness The reference crimping time adjustment value for the next wire harness The reference contact resistance adjustment value for the next wire harness The reference crimping energy adjustment value for the next wire harness Reference crimping power adjustment for the next wire harness These values ​​will serve as the reference crimping force characteristic values ​​for the next wire harness throughout the entire crimping process. , reference pressing displacement characteristic value Reference crimping time Reference contact resistance Reference crimping energy With reference crimp power .

[0038] It should be noted that the next wire harness to be tested is the next wire harness of the same specifications as the current wire harness to be tested. Essentially, it is the deviation between the actual crimping force characteristic value and the reference crimping force characteristic value. A positive value indicates that the actual crimping force characteristic value is greater than the reference crimping force characteristic value. A negative value indicates that the actual crimping force characteristic value is less than the reference crimping force characteristic value, matching the fluctuation characteristics of the crimping force parameters in dynamic crimping; Essentially, it is the deviation between the actual crimping displacement characteristic value and the reference crimping displacement characteristic value. A positive value indicates that the actual crimping displacement characteristic value is greater than the reference crimping displacement characteristic value. A negative value indicates that the actual crimping displacement characteristic value is less than the reference crimping displacement characteristic value, which conforms to the dynamic crimping displacement variation law. Essentially, it's the deviation between the actual crimping time and the reference crimping time. A positive value indicates that the actual crimping time is greater than the reference crimping time. A negative value indicates that the actual crimping time is less than the reference crimping time, reflecting the deviation in the dynamic crimping rhythm of the wire harness; Essentially, it is the deviation between the actual contact resistance and the reference contact resistance. A positive value indicates that the actual contact resistance is greater than the reference contact resistance, and the contact effect between the terminals and the wires of the harness is poor. A negative value indicates that the actual contact resistance is less than the reference contact resistance, and the contact effect between the terminals and the wires of the harness is better.

[0039] Furthermore, the mathematical expression for the parameter deviation is directly calculated by subtracting the reference eigenvalue from the actual eigenvalue, where the actual pressing force eigenvalue is... and actual crimp displacement characteristic value These are all average values ​​for the entire crimping process, not instantaneous values. They accurately reflect the overall deviation of the dynamic crimping process of the wire harness, rather than a single instantaneous fluctuation. By introducing the actual crimping time deviation, the parameters required for crimping power in the mathematical expression are matched, providing an accurate basis for subsequent parameter adjustments and conforming to the rules of dynamic control.

[0040] Furthermore, in middle, Based on wire harness specifications, these are characteristic values ​​of the entire crimping process obtained through sample wire harness testing. They objectively reflect the basic clamping force required for crimping wire harnesses of this specification, serving as a key benchmark for subsequent adjustments. This ensures that adjustments have a clear basis and conform to the actual working condition of crimping force fluctuating over time during dynamic crimping of wire harnesses. This serves as a benchmark for adjustments, preventing uncontrolled fluctuations due to a lack of reference points, ensuring accurate deviation calculations, and providing a reliable basis for subsequent corrections. Calculated directly from the actual eigenvalue minus the benchmark eigenvalue, where It is the average value of the crimping force throughout the entire actual crimping process, rather than the instantaneous value. It can accurately reflect the overall deviation of the crimping force during dynamic crimping rather than a single instantaneous fluctuation, thus avoiding erroneous adjustments caused by instantaneous interference. The sign of the value directly indicates the direction of deviation, providing clear guidance for adjustment. Matching the fluctuation characteristics of the dynamic pressing force parameters, it accurately captures the overall deviation of the pressing force, serving as a crucial basis for subsequent corrections. This ensures that adjustments specifically address the deviation between the actual pressing force and the benchmark, rather than being blind adjustments. (Correction item) This is the focus of optimization, among which Inner > This indicates poor contact between the terminals and wires of the wiring harness; this ratio... A value less than 1 will reduce the correction range, avoid excessive crimping force that could cause terminal deformation, and also take into account the electrical contact effect. Essentially, it is the ratio of the reference pressure to the actual crimping power. < This indicates that the efficiency is too low. If the ratio is greater than 1, the correction range will be increased to ensure that the efficiency reaches the standard after the pressing force is adjusted. In It represents the actual pressing energy, reflecting the cumulative work done by the pressing force on the displacement. It is the baseline crimping energy, the square root of the ratio of the two, which can quantify the mechanical accumulation of dynamic crimping. < This indicates insufficient compaction accumulation; the square root of this term is greater than 1, which will increase the correction range to ensure that the mechanical accumulation effect meets the standard after the clamping force is adjusted. > This indicates excessive compression. If the square root term is less than 1, the correction range will be reduced to avoid damage to the wires or terminals, which is consistent with the cumulative effect characteristics of dynamic crimping. In It is the characteristic value of the actual pressing displacement. It is the characteristic value of the reference displacement, the square root of the ratio of the two, corresponding to the matching of the pressing force and the displacement. > This indicates that the displacement is too large. If the square root of the term is >1, the correction range will be reduced to avoid excessive deformation of the terminal due to excessive crimping force. Conversely, if the square root of the term is <1, the correction range will be increased to ensure that the crimping force and displacement work together to achieve full compression and conform to the physical law of crimping force and displacement linkage. The multi-parameter coordination mechanism is designed to match complex dynamic operating conditions. Its correction terms are linked to four key parameters: electrical performance, crimping efficiency, cumulative mechanical effects, and displacement, rather than a single parameter correction. This allows it to adapt to the complex scenarios in dynamic crimping of wire harnesses. By quantifying the impact of parameter fluctuations through the square root term, the adjustment range can be accurately controlled. This avoids both excessive adjustment that could deform terminals or damage wires, and insufficient adjustment that would fail to correct deviations, ensuring the accuracy of the adjusted parameters. It can match the current crimping conditions and improve the consistency of crimping quality; its correction terms can offset the instantaneous fluctuations in dynamic crimping, and based on the overall characteristics of the entire crimping process, avoid erroneous adjustments caused by instantaneous fluctuations and improve the stability of dynamic control.

[0041] Furthermore, in middle, It is a characteristic value of the entire crimping process obtained through experimental quantification based on the wire harness specification, rather than a constant value throughout the process. It objectively reflects the basic displacement benchmark required for crimping the wire harness of this specification, and closely matches the actual working condition of the dynamic change of displacement over time in actual crimping. Calculated directly from the actual eigenvalue minus the benchmark eigenvalue, where It is the average displacement value throughout the entire actual pressing process, rather than the instantaneous displacement value. It can accurately reflect the overall displacement deviation during dynamic pressing, rather than a single instantaneous fluctuation, thus avoiding erroneous adjustments caused by instantaneous interference. The sign of the value can be used to directly determine the direction of displacement deviation. A positive value indicates that the actual displacement is greater than the reference displacement, which may lead to excessive deformation of the terminal. A negative value indicates that the actual displacement is less than the reference displacement, which may lead to insufficient clamping between the terminal and the wire. This provides clear guidance for the direction of displacement adjustment, perfectly matching the characteristics of displacement fluctuations in dynamic crimping, and meeting the key requirements of dynamic control; Correction item of In The baseline compression force characteristic value, This is the actual characteristic value of the pressing force. > This indicates that the actual crimping force is too high. A ratio less than 1 will reduce the displacement adjustment range to prevent excessive displacement from causing excessive deformation of the terminal or damage to the wire. < This indicates that the actual pressing force is too small. A ratio greater than 1 will increase the displacement adjustment range, ensuring that the displacement and pressing force work together to achieve full compression, which is in line with the physical law of pressing force and displacement linkage. As the reference crimping power, This is the actual crimping power. < This indicates that the crimping efficiency is too low. Since the ratio is >1, the displacement adjustment range can be appropriately increased to avoid insufficient crimping and further reduction in efficiency due to insufficient displacement. > This indicates that the crimping efficiency is too high. Since the ratio is <1, the displacement adjustment range can be reduced to avoid excessive displacement leading to a decrease in efficiency, thus achieving a balance between displacement adjustment and efficiency. In It is the actual pressing energy, reflecting the cumulative work effect of the pressing force on the displacement; It is the reference crimping energy, and the square root of the ratio between the two can quantify the cumulative mechanical deviation of dynamic crimping. < This indicates insufficient cumulative compression effect. Regardless of displacement fluctuations during dynamic pressing, the overall cumulative work is not up to standard. Since the square root of this term is greater than 1, the displacement adjustment range should be increased to ensure that the mechanical cumulative effect meets the standard after displacement adjustment. > This indicates excessive compression and excessive cumulative work. The square root term <1 will reduce the displacement adjustment range and avoid excessive displacement leading to terminal deformation, which is consistent with the cumulative effect characteristics of dynamic crimping. The amplitude of pressure fluctuation can be quantified to avoid displacement adjustment imbalance caused by a single pressure deviation. > This indicates that the crimping force was too high. >1 will reduce the overall correction range, avoid excessive displacement adjustment, and prevent excessive deformation of the terminals due to large crimping force and large crimping displacement; if < This indicates that the crimping force is too small. A value less than 1 will increase the overall correction range, ensuring that the displacement adjustment can compensate for the insufficient pressing force, achieve coordinated stability of large pressing force and pressing displacement, and match the uncertainty of pressing force fluctuation in dynamic pressing.

[0042] Furthermore, in middle, This is a baseline value obtained based on the wire harness specifications, rather than a constant value throughout the process. It objectively reflects the basic time required for crimping wire harnesses of that specification, ensuring sufficient crimping. It avoids insufficient crimping and poor contact due to excessively short time, while also considering production efficiency and avoiding impacting capacity due to excessive time. It serves as the benchmark for time adjustment. It accurately reflects the overall deviation of the dynamic crimping rhythm of the wire harness by directly calculating the difference between the actual value and the reference value. A positive value indicates that the actual crimping time is too long and the efficiency is too low. A negative value indicates that the actual crimping time is too short, which may lead to insufficient crimping. Calculating based on the total duration of a single crimping operation, rather than instantaneous time fluctuations, avoids misjudgments caused by minor sensor erroneous data acquisition and instantaneous equipment vibrations. This aligns with the characteristics of time fluctuations in dynamic crimping and provides accurate deviation data for subsequent corrections, conforming to the rules of dynamic control. (Correction item) of In It is the integral value of the entire pressing process, reflecting the cumulative effect of compression. < This indicates insufficient compression. >1 will increase the time adjustment range, appropriately extending the pressing time to ensure sufficient tightening; if > This indicates excessive compression. If the value is less than 1, the adjustment range will be reduced to avoid overheating of the terminals due to excessive time. > This indicates poor contact. A value less than 1 will reduce the time adjustment range, avoiding excessive time extension that could cause terminal deformation, while also ensuring electrical contact performance; the two work together to ensure that the time adjustment meets both mechanical clamping requirements and electrical performance standards. Quantifiable efficiency fluctuation range < This will increase the time adjustment range, appropriately extend the pressing time, improve the fullness of pressing, and improve efficiency; if > This indicates that the efficiency is too high, so the adjustment range will be reduced to avoid crimping defects caused by excessively short time, thus achieving a balance between time adjustment and efficiency; if > This indicates that the crimping time was too long. A value greater than 1 will reduce the overall correction range, thus avoiding longer adjustment times and lower efficiency. < This indicates that the crimping time was too short. A value less than 1 will increase the correction range, ensuring sufficient pressing time after adjustment, avoiding insufficient pressing, and matching the uncertainty of time fluctuations in dynamic pressing.

[0043] Furthermore, in middle, It is a fixed reference threshold obtained based on the quantification of wire harness specifications. It serves as a benchmark for judging electrical performance, ensuring the electrical contact effect between the wire and the terminal after crimping, and avoiding problems such as reduced electrical transmission efficiency and overheating caused by excessive contact resistance. Accurately reflects the overall deviation between actual electrical performance and reference requirements, matching the fluctuation characteristics of dynamic crimping; correction items of Achieving a synergistic correction between mechanical properties and crimping efficiency, in which... As a reference crimping energy, Both are important parameters of the actual pressing energy and the pressing mechanical properties, reflecting the cumulative pressing effect. < This indicates insufficient cumulative compaction effect. A value greater than 1 will increase the correction range to ensure that the electrical contact effect matches the mechanical clamping effect, avoiding excessive contact resistance due to insufficient clamping; conversely, a value less than 1 will decrease the correction range to avoid excessive adjustment leading to excessively high electrical performance standards and increased production difficulty. As the reference crimping power, Both represent the actual crimping power and reflect the crimping efficiency. If < This indicates that the crimping efficiency is low. >1 will increase the correction range and adjust Matching the current efficiency condition avoids unstable contact resistance due to excessively low crimping efficiency; conversely, reducing the correction range avoids poor contact due to excessively high crimping efficiency, thus achieving a balance between electrical performance and crimping efficiency; if > This indicates that the actual contact resistance is too high, and there is poor contact between the terminal and the wire. A value less than 1 will reduce the overall correction range and prevent excessive reduction. This results in excessively high electrical performance standards, which are difficult to achieve and increase production costs; if < This indicates that the actual contact resistance is low, but the contact effect is good. A value greater than 1 will increase the correction range; adjustments should be made accordingly. This ensures that the reference threshold better reflects the actual electrical performance, avoiding misjudgments caused by an excessively high reference, while also ensuring stable electrical performance and matching the fluctuation characteristics of contact resistance during dynamic crimping; and by introducing It further matches the electrical contact requirements, ensuring that electrical performance and mechanical performance are stable in sync.

[0044] In a preferred embodiment, the method for adjusting the quality pass threshold of the next wire harness specifically includes: crimping quality assessment value In mathematical expressions , and The reference contact resistance value of each wire harness is adjusted accordingly. The reference crimping energy adjustment value for the next wire harness Reference crimping power adjustment for the next wire harness The new crimping quality assessment value is formed by replacing the previous one. The mathematical expression for applying this new crimping quality assessment value. The mathematical expression is combined with the actual dynamic parameters of the entire crimping process of each qualified sample wire harness, which are collected in real time, to update and calculate the crimping quality assessment value of all qualified sample wire harnesses. The minimum value of the updated crimping quality assessment value of all qualified sample wire harnesses is taken as the quality qualification threshold of the wire harness. The adjustment value is the quality qualification threshold for this wire harness. The adjustment value is the quality qualification threshold for the next wire harness, realizing continuous optimization of both the crimping process and the judgment standard.

[0045] It should be noted that the intelligent detection and control method for wire harness crimping of the present invention may further include: The actual dynamic parameters, reference parameters, actual crimping force characteristic value, actual crimping displacement characteristic value, crimping quality assessment value, initial value of the quality qualification threshold of the wire harness, result of determining whether the crimping quality of the current wire harness to be tested is qualified, and adjustment value of the reference crimping force characteristic value of the next wire harness are all recorded for each wire harness. Adjustment value of the reference crimping displacement characteristic value of the next wire harness The reference crimping time adjustment value for the next wire harness The reference contact resistance adjustment value for the next wire harness The reference crimping energy adjustment value for the next wire harness The reference crimping power adjustment amount for the next wire harness The quality pass threshold for the next wire harness is stored in the controller's memory to establish a traceable architecture, which facilitates subsequent quality review, defect analysis and process optimization. At the same time, the update record of the quality pass threshold for the next wire harness is stored. The update record includes its update time, the corresponding baseline parameter and the updated value, to ensure that the adjustment of the quality pass threshold is traceable and verifiable.

[0046] The purpose of this invention is to overcome the shortcomings of current wire harness crimping quality detection and control methods, which rely on manual visual inspection combined with offline sampling tensile testing, resulting in low detection efficiency and high subjectivity. This invention provides an intelligent detection and control method for wire harness crimping, adapting to actual working conditions where crimping force and displacement dynamically change over time. It achieves real-time, comprehensive, and accurate detection of wire harness crimping quality, while simultaneously enabling dynamic control of crimping parameters, improving the stability of crimping quality detection, reducing the failure rate of wire harness quality detection, and meeting the needs of high-volume, high-speed wire harness production.

[0047] It should be recognized that embodiments of the present invention may be implemented or carried out by computer hardware, a combination of hardware and software, or by computer instructions stored in a non-transitory computer-readable storage medium.

[0048] The method can be implemented using standard programming techniques, including a non-transitory computer-readable storage medium configured with a computer program in the computer program, wherein the storage medium is configured such that the computer operates in a specific and predefined manner.

[0049] Each program can be implemented in a high-level procedural or object-oriented programming language to communicate with the computer system; however, if necessary, the program can be implemented in assembly or machine language.

[0050] In any case, the language can be either compiled or interpreted.

[0051] Furthermore, for this purpose, the program can run on a programmed application-specific integrated circuit.

[0052] The processes described herein (or variations and / or combinations thereof) can be executed under the control of one or more computer systems configured with executable instructions, and can be implemented by hardware or a combination thereof as code (e.g., executable instructions, one or more computer programs, or one or more applications) that commonly executes on one or more processors. The computer program includes a plurality of instructions executable by one or more processors.

[0053] Furthermore, the method can be implemented in any suitable computing platform, including but not limited to personal computers, minicomputers, mainframes, workstations, networked or distributed computing environments, standalone or integrated computer platforms, or in communication with charged particle tools or other imaging devices.

[0054] Various aspects of the present invention can be implemented in machine-readable code stored on a non-transitory storage medium or device, whether portable or integrated into a computing platform, such as a hard disk, optical read and / or write storage medium, RAM, ROM, etc., such that it can be read by a programmable computer, and when the storage medium or device is read by the computer, it can be used to configure and operate the computer to perform the processes described herein.

[0055] Furthermore, machine-readable code, or parts thereof, can be transmitted via wired or wireless networks.

[0056] When such media includes instructions or programs that combine with a microprocessor or other data processor to implement the steps described above, the invention described herein includes these and other different types of non-transitory computer-readable storage media.

[0057] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A method for intelligent detection and control of wire harness crimping, characterized in that, include: Initialize the crimping parameters for wire harness crimping, that is, set the reference parameters for wire harness crimping during the crimping process; During the crimping process of each wire harness to be tested, the actual dynamic parameters of the entire crimping process are collected in real time. Based on the collected actual dynamic parameters and benchmark parameters, the crimping quality assessment value is calculated. According to the crimping quality assessment value The value determines whether the crimping quality of the wire harness to be inspected is qualified; If the crimping quality of the current wire harness to be tested is determined to be qualified, the parameter deviation is calculated by comparing its actual dynamic parameters with the reference parameters. The crimping reference parameters and quality qualification threshold of the next wire harness are then adjusted accordingly to achieve dynamic control.

2. The intelligent detection and control method for wire harness crimping according to claim 1, characterized in that, The method for setting the reference parameters for wire harness crimping during the crimping process specifically includes: According to the wire harness specifications, reference parameters are set for the crimping process. These reference parameters are characteristic reference values ​​of the wire harness throughout the entire crimping process, specifically including the reference crimping force characteristic value. , reference pressing displacement characteristic value Reference contact resistance and reference crimping time Simultaneously set the reference crimping energy. and reference crimping power , , .

3. The intelligent detection and control method for wire harness crimping according to claim 2, characterized in that, The wire harness crimping is performed using a crimping machine. The crimping machine is equipped with a pressure sensor, a displacement sensor, and a contact resistance sensor that are connected to the controller of the crimping machine. A timer is also installed in the controller of the crimping machine. The pressure sensor is located at the connection between the pressure head and the drive component of the crimping machine used for wire harness crimping; The displacement sensor is installed on the side of the pressing head of the crimping machine; The contact resistance sensor is installed in the terminal positioning part of the crimping machine.

4. The intelligent detection and control method for wire harness crimping according to claim 3, characterized in that, The actual dynamic parameters of the entire crimping process include: The actual crimping force dynamic sequence is the instantaneous crimping force that is collected in real time by a pressure sensor and transmitted to the controller throughout the entire crimping process of the wire harness. The controller will instantly apply pressure. Arranging them according to the order of their collection times forms the actual pressure relay dynamic sequence; The actual pressing displacement dynamic sequence is the instantaneous pressing displacement that is collected in real time by a displacement sensor and transmitted to the controller throughout the entire wire harness pressing process. The controller will instantly press the displacement. Arranging them according to the order of their collection times forms the actual pressing displacement dynamic sequence; Actual crimping time It is a timer that records the total time from when the crimping machine starts contacting the terminal to when the crimping is completed; Actual contact resistance The contact resistance value is collected by the contact resistance sensor and transmitted to the controller after the wire harness to be tested has been crimped for 3-5 seconds. Actual crimping energy ; Actual crimping power .

5. The intelligent detection and control method for wire harness crimping according to claim 4, characterized in that, Actual crimping energy This is the integral value of the instantaneous crimping force and the corresponding instantaneous crimping displacement of the wire harness under test throughout the entire crimping process, i.e. ; Actual crimping power ; The specific implementation methods include: Based on the dynamic sequence of actual pressure relay force formed by synchronous data acquisition and the actual pressing displacement dynamic sequence Calculate , in This refers to the instantaneous crimping force or instantaneous crimping displacement during the entire wire harness crimping process. For the first time collected A momentary pressure relay, For the first time collected A momentary pressing displacement , Set to 0.

6. The intelligent detection and control method for wire harness crimping according to claim 5, characterized in that, Based on the collected actual dynamic parameters and benchmark parameters, the crimping quality assessment value is calculated. The mathematical expression is: ； In this mathematical expression, This is the assessment value for the crimping quality; This refers to the actual crimping energy. As a reference crimping energy; This refers to the actual crimping power; The reference crimping power; This represents the actual contact resistance. This is the reference contact resistance.

7. The intelligent detection and control method for wire harness crimping according to claim 6, characterized in that, Based on the crimping quality assessment value The method for determining whether the crimping quality of the wire harness to be inspected is qualified by the value includes: when ≥ When the crimping quality of the wire harness to be tested is deemed acceptable, it is determined that the crimping quality is acceptable. < If the controller determines that the crimping quality of the wire harness to be inspected is unqualified, it will trigger an alarm signal in real time and hand over the unqualified wire harness to on-site personnel for scrapping or rework. This is the quality pass threshold for the wire harness.

8. The intelligent detection and control method for wire harness crimping according to claim 7, characterized in that, Wire harness quality pass threshold The methods for setting initial values ​​include: Select sample wire harnesses with specifications consistent with the wire harness to be tested in advance, and crimp each sample wire harness according to the crimping process requirements specified in the industry standard. After all sample wire harnesses have been crimped, each sample wire harness is subjected to offline destructive testing to screen out all qualified sample wire harnesses. Application of crimping quality assessment value The mathematical expression is combined with the actual dynamic parameters of each qualified sample wire harness to calculate the crimping quality assessment value of all qualified sample wire harnesses. The minimum value of the crimping quality assessment value of all qualified sample wire harnesses is taken as the quality qualification threshold of the wire harness. The initial value.

9. The intelligent detection and control method for wire harness crimping according to claim 8, characterized in that, If the crimping quality of the wire harness to be inspected is determined to be qualified, the mathematical expression for calculating the parameter deviation by comparing its actual dynamic parameters with the reference parameters is as follows: Deviation of actual pressing force characteristic value ; Actual crimping displacement characteristic value deviation ; Actual crimping time deviation ; Actual contact resistance deviation ; In the mathematical expression for parameter deviation, This represents the characteristic value of the actual pressing force. The value is the average of all instantaneous pressure forces in the actual pressure force dynamic sequence; This represents the characteristic value of the actual pressing displacement. The value is the average of all instantaneous pressing displacements in the actual pressing displacement dynamic sequence; The method for adjusting the crimping reference parameters of the next wire harness specifically includes: Adjustment value of the reference crimping force characteristic value of the next wire harness ; Adjustment value of the reference crimping displacement characteristic value of the next wire harness ; Reference crimping time adjustment value for the next wire harness ; Reference contact resistance adjustment value for the next wire harness ; The reference crimping energy adjustment value for the next wire harness is updated synchronously. and reference crimping power adjustment amount Adjust the reference crimping force characteristic value of the next wire harness. Adjustment value of the reference crimping displacement characteristic value of the next wire harness The reference crimping time adjustment value for the next wire harness The reference contact resistance adjustment value for the next wire harness The reference crimping energy adjustment value for the next wire harness Reference crimping power adjustment for the next wire harness These values ​​will serve as the reference crimping force characteristic values ​​for the next wire harness throughout the entire crimping process. , reference pressing displacement characteristic value Reference crimping time Reference contact resistance Reference crimping energy With reference crimping power .

10. The intelligent detection and control method for wire harness crimping according to claim 9, characterized in that, The method for adjusting the quality pass threshold of the next wire harness specifically includes: crimping quality assessment value In mathematical expressions , and The reference contact resistance value of each wire harness is adjusted accordingly. The reference crimping energy adjustment value for the next wire harness Reference crimping power adjustment for the next wire harness The new crimping quality assessment value is formed by replacing the previous one. The mathematical expression for applying this new crimping quality assessment value. The mathematical expression is combined with the actual dynamic parameters of the entire crimping process of each qualified sample wire harness, which are collected in real time, to update and calculate the crimping quality assessment value of all qualified sample wire harnesses. The minimum value of the updated crimping quality assessment value of all qualified sample wire harnesses is taken as the quality qualification threshold of the wire harness. The adjustment value is the quality qualification threshold for this wire harness. The adjustment value is the quality qualification threshold for the next wire harness.

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