An automatic assembly machine for 2-pin wire harnesses

Abstract

This invention belongs to the field of wire harness processing technology and provides an automatic assembly machine for 2-pin wire harnesses. It includes a frame with a manual wire-aligning station at one end. A double-layer circulating tooling conveyor line connects the frame and the manual wire-aligning station. Several transfer tools are arranged on the double-layer circulating tooling conveyor line. Along the upper conveying direction of the double-layer circulating tooling conveyor line, the frame is sequentially equipped with a CCD detection device, a top cover flip-locking device, a locking plate feeding and locking device, a locking plate height detection device, a wire cap breakage detection device, a continuity testing device, an unloading device, and a sheath feeding device. This invention is suitable for the automated assembly of novel wire harness products where the plastic shell and top cover are hinged together. The machine features a modular integrated design, high assembly and testing accuracy, long service life, low maintenance costs, and full production process traceability. It effectively meets the needs of high-precision, high-yield, large-scale, and digital automated production of 2-pin wire harnesses, and has extremely high market promotion and industrial application value.

Description

Technical Field

[0001] This invention relates to the field of wire harness processing technology, and in particular to an automatic assembly machine for 2-pin wire harnesses. Background Technology

[0002] In the wire harness manufacturing process, the assembly of wire harnesses is mostly done manually. Typically, the wires, magnetic rings, and terminals are pre-assembled, then the pre-assembled components are precisely placed into a plastic housing. The top cover is then fastened onto the housing, and finally, a locking clip is inserted to secure it. The entire assembly process is largely manual, resulting in high labor intensity, low assembly efficiency, and poor assembly consistency.

[0003] Chinese invention patent No. 202310523427.9 discloses a wire harness integrated processing machine, including a manual feeding station and a production line assembly table. A tray conveying mechanism is provided on the upper side of both the manual feeding station and the production line assembly table, conveying multiple tray fixtures for placing wire harness products. Along the forward conveying direction of the tray conveying mechanism, a CVR feeding assembly mechanism, a CPA feeding assembly mechanism, an electrical testing mechanism, an unloading mechanism, and an HSG feeding mechanism are sequentially arranged on the upper side of the production line assembly table. At the manual feeding station, wires, magnetic rings, and terminals are assembled manually. This invention can reduce the input of traditional manual assembly, testing, and coding operations to a certain extent. Furthermore, the multi-station coordinated operation improves the overall assembly efficiency of wire harnesses, ensuring stable quality. In addition, the layered fixture flow design results in a compact structure, small footprint, reduced equipment space, and lower production costs.

[0004] However, in practical applications, the aforementioned wire harness assembly equipment has gradually revealed the following shortcomings: (1) Traditional wire harness products, since the plastic shell and the top cover are two separate parts, the above equipment requires two sets of feeding mechanisms to feed and assemble the plastic shell and the top cover respectively. During the assembly process, defects such as the top cover falling off, mixing materials, missing parts, and incorrect assembly are likely to occur. A new wire harness product has its top cover hinged to the plastic shell to form a protective shell structure that integrates the two. When assembling the wire harness, the pre-assembled components are placed into the plastic shell and then the top cover is flipped and fastened onto the plastic shell. After the top cover is flipped, its buckle will automatically align with the locking position of the plastic shell. There is no need to feed and position the top cover separately. Therefore, a set of feeding and positioning assembly parts can be reduced, and the assembly operation is simpler and more efficient. However, the above wire harness assembly equipment cannot realize the automatic assembly of new wire harness products.

[0005] (2) Wireless cap discontinuity detection function; When processing wire harnesses, the wire ends are stripped to expose the conductors. The bare wire area is used as a conductivity detection point. The process requires that the axial position of the conductivity test position of the two wires in the same wire harness be consistent. However, the above-mentioned wire harness assembly equipment is not equipped with a dedicated wire cap discontinuity detection station and matching detection components. It cannot identify the axial position deviation of the conductivity test position of the two wires. If the discontinuity exceeds the tolerance, the workpiece will flow into the subsequent process, which will directly cause the electrical test to fail and the conductivity performance of the finished product will be unqualified.

[0006] (3) The locking plate is not inserted into the guide assembly, resulting in low locking plate assembly accuracy. During the locking plate feeding process, it is easy to deviate or tilt, making it difficult to accurately align with the plastic shell slot. This easily leads to defects such as the locking plate not being fully inserted, improper assembly, or locking plate jamming and deformation, resulting in poor locking reliability.

[0007] (4) The electrical testing probes are severely worn, resulting in high equipment failure rate and maintenance costs. During electrical testing, the probe guide seat wraps the wire and drives it to move along the axial direction of the wire through the power module. During the movement, the testing probe is always pressed against the outer sheath of the wire until it reaches the stripped conductor area to complete the conductivity test. The probe is constantly rubbing against the insulation sheath for a long time, which easily leads to probe wear, elastic failure, poor contact and other faults. The service life of the probe is greatly shortened, and the probe assembly needs to be frequently disassembled and replaced. The equipment downtime maintenance is time-consuming and laborious, and the production and maintenance costs are significantly increased. Moreover, there is no corresponding matching marking assembly, so it is impossible to mark the qualified workpieces for electrical testing. It is difficult to quickly distinguish between qualified and unqualified parts by visual inspection.

[0008] (5) During the feeding process of plastic shells, the incoming materials generally have problems such as edge lifting and offset, making it difficult to accurately grasp the plastic shells. The gripping and clamping will cause clamping damage to the plastic shells, and the incorrect clamping position makes it difficult to accurately and stably place the plastic shells into the material tray tooling, resulting in positioning deviations in the subsequent assembly and inspection processes.

[0009] (6) It is impossible to collect wire harness assembly information online, lacks single-item data collection and process information traceability functions, and it is difficult to achieve full-process digital control. In addition, in processes such as conductivity testing, wire harnesses are prone to lifting, shifting and deviating due to testing operations, which directly affects the accuracy of product assembly and testing.

[0010] In summary, existing wire harness integrated processing machines still need further improvement in terms of overall automation integration, assembly and testing accuracy, equipment lifespan, and traceability capabilities throughout the entire production process, making it difficult to meet the demands of large-scale automated production of wire harnesses with high precision and high yield. Summary of the Invention

[0011] In order to overcome the shortcomings of the prior art as mentioned above, in-depth research was conducted, and after a great deal of creative work, the present invention was completed.

[0012] Specifically, the technical problem to be solved by the present invention is to provide an automatic 2-pin wire harness assembly machine to solve the technical problems of poor assembly and testing accuracy, low service life and difficulty in meeting the high-precision and high-yield production requirements of current wire harness assembly equipment.

[0013] To solve the above-mentioned technical problems, the technical solution of the present invention is as follows: An automatic 2-pin wire harness assembly machine includes a frame, one end of which has a manual wire alignment station. The frame and the manual wire alignment station are connected to a double-layer circulating tooling conveyor line. The double-layer circulating tooling conveyor line has several transfer tooling fixtures. Along the upper conveying direction of the double-layer circulating tooling conveyor line, the frame is sequentially equipped with a CCD detection device, a top cover flip-locking device, a locking plate feeding and locking device, a locking plate height detection device, a wire cap breakage detection device, a continuity testing device, an unloading device, and a sheath feeding device. The top cover flip-locking device includes a plastic shell pressing mechanism and a top cover flip-pressing mechanism; The locking plate feeding and locking device includes a locking plate feeding and distributing mechanism, a locking plate insertion and guiding mechanism, and a locking plate picking, placing and pressing mechanism; The wire cap breakage detection device includes a breakage straightening mechanism and a breakage detection mechanism; The continuity testing device includes a continuity tester, a wire continuity testing mechanism, a terminal continuity testing mechanism, and a testing marking mechanism. The unloading device includes a wire harness picking and placing mechanism and a wire harness receiving box; The sheath feeding device includes a sheath feeding and distributing mechanism and a sheath picking and placing mechanism.

[0014] As an improved technical solution, the transfer tooling includes a tooling base plate, on which a positioning plate is fixedly installed. The positioning plate has a plastic shell placement groove for positioning and placing the plastic shell, and a gripper clearance groove communicating with the plastic shell placement groove. There are two gripper clearance grooves, and the two gripper clearance grooves are respectively arranged on both sides of the plastic shell placement groove. A tooling support plate is fixedly installed at one end of the positioning plate, and a top cover clearance groove and a dot clearance groove are opened at the other end of the positioning plate. Both sides of the positioning plate are provided with clamping components for positioning and clamping the plastic shell. The clamping assembly includes a spring baffle, an adjusting nut, a locking pin, and a first compression spring. The spring baffle is fixedly installed on the positioning plate, the adjusting nut is threaded onto the spring baffle, and the locking pin is slidably installed in the positioning plate along the direction of approaching / moving away from the plastic shell placement groove. The locking pin has a spherical locking end. The first compression spring is located between the adjusting nut and the locking pin, and under the action of the first compression spring, the locking end of the locking pin extends into the plastic shell placement groove.

[0015] As an improved technical solution, the plastic shell pressing mechanism includes a first mounting bracket fixedly installed on the frame, a first slide cylinder fixedly installed on the first mounting bracket along the Y-axis direction, a second slide cylinder fixedly installed on the slide end of the first slide cylinder along the Z-axis direction, a first gripper cylinder fixedly installed on the slide end of the second slide cylinder along the Y-axis direction, and the gripping claws of the first gripper cylinder are respectively fixedly installed with plastic shell pressing plates through a first connecting plate; The top cover flipping and pressing mechanism includes a second mounting bracket fixedly mounted on the frame. A first electric cylinder is fixedly mounted on the second mounting bracket along the Y-axis. A second electric cylinder is fixedly mounted on the slide end of the first electric cylinder along the Z-axis. A mounting base plate is fixedly connected to the slide end of the second electric cylinder. Two corresponding roller mounting plates are fixedly mounted on the mounting base plate. Several rollers are rotatably mounted on the ends of the two roller mounting plates away from the mounting base plate, and the several rollers are evenly arranged along the X-axis.

[0016] As an improved technical solution, the locking plate feeding and distributing mechanism includes a first vibrating plate, a first linear feeder, and a locking plate distributing unit. The first linear feeder is located between the first vibrating plate and the locking plate distributing unit, and the two ends of the first linear feeder are respectively connected to the discharge end of the first vibrating plate and the receiving end of the locking plate distributing unit. The locking plate insertion guide mechanism includes a third mounting bracket fixedly mounted on the frame. A third slide cylinder is fixedly mounted on the third mounting bracket along the Y-axis direction. A fourth slide cylinder is fixedly mounted on the slide end of the third slide cylinder along the Z-axis direction. A second gripper cylinder is fixedly mounted on the slide end of the fourth slide cylinder along the Y-axis direction. The gripping claws of the second gripper cylinder are respectively fixedly mounted with locking plate guide plates through a second connecting plate. Guide grooves are opened on opposite sides of the guide ends of the two locking plate guide plates. The guide grooves are open groove structures with a guide slope and a contour adapted to the locking plate. The locking plate picking and pressing mechanism includes a fourth mounting bracket fixedly installed on the frame. A third electric cylinder is fixedly installed on the fourth mounting bracket along the Y-axis. A fourth electric cylinder is fixedly installed on the slide end of the third electric cylinder along the Z-axis. A fifth slide cylinder is fixedly installed on the slide end of the fourth electric cylinder along the X-axis. A suction nozzle mounting plate is fixedly connected to the slide end of the fifth slide cylinder. A locking plate suction nozzle is fixedly installed on the suction nozzle mounting plate.

[0017] As an improved technical solution, a first clamping plate for clamping and fixing the wire harness is also fixedly installed on the frame at the wire cap breakage detection device; The differential wire straightening mechanism includes a fifth mounting bracket fixedly installed on the frame. A fifth electric cylinder is fixedly installed on the fifth mounting bracket along the Y-axis direction. A sixth sliding cylinder is fixedly installed on the sliding end of the fifth electric cylinder along the Z-axis direction. A third gripper cylinder is fixedly installed on the sliding end of the sixth sliding cylinder along the Y-axis direction. A wire separator plate is fixedly installed on the third gripper cylinder. A wire straightening plate is fixedly installed on the gripping claws of the third gripper cylinder. The two wire straightening plates are arranged correspondingly. The wire separator plate is located between the two wire straightening plates, and a wire straightening groove adapted to the outer diameter of the wire is opened on the side of the wire straightening plate facing the wire separator plate. The discontinuity detection mechanism includes a sixth mounting bracket fixedly installed on the frame. A sixth electric cylinder is fixedly installed on the sixth mounting bracket along the Y-axis. A camera mounting plate is fixedly installed on the slide end of the sixth electric cylinder. A discontinuity detection camera is fixedly installed on the camera mounting plate. A discontinuity detection light source is also fixedly installed on the frame. The discontinuity detection light source is located directly below the discontinuity detection camera. When in the discontinuity detection state, the wire cap is located between the discontinuity detection camera and the discontinuity detection light source and is set close to the discontinuity detection light source.

[0018] As an improved technical solution, the continuity tester is fixedly installed on the frame, and the continuity tester is located above the wire connection electrical testing mechanism; A second clamping plate for securing the wire harness is also fixedly installed on the frame at the conductive electrical testing device. The wire connection electrical testing mechanism includes a seventh mounting bracket fixedly installed on the frame. A seventh electric cylinder is fixedly installed on the seventh mounting bracket along the Y-axis direction. A seventh slide cylinder arranged along the Z-axis direction is fixedly installed on the slide end of the seventh electric cylinder. An electrical testing bracket is fixedly installed on the slide end of the seventh slide cylinder. Two sets of corresponding electrical testing components are provided on the electrical testing bracket. The electrical testing assembly includes a servo cylinder fixedly mounted on the electrical testing bracket along the Y-axis. An electrical testing mounting plate is fixedly mounted on the slide end of the servo cylinder. A first and second wire-straightening partition are fixedly mounted side-by-side along the Y-axis on one side of the mounting plate. A first and second wire-straightening cylinder are fixedly mounted on the other side of the mounting plate. A first wire-straightening seat driven by the first wire-straightening cylinder is provided between the first wire-straightening cylinder and the first wire-straightening partition. The first wire-straightening seat is correspondingly positioned to the first wire-straightening partition and slides along a direction close to / away from the first wire-straightening partition. A first guide hole is provided on the electrical testing mounting plate for the first wire-straightening seat to pass through. The wire-straightening end of the first wire-straightening seat passes through the first guide hole into the electrical testing mounting plate, and the first wire-straightening seat is close to the first wire-straightening partition. One end of the device has a first opening slot adapted to the outer diameter of the conductor. A second winding seat driven by the second winding cylinder is provided between the second winding cylinder and the second winding partition. The second winding seat is correspondingly arranged with the second winding partition and is slidably arranged in the direction of approaching / away from the second winding partition. A second guide hole is provided on the electrical testing mounting plate for the second winding seat to pass through. The winding end of the second winding seat passes through the electrical testing mounting plate through the second guide hole. A second opening slot adapted to the outer diameter of the conductor is provided at the end of the second winding seat near the second winding partition. A conductor detection probe is provided inside the second winding seat. The detection end of the conductor detection probe extends into the second opening slot. An optical fiber sensor is also fixedly installed at the end of the second winding partition away from the first winding partition. The electrical testing marking mechanism includes a marking bracket fixedly installed on the frame, a marking cylinder fixedly installed on the marking bracket along the Y-axis, a marking rod fixedly installed on the slide end of the marking cylinder, and a marking guide block fixedly installed at one end of the marking bracket near the double-layer circulating tooling conveyor line. The marking guide block has a marking guide hole for the marking rod to pass through.

[0019] As an improved technical solution, the wire harness picking and placing mechanism includes an eighth mounting bracket fixedly installed on the frame. An eighth electric cylinder is fixedly installed on the eighth mounting bracket along the Y-axis direction. A ninth electric cylinder is fixedly installed on the slide end of the eighth electric cylinder along the Z-axis direction. An eighth slide cylinder is fixedly installed on the slide end of the ninth electric cylinder along the X-axis direction. A first rotary cylinder is fixedly installed on the slide end of the eighth slide cylinder. A fourth gripper cylinder is fixedly installed on the turntable of the first rotary cylinder. The gripping claws of the fourth gripper cylinder are respectively fixedly installed with unloading clamping plates. The unloading clamping plates have unloading slots on opposite sides, and unloading wire support plates are respectively fixedly installed on the unloading clamping plates. The unloading wire support plates have an integrally formed wire support part. The wire harness housing includes a good product placement box and a bad product placement box.

[0020] As an improved technical solution, the sheath feeding and distributing mechanism includes a second vibrating plate, a second linear feeder, and a sheath distributing unit. The second linear feeder is located between the second vibrating plate and the sheath distributing unit, and the two ends of the second linear feeder are respectively connected to the discharge end of the second vibrating plate and the receiving end of the sheath distributing unit. The sheath housing picking and placing mechanism includes a ninth mounting bracket fixedly installed on the frame. A tenth electric cylinder is fixedly installed on the ninth mounting bracket along the Y-axis direction. An eleventh electric cylinder is fixedly installed on the slide end of the tenth electric cylinder along the Z-axis direction. A ninth slide cylinder is fixedly installed on the slide end of the eleventh electric cylinder along the X-axis direction. A second rotary cylinder is fixedly installed on the slide end of the ninth slide cylinder. A fifth gripper cylinder is fixedly installed on the turntable of the second rotary cylinder. The gripping claws of the fifth gripper cylinder are respectively fixedly installed with feeding clamps. The opposite side of the feeding clamps has a feeding slot. The fifth gripper cylinder is also equipped with a plastic shell positioning and holding assembly. The plastic shell positioning and holding assembly includes a fixing block that is fixedly installed on both sides of the fifth gripper cylinder. A connecting block is provided below the fixing block. The connecting block is located between the two feeding clamps. Both ends of the connecting block are connected to the fixing block by a second compression spring. Two pressure rods for positioning and holding the plastic shell are fixedly connected to the side of the connecting block away from the fifth gripper cylinder. The holding ends of the pressure rods extend to the bottom of the feeding clamp.

[0021] As an improved technical solution, the frame is also equipped with several tooling scanning devices, which are located downstream of the locking plate height detection device, the wire cap breakage detection device, the continuity testing device and the unloading device, respectively. The tooling scanning device includes a scanning bracket fixedly installed on the frame. The top of the scanning bracket is provided with a mounting block, and a barcode scanner is fixedly installed on the mounting block. One end of the mounting block is rotatably installed on the scanning bracket. The top of the scanning bracket is provided with an arc-shaped slot. The other end of the mounting block is provided with a positioning knob for swing adjustment. The positioning knob passes through the arc-shaped slot and is threadedly connected to the other end of the mounting block.

[0022] As an improved technical solution, the double-layer circulating tooling conveyor line includes an upper tooling conveyor line, a lower tooling conveyor line, and a tooling transfer mechanism. The tooling transfer mechanism is located at the end of the frame away from the manual line-following station. A protective shell is provided on one side of the frame of the double-layer circulating tooling conveyor line. The frame is also fixedly equipped with a cover covering the top cover flip-locking device, the locking plate feeding locking device, the locking plate height detection device, the wire cap breakage detection device, the conductivity testing device, the unloading device, and the protective cover feeding device. The protective cover is equipped with an audible and visual alarm device.

[0023] After adopting the above technical solution, the beneficial effects of the present invention are: This 2-pin wire harness automatic assembly machine is suitable for the automated assembly of new wire harness products with a hinged connection between the plastic shell and the top cover. The equipment has a more compact and reasonable configuration and effectively improves the wire harness assembly efficiency. The wire cap breakage detection station effectively identifies wire test position breakage deviations through wire straightening and correction combined with high-precision imaging detection, avoiding quality risks such as electrical testing failures and unqualified conductivity of finished products from the source, and improving the comprehensive quality inspection system. The equipment is equipped with a locking plate locking mechanism with a guide structure, which can realize the integrated operation of precise locking plate guidance, alignment and pressing, completely solving problems such as locking plate assembly offset, jamming and incomplete positioning, and significantly improving assembly accuracy and product locking reliability. Meanwhile, the equipment optimizes the electrical testing structure, achieving conductivity testing while avoiding ineffective friction between the testing probe and the wire sheath, significantly reducing equipment failure rate, extending component lifespan, and reducing production and maintenance costs. It also features an added electrical testing marking mechanism for rapid and visual differentiation between good and defective products. The equipment includes a sheath picking and placing mechanism with plastic shell positioning and holding components, effectively correcting issues such as edge warping and misalignment of incoming materials, ensuring precise gripping and placement of the plastic shell, guaranteeing consistent positioning benchmarks throughout the entire process, and comprehensively improving assembly and testing accuracy. Furthermore, the equipment is equipped with a multi-station barcode scanning and traceability system, enabling full-process data collection, traceability, and digital management of individual products. Combined with the closed-loop flow design of the double-layer circulating tooling conveyor line and the multi-station collaborative operation mode, it significantly improves production flow efficiency and assembly consistency.

[0024] This 2pin wire harness automatic assembly machine features high modular integration, stable operation, and high safety. It completely solves the core pain points of traditional equipment, such as low automation, poor assembly accuracy, low yield, and cumbersome maintenance. It can effectively meet the needs of high-precision, high-yield, large-scale, and digital automated production of 2pin wire harnesses, and has extremely high market promotion and industrial application value. Attached Figure Description

[0025] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the accompanying drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. In all the drawings, similar elements or parts are generally identified by similar reference numerals. In the drawings, the elements or parts are not necessarily drawn to scale.

[0026] Figure 1This is a three-dimensional structural diagram of the 2-pin wire harness automatic assembly machine of the present invention; Figure 2 This is another three-dimensional structural schematic diagram of the 2-pin wire harness automatic assembly machine of the present invention; Figure 3 This is a schematic diagram of the assembly process structure of the wire harness of the present invention on the transfer tooling; Figure 4 This is a schematic diagram of the positioning part of the wire harness and transfer tooling of the present invention; Figure 5 This is a schematic diagram of the structure of the cover flip-lock device of the present invention; Figure 6 This is a schematic diagram of the plastic shell pressing mechanism of the present invention; Figure 7 This is a schematic diagram of the structure of the locking plate feeding and locking device of the present invention; Figure 8 This is a schematic diagram of the material distribution section of the locking plate of the present invention; Figure 9 This is a schematic diagram of the locking plate insertion guide mechanism of the present invention; Figure 10 This is a schematic diagram of the structure of the cap breakage detection device of the present invention; Figure 11 This is a schematic diagram of the winding section of the differential winding mechanism of the present invention; Figure 12 This is a schematic diagram of the winding state of the winding section of the differential winding mechanism of the present invention; Figure 13 This is a schematic diagram of the structure of the conductor separator and the wire straightening plate of the present invention; Figure 14 This is a schematic diagram of the structure of the conduction measuring device of the present invention; Figure 15 This is a schematic diagram of the structure of the conductor connection electrical measurement part and the electrical measurement marking part of the present invention; Figure 16 This is a three-dimensional structural diagram of the wire connection electrical measurement part of the present invention; Figure 17 This is another three-dimensional structural diagram of the wire connection electrical measurement part of the present invention; Figure 18 This is a schematic diagram of the corresponding installation structure of the two sets of electrical measurement components of the present invention; Figure 19 This is a schematic diagram of the structure of a single electrical measurement component of the present invention; Figure 20 This is a schematic diagram of the structure of the first winding seat and the second winding seat of the present invention; Figure 21 This is a schematic diagram of the electrical measurement marking mechanism of the present invention; Figure 22 This is a schematic diagram of the unloading device of the present invention; Figure 23 This is a schematic diagram of the installation structure of the unloading clamp plate and the unloading line support plate of the present invention on the fourth clamping claw cylinder. Figure 24 This is a schematic diagram of the structure of the sheath feeding device of the present invention; Figure 25 This is a schematic diagram of the material distribution section of the sheath shell of the present invention; Figure 26 This is a schematic diagram of the installation structure of the feeding clamp and the plastic shell positioning and holding assembly of the present invention. Figure 27 This is a schematic diagram of the structure of the double-layer circulating tooling conveyor line of the present invention; Figure 28 This is a schematic diagram of the tooling scanning device of the present invention; Reference numerals: 1-Frame; 2-CCD inspection device; 3-Top cover flip-locking device; 31-Plastic shell pressing mechanism; 311-First mounting bracket; 312-First slide cylinder; 313-Second slide cylinder; 314-First gripper cylinder; 315-First connecting plate; 316-Plastic shell pressing plate; 32-Top cover flip-pressing mechanism; 321-Second mounting bracket; 322-First electric cylinder; 323-Second electric cylinder; 324-Roller mounting plate; 325-Roller; 4- Locking plate feeding and locking device; 41- Locking plate feeding and distributing mechanism; 411- First vibratory feeder; 412- First linear feeder; 413- Locking plate distributing assembly; 4131- First distributing bracket; 4132- First distributing cylinder; 4133- First sliding mounting plate; 4134- First limit bolt; 4135- Locking plate distributing and receiving block; 42- Locking plate insertion guide mechanism; 421- Third mounting bracket; 422- Third slide cylinder; 423- Fourth slide cylinder; 424- Second gripper cylinder; 425- Second connecting plate; 426- Locking plate guide plate; 4261- Guide groove; 43- Locking plate picking and pressing mechanism; 431- Fourth mounting bracket; 432- Third electric cylinder; 433- Fourth electric cylinder; 434- Fifth slide cylinder; 435- Locking plate suction nozzle; 5- Lock plate height detection device; 6-Wire cap breakage detection device; 61-Breakage straightening mechanism; 611-Fifth mounting bracket; 612-Fifth electric cylinder; 613-Sixth slide cylinder; 614-Third gripper cylinder; 615-Wire separator plate; 616-Straightening plate; 6161-Straightening groove; 62-Breakage detection mechanism; 621-Sixth mounting bracket; 622-Sixth electric cylinder; 623-Camera mounting plate; 624-Breakage detection camera; 625-Breakage detection light source; 63-First pressure plate; 7-Conductivity testing device; 71-Conductivity tester; 72-Wire connection testing mechanism; 721-Seventh mounting bracket; 722-Seventh electric cylinder; 723-Seventh slide cylinder; 724-Testing bracket; 725-Servo electric cylinder; 726-Testing mounting plate; 727-First wire straightening partition; 728-Second wire straightening partition; 729-First wire straightening cylinder; 7210-Second wire straightening cylinder; 7211-First wire straightening seat; 72111-First open slot; 7212-Second wire straightening seat; 72121-Second open slot; 7213-Wire detection probe; 7214-Fiber optic sensor; 73-Testing marking mechanism; 731-Marking bracket; 732-Marking cylinder; 733-Marking rod; 734-Marking guide block; 74-Second pressure plate; 8-Unloading device; 81-Wire harness picking and placing mechanism; 811-Eighth mounting bracket; 812-Eighth electric cylinder; 813-Ninth electric cylinder; 814-Eighth slide cylinder; 815-First rotary cylinder; 816-Fourth gripper cylinder; 817-Unloading clamp plate; 818-Unloading wire support plate; 82-Wire harness receiving box; 9-Sheath feeding device; 91-Sheath feeding and distributing mechanism; 911-Second vibratory feeder; 912-Second linear feeder; 913-Sheath distributing unit; 9131-Second distributing bracket; 9132-Second distributing cylinder; 9133-Second sliding mounting plate; 9134-Second limit bolt; 9135-Sheath distributing receiving block; 92-Sheath picking and placing mechanism; 921-Ninth mounting bracket; 922-Tenth electric cylinder; 923-Eleventh electric cylinder; 924-Ninth sliding table cylinder; 925-Second rotary cylinder; 926-Fifth gripper cylinder; 927-Feeding clamping plate; 928-Fixing block; 929-Connecting block; 9210-Second compression spring; 9211-Pressure rod; 10-Tooling scanning device; 101-Scanning bracket; 102-Mounting block; 103-Scanning gun; 11-Manual assembly line station; 12-Double-layer circulating tooling conveyor line; 121-Upper tooling conveyor line; 122-Lower tooling conveyor line; 123-Tooling transfer mechanism; 13-Transfer tooling; 131-Tooling base plate; 132-Positioning plate; 1321-Plastic shell placement slot; 1322-Gripper clearance slot; 1323-Top cover clearance slot; 1324-Marking clearance slot; 133-Tooling cable support plate; 134-Spring baffle; 135-Adjusting nut; 136-Clamping pin; 137-First compression spring; 138-Stop block; 14-Protective housing; 15-Protective cover; 16-Audible and visual alarm device; 17-Wire harness; 171-Wire conductor; 172-Plastic shell; 173-Top cover; 174-Locking plate. Detailed Implementation

[0027] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0028] It should be noted that all directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of the present invention are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indication will also change accordingly.

[0029] Meanwhile, the meaning of "and / or" or "and / or" appearing throughout the text is that it includes three options. Taking "A and / or B" as an example, it includes option A, option B, or an option that satisfies both A and B.

[0030] Furthermore, in this invention, descriptions involving "first," "second," etc., are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature. Additionally, the technical solutions of the various embodiments can be combined with each other, but only on the basis of being achievable by those skilled in the art. When the combination of technical solutions is contradictory or impossible to implement, such a combination of technical solutions should be considered non-existent and not within the scope of protection claimed by this invention.

[0031] like Figure 1 and Figure 2 As shown in the figure, the present invention provides an automatic assembly machine for 2pin wire harnesses, including a frame 1, one end of which is provided with a manual wire alignment station 11, and the frame 1 and the manual wire alignment station 11 are provided with a double-layer circulating tooling conveyor line 12, on which a plurality of transfer tools 13 are provided, and the transfer tools 13 are conveyed in a closed loop through the double-layer circulating tooling conveyor line 12.

[0032] like Figure 2As shown, along the upper conveying direction of the double-layer circulating tooling conveyor line 12, the frame 1 is equipped with a CCD detection device 2, a cover flip-locking device 3, a locking plate feeding and locking device 4, a locking plate height detection device 5, a wire cap breakage detection device 6, a continuity testing device 7, a unloading device 8, and a sheath feeding device 9. The workstations of each process are connected in sequence and work together to complete the fully automated assembly and testing operations, including wire harness pre-assembly verification, cover 173 fastening, locking plate 174 assembly and testing, wire cap breakage detection, electrical performance testing, sorting of good and bad products, and automatic feeding of sheaths.

[0033] In this embodiment, as Figure 3 and Figure 4 As shown, the wire harness products that need to be assembled include wires 171, magnetic rings, terminals, plastic shells 172, top covers 173, and locking plates 174. The top cover 173 is hinged to the plastic shell 172 to form a protective shell that is integrated with the plastic shell. The top cover 173 can be flipped over when it is not fastened.

[0034] When assembling this wire harness product, the wires 171, magnetic rings, and terminals are pre-assembled first. Then, the pre-assembled components are placed into the plastic shell 172. After that, the top cover 173 is flipped and fastened, and finally, the locking piece 174 is inserted to lock it in place. During the assembly process, the double-layer circulating tooling conveyor line 12 transports the transfer tooling 13. At the manual line-following station 11, the pre-assembled components are manually placed into the plastic shell 172. During the forward transport of the transfer tooling 13, the CCD detection device 2 detects whether the magnetic ring has any color sequence errors. The top cover flipping and locking device 3 completes the flipping of the top cover 173. The locking process involves several steps: First, the locking piece 174 is inserted and locked using the locking piece feeding and locking device 4. Second, the locking piece height detection device 5 checks if the locking piece 174 is properly assembled. Third, the wire cap breakage detection device 6 checks if the breakage of the wire cap at the end of the conductor 171 is acceptable. Fourth, the conductivity test device 7 tests the conductivity of the assembled wire harness. Fifth, the unloading device 8 sorts qualified and unqualified products. Sixth, the sheath shell feeding device 9 precisely places the sheath shell into the transfer fixture 13. Finally, the double-layer circulating fixture conveyor line 12 reverses the flow fixture 13 containing the sheath shell and transports it back to the manual line-following station 11. This process is repeated.

[0035] like Figure 27As shown, the double-layer circulating tooling conveyor line 12 includes an upper tooling conveyor line 121, a lower tooling conveyor line 122, and a tooling transfer mechanism 123. The tooling transfer mechanism 123 is located at the end of the frame 1 away from the manual line-following station 11. The upper tooling conveyor line 121 is used to transport the circulating tooling 13 from the manual line-following station 11 in the forward direction and sequentially pass through the CCD detection device 2, the cover flip-locking device 3, the locking plate feeding and locking device 4, the locking plate height detection device 5, the wire cap breakage detection device 6, the continuity testing device 7, the unloading device 8, and the sheath feeding device 9. After the sheath is fed at the sheath feeding device 9, the tooling transfer mechanism 123 transfers the circulating tooling 13 on the upper tooling conveyor line 121 to the lower tooling conveyor line 122. The lower tooling conveyor line 122 is used to transport the circulating tooling 13 back to the manual line-following station 11 in the reverse direction, thus realizing the circulation of the circulating tooling 13.

[0036] like Figure 3 and Figure 4 As shown, the transfer fixture 13 includes a fixture base plate 131, on which a positioning plate 132 is fixedly installed. The positioning plate 132 has a plastic shell placement groove 1321 for positioning the plastic shell 172, and a gripper clearance groove 1322 communicating with the plastic shell placement groove 1321. There are two gripper clearance grooves 1322, which are respectively located on both sides of the plastic shell placement groove 1321, providing clearance space for the grippers to pick up and place the plastic shell 172, facilitating the picking up and placing of the plastic shell 172 and ensuring safe handling. The material flows smoothly. One end of the positioning plate 132 is fixedly installed with a tooling wire support plate 133. The tooling wire support plate 133 is used to support the wires 171 of the wire harness and prevent the wires 171 from sagging or shifting. The other end of the positioning plate 132 is provided with a cover clearance groove 1323 and a dotting clearance groove 1324. The cover clearance groove 1323 is used to position the cover 173 when it is not flipped and fastened. The dotting clearance groove 1324 facilitates the avoidance of the dotting rod 733 during subsequent electrical testing dotting and marking operations, ensuring the accurate completion of the dotting operation.

[0037] like Figure 4As shown, both sides of the positioning plate 132 are provided with clamping components for positioning and clamping the plastic shell 172, which are used for self-adaptive clamping and positioning of the plastic shell 172 to prevent the plastic shell 172 from shifting or shaking. The clamping assembly includes a spring baffle 134, an adjusting nut 135, a locking pin 136, and a first compression spring 137. The spring baffle 134 is fixedly installed on the positioning plate 132. The adjusting nut 135 is threaded onto the spring baffle 134. The locking pin 136 is slidably installed in the positioning plate 132 along the direction of approaching / moving away from the plastic shell placement groove 1321, and the locking pin 136 has a spherical locking end. The first compression spring 137 is located between the adjusting nut 135 and the locking pin 136. The two ends of the first compression spring 137 abut against the adjusting nut 135 and the locking pin 136 respectively. Under the action of the first compression spring 137, the locking end of the locking pin 136 extends into the plastic shell placement groove 1321 to elastically clamp and position the inserted plastic shell 172, ensuring that the plastic shell 172 is accurately and stably placed in the positioning plate 132.

[0038] On the frame 1, a tooling lifting mechanism is installed at the corresponding positions of the CCD detection device 2, the top cover flip-locking device 3, the locking plate feeding locking device 4, the locking plate height detection device 5, the wire cap breakage detection device 6, the continuity testing device 7, the unloading device 8, and the sheath feeding device 9. When the material passes through each assembly or testing position, the tooling lifting mechanism lifts the transfer tooling 13 from the conveyor line to ensure more accurate and reliable assembly and testing of the material. After the assembly or testing of the current process is completed, the tooling lifting mechanism puts the transfer tooling 13 back onto the conveyor line, which then transports it to the next process. A stop block 138 is fixedly installed at one end of the tooling base plate 131. When the tooling lifting mechanism positions and blocks the transfer tooling 13, the stop pin abuts against the stop block 138.

[0039] At the manual conveyor station 11, the operator removes the transfer fixture 13 that has been transported back from the lower tooling conveyor line 122, and then inserts the blue and yellow wires 171 into the corresponding holes of the magnetic ring. Next, the magnetic ring with the wires 171 is installed into the plastic shell 172 on the transfer fixture 13, and the terminals of the blue and yellow wires are inserted into the corresponding holes of the plastic shell 172. Then, the transfer fixture 13 is placed at the beginning of the upper tooling conveyor line 121, and is transported by the upper tooling conveyor line 121 to the next process for testing of the magnetic ring and color sequence.

[0040] The transfer fixture 13 is conveyed to the magnetic ring and color sequence detection station. The CCD detection device 2 checks whether a magnetic ring is installed inside the plastic shell 172 on the transfer fixture 13. If a magnetic ring is missing, the equipment will alarm. The CCD detection device 2 will also check whether the blue and yellow wires are inserted into the corresponding correct holes. If the wire 171 is inserted backwards, i.e., the color sequence is incorrect, the equipment will also alarm. If an alarm is issued, the display will show the specific type of defect, i.e., missing magnetic ring or incorrect color sequence. If all inspections are qualified, the transfer fixture 13 will be conveyed to the next process, entering the top cover flip-lock station.

[0041] The manual feeding station 11, the double-layer circulating tooling conveyor line 12, the tooling lifting mechanism, and the CCD detection device 2 can adopt the same structural design as the manual feeding station, the material tray conveying mechanism, the transfer mechanism, the stop mechanism, and the first vision detection component in the existing invention patent with patent number 202310523427.9, which will not be described in detail here.

[0042] like Figure 5 As shown, the top cover flip-locking device 3 includes a plastic shell pressing mechanism 31 and a top cover flip-pressing mechanism 32. The plastic shell pressing mechanism 31 is used to press the plastic shell 172, and the top cover flip-pressing mechanism 32 is used to automatically flip and press the top cover 173. The plastic shell pressing mechanism 31 and the top cover flip-pressing mechanism 32 work together to complete the automatic flipping of the top cover 173 and the precise fastening on the plastic shell 172.

[0043] like Figure 5 and Figure 6 As shown, the plastic shell pressing mechanism 31 includes a first mounting bracket 311 fixedly mounted on the frame 1. A first slide cylinder 312 is fixedly mounted on the first mounting bracket 311 along the Y-axis direction. A first cylinder mounting plate is fixedly connected to the slide end of the first slide cylinder 312. A second slide cylinder 313 is fixedly mounted on the first cylinder mounting plate along the Z-axis direction. A second cylinder mounting plate is fixedly connected to the slide end of the second slide cylinder 313. A first gripper cylinder 314 is fixedly mounted on the second cylinder mounting plate along the Y-axis direction. The gripping claws of the first gripper cylinder 314 are respectively fixedly mounted with plastic shell pressing plates 316 through a first connecting plate 315. During operation, the first slide cylinder 312, the second slide cylinder 313, and the first gripper cylinder 314 work together to drive the plastic shell pressing plate 316 to precisely press the plastic shell 172, preventing the plastic shell 172 from shifting or lifting during the flipping of the upper cover 173. After the upper cover flipping and pressing mechanism 32 completes the flipping of the upper cover 173, the above-mentioned cylinders drive the plastic shell pressing plate 316 to reset, and then the upper cover 173 is pressed and locked by the upper cover flipping and pressing mechanism 32.

[0044] like Figure 5As shown, the top cover flipping and pressing mechanism 32 includes a second mounting bracket 321 fixedly mounted on the frame 1. A first electric cylinder 322 is fixedly mounted on the second mounting bracket 321 along the Y-axis direction. A first electric cylinder mounting plate is fixedly connected to the slide end of the first electric cylinder 322. A second electric cylinder 323 is fixedly mounted on the first electric cylinder mounting plate along the Z-axis direction. A mounting base plate is fixedly connected to the slide end of the second electric cylinder 323. Two corresponding roller mounting plates 324 are fixedly mounted on the mounting base plate. Several rollers 325 are rotatably mounted on the ends of the two roller mounting plates 324 away from the mounting base plate, and the several rollers 325 are evenly arranged along the X-axis direction. During operation, after the plastic shell pressing mechanism 31 presses the plastic shell 172, the first electric cylinder 322 and the second electric cylinder 323 work together to first move the roller 325 below the upper cover 173 and drive the roller 325 to adhere to the surface of the upper cover 173. Then, the roller 325 is driven to lift and move forward at the same time, completing the flipping of the upper cover 173. After the upper cover 173 is flipped, the plastic shell pressing mechanism 31 releases the pressing of the plastic shell 172. Finally, the first electric cylinder 322 and the second electric cylinder 323 drive the roller 325 to press the upper cover 173 onto the plastic shell 172, completing the locking of the upper cover 173.

[0045] like Figure 7 As shown, the locking plate feeding and locking device 4 includes a locking plate feeding and distributing mechanism 41, a locking plate insertion and guiding mechanism 42, and a locking plate picking, placing, and pressing mechanism 43. The mechanisms work together to achieve automatic feeding, precise distributing, guiding and positioning, and pressing and locking of the locking plates 174 in an integrated operation.

[0046] like Figure 7 As shown, the locking plate feeding and distributing mechanism 41 includes a first vibrating plate 411, a first linear feeder 412, and a locking plate distributing unit 413. The first linear feeder 412 is located between the first vibrating plate 411 and the locking plate distributing unit 413, and the two ends of the first linear feeder 412 are respectively connected to the discharge end of the first vibrating plate 411 and the receiving end of the locking plate distributing unit 413, so as to realize the orderly feeding and distributing of the locking plates 174.

[0047] like Figure 8As shown, the locking piece dispensing unit 413 includes a first dispensing bracket 4131 fixedly installed on the frame 1. A first sliding mounting plate 4133 driven by a first dispensing cylinder 4132 is slidably installed on the first dispensing bracket 4131 along the Y-axis direction. The top of the first dispensing bracket 4131 is also threaded with a first limiting bolt 4134 for limiting the sliding stroke of the first sliding mounting plate 4133. Two first limiting bolts 4134 are provided, and the distance between the two first limiting bolts 4134 is the maximum sliding stroke of the first sliding mounting plate 4133, so as to realize the precise adjustable limit of the dispensing stroke. A locking piece dispensing receiving block 4135 is fixedly installed on the first sliding mounting plate 4133. A locking piece receiving groove for positioning the locking piece 174 is opened on the side of the locking piece dispensing receiving block 4135 near the first linear feeder 412.

[0048] Specifically, a first guide rail is fixedly installed on the top of the first material distribution bracket 4131 along the Y-axis direction, a first slider is slidably installed on the first guide rail, a first sliding mounting plate 4133 is fixedly connected to the first slider, and the first sliding mounting plate 4133 is slidably installed on the first material distribution bracket 4131 through the first guide rail and the first slider; a first material distribution cylinder 4132 is fixedly installed on the first material distribution bracket 4131, and the piston shaft end of the first material distribution cylinder 4132 is fixedly connected to the first sliding mounting plate 4133.

[0049] like Figure 7 and Figure 9 As shown, the locking plate insertion guide mechanism 42 includes a third mounting bracket 421 fixedly mounted on the frame 1. A third slide cylinder 422 is fixedly mounted on the third mounting bracket 421 along the Y-axis direction. A third cylinder mounting plate is fixedly connected to the slide end of the third slide cylinder 422. A fourth slide cylinder 423 is fixedly mounted on the third cylinder mounting plate along the Z-axis direction. A fourth cylinder mounting plate is fixedly connected to the slide end of the fourth slide cylinder 423. A second gripper cylinder 424 is fixedly mounted on the fourth cylinder mounting plate along the Y-axis direction. The gripping claws of the second gripper cylinder 424 are respectively fixedly mounted with locking plate guide plates 426 through the second connecting plate 425. Guide grooves 4261 are opened on opposite sides of the guide ends of the two locking plate guide plates 426. The guide grooves 4261 are open groove structures with a guide slope and an outline that matches the locking plate 174. During operation, the third slide cylinder 422, the fourth slide cylinder 423, and the second gripper cylinder 424 work together to drive the locking plate guide plate 426 to precisely move to the locking plate insertion position of the sheath. A precise guiding channel is formed between the two locking plate guide plates 426 to correct and position the locking plate 174 that has been delivered to the position, solving the problem of the locking plate 174 being offset or skewed during feeding, and providing a reliable guarantee for the precise pressing and assembly of the locking plate 174.

[0050] like Figure 7As shown, the locking plate picking and pressing mechanism 43 includes a fourth mounting bracket 431 fixedly mounted on the frame 1. A third electric cylinder 432 is fixedly mounted on the fourth mounting bracket 431 along the Y-axis direction. A second electric cylinder mounting plate is fixedly connected to the slide end of the third electric cylinder 432. A fourth electric cylinder 433 is fixedly mounted on the second electric cylinder mounting plate along the Z-axis direction. A fifth cylinder mounting plate is fixedly mounted on the slide end of the fourth electric cylinder 433. A fifth slide cylinder 434 is fixedly mounted on the fifth cylinder mounting plate along the X-axis direction. A suction nozzle mounting plate is fixedly connected to the slide end of the fifth slide cylinder 434. A locking plate suction nozzle 435 is fixedly mounted on the suction nozzle mounting plate. During operation, the third electric cylinder 432, the fourth electric cylinder 433, and the fifth slide cylinder 434 work together to drive the locking plate suction nozzle 435 to move to the material picking position, accurately pick up the locking plate 174 after material distribution, and move the locking plate 174 to the corresponding insertion position. With the guidance and positioning of the locking plate insertion guide mechanism 42, the locking plate 174 is accurately pressed into the slot of the plastic shell 172, completing the assembly of the locking plate 174.

[0051] The locking plate height detection device 5 can adopt the same structural design as the CPA height detection component in the existing invention patent with patent number 202310523427.9, which will not be described in detail here.

[0052] like Figure 10 As shown, the wire cap breakage detection device 6 includes a breakage straightening mechanism 61 and a breakage detection mechanism 62, which can accurately detect the axial breakage at the stripped conductivity test position of two wires 171, and prevent electrical testing failure and finished product conductivity failure caused by excessive breakage.

[0053] like Figure 11 As shown, a first pressing plate 63 for pressing and fixing the wire harness 17 is also fixedly installed on the frame 1 at the wire cap breakage detection device 6. After the tooling lifting mechanism lifts the transfer tooling 13, the first pressing plate 63 abuts against the wire harness 17 to press and fix the wire harness 17, so as to avoid pulling the wire harness 17 up or pulling it out of the transfer tooling 13 during the wire breaking detection process, thus ensuring the stability of the detection.

[0054] like Figures 10 to 13As shown, the differential winding mechanism 61 includes a fifth mounting bracket 611 fixedly mounted on the frame 1. A fifth electric cylinder 612 is fixedly mounted on the fifth mounting bracket 611 along the Y-axis direction. A sixth cylinder mounting plate is fixedly connected to the slide end of the fifth electric cylinder 612. A sixth slide cylinder 613 is fixedly mounted on the sixth cylinder mounting plate along the Z-axis direction. A seventh cylinder mounting plate is fixedly connected to the slide end of the sixth slide cylinder 613. A third gripper cylinder 614 is fixedly mounted on the seventh cylinder mounting plate along the Y-axis direction. A wire separator plate 615 is fixedly mounted on the third gripper cylinder 614. Winding plates 616 are fixedly mounted on the gripping claws of the third gripper cylinder 614. Two winding plates 616 are arranged correspondingly. The wire separator plate 615 is located between the two winding plates 616. A winding groove 6161 adapted to the outer diameter of the wire 171 is opened on the side of the winding plate 616 facing the wire separator plate 615. During operation, the fifth electric cylinder 612 and the sixth slide cylinder 613 work together to drive the wire separator 615 to precisely separate the two wires 171. Then, the third gripper cylinder 614 works to drive the two straightening plates 616 to close. The wire 171 is clamped between the straightening plate 616 and the wire separator 615 through the straightening groove 6161. After that, the fifth electric cylinder 612 drives the entire straightening unit to move, completing the straightening and precise alignment correction of the wire 171, eliminating the detection error caused by the bending and offset of the wire 171, and ensuring the standard uniformity of the wire cap breakage detection.

[0055] like Figure 10 As shown, the fault detection mechanism 62 includes a sixth mounting bracket 621 fixedly mounted on the frame 1. A sixth electric cylinder 622 is fixedly mounted on the sixth mounting bracket 621 along the Y-axis. A camera mounting plate 623 is fixedly mounted on the slide end of the sixth electric cylinder 622. A fault detection camera 624 is fixedly mounted on the camera mounting plate 623. A strip-shaped mounting hole is vertically opened on the camera mounting plate 623. The camera mounting plate 623 is fixedly mounted on the slide end of the sixth electric cylinder 622 by positioning bolts passing through the strip-shaped mounting hole, which facilitates vertical fine adjustment of the camera mounting plate 623, thereby realizing vertical fine adjustment of the fault detection camera 624. A fault detection light source 625 is also fixedly mounted on the frame 1. The fault detection light source 625 is located directly below the fault detection camera 624. When in fault detection state, the cap of the wire 171 is located between the fault detection camera 624 and the fault detection light source 625 and is set close to the fault detection light source 625. During the inspection process, high-precision imaging combined with light source supplementation is used to accurately collect the axial position data of the 171 test positions of the two wires. The data is compared with the detection value range set by the system to automatically determine whether the breakage is within the allowable range of the process and accurately identify defective products with excessive breakage.

[0056] like Figure 14As shown, the continuity testing device 7 includes a continuity tester 71, a wire connection continuity testing mechanism 72, a terminal connection continuity testing mechanism, and a test marking mechanism 73. The mechanisms work together to achieve product conductivity testing while eliminating invalid friction between the probe and the outer sheath of the wire 171, reducing probe wear and equipment maintenance costs. At the same time, the marking function is added to achieve visual differentiation between good and defective products.

[0057] like Figure 2 As shown, the continuity tester 71 is fixedly installed on the frame 1, and the continuity tester 71 is located above the wire connection electrical testing mechanism 72, and is responsible for collecting and analyzing conductivity test data.

[0058] like Figure 15 As shown, a second holding plate 74 for pressing and fixing the wire harness 17 is also fixedly installed on the frame 1 at the conductive testing device 7; after the tooling lifting mechanism lifts the transfer tooling 13, the second holding plate 74 abuts against the wire harness 17 to press and fix the wire harness 17, so as to avoid pulling the wire harness 17 up or pulling it out of the transfer tooling 13 during the wire pulling process during electrical testing, thus ensuring the stability of the test.

[0059] like Figures 14 to 17 As shown, the wire connection electrical testing mechanism 72 includes a seventh mounting bracket 721 fixedly mounted on the frame 1. A seventh electric cylinder 722 is fixedly mounted on the seventh mounting bracket 721 along the Y-axis. An eighth cylinder mounting plate is fixedly mounted on the slide end of the seventh electric cylinder 722. A seventh slide cylinder 723 is fixedly mounted on the eighth cylinder mounting plate along the Z-axis. An electrical testing bracket 724 is fixedly mounted on the slide end of the seventh slide cylinder 723. Two sets of corresponding electrical testing components are provided on the electrical testing bracket 724, and the two sets of electrical testing components are respectively for detecting two wires 171.

[0060] like Figures 16 to 20As shown, the electrical testing assembly includes a servo cylinder 725 fixedly mounted on an electrical testing bracket 724 along the Y-axis. An electrical testing mounting plate 726 is fixedly mounted on the slide end of the servo cylinder 725. A first wire-straightening partition 727 and a second wire-straightening partition 728 are fixedly mounted side-by-side along the Y-axis on one side of the mounting plate 726. A first wire-straightening cylinder 729 and a second wire-straightening cylinder 7210 are fixedly mounted on the other side of the mounting plate 726. A space is provided between the first wire-straightening cylinder 729 and the first wire-straightening partition 727. The first winding cylinder 729 drives the first winding seat 7211, which is correspondingly disposed with the first winding partition 727. The first winding seat 7211 is slidably disposed in the direction of approaching / moving away from the first winding partition 727. The electrical testing mounting plate 726 has a first guide hole for the first winding seat 7211 to pass through. The winding end of the first winding seat 7211 passes through the electrical testing mounting plate 726 through the first guide hole, and the end of the first winding seat 7211 near the first winding partition 727 has an opening. A first opening slot 72111 adapted to the outer diameter of the conductor 171 is provided. A second cable-strapping seat 7212 driven by the second cable-strapping cylinder 7210 is provided between the second cable-strapping cylinder 7210 and the second cable-strapping partition 728. The second cable-strapping seat 7212 is correspondingly arranged with the second cable-strapping partition 728, and the second cable-strapping seat 7212 is slidably arranged in the direction of approaching / moving away from the second cable-strapping partition 728. A second guide hole is provided on the electrical testing mounting plate 726 for the second cable-strapping seat 7212 to pass through. The wire-strapping end of 12 passes through the electrical testing mounting plate 726 through the second guide hole, and the second wire-strapping base 7212 near the second wire-strapping partition 728 has a second open slot 72121 that matches the outer diameter of the wire 171. The second wire-strapping base 7212 is provided with a wire detection probe 7213, and the detection end of the wire detection probe 7213 extends into the second open slot 72121. The end of the second wire-strapping partition 728 away from the first wire-strapping partition 727 is also fixedly installed with an optical fiber sensor 7214.During operation, the seventh electric cylinder 722 and the seventh slide cylinder 723 work together to drive the first straightening partition 727 and the second straightening partition 728 to separate the two wires 171. Then, the first straightening cylinder 729 drives the first straightening seat 7211 to move along the direction close to the first straightening partition 727, clamping the wire 171 between the first straightening seat 7211 and the first straightening partition 727 through the first opening slot 72111. Afterward, the seventh electric cylinder 722 drives the two sets of electrical testing components to move, completing the straightening of the wire 171. When it is about to reach the test position of the wire 171, the fiber optic sensor 72... Upon detecting the positioning information, the second winding cylinder 7210 drives the second winding base 7212 to move along the direction close to the second winding partition 728. The wire 171 is clamped between the second winding base 7212 and the second winding partition 728 via the second opening slot 72121. At this time, the wire detection probe 7213 abuts against the insulation sheath of the wire 171. Finally, the servo cylinder 725 operates, requiring only a short movement to bring the wire detection probe 7213 to the test position of the wire 171. The wire detection probe 7213 contacts the bare wire area of ​​the wire 171, completing the conductivity detection. Because the wire detection probe 7213 does not contact the insulation sheath of the wire 171 during the winding process, wear on the wire detection probe 7213 is significantly reduced, greatly extending its service life.

[0061] The terminal connection electrical testing mechanism can adopt the same structural design as the second detection component in the existing invention patent with patent number 202310523427.9, which will not be described in detail here.

[0062] like Figure 21 As shown, the electrical testing marking mechanism 73 is used for visual marking of qualified products. It includes a marking bracket 731 fixedly installed on the frame 1. A marking cylinder 732 is fixedly installed on the marking bracket 731 along the Y-axis. A marking rod 733 is fixedly installed on the slide end of the marking cylinder 732. A marking guide block 734 is also fixedly installed at one end of the marking bracket 731 near the double-layer circulating tooling conveyor line 12. The marking guide block 734 has a marking guide hole for the marking rod 733 to pass through. The marking guide hole enables precise guidance of the marking rod 733. Through this electrical testing marking mechanism 73, the electrically qualified wire harness products are marked with fixed points, realizing the rapid visual distinction between good and bad products and avoiding mixing of materials.

[0063] like Figure 2 and Figure 22 As shown in the figure, the unloading device 8 includes a wire harness picking and placing mechanism 81 and a wire harness holding box 82. The wire harness holding box 82 includes a good product placement box and an NG product placement box, which are used to classify and store products in different states. There may be two or more NG product placement boxes, which are used to place defective products with different conditions such as missing magnetic rings, incorrect color sequence, excessive breakage, and poor conductivity.

[0064] like Figure 22 and Figure 23 As shown, the wire harness picking and placing mechanism 81 includes an eighth mounting bracket 811 fixedly mounted on the frame 1. An eighth electric cylinder 812 is fixedly mounted on the eighth mounting bracket 811 along the Y-axis. A third electric cylinder mounting plate is fixedly mounted on the slide end of the eighth electric cylinder 812. A ninth electric cylinder 813 is fixedly mounted on the third electric cylinder mounting plate along the Z-axis. A ninth cylinder mounting plate is fixedly mounted on the slide end of the ninth electric cylinder 813. An eighth slide cylinder 814 is fixedly mounted on the ninth cylinder mounting plate along the X-axis. A first rotary cylinder 815 is fixedly mounted on the slide end of the eighth slide cylinder 814. The turntable of cylinder 815 is fixedly equipped with a fourth gripper cylinder 816. The gripper of the fourth gripper cylinder 816 is fixedly equipped with a discharge clamping plate 817. The discharge clamping plate 817 has a discharge slot on the opposite side. When picking up and putting down products, the discharge clamping plate 817 clamps the plastic shell 172 and the top cover 173 in the snap-fit ​​state through the discharge slot. The discharge clamping plate 817 is fixedly equipped with a discharge wire support plate 818. The discharge wire support plate 818 has an integrally formed wire support part. When picking up and putting down products, the wire support part can stably support the wire 171 and avoid the wire 171 from drooping or bending excessively during the discharge process, which would affect the discharge. During operation, the eighth electric cylinder 812, the ninth electric cylinder 813, the eighth slide cylinder 814, the first rotary cylinder 815, and the fourth gripper cylinder 816 work together to achieve precise picking, placing, and sorting of products, and placing the products on the transfer fixture 13 into the corresponding wire harness receiving box 82 according to whether they are good or defective.

[0065] like Figure 24 As shown, the sheath feeding device 9 includes a sheath feeding and distributing mechanism 91 and a sheath picking and placing mechanism 92. The two mechanisms work together to realize automatic feeding, precise distributing, and orderly feeding of the sheaths onto the transfer tooling 13.

[0066] like Figure 24 As shown, the sheath shell feeding and distributing mechanism 91 includes a second vibrating plate 911, a second linear feeder 912, and a sheath shell distributing unit 913. The second linear feeder 912 is located between the second vibrating plate 911 and the sheath shell distributing unit 913, and the two ends of the second linear feeder 912 are respectively connected to the discharge end of the second vibrating plate 911 and the receiving end of the sheath shell distributing unit 913, so as to realize the orderly feeding and distributing of the sheath shell.

[0067] like Figure 25As shown, the sheath housing dispensing unit 913 includes a second dispensing bracket 9131 fixedly installed on the frame 1. A second sliding mounting plate 9133 driven by a second dispensing cylinder 9132 is slidably installed on the second dispensing bracket 9131 along the X-axis direction. A second limiting bolt 9134 for limiting the sliding stroke of the second sliding mounting plate 9133 is also threadedly installed on the top of the second dispensing bracket 9131. Two second limiting bolts 9134 are provided, and the distance between the two second limiting bolts 9134 is the maximum sliding stroke of the second sliding mounting plate 9133, so as to realize the precise adjustable limit of the dispensing stroke. A sheath housing dispensing receiving block 9135 is fixedly installed on the second sliding mounting plate 9133. A sheath housing receiving groove for positioning the sheath housing is opened on the side of the sheath housing dispensing receiving block 9135 near the second linear feeder 912.

[0068] Specifically, a second guide rail is fixedly installed on the top of the second material distribution bracket 9131 along the X-axis direction, a second slider is slidably installed on the second guide rail, a second sliding mounting plate 9133 is fixedly connected to the second slider, and the second sliding mounting plate 9133 is slidably installed on the second material distribution bracket 9131 through the second guide rail and the second slider; the second material distribution cylinder 9132 is fixedly installed on the second material distribution bracket 9131, and the piston shaft end of the second material distribution cylinder 9132 is fixedly connected to the second sliding mounting plate 9133.

[0069] like Figure 24 and Figure 26 As shown, the sheath housing loading and unloading mechanism 92 includes a ninth mounting bracket 921 fixedly mounted on the frame 1. A tenth electric cylinder 922 is fixedly mounted on the ninth mounting bracket 921 along the Y-axis. A fourth electric cylinder mounting plate is fixedly mounted on the slide end of the tenth electric cylinder 922. An eleventh electric cylinder 923 is fixedly mounted on the fourth electric cylinder mounting plate along the Z-axis. A tenth cylinder mounting plate is fixedly mounted on the slide end of the eleventh electric cylinder 923. A tenth cylinder mounting plate is fixedly mounted on the tenth cylinder mounting plate along the X-axis. The ninth slide cylinder 924 has a second rotary cylinder 925 fixedly installed on its slide end. The turntable of the second rotary cylinder 925 has a fifth gripper cylinder 926 fixedly installed on it. The grippers of the fifth gripper cylinder 926 are each fixedly fitted with a feeding clamping plate 927. The feeding clamping plate 927 has a feeding slot on its opposite side. The feeding slot is adapted to the thickness of the plastic shell 172. When feeding the protective shell, the feeding clamping plate 927 clamps the plastic shell 172 through the feeding slot. During operation, the tenth electric cylinder 922, the eleventh electric cylinder 923, the ninth slide cylinder 924, the second rotary cylinder 925, and the fifth gripper cylinder 926 work together to achieve precise picking and placing of the protective shell, completing the orderly feeding of the protective shell onto each transfer tooling 13.

[0070] Because the sheath shell inevitably experiences edge lifting and positional misalignment within the material receiving groove during the feeding and dispensing process, the sheath shell picking and placing mechanism 92 struggles to accurately grip the plastic shell 172 during material handling. This gripping and clamping can cause damage to the plastic shell 172, and incorrect clamping position makes it difficult to accurately and stably place the plastic shell 172 into the material tray fixture. Therefore, if... Figure 26 As shown, the fifth gripper cylinder 926 is also equipped with a plastic shell positioning and holding assembly. The plastic shell positioning and holding assembly includes a fixing block 928 that is fixedly installed on both sides of the fifth gripper cylinder 926. A connecting block 929 is provided below the fixing block 928. The connecting block 929 is located between the two feeding clamps 927, and both ends of the connecting block 929 are connected to the fixing block 928 by the second compression spring 9210. Two pressure rods 9211 for positioning and holding the plastic shell 172 are fixedly connected to the side of the connecting block 929 away from the fifth gripper cylinder 926. The holding end of the pressure rod 9211 extends to the bottom of the feeding clamp 927. The provided plastic shell positioning and holding component will first press against the plastic shell 172 when picking up the material, so as to position and hold the plastic shell 172, ensuring that the plastic shell 172 is gripped in a regular posture and accurately positioned, avoiding clamping damage. At the same time, it ensures that the plastic shell 172 can be smoothly placed into the plastic shell placement slot 1321 of the transfer tooling 13, and unifying the positioning benchmark of the whole process.

[0071] like Figure 2 As shown, the frame 1 is also equipped with several tooling scanning devices 10. These tooling scanning devices 10 are located downstream of the locking plate height detection device 5, the wire cap breakage detection device 6, the continuity test device 7, and the unloading device 8, respectively, to realize the data collection and traceability of the entire process of a single product.

[0072] like Figure 28 As shown, the tooling scanning device 10 includes a scanning bracket 101 fixedly mounted on the frame 1. A mounting block 102 is provided on the top of the scanning bracket 101, and a barcode scanner 103 is fixedly mounted on the mounting block 102. One end of the mounting block 102 is rotatably mounted on the scanning bracket 101. An arc-shaped slot is provided on the top of the scanning bracket 101, and a positioning knob for adjusting the swing of the mounting block 102 is provided on the other end. The positioning knob passes through the arc-shaped slot and is threadedly connected to the other end of the mounting block 102. The positioning knob allows for fine-tuning of the position of the barcode scanner 103, ensuring accurate scanning of the transfer tooling 13. Each tooling scanning device 10 can collect process operation data and inspection data for each wire harness product, establishing a dedicated data file for each product, achieving full-process digital control and process information traceability.

[0073] like Figure 2As shown, a protective shell 14 is provided on one side of the double-layer circulating tooling conveyor line 12 on the frame 1. The protective shell 14 provides safety protection for the drive motor of the double-layer circulating tooling conveyor line 12. The frame 1 is also fixedly installed with a cover 15 consisting of a cover flip-locking device 3, a locking plate feeding lock 4, a locking plate height detection device 5, a wire cap breakage detection device 6, a continuity testing device 7, a unloading device 8, and a protective shell feeding device 9. The cover 15 ensures the safety of equipment operation. The cover 15 is equipped with an audible and visual alarm device 16. In case of equipment failure, the audible and visual alarm device 16 can promptly notify the staff to check and repair.

[0074] Based on the above structure, the automatic assembly machine for 2-pin wire harnesses operates by conveying the transfer fixture 13 via a double-layer circulating tooling conveyor line 12. At the manual line-following station 11, pre-assembled components are manually placed into the plastic shell 172. During the forward conveying of the transfer fixture 13, a CCD detection device 2 detects the presence and color sequence errors of the magnetic ring. The top cover 173 is flipped and locked by the top cover flipping and locking device 3, and the locking plate 174 is inserted and locked by the locking plate feeding and locking device 4. The height detection device 5 checks whether the locking piece 174 is properly assembled. The wire cap breakage detection device 6 checks whether the breakage of the wire cap at the end of the wire 171 is qualified. The conductivity test device 7 tests the conductivity of the assembled wire harness product. The unloading device 8 sorts qualified and unqualified products. The sheath loading device 9 accurately places the sheath into the transfer fixture 13. Finally, the double-layer circulating fixture conveyor line 12 reverses the flow fixture 13 containing the sheath and transports it back to the manual line-following station 11. This process is repeated.

[0075] This 2-pin wire harness automatic assembly machine is suitable for the automated assembly of new wire harness products where the plastic shell 172 and the top cover 173 are hinged together. The equipment has a more compact and reasonable configuration and effectively improves the assembly efficiency of the wire harness 17. The wire cap breakage detection station effectively identifies the breakage deviation of the test position of the wire 171 by straightening and correcting the wire and using high-precision imaging detection. This avoids quality problems such as electrical testing failure and unqualified conductivity of finished products from the source, and improves the comprehensive quality inspection system. The equipment is equipped with a locking plate locking mechanism with a guide structure, which can realize the precise guidance, alignment and pressing of the locking plate 174 in one integrated operation, completely solving the problems of assembly offset, jamming and incomplete positioning of the locking plate 174, and greatly improving the assembly accuracy and product locking reliability. Meanwhile, the equipment optimizes the electrical testing structure, achieving conductivity testing while avoiding ineffective friction between the testing probe and the outer sheath of the wire 171, significantly reducing equipment failure rate, extending component lifespan, and reducing production and maintenance costs. It also features an added electrical testing marking mechanism 73 for rapid and visual differentiation between good and defective products. The included sheath picking and placing mechanism 92, equipped with a plastic shell positioning and holding component, effectively corrects issues such as edge warping and misalignment of incoming materials, ensuring precise gripping and placement of the plastic shell 172, guaranteeing consistent positioning benchmarks throughout the entire process, and comprehensively improving assembly and testing accuracy. Furthermore, the equipment incorporates a multi-station barcode traceability system, enabling full-process data collection, traceability, and digital management of individual products. Combined with the closed-loop design of the double-layer circulating tooling conveyor line 12 and the multi-station collaborative operation mode, it significantly improves production flow efficiency and assembly consistency.

[0076] This 2-pin wire harness automatic assembly machine features high modular integration, stable operation, and high safety. It completely solves the core pain points of traditional equipment, such as low automation, poor assembly accuracy, low yield, and cumbersome maintenance. At the same time, it effectively addresses the technical defects of existing wire harness assembly equipment, such as incompatibility with integrated sheath products, lack of breakage detection function, low locking plate assembly accuracy, severe wear of electrical test probes, easy damage to plastic shells during feeding, and lack of full-process traceability. It can effectively meet the needs of high-precision, high-yield, large-scale, and digital automated production of 2-pin wire harnesses, and has extremely high market promotion and industrial application value.

[0077] It should be understood that these embodiments are for illustrative purposes only and are not intended to limit the scope of protection of the invention. Furthermore, it should be understood that after reading the technical description of this invention, those skilled in the art can make various alterations, modifications, and / or variations to the invention, and all such equivalent forms also fall within the scope of protection defined by the appended claims.

Claims

1. An automatic assembly machine for 2-pin wire harnesses, comprising a frame, a manual wire-aligning station at one end of the frame, and a double-layer circulating tooling conveyor line connecting the frame and the manual wire-aligning station, wherein a plurality of transfer tooling is provided on the double-layer circulating tooling conveyor line, characterized in that, The frame is sequentially equipped with a CCD detection device, a top cover flip-locking device, a locking plate feeding locking device, a locking plate height detection device, a wire cap breakage detection device, a continuity testing device, a unloading device, and a sheath feeding device along the upper conveying direction of the double-layer circulating tooling conveyor line; wherein... The top cover flip-locking device includes a plastic shell pressing mechanism and a top cover flip-pressing mechanism; The locking plate feeding and locking device includes a locking plate feeding and distributing mechanism, a locking plate insertion and guiding mechanism, and a locking plate picking, placing and pressing mechanism; The wire cap breakage detection device includes a breakage straightening mechanism and a breakage detection mechanism; The continuity testing device includes a continuity tester, a wire continuity testing mechanism, a terminal continuity testing mechanism, and a testing marking mechanism. The unloading device includes a wire harness picking and placing mechanism and a wire harness receiving box; The sheath feeding device includes a sheath feeding and distributing mechanism and a sheath picking and placing mechanism.

2. The 2-pin wire harness automatic assembly machine according to claim 1, characterized in that, The transfer fixture includes a fixture base plate, on which a positioning plate is fixedly installed. The positioning plate has a plastic shell placement groove for positioning and placing the plastic shell, and a gripper clearance groove communicating with the plastic shell placement groove. There are two gripper clearance grooves, which are respectively arranged on both sides of the plastic shell placement groove. A fixture support plate is fixedly installed at one end of the positioning plate, and a top cover clearance groove and a dot clearance groove are opened at the other end of the positioning plate. Both sides of the positioning plate are provided with clamping components for positioning and clamping the plastic shell. The clamping assembly includes a spring baffle, an adjusting nut, a locking pin, and a first compression spring. The spring baffle is fixedly installed on the positioning plate, the adjusting nut is threaded onto the spring baffle, and the locking pin is slidably installed in the positioning plate along the direction of approaching / moving away from the plastic shell placement groove. The locking pin has a spherical locking end. The first compression spring is located between the adjusting nut and the locking pin, and under the action of the first compression spring, the locking end of the locking pin extends into the plastic shell placement groove.

3. The 2-pin wire harness automatic assembly machine according to claim 2, characterized in that, The plastic shell pressing mechanism includes a first mounting bracket fixedly mounted on the frame, a first slide cylinder fixedly mounted on the first mounting bracket along the Y-axis direction, a second slide cylinder fixedly mounted on the slide end of the first slide cylinder along the Z-axis direction, a first gripper cylinder fixedly mounted on the slide end of the second slide cylinder along the Y-axis direction, and plastic shell pressing plates fixedly mounted on the gripper of the first gripper cylinder through a first connecting plate. The top cover flipping and pressing mechanism includes a second mounting bracket fixedly mounted on the frame. A first electric cylinder is fixedly mounted on the second mounting bracket along the Y-axis. A second electric cylinder is fixedly mounted on the slide end of the first electric cylinder along the Z-axis. A mounting base plate is fixedly connected to the slide end of the second electric cylinder. Two corresponding roller mounting plates are fixedly mounted on the mounting base plate. Several rollers are rotatably mounted on the ends of the two roller mounting plates away from the mounting base plate, and the several rollers are evenly arranged along the X-axis.

4. The 2-pin wire harness automatic assembly machine according to claim 3, characterized in that, The locking plate feeding and distributing mechanism includes a first vibrating plate, a first linear feeder, and a locking plate distributing unit. The first linear feeder is located between the first vibrating plate and the locking plate distributing unit, and the two ends of the first linear feeder are respectively connected to the discharge end of the first vibrating plate and the receiving end of the locking plate distributing unit. The locking plate insertion guide mechanism includes a third mounting bracket fixedly mounted on the frame. A third slide cylinder is fixedly mounted on the third mounting bracket along the Y-axis direction. A fourth slide cylinder is fixedly mounted on the slide end of the third slide cylinder along the Z-axis direction. A second gripper cylinder is fixedly mounted on the slide end of the fourth slide cylinder along the Y-axis direction. The gripping claws of the second gripper cylinder are respectively fixedly mounted with locking plate guide plates through a second connecting plate. Guide grooves are opened on opposite sides of the guide ends of the two locking plate guide plates. The guide grooves are open groove structures with a guide slope and a contour adapted to the locking plate. The locking plate picking and pressing mechanism includes a fourth mounting bracket fixedly installed on the frame. A third electric cylinder is fixedly installed on the fourth mounting bracket along the Y-axis. A fourth electric cylinder is fixedly installed on the slide end of the third electric cylinder along the Z-axis. A fifth slide cylinder is fixedly installed on the slide end of the fourth electric cylinder along the X-axis. A suction nozzle mounting plate is fixedly connected to the slide end of the fifth slide cylinder. A locking plate suction nozzle is fixedly installed on the suction nozzle mounting plate.

5. The 2-pin wire harness automatic assembly machine according to claim 4, characterized in that, A first clamping plate for clamping and fixing the wire harness is also fixedly installed on the frame at the wire cap breakage detection device. The differential wire straightening mechanism includes a fifth mounting bracket fixedly installed on the frame. A fifth electric cylinder is fixedly installed on the fifth mounting bracket along the Y-axis direction. A sixth sliding cylinder is fixedly installed on the sliding end of the fifth electric cylinder along the Z-axis direction. A third gripper cylinder is fixedly installed on the sliding end of the sixth sliding cylinder along the Y-axis direction. A wire separator plate is fixedly installed on the third gripper cylinder. A wire straightening plate is fixedly installed on the gripping claws of the third gripper cylinder. The two wire straightening plates are arranged correspondingly. The wire separator plate is located between the two wire straightening plates, and a wire straightening groove adapted to the outer diameter of the wire is opened on the side of the wire straightening plate facing the wire separator plate. The discontinuity detection mechanism includes a sixth mounting bracket fixedly installed on the frame. A sixth electric cylinder is fixedly installed on the sixth mounting bracket along the Y-axis. A camera mounting plate is fixedly installed on the slide end of the sixth electric cylinder. A discontinuity detection camera is fixedly installed on the camera mounting plate. A discontinuity detection light source is also fixedly installed on the frame. The discontinuity detection light source is located directly below the discontinuity detection camera. When in the discontinuity detection state, the wire cap is located between the discontinuity detection camera and the discontinuity detection light source and is set close to the discontinuity detection light source.

6. The 2-pin wire harness automatic assembly machine according to claim 5, characterized in that, The continuity tester is fixedly installed on the frame, and the continuity tester is located above the wire connection electrical testing mechanism; A second clamping plate for securing the wire harness is also fixedly installed on the frame at the conductive electrical testing device. The wire connection electrical testing mechanism includes a seventh mounting bracket fixedly installed on the frame. A seventh electric cylinder is fixedly installed on the seventh mounting bracket along the Y-axis direction. A seventh slide cylinder arranged along the Z-axis direction is fixedly installed on the slide end of the seventh electric cylinder. An electrical testing bracket is fixedly installed on the slide end of the seventh slide cylinder. Two sets of corresponding electrical testing components are provided on the electrical testing bracket. The electrical testing assembly includes a servo cylinder fixedly mounted on the electrical testing bracket along the Y-axis. An electrical testing mounting plate is fixedly mounted on the slide end of the servo cylinder. A first and second wire-straightening partition are fixedly mounted side-by-side along the Y-axis on one side of the mounting plate. A first and second wire-straightening cylinder are fixedly mounted on the other side of the mounting plate. A first wire-straightening seat driven by the first wire-straightening cylinder is provided between the first wire-straightening cylinder and the first wire-straightening partition. The first wire-straightening seat is correspondingly positioned to the first wire-straightening partition and slides along a direction close to / away from the first wire-straightening partition. A first guide hole is provided on the electrical testing mounting plate for the first wire-straightening seat to pass through. The wire-straightening end of the first wire-straightening seat passes through the first guide hole into the electrical testing mounting plate, and the first wire-straightening seat is close to the first wire-straightening partition. One end of the device has a first opening slot adapted to the outer diameter of the conductor. A second winding seat driven by the second winding cylinder is provided between the second winding cylinder and the second winding partition. The second winding seat is correspondingly arranged with the second winding partition and is slidably arranged in the direction of approaching / away from the second winding partition. A second guide hole is provided on the electrical testing mounting plate for the second winding seat to pass through. The winding end of the second winding seat passes through the electrical testing mounting plate through the second guide hole. A second opening slot adapted to the outer diameter of the conductor is provided at the end of the second winding seat near the second winding partition. A conductor detection probe is provided inside the second winding seat. The detection end of the conductor detection probe extends into the second opening slot. An optical fiber sensor is also fixedly installed at the end of the second winding partition away from the first winding partition. The electrical testing marking mechanism includes a marking bracket fixedly installed on the frame, a marking cylinder fixedly installed on the marking bracket along the Y-axis, a marking rod fixedly installed on the slide end of the marking cylinder, and a marking guide block fixedly installed at one end of the marking bracket near the double-layer circulating tooling conveyor line. The marking guide block has a marking guide hole for the marking rod to pass through.

7. The 2-pin wire harness automatic assembly machine according to claim 6, characterized in that, The wire harness picking and placing mechanism includes an eighth mounting bracket fixedly installed on the frame. An eighth electric cylinder is fixedly installed on the eighth mounting bracket along the Y-axis direction. A ninth electric cylinder is fixedly installed on the slide end of the eighth electric cylinder along the Z-axis direction. An eighth slide cylinder is fixedly installed on the slide end of the ninth electric cylinder along the X-axis direction. A first rotary cylinder is fixedly installed on the slide end of the eighth slide cylinder. A fourth gripper cylinder is fixedly installed on the turntable of the first rotary cylinder. The grippers of the fourth gripper cylinder are respectively fixedly installed with unloading clamping plates. The unloading clamping plates have unloading slots on opposite sides, and unloading wire support plates are respectively fixedly installed on the unloading clamping plates. The unloading wire support plates have an integrally formed wire support part. The wire harness housing includes a good product placement box and a bad product placement box.

8. The 2-pin wire harness automatic assembly machine according to claim 7, characterized in that, The sheath feeding and distributing mechanism includes a second vibrating plate, a second linear feeder, and a sheath distributing unit. The second linear feeder is located between the second vibrating plate and the sheath distributing unit, and the two ends of the second linear feeder are respectively connected to the discharge end of the second vibrating plate and the receiving end of the sheath distributing unit. The sheath housing picking and placing mechanism includes a ninth mounting bracket fixedly installed on the frame. A tenth electric cylinder is fixedly installed on the ninth mounting bracket along the Y-axis direction. An eleventh electric cylinder is fixedly installed on the slide end of the tenth electric cylinder along the Z-axis direction. A ninth slide cylinder is fixedly installed on the slide end of the eleventh electric cylinder along the X-axis direction. A second rotary cylinder is fixedly installed on the slide end of the ninth slide cylinder. A fifth gripper cylinder is fixedly installed on the turntable of the second rotary cylinder. The gripping claws of the fifth gripper cylinder are respectively fixedly installed with feeding clamps. The opposite side of the feeding clamps has a feeding slot. The fifth gripper cylinder is also equipped with a plastic shell positioning and holding assembly. The plastic shell positioning and holding assembly includes a fixing block that is fixedly installed on both sides of the fifth gripper cylinder. A connecting block is provided below the fixing block. The connecting block is located between the two feeding clamps. Both ends of the connecting block are connected to the fixing block by a second compression spring. Two pressure rods for positioning and holding the plastic shell are fixedly connected to the side of the connecting block away from the fifth gripper cylinder. The holding ends of the pressure rods extend to the bottom of the feeding clamp.

9. The 2-pin wire harness automatic assembly machine according to any one of claims 1-8, characterized in that, The frame is also equipped with several tooling scanning devices, which are located downstream of the locking plate height detection device, the wire cap breakage detection device, the continuity testing device, and the unloading device. The tooling scanning device includes a scanning bracket fixedly installed on the frame. The top of the scanning bracket is provided with a mounting block, and a barcode scanner is fixedly installed on the mounting block. One end of the mounting block is rotatably installed on the scanning bracket. The top of the scanning bracket is provided with an arc-shaped slot. The other end of the mounting block is provided with a positioning knob for swing adjustment. The positioning knob passes through the arc-shaped slot and is threadedly connected to the other end of the mounting block.

10. The 2-pin wire harness automatic assembly machine according to claim 9, characterized in that, The double-layer circulating tooling conveyor line includes an upper tooling conveyor line, a lower tooling conveyor line, and a tooling transfer mechanism. The tooling transfer mechanism is located at the end of the frame away from the manual line-following station. A protective shell is provided on one side of the frame of the double-layer circulating tooling conveyor line. The frame is also fixedly equipped with a cover covering the top cover flip-locking device, the locking plate feeding locking device, the locking plate height detection device, the wire cap breakage detection device, the conductivity testing device, the unloading device, and the protective cover feeding device. The protective cover is equipped with an audible and visual alarm device.

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