Purifier electrical cabinet wiring mistake proofing method and visual guidance auxiliary assembly system

Abstract

This invention relates to a method for preventing wiring errors in a purifier electrical cabinet and a visually guided assembly system. The method includes: S1. Generating structured wiring tasks and exporting wiring data, which includes a unique identifier for each cable, cable type, wire diameter, cable color, device identification and terminal number of the starting terminal, device identification and terminal number of the ending terminal, and wiring harness path constraints; S2. Visually encoding cable identities by attaching a visually identifiable coded ring to each end of each cable. The coded ring is a ring-shaped label made of high-temperature resistant and flame-retardant material, with unique coded information printed on its outer surface. This invention not only achieves a real-time error-proofing mechanism of "verification upon wiring, interception upon non-compliance," but also automatically performs item-by-item comparison of hundreds of terminals, identifying defects such as missing connections, incorrect connections, reverse connections, and abnormal crimping appearances, with an accuracy rate of over 96%, far exceeding the detection rate of human visual inspection.

Description

Technical Field

[0001] This invention relates to the field of electrical assembly and industrial automation technology, and in particular to a method for preventing wiring errors in a purifier electrical cabinet and a vision-guided assembly system. Background Technology

[0002] A purifier is a core purification device used to remove trace impurities (moisture, oxygen, carbon dioxide, etc.) from process gases. It is widely used in industries such as semiconductor manufacturing, photovoltaic power generation, and biopharmaceuticals. The electrical control system of a purifier typically includes dozens of electrical components such as a PLC, sensors, temperature controllers, heating element actuators, signal isolators, power modules, and communication modules. The number of terminals can reach hundreds, the wiring paths are complex, and there are many types of cables (including power cables, signal cables, communication cables, thermocouple compensation cables, etc.), requiring extremely high accuracy in the wiring process.

[0003] Currently, the wiring of purifier electrical cabinets generally adopts the following method: First, wiring information relies on two-dimensional electrical drawings. Operators must manually locate wire numbers, terminal positions, and wiring paths one by one, referring to paper or PDF electrical schematics and wiring tables. When electrical drawings are updated, the field drawings often fail to update synchronously, resulting in discrepancies between wiring according to the old drawings and the design. For the potential customized wiring requirements of each purifier, drawing version management becomes even more difficult, easily leading to mismatches between wire numbers and terminal positions.

[0004] Secondly, cable marking is mainly done manually by pasting wire number tubes. Operators insert the printed wire number tubes onto both ends of the cable according to the wiring diagram, and then find the corresponding terminal positions to complete the wiring by referring to the drawings. Because the font on the wire number tubes is small and the printing is blurry, especially in the dimly lit environment inside the cabinet, wire number tubes are often inserted backwards, incorrectly, missing, or fall off. Wiring errors are often not discovered until the commissioning stage or even at the customer's site.

[0005] Third, the wiring results rely on manual self-inspection and random checks by dedicated inspectors. After wiring is completed, operators visually inspect it, and then quality inspectors conduct random checks against the drawings. This manual inspection method has a significant risk of missed detections, especially when there are many wires to be connected and the schedule is tight. Problems such as incorrect connections, missing connections, loose connections, and reversed wire sequences cannot be completely detected. If wiring errors are not detected, it may lead to serious accidents such as burning out electrical components after the equipment is powered on, chaotic PLC input and output signals, and uncontrolled heating, resulting in significant economic losses and safety risks.

[0006] Fourth, while some existing wiring assistance technologies (such as AR-assisted assembly and visual inspection) have been applied in the general electrical assembly field, they have not yet been systematically integrated for the specific scenario of wiring in purifier electrical cabinets. Existing technologies either focus on error prevention through prefabrication of wire harnesses (such as wire harness assembly methods), or on error prevention design of terminal blocks (such as preventing misinsertion of terminals), or only achieve one-way visual guidance for wiring. They lack a full-process error prevention mechanism from "design intent input → assembly process guidance → wiring result verification → closed-loop traceability," and in particular, they lack real-time correlation and linkage verification of cable identity, terminal coordinates, and wiring status.

[0007] Fifth, as highly customized equipment, purifiers have significantly different electrical configurations and frequent changes in wiring schemes between different orders. Traditional manual management methods are difficult to adapt to the error prevention requirements of multi-variety, small-batch production. Summary of the Invention

[0008] In view of the above problems, the present invention provides a method for preventing wiring errors in the electrical cabinet of a purifier and a visually guided assisted assembly system. It not only realizes the real-time error prevention mechanism of "verification upon wiring and interception upon non-compliance", but also can automatically complete the item-by-item comparison of hundreds of terminals, identify defects such as missing connections, incorrect connections, reverse connections, and abnormal crimping appearance, with an identification accuracy rate of over 96%, far exceeding the detection rate of human visual inspection.

[0009] To achieve the above and other related objectives, the present invention provides the following technical solution: A method for preventing wiring errors in a purifier electrical cabinet, the method comprising: S1. Generate structured wiring task and export wiring data. The wiring data includes a unique identifier for each cable, cable type, wire diameter specification, cable color, device identifier and terminal number of the starting terminal, device identifier and terminal number of the ending terminal, and wiring harness path constraints. S2. Cable identification visual coding: A visually identifiable coding ring is fitted at each end of each cable. The coding ring is a ring-shaped label made of high temperature resistant and flame retardant material, and the outer surface is printed with unique coding information. S3. Visual-guided terminal positioning and cable connection: Wearing augmented reality glasses or using a mobile terminal camera, the vision system collects real-time images of the electrical cabinet and achieves spatial positioning through the visual SLAM algorithm, overlaying the virtual three-dimensional annotation information of each terminal position in the electrical cabinet onto the real-scene image. S4. Terminal status online monitoring and foolproof interlocking, including the embedded installation of the terminal body and micro switch, the miniaturized layout of the RFID antenna, the integration of the miniature pressure sensor and the overall packaging and protection; S5. Visual verification and closed-loop traceability of the entire cabinet after wiring is completed; S6. In-depth application of digital quality archives.

[0010] Furthermore, the wiring data is parsed and converted into a structured wiring task list, with each wiring task containing the following field: Task Number T ID Cable unique identification code W ID The system includes starting point information, ending point information, cable attributes, and expected wiring status markers, and automatically generates a wiring task sequence. The sorting criteria for the wiring task sequence include: spatial order of the wire harness path, electrical safety priority, and terminal density.

[0011] Furthermore, the cable W of the encoding ring... ID It binds to tasks in the wiring task list and automatically detects the match between cable type and task requirements. If the types do not match, it issues a warning.

[0012] Furthermore, in step S3, the step of achieving spatial positioning through a visual SLAM algorithm and overlaying the virtual 3D annotation information of each terminal position in the electrical cabinet onto the real-world image includes: S31. The starting terminal is visually highlighted. In the augmented reality interface, the device and specific terminal position of the starting terminal are highlighted with a flashing green outline. At the same time, the device name, terminal number and cable connection diagram of the terminal are displayed. S32. Cable connection confirmation: The operator places the coded ring within the camera's field of view, and the system automatically identifies the cable W. ID The system extends the virtual model of the cable from the current hand position to the target terminal position in the form of a trailing light effect. When the cable end enters the preset area of ​​interest of the terminal position, the system triggers an audio prompt "in position". S33. Connection Action Detection: After the operator completes the wiring operation, the system automatically detects whether the terminal has been reliably connected to the cable through the terminal status monitoring unit. If the detection is successful, the current wiring task is automatically marked as "completed" and the next wiring task is automatically loaded. The highlight display of the starting terminal is transferred to the starting terminal position of the next task. S34. Repeated guidance for the terminal block: Repeat the above process to guide the operator to complete the connection of the other end of the cable.

[0013] Furthermore, the terminal body is a standard DIN rail type terminal block with a width of 5.2mm, a rated voltage of 800V, and a rated current of 24A. The micro switch is embedded in a mounting hole with a diameter of 2.5mm, located below the terminal screw and at the top of the clamping frame. The micro switch is embedded in this hole, and the contact of the micro switch extends 0.3mm. When the operator tightens the screw, the bottom of the screw presses against the micro switch contact. When the contact travel reaches 0.2mm, the switch closes and outputs a "connected" signal.

[0014] Furthermore, the miniaturized layout of the RFID antenna involves embedding a flexible PCB antenna within the insulating shell of the terminal block. The antenna is connected to the terminal block bus via conductive adhesive. The RFID antenna operates at a frequency of 13.56MHz and has a read distance of 5-12mm. A miniature passive RFID tag is embedded in the insulation of the cable end, approximately 8mm from the cable end. When the cable end is inserted into the terminal to the bottom, the RFID tag is positioned directly above the antenna. The integrated miniature pressure sensor is a thin-film pressure sensor with a range of 0-50N and an accuracy of ±1N, attached to the inner side of the conductive clamping arm of the terminal. The sensor lead extends along the wiring groove of the clamping arm and connects to the signal acquisition module via the terminal block bus. The sensor outputs a pressure value when the clamping arm presses the cable, used to determine the crimping quality. The overall encapsulation and protection consist of the terminal body, the embedded installation of the micro switch, the miniaturized layout of the RFID antenna, and the integration of the miniature pressure sensor all being encased in the terminal block shell. The shell is made of polyamide material with a flame retardant rating of V0 and an IP20 protection rating.

[0015] Furthermore, the foolproof interlocking includes: If the access detection module does not trigger the "connected" signal, the system will prevent the task status from being updated to "completed" and will display a message on the augmented reality interface that reads "Wiring not completed, please check if the terminal screws are tightened". If the authentication module outputs "Authentication failed", the system will immediately issue an audible and visual alarm and mark the current terminal position and cable coding ring with a red flashing outline on the augmented reality interface, prompting "Cable error, please remove the current cable, check the wire number and reconnect it"; If the crimping force value is lower than the threshold, the system marks the terminal as "to be re-inspected" and automatically includes it in the re-inspection task queue. The re-inspection will be carried out uniformly after the wiring of the entire cabinet is completed. The system will only automatically mark the current connection task as "completed" and jump to the next task when the access detection and authentication are successful.

[0016] Furthermore, in step S5, the visual verification and closed-loop traceability of the entire cabinet after the wiring is completed includes: S51. Automatic cruise scanning: The mobile or track-type visual inspection device automatically traverses all wiring areas in the electrical cabinet along a preset trajectory, and captures wiring images of each terminal block with a high-resolution camera. S52. Image recognition and comparison: Based on a deep learning-based target detection model, the acquired images are analyzed in real time to identify the cable connection status, cable color, and coding ring information of each terminal in the image, and are compared item by item with the expected configuration in the wiring task list to identify the abnormal type. S53. Anomaly location and rework guidance: For detected anomalies, the system automatically associates the terminal positions and equipment coordinates involved in the anomaly, generates an anomaly list, and marks the spatial location of the abnormal terminal with a bright red ghost image in the augmented reality interface, and displays rework operation guidance. S54. Quality file generation: The system binds all data in this wiring process with the unique serial number of the purifier equipment to generate an "Electrical Wiring Digital Quality File", which serves as part of the equipment's factory quality certificate.

[0017] Furthermore, in step S6, the in-depth application of the digital quality archive includes: S61. Full lifecycle traceability: the records are stored in a cloud database. After the device leaves the factory, customers can query the records through the device serial number to verify the wiring quality. S62. Based on big data, predictive maintenance is implemented by compiling wiring records for all devices and establishing a historical database of crimping force values. S63. Continuous process optimization: By statistically analyzing the wiring quality data of different operators and different batches, we can identify the process links or personnel with poor consistency in crimping force values, and provide data basis for process improvement and personnel training.

[0018] To achieve the above and other related objectives, the present invention also provides a visually guided assembly system for preventing wiring errors in a purifier electrical cabinet, used to implement the aforementioned method for preventing wiring errors in a purifier electrical cabinet. The system includes: Wiring task management unit: includes electrical design software interface, wiring data parsing module, and task sequence generation module, used to convert electrical design drawings into a structured wiring task list; Cable identification coding unit: includes coding ring prefabrication device, QR code / Data Matrix code laser engraving module, and coding ring scanning and binding module, used to uniquely visually encode and register the identity of each cable; Visual guidance assembly unit: includes augmented reality glasses or mobile terminal, visual SLAM positioning module, virtual annotation overlay module, and access motion recognition module, used to highlight terminal positions in the operator's field of vision and provide wiring guidance; Terminal status monitoring unit: includes access detection module, RFID authentication module, crimping quality detection module and terminal block bus, used to monitor the wiring status, cable identity and crimping force value of each terminal in real time; The whole cabinet visual inspection unit includes a mobile or track-mounted visual inspection device, a deep learning image recognition module, and an anomaly location and rework guidance module, which are used for automatic detection of the whole cabinet and anomaly closed-loop processing after wiring is completed. Data Management and Traceability Unit: Includes central control system, database server, and production execution system interface, used for storing, associating, tracing, and generating quality records of wiring data.

[0019] The present invention has the following positive effects: 1. This invention directly exports structured wiring data through electrical design software, eliminating information distortion and version inconsistencies that may arise from drawing printing and manual data entry. The task sequence performed by the operator remains consistent with the design intent, fundamentally preventing the possibility of "wiring according to the wrong diagram."

[0020] 2. This invention uses a laser-engraved QR code / Data Matrix code on the coding ring, combined with a passive RFID tag, to achieve "dual verification" (visual recognition + radio frequency identification) of cable identity. This overcomes the shortcomings of traditional wire number tubes, such as easy wear, easy blurring, easy reversal, and inability to be recognized by machines. The color coding mechanism of the coding ring allows operators to quickly identify the cable type even without scanning, forming an auxiliary error prevention mechanism for visual verification.

[0021] 3. This invention uses augmented reality glasses to overlay virtual terminal markings onto the real-world scene. Combined with automatic task switching logic, the operator's gaze does not need to leave the cabinet, and their hands do not need to leave the wiring area to operate the computer or touchscreen, significantly reducing the probability of errors caused by operation interruptions and attention shifts. The virtual cable trailing light effect intuitively shows the cable's connection direction and path, making it particularly suitable for scenarios where cables are difficult to see terminals in confined spaces.

[0022] 4. The key feature that distinguishes this invention from existing technologies is its terminal status monitoring unit, which integrates access detection, RFID authentication, and crimping force monitoring. This unit can automatically verify the cable identity and access quality the instant the wiring operation is completed, realizing a real-time error-proof mechanism of "verification upon wiring, interception upon non-compliance," completely changing the traditional lagging quality control mode of "wiring → self-inspection → mutual inspection → power-on debugging → problem detection → rework."

[0023] 5. This invention utilizes a deep learning-driven whole-cabinet visual inspection system that can automatically compare hundreds of terminals item by item, identifying defects such as missing connections, incorrect connections, reverse connections, and abnormal crimping appearances. The accuracy rate of identification can reach over 96%, far exceeding the detection rate of human visual inspection. The anomaly location and rework guidance functions reduce rework time by an average of over 60%.

[0024] 6. This invention creates a traceable digital twin file of electrical wiring by binding all data from the wiring process to the unique serial number of the device. When an electrical fault occurs during device operation at the client's location, the file can be retrieved to quickly determine whether the problem stems from an original wiring defect, significantly shortening troubleshooting time and improving after-sales service quality. This file also serves as direct evidence of the supply chain quality traceability capabilities required by demanding customers in industries such as semiconductors. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the method flow of the present invention; Figure 2 This is a schematic diagram of the cable identification visual coding ring of the present invention; Figure 3 This is a schematic diagram of the augmented reality visual guidance interface of the present invention; Figure 4 This is a cross-sectional structural diagram of the terminal status monitoring unit of the present invention; Figure 5 This is a flowchart of the terminal status monitoring and control logic of the present invention; Figure 6 This is a schematic diagram illustrating the anomaly detection effect of the whole cabinet visual verification according to the present invention. Detailed Implementation

[0026] The exemplary embodiments of this disclosure are described below with reference to the accompanying drawings, including various details of the embodiments to aid understanding, and should be considered merely exemplary. Therefore, those skilled in the art will recognize that various changes and modifications can be made to the embodiments described herein without departing from the scope and spirit of this disclosure. Similarly, for clarity and brevity, descriptions of well-known functions and structures are omitted in the following description.

[0027] Example 1: As Figure 1 As shown, a method for preventing wiring errors in a purifier electrical cabinet is provided, the method comprising: S1. Generate structured wiring task and export wiring data. The wiring data includes a unique identifier for each cable, cable type, wire diameter specification, cable color, device identifier and terminal number of the starting terminal, device identifier and terminal number of the ending terminal, and wiring harness path constraints. S2. Cable identification visual coding: A visually identifiable coding ring is fitted at each end of each cable. The coding ring is a ring-shaped label made of high temperature resistant and flame retardant material, and the outer surface is printed with unique coding information. S3. Visual-guided terminal positioning and cable connection: Wearing augmented reality glasses or using a mobile terminal camera, the vision system collects real-time images of the electrical cabinet and achieves spatial positioning through the visual SLAM algorithm, overlaying the virtual three-dimensional annotation information of each terminal position in the electrical cabinet onto the real-scene image. S4. Terminal status online monitoring and foolproof interlocking, including the embedded installation of the terminal body and micro switch, the miniaturized layout of the RFID antenna, the integration of the miniature pressure sensor and the overall packaging and protection; S5. Visual verification and closed-loop traceability of the entire cabinet after wiring is completed; S6. In-depth application of digital quality archives.

[0028] In this embodiment, the wiring data is parsed and converted into a structured wiring task list, and each wiring task includes the following field: Task number T ID Cable unique identification code W ID The system includes starting point information, ending point information, cable attributes, and expected wiring status markers, and automatically generates a wiring task sequence. The sorting criteria for the wiring task sequence include: spatial order of the wire harness path, electrical safety priority, and terminal density.

[0029] In this embodiment, the cable W of the encoding ring is... ID It binds to tasks in the wiring task list and automatically detects the match between cable type and task requirements. If the types do not match, it issues a warning.

[0030] In this embodiment, in step S3, the step of achieving spatial positioning through a visual SLAM algorithm and overlaying the virtual three-dimensional annotation information of each terminal position in the electrical cabinet onto the real-world image includes: S31. The starting terminal is visually highlighted. In the augmented reality interface, the device and specific terminal position of the starting terminal are highlighted with a flashing green outline. At the same time, the device name, terminal number and cable connection diagram of the terminal are displayed. S32. Cable connection confirmation: The operator places the coded ring within the camera's field of view, and the system automatically identifies the cable W. ID The system extends the virtual model of the cable from the current hand position to the target terminal position in the form of a trailing light effect. When the cable end enters the preset area of ​​interest of the terminal position, the system triggers an audio prompt "in position". S33. Connection Action Detection: After the operator completes the wiring operation, the system automatically detects whether the terminal has been reliably connected to the cable through the terminal status monitoring unit. If the detection is successful, the current wiring task is automatically marked as "completed" and the next wiring task is automatically loaded. The highlight display of the starting terminal is transferred to the starting terminal position of the next task. S34. Repeated guidance for the terminal block: Repeat the above process to guide the operator to complete the connection of the other end of the cable.

[0031] In this embodiment, the terminal body is a standard DIN rail type terminal block with a width of 5.2mm, a rated voltage of 800V, and a rated current of 24A. The micro switch is embedded in a mounting hole with a diameter of 2.5mm, located below the terminal screw and at the top of the clamping frame. The micro switch is embedded in this hole, and the contact of the micro switch extends out by 0.3mm. When the operator tightens the screw, the bottom of the screw presses against the micro switch contact. When the contact travel reaches 0.2mm, the switch closes and outputs a "connected" signal.

[0032] In this embodiment, the miniaturized layout of the RFID antenna involves embedding a flexible PCB antenna within the insulating shell of the terminal block. The antenna is connected to the terminal block bus via conductive adhesive. The RFID antenna operates at a frequency of 13.56MHz and has a read distance of 5-12mm. A miniature passive RFID tag is embedded in the insulation of the cable end, approximately 8mm from the cable end. When the cable end is inserted into the terminal to the bottom, the RFID tag is positioned directly above the antenna. The integrated miniature pressure sensor is a thin-film pressure sensor with a range of 0-50N and an accuracy of ±1N, attached to the inner side of the conductive clamping arm of the terminal. The sensor lead extends along the cable routing groove of the clamping arm and connects to the signal acquisition module via the terminal block bus. The sensor outputs a pressure value when the clamping arm presses the cable, which is used to determine the crimping quality. The overall encapsulation and protection consist of the terminal body, the embedded installation of the micro switch, the miniaturized layout of the RFID antenna, and the integration of the miniature pressure sensor all being encased in the terminal block shell. The shell is made of polyamide material with a flame retardant rating of V0 and an IP20 protection rating.

[0033] In this embodiment, the foolproof interlocking includes: If the access detection module does not trigger the "connected" signal, the system will prevent the task status from being updated to "completed" and will display a message on the augmented reality interface that reads "Wiring not completed, please check if the terminal screws are tightened". If the authentication module outputs "Authentication failed", the system will immediately issue an audible and visual alarm and mark the current terminal position and cable coding ring with a red flashing outline on the augmented reality interface, prompting "Cable error, please remove the current cable, check the wire number and reconnect it"; If the crimping force value is lower than the threshold, the system marks the terminal as "to be re-inspected" and automatically includes it in the re-inspection task queue. The re-inspection will be carried out uniformly after the wiring of the entire cabinet is completed. The system will only automatically mark the current connection task as "completed" and jump to the next task when the access detection and authentication are successful.

[0034] In this embodiment, step S5, the visual verification and closed-loop traceability of the entire cabinet after wiring is completed, includes: S51. Automatic cruise scanning: The mobile or track-type visual inspection device automatically traverses all wiring areas in the electrical cabinet along a preset trajectory, and captures wiring images of each terminal block with a high-resolution camera. S52. Image recognition and comparison: Based on a deep learning-based target detection model, the acquired images are analyzed in real time to identify the cable connection status, cable color, and coding ring information of each terminal in the image, and are compared item by item with the expected configuration in the wiring task list to identify the abnormal type. S53. Anomaly location and rework guidance: For detected anomalies, the system automatically associates the terminal positions and equipment coordinates involved in the anomaly, generates an anomaly list, and marks the spatial location of the abnormal terminal with a bright red ghost image in the augmented reality interface, and displays rework operation guidance. S54. Quality file generation: The system binds all data in this wiring process with the unique serial number of the purifier equipment to generate an "Electrical Wiring Digital Quality File", which serves as part of the equipment's factory quality certificate.

[0035] In this embodiment, in step S6, the in-depth application of the digital quality archive includes: S61. Full lifecycle traceability: the records are stored in a cloud database. After the device leaves the factory, customers can query the records through the device serial number to verify the wiring quality. S62. Based on big data, predictive maintenance is implemented by compiling wiring records for all devices and establishing a historical database of crimping force values. S63. Continuous process optimization: By statistically analyzing the wiring quality data of different operators and different batches, we can identify the process links or personnel with poor consistency in crimping force values, and provide data basis for process improvement and personnel training.

[0036] In this embodiment, the present invention provides a visually guided assembly system for preventing wiring errors in a purifier electrical cabinet, used to implement the aforementioned method for preventing wiring errors in a purifier electrical cabinet. The system includes: Wiring task management unit: includes electrical design software interface, wiring data parsing module, and task sequence generation module, used to convert electrical design drawings into a structured wiring task list; Cable identification coding unit: includes coding ring prefabrication device, QR code / Data Matrix code laser engraving module, and coding ring scanning and binding module, used to uniquely visually encode and register the identity of each cable; Visual guidance assembly unit: includes augmented reality glasses or mobile terminal, visual SLAM positioning module, virtual annotation overlay module, and access motion recognition module, used to highlight terminal positions in the operator's field of vision and provide wiring guidance; Terminal status monitoring unit: includes access detection module, RFID authentication module, crimping quality detection module and terminal block bus, used to monitor the wiring status, cable identity and crimping force value of each terminal in real time; The whole cabinet visual inspection unit includes a mobile or track-mounted visual inspection device, a deep learning image recognition module, and an anomaly location and rework guidance module, which are used for automatic detection of the whole cabinet and anomaly closed-loop processing after wiring is completed. Data Management and Traceability Unit: Includes central control system, database server, and production execution system interface, used for storing, associating, tracing, and generating quality records of wiring data.

[0037] Example 2: Based on the error-proof wiring method for the electrical cabinet of a purifier in Example 1, the present invention will be further explained and described below.

[0038] like Figure 1 As shown, a method for preventing wiring errors in a purifier electrical cabinet includes the following steps: Step S1: Generating Structured Wiring Tasks Based on the purifier electrical design drawings, wiring data is exported using electrical design software (such as EPLAN, AutoCAD Electrical). The wiring data includes: a unique identifier for each cable, cable type (power / signal / communication / compensation), wire diameter, cable color, device identification and terminal number of the starting terminal, device identification and terminal number of the ending terminal, and wiring harness path constraints.

[0039] The central control system parses the wiring data and converts it into a structured wiring task list. Each wiring task contains the following field: Task number T ID Cable unique identification code W ID 1. Start point information (device ID + terminal number + terminal X / Y / Z coordinates), 2. End point information (device ID + terminal number + terminal X / Y / Z coordinates), 3. Cable attributes, 4. Expected wiring status marker (initially "to be wired").

[0040] Simultaneously, the system automatically generates a wiring task sequence. The sequence is sorted according to the following criteria: spatial order of the wire harness path (from inside to outside, from bottom to top), electrical safety priority (signal lines first, then power lines), and terminal density (sparse areas first, then dense areas). This task sequence is optimized for wiring accessibility, minimizing path crossing interference and tool changes during the wiring process.

[0041] Step S2: Visual Encoding of Cable Identification like Figure 2As shown, a visually identifiable coded ring is fitted at each end of each cable. The coded ring is a ring-shaped label made of high-temperature resistant and flame-retardant material, and its outer surface is printed with unique coded information (including the cable's unique identification code W). ID (And cable type color codes). The encoding information of the encoding ring is presented in the form of a QR code or a Data Matrix code, and the ring color corresponds to the cable type (e.g., red for power line, blue for signal line, yellow for communication line, green for grounding line, white for thermocouple compensation line).

[0042] Before assembly begins, the central control system scans the coded ring of each cable using a QR code scanner, marking the cable as a wire. ID It binds to tasks in the wiring task list and automatically detects the match between cable type and task requirements. If the types do not match, it issues a warning to prevent cable misuse.

[0043] Step S3: Visually guided terminal positioning and cable connection like Figure 3 As shown, operators wear augmented reality glasses or use a mobile terminal camera. The vision system collects real-time images of the electrical cabinet and uses a visual SLAM algorithm to achieve spatial positioning, overlaying the virtual 3D annotation information of each terminal position in the electrical cabinet onto the real-world image.

[0044] When an operator scans a wiring task, the system executes the following boot process: S3.1 Visual Highlighting of Starting Terminal: In the augmented reality interface, the device where the starting terminal is located and its specific terminal position are highlighted with a flashing green outline. At the same time, the device name, terminal number and cable connection diagram of the terminal are displayed.

[0045] S3.2 Cable Connection Confirmation: The operator places the coded ring within the camera's field of view, and the system automatically identifies the cable W. ID The system then extends a virtual model of the cable from the current hand position to the target terminal with a trailing light effect, guiding the operator to insert the cable end into the target terminal. When the cable end enters the preset region of interest (ROI) of the terminal, the system triggers an audio prompt "In place".

[0046] S3.3 Connection Action Detection: After the operator completes the wiring operation (such as tightening the screw or inserting the spring terminal), the system automatically detects whether the terminal has been reliably connected to the cable through the terminal status monitoring unit (see step S4 for details). If the detection is successful, the current wiring task is automatically marked as "completed" and the next wiring task is automatically loaded. The highlight display of the starting terminal is transferred to the starting terminal position of the next task.

[0047] S3.4 Repeated guidance for the end terminal: Repeat the above process to guide the operator to complete the connection of the other end of the cable.

[0048] The above process enables continuous wiring operations without leaving the operator's field of vision or operating the touchscreen. The operator's hands remain within the wiring area, and their eyes do not need to leave the cabinet, significantly improving wiring efficiency and error prevention reliability.

[0049] S3.5 Multi-task queue management and suspension / resumption mechanism To address potential issues such as path interference and insufficient cable length during wiring, the system has a built-in task suspension and resumption mechanism: Suspension trigger conditions: Operators can suspend the current task in the following two ways: Manual trigger: Select "Suspend Task" using gestures or voice commands in the augmented reality interface; Automatic system detection: When the vision system detects that the cable path intersects with the already connected cable and cannot be bypassed (by judging the cable path conflict through image segmentation algorithm), or when the operator tries to straighten the cable but the end is more than the cable length away from the terminal, the system will automatically pop up a "Suspend task?" prompt.

[0050] Post-Suspension Handling: The system places the task in a "Suspension Queue" and records the following context information: Task ID, the completed end (start or end point), current cable placement position (3D coordinates recorded via visual SLAM), and reason for suspension (manual intervention / path interference / insufficient length). Simultaneously, in the augmented reality interface, the start and end points of the suspended task are displayed with orange semi-transparent outlines, distinguishing them from the green outlines of currently executing tasks and the gray outlines of completed tasks.

[0051] Recovery Mechanism: After the operator completes the current task, the system automatically checks the suspended task queue. If a suspended task exists, the system assesses whether it meets the recovery conditions: whether path interference has been resolved (by comparing the current scene image with the image recorded when the task was suspended to determine if the interfering cable has been reconnected or adjusted), and whether the cable length issue has been resolved (e.g., by replacing it with a longer cable). If the conditions are met, the system highlights the suspended task in the task list and provides a voice prompt: "Suspended task T023 can be recovered." The operator can choose to resume immediately or continue processing other tasks. After recovery, the system automatically loads the task's context information, and the augmented reality interface redisplays the task's start and end point guidance, allowing the operator to continue working from the point of interruption.

[0052] The technical benefits of this mechanism are: it avoids interruptions in the wiring operation of the entire cabinet due to a single point of failure; operators do not need to remember the interruption location and status; the system automatically manages the context, significantly improving the continuity of operations and user experience in complex wiring scenarios.

[0053] Step S4: Online monitoring of terminal status and foolproof interlocking like Figure 4 The diagram shows a cross-sectional view of the monitoring unit mounted on a terminal block, with the specific structure including: Terminal body: Standard DIN rail type terminal block (such as Weidmüller Z series or Phoenix Contact PT series), 5.2mm wide, rated voltage 800V, rated current 24A.

[0054] Embedded mounting of the micro switch: A 2.5mm diameter mounting hole is provided below the terminal screw and at the top of the wire clamp frame. The micro switch (model: Omron D2HW, dimensions: 5.0mm × 3.5mm × 2.0mm) is embedded in this hole, with the micro switch contact extending 0.3mm. When the operator tightens the screw, the bottom of the screw presses against the micro switch contact. When the contact travel reaches 0.2mm, the switch closes, outputting a "connected" signal. This mounting method does not affect the normal rotation of the screw (there is an initial gap of 0.1mm between the screw and the micro switch contact, making contact only when nearly fully tightened), and the triggering force of the micro switch is only 0.5N, far less than the screw's tightening torque (typically 0.5-1.0N·m), therefore it will not interfere with normal wiring operations.

[0055] Miniaturized RFID antenna layout: A flexible PCB antenna (4.0mm × 3.0mm, 0.2mm thickness, 8 coil turns) is embedded in the inner wall of the terminal block's insulating shell. The antenna is connected to the terminal block bus via conductive adhesive. The antenna operates at 13.56MHz with a read distance of 5~12mm. A miniature passive RFID tag (model: NXP NTAG213, 2.5mm × 2.5mm × 0.3mm) is embedded in the cable end insulation, approximately 8mm from the cable end. When the cable end is inserted to the bottom of the terminal, the RFID tag is positioned directly above the antenna (vertical distance ≤ 2mm), ensuring reliable reading. This miniaturized design allows adjacent antennas to operate independently without interference, even with a dense 5.2mm terminal spacing (measured isolation ≥ 20dB).

[0056] Integration of a miniature pressure sensor: A thin-film pressure sensor (model: Tekscan FlexiForce A201, thickness 0.2mm, sensing area diameter 3mm) is attached to the inside of the conductive clamping arm of the terminal (the surface in contact with the cable). The sensor has a range of 0~50N and an accuracy of ±1N. The sensor leads are led out along the cable routing groove of the clamping arm and connected to the signal acquisition module via the terminal block bus. This sensor outputs a pressure value when the clamping arm presses the cable, used to determine the crimping quality.

[0057] Overall Encapsulation and Protection: All the above electronic components are encased in a terminal block housing made of polyamide material with a flame retardant rating of V0 and an IP20 protection rating. The leads of the microswitches and pressure sensors are sealed inside the terminals with adhesive to prevent dust and moisture intrusion.

[0058] like Figure 5 As shown, this step involves installing a miniature terminal status monitoring unit at each terminal of the electrical cabinet. The monitoring unit includes: Terminal connection detection module: A micro switch or conductive contact is embedded below the terminal screw or in the spring clamping mechanism. When the cable end is correctly inserted and the specified clamping force is reached, the micro switch triggers a closing signal and outputs the terminal status "connected".

[0059] Cable authentication module: An NFC / RFID reader is placed near the terminal, and a miniature passive RFID tag is pre-embedded under the insulation of each cable end (the tag stores the cable's unique identification code W). ID When the cable end is inserted into the terminal, the RFID reader automatically reads the W inside the tag. ID And connect it to the W terminal that should be connected in the wiring task list. ID The system performs a comparison. If a match is found, the system outputs "Authentication successful"; otherwise, it outputs "Authentication failed".

[0060] Crimping quality inspection module: A miniature pressure sensor is installed on the conductive clamping arm of the terminal to continuously monitor the clamping force F(t) after the cable is connected. If F(t) is lower than a preset threshold F... min (e.g., 5N) is judged as a loose connection and triggers the "insufficient crimping" alarm; if F(t) decreases by more than 15% of the initial value within 24 hours after wiring, it is judged as stress relaxation and triggers the "loose wiring warning".

[0061] The data from the above three modules (access status, authentication result, and crimping force value) are aggregated to the central control system via the terminal block bus to form a real-time status dashboard for each terminal.

[0062] After the operator completes a wiring task in step S3, the central control system automatically executes the following foolproof interlocking logic: If the access detection module does not trigger the "connected" signal, the system will prevent the task status from being updated to "completed" and will display a message on the augmented reality interface that reads "Wiring not completed, please check if the terminal screws are tightened".

[0063] If the authentication module outputs "Authentication failed", the system will immediately issue an audible and visual alarm and mark the current terminal and cable coding ring with a red flashing outline on the augmented reality interface, prompting "Cable error, please remove the current cable, check the wire number and reconnect".

[0064] If the crimping force value is lower than the threshold, the system marks the terminal as "to be re-inspected" and automatically includes it in the re-inspection task queue. The re-inspection will be carried out uniformly after the wiring of the entire cabinet is completed.

[0065] The system will only automatically mark the current connection task as "completed" and jump to the next task when the access detection and authentication are successful.

[0066] Dynamic pressure threshold algorithm: preset threshold F for pressure value min The system dynamically sets thresholds based on multiple factors, not just wire diameter. The system incorporates the following dynamic threshold models: F min =F base ×k gauge ×k material ×k temp , Wherein: F base = 5N (reference value, corresponding to 1.5mm) 2 Recommended clamping force for copper conductors at 20°C); k gauge Wire diameter factor: Refer to the table according to wire diameter specifications, 0.5-1.5mm. 2 Use 0.6-1.0 mm, 1.5-4 mm. 2 Take 1.0-1.6 mm. 2 The values ​​above are 1.6-2.4; k material Material coefficients: 1.0 for copper wires, 1.3 for aluminum wires (aluminum exhibits more pronounced creep characteristics, requiring a higher initial clamping force); k temp Ambient temperature compensation coefficient: based on the temperature sensor measurement value T near the terminal. env Calculate, k temp =1+0.005×(T env -20), meaning that for every 10°C increase in temperature, the clamping force needs to be increased by 5% to compensate for the decrease in clamping force caused by metal expansion at high temperatures.

[0067] The dynamic threshold model has been experimentally verified: under different combinations of wire diameter, material and ambient temperature, the clamping force set according to this threshold can ensure that the contact resistance is ≤5mΩ, and the contact resistance change is ≤10% after 100 thermal cycles (-40℃-85℃).

[0068] Step S5: Visual verification and closed-loop traceability of the entire cabinet after wiring is completed. After all wiring tasks are completed, the system automatically triggers the whole cabinet visual verification process: S5.1 Automatic Cruise Scan: The mobile or track-mounted visual inspection device automatically traverses all wiring areas within the electrical cabinet along a preset trajectory, capturing wiring images of each terminal block with a high-resolution camera.

[0069] S5.2 Image Recognition and Comparison: A deep learning-based target detection model (such as YOLOv8) is used to analyze the acquired images in real time, identifying the cable connection status, cable color, and coded ring information of each terminal in the image. This information is then compared item by item with the expected configuration in the wiring task list to identify the following anomaly types: Missing connection: The terminal is identified at the terminal location, but no cable is present; Incorrect connection: The cable color or coding ring information does not match the expected value; Reverse connection: Reverse the wire sequence (only applicable to polarity-sensitive signal lines); Abnormal appearance: damaged cable insulation, poor wire clamping, etc.

[0070] S5.3 Anomaly Location and Rework Guidance: For detected anomalies, the system automatically associates the terminal locations and equipment coordinates involved in the anomaly, generates an anomaly list, and highlights the spatial location of the anomaly terminal with a bright red phantom in the augmented reality interface, displaying rework operation instructions. After the operator completes the rework, the system re-executes the verification process until all anomalies are eliminated.

[0071] S5.4 Quality File Generation: The system binds all data from this wiring process (including: execution timestamps for each wiring task, historical curves of crimping force values ​​collected by the terminal status monitoring unit, cabinet verification images and recognition results, and operator identification information) with the purifier's unique serial number to generate an "Electrical Wiring Digital Quality File," which serves as part of the equipment's factory quality certification document. When electrical faults occur during equipment operation at the client end, this file can be retrieved to trace abnormal records during the wiring process and quickly pinpoint the root cause of the problem.

[0072] Step S6: In-depth application of digital quality archives Based on the electrical wiring digital quality profile generated in step S5, the system further provides the following enhanced application functions: S6.1 Full Lifecycle Traceability: The records are stored in a cloud database. After the device leaves the factory, customers can query the records using the device serial number to verify the wiring quality. When an electrical fault occurs at the customer's site, after-sales service engineers can remotely retrieve the records to quickly determine whether the fault originated from an original wiring defect.

[0073] S6.2 Predictive Maintenance Based on Big Data: The system aggregates wiring records for all devices and establishes a historical database of crimping force values. Statistical analysis reveals that crimping force values ​​below F... min Terminals with a contact resistance of ×1.2 are three times more likely to experience an increase in contact resistance after two years of equipment operation compared to normal terminals. Based on this, the system can generate predictive maintenance recommendations: "It is recommended to focus on checking the following terminals on terminal block X2 during the next maintenance: T023, T045, and T067, as their initial crimping force values ​​are too low."

[0074] S6.3 Continuous Process Optimization: By statistically analyzing the wiring quality data of different operators and different batches, it is possible to identify process links or personnel with poor consistency in crimping force values, providing data basis for process improvement and personnel training.

[0075] 4.3 Preferred Technical Solution Preferably, in step S2, the QR code / Data Matrix code of the encoding ring is engraved on the surface of the ring-shaped stainless steel sheet using laser engraving technology. It has a temperature resistance range of -40℃ to 200℃, is resistant to oil and solvent corrosion, and is suitable for the high-temperature and oily environment of the purifier electrical cabinet.

[0076] Preferably, in step S4, the reading distance of the miniature passive RFID tag is designed to be 5-15mm, the tag size is ≤3mm×5mm, and it can be embedded in the cable insulation without affecting the cable bending and wiring operation. The tag working frequency is 13.56MHz (high frequency HF) or 125kHz (low frequency LF).

[0077] Preferably, the preset threshold F of the pressing force value in step S4 min Dynamically set according to wire diameter and terminal type: for wire diameters of 0.5-1.5mm 2 F min =3N; for wire diameter 1.5-4mm 2 F min =5N; for wire diameter 4mm 2 Above, F min =8N.

[0078] Preferably, the visual guidance system in step S3 has a built-in multi-task queue management module, allowing operators to temporarily "suspend" the current task when it is blocked (e.g., insufficient cable length or path interference). The system places the task in the suspension queue and automatically jumps to the next executable task. When the conditions for suspending the task are met (e.g., adding cables or adjusting the path), the system reminds the operator to return to the task through an augmented reality interface. This mechanism avoids interruptions to the entire cabinet wiring operation due to a single point of failure.

[0079] Taking the electrical control cabinet of a certain model of high-purity nitrogen purifier as the construction object, the control cabinet includes one PLC module (16 inputs / 16 outputs), two temperature controllers, eight solid-state relays, one power supply module, four signal isolators, and three sets of terminal blocks (a total of 128 terminals). According to the electrical design drawings, a total of 86 cables need to be connected, including 56 signal cables, 18 power cables, 8 communication cables, and 4 compensation cables.

[0080] Step S1: Generating Structured Wiring Tasks The wiring data file (CSV format) was exported using EPLAN software, containing 86 wiring records. The central control system parsed the data to generate a wiring task list and optimized the task sequence according to path spatial order: starting from the terminal blocks at the bottom of the cabinet (power cable area), moving upwards to the middle PLC module (signal cable area), and finally to the top signal isolator and temperature controller (sensitive signal area). After sequence optimization, the tool travel distance required for operators to complete all wiring was reduced by approximately 35%.

[0081] Step S2: Visual Encoding of Cable Identification DataMatrix codes were laser-engraved onto the surface of a ring-shaped stainless steel sheet (8mm outer diameter, 4mm inner diameter, 0.3mm thickness). Each coded ring recorded a 12-digit unique identification code (format: WC-YYYYMMDD-XXX, where WC is an abbreviation for Wire Code). After the coded rings were inserted into both ends of the cable, they were scanned and bound to the wiring task using a scanner. A total of 172 coded rings were pre-made (86 wires x 2 ends). Among the 86 cables, 2 signal wires were found to be mismatched with the task requirements during the binding stage (wire diameter 0.75mm). 2 vs. requires 1.0mm 2 The system issued an early warning, and the operator replaced the cable and re-tethered it, thus preventing the wrong cable from entering the assembly process.

[0082] Step S3: Visually guided terminal positioning and cable connection The operator puts on HoloLens2 augmented reality glasses and starts the wiring assistance application. The first wiring task is scanned (task number T001: cable WC-20260410-001, start point: power module PE terminal, end point: terminal block X1:01).

[0083] In the augmented reality interface, the power module casing is highlighted with a light blue semi-transparent light, while the PE terminal is marked with a flashing green outline, displaying the word "PE" and a grounding symbol. The operator picks up the cable, aligns the coded ring with the glasses' camera, and the system automatically identifies cable WC-20260410-001. A blue trailing light effect then extends from the operator's hand to the PE terminal, guiding the insertion direction. When the cable end enters the PE terminal's ROI area, the glasses' speaker emits a "beep" sound. After the operator tightens the screw, the system detects the connection signal from the terminal status monitoring unit, automatically marks T001 as completed, and automatically loads task T002. The highlighted display of the starting terminal shifts to the starting terminal of T002.

[0084] The operator completed 86 wiring tasks consecutively without any task switching confusion. Because there was no need to switch tasks by touching glasses or mobile terminals, the average wiring time per operator was reduced from 4.5 minutes in the traditional method to 3.2 minutes, an efficiency improvement of approximately 29%.

[0085] Step S4: Online monitoring of terminal status and foolproof interlocking During the wiring process, the terminal status monitoring unit collects data in real time. Taking a signal line (WC-20260410-045, start point: PLC input terminal I0.0, end point: pressure sensor signal +) as an example: Access detection module: After the operator tightens the screw, the micro switch triggers a closing signal and outputs "connected".

[0086] Authentication module: The RFID tag (ID: 506B2C1A) on the cable end is read by the RFID reader on the terminal block and matched with the W terminal that should be connected to the I0.0 terminal in the wiring task list. ID (WC-20260410-045) Comparison, match passed.

[0087] Crimping quality inspection module: The miniature pressure sensor measures the initial clamping force F0 = 6.2N (threshold F). min =5N), which is considered qualified.

[0088] In another wiring task (T062, WC-20260410-062, start point: terminal block X2:12, end point: temperature controller T / C-), the operator negligently inserted the WC-20260410-062 cable into the incorrect terminal block X2:13. The RFID reader read the W... ID Expected W with X2:13 terminal ID Upon detection of a mismatch, the system immediately triggers an audible and visual alarm. The X2:13 terminal is displayed with a flashing red outline on the augmented reality interface, and the coded ring is highlighted with a red frame. A message pops up stating, "Cable error, please remove and verify the wire number." After the operator checks and removes the cable, it is reinserted into the correct X2:12 terminal. Authentication is successful, and the task is completed. This foolproof interlocking successfully prevented a misconnection incident, avoiding troubleshooting during subsequent debugging.

[0089] During the entire wiring process, two authentication failure alarms were triggered (both have been corrected), and no alarms were triggered indicating that the crimping force was below the threshold. After all 86 wiring tasks were completed, the initial crimping force values ​​of each terminal ranged from 5.1N to 8.3N, all of which were above the threshold.

[0090] Step S5: Visual verification and closed-loop traceability of the entire cabinet like Figure 6As shown, after wiring is completed, the track-mounted visual inspection device is activated. The camera automatically scans all three sets of terminal blocks along a preset trajectory, acquiring 128 images. A deep learning model (YOLOv8, trained on 5000 labeled images, mAP@0.5=0.96) performs real-time image analysis. Test results: Two anomalies were identified: no cable was connected at terminal block X3:07 (missing connection), and the cable at terminal block X2:05 was blue but should have been red (incorrect connection).

[0091] Anomaly Location: The system automatically analyzes the three-dimensional spatial coordinates of the abnormal terminal, generates an anomaly list, highlights the positions of terminals X3:07 and X2:05 in the augmented reality interface, and displays the repair instructions "Please connect cable WC-20260410-078" and "Please replace cable WC-20260410-022 with a red cable" respectively.

[0092] Repair and Re-inspection: Operators complete the repair according to the instructions (replacing missing cables and replacing incorrectly connected cables), and rerun the visual verification process. If no abnormalities are detected after the second scan, the wiring of the entire cabinet is deemed qualified.

[0093] Data traceability and quality record generation The system binds all data from this wiring process (execution timestamps of 86 wiring tasks, historical connection status of each terminal, crimping force curves, 128 images of the entire cabinet for verification and their recognition results, 2 records of mistake-proof interception, 2 records of visual verification anomalies and rework records) to equipment number N2-20260410-001 to generate an "Electrical Wiring Digital Quality File." This file is provided to the customer along with the technical documents upon equipment delivery. The crimping force curves stored in the file show that the initial crimping force values ​​of all 86 terminals are within the acceptable range, and the crimping force attenuation within 24 hours after wiring is less than 5%, eliminating the risk of poor connection due to stress relaxation.

[0094] During the wiring process, the crimping force threshold of a 4mm² aluminum wire (ambient temperature 35℃) is calculated as follows: F min =5N × 1.6 (wire diameter coefficient) × 1.3 (aluminum material) × 1.075 (temperature compensation coefficient, kJ) temp =1 + 0.005 × 15) = 11.18 N, The actual measured initial compression force was 12.3N, which is acceptable.

[0095] In contrast, if a traditional fixed threshold of 5N is used, the crimping force of this terminal will be severely insufficient (although the actual force of 12.3N is higher than 5N, it is not identified as requiring attention), while the dynamic threshold of this invention identifies it as close to the lower limit and includes it in the watchlist.

[0096] Taking the production of two different specifications of purifiers (Type A: 128 terminals / 86 cables; Type B: 96 terminals / 62 cables) on the same production line as an example, in the traditional way, changing the type requires reprinting the drawings and rechecking the wire numbers, which takes about 2 hours. In addition, it is easy to cause wiring errors due to confusion of drawings.

[0097] After adopting the method of the present invention, the model changeover process is as follows: 1. Switch equipment models in the central control system, and the system will automatically load the corresponding wiring task list.

[0098] 2. By scanning and binding the coded ring, the system automatically detects whether the current cable configuration matches the new task. If they do not match, it prompts the user to replace the cable reel.

[0099] 3. After the operator puts on the augmented reality glasses, the system automatically loads a new task sequence, and the terminal markings in the visual guidance interface are automatically updated to the layout of the Type B electrical cabinet.

[0100] 4. During the wiring process, the terminal status monitoring unit automatically identifies the cable and compares it with the new task.

[0101] Changeover time was reduced to 15 minutes (mainly due to the time spent replacing cable reels and rescanning the binding), improving changeover efficiency by 87.5%. Five Type B purifiers were produced consecutively, and the first-pass yield rate of the entire cabinet visual inspection reached 98.4% (only two missing terminals were detected, both due to operator distraction; no incorrect wiring was missed), a significant improvement over the traditional manual sampling method (first-pass yield rate of approximately 85%).

[0102] Comparison effect The method of this invention was compared with the traditional manual wiring method (drawings + wire number tubes + manual inspection) on the same model of purifier (128 terminals / 86 cables). Five units of each method were produced. The results are shown in Table 1. Table 1

[0103] The above data shows that the method of the present invention significantly improves the efficiency, accuracy and traceability of the electrical wiring of the purifier through a four-fold error prevention mechanism of structured task generation, visual guidance, online monitoring of terminal status, and visual verification of the entire cabinet.

[0104] When the operator is performing task T023 (cable from PLC I0.0 to terminal block X2:15), the vision system detects that the cable's predetermined path intersects with the already connected cable T015 and cannot be bypassed. The system automatically displays a suspension prompt. After the operator confirms, task T023 is placed in the suspension queue, and the system records the interruption point.

[0105] The operator continued executing T024 (cable from PLC I0.1 to terminal block X2:16). Upon completion, the system displayed "Suspended task T023 can be resumed." After resuming the task, the augmented reality interface redisplayed the start and end points of T023, allowing the operator to continue from the point of interruption and successfully complete the wiring.

[0106] Fifty wiring samples were prepared using the method of this invention (dynamic threshold + real-time monitoring) and 50 using the traditional manual wiring method. High and low temperature cycling tests were conducted (-40℃ to 85℃, 100 cycles, with 30 minutes of heat preservation per cycle). The changes in contact resistance before and after the test were measured, as shown in Table 2. Table 2

[0107] Data shows that the method of the present invention significantly improves the long-term reliability of wiring through the dynamic threshold of initial crimping force and real-time monitoring.

[0108] In summary, this invention not only realizes a real-time error-proof mechanism of "verification upon wiring and interception upon non-compliance", but also can automatically complete the item-by-item comparison of hundreds of terminals, identify defects such as missing connections, incorrect connections, reverse connections, and abnormal crimping appearance, with an identification accuracy rate of over 96%, far exceeding the detection rate of human visual inspection.

[0109] The specific embodiments described above do not constitute a limitation on the scope of protection of this disclosure. Those skilled in the art should understand that various modifications, combinations, sub-combinations, and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this disclosure should be included within the scope of protection of this disclosure.

Claims

1. A method for preventing wiring errors in a purifier electrical cabinet, characterized in that, The method includes: S1. Generate structured wiring task and export wiring data. The wiring data includes a unique identifier for each cable, cable type, wire diameter specification, cable color, device identifier and terminal number of the starting terminal, device identifier and terminal number of the ending terminal, and wiring harness path constraints. S2. Cable identification visual coding: A visually identifiable coding ring is fitted at each end of each cable. The coding ring is a ring-shaped label made of high temperature resistant and flame retardant material, and the outer surface is printed with unique coding information. S3. Visual-guided terminal positioning and cable connection: Wearing augmented reality glasses or using a mobile terminal camera, the vision system collects real-time images of the electrical cabinet and achieves spatial positioning through the visual SLAM algorithm, overlaying the virtual three-dimensional annotation information of each terminal position in the electrical cabinet onto the real-scene image. S4. Terminal status online monitoring and foolproof interlocking, including the embedded installation of the terminal body and micro switch, the miniaturized layout of the RFID antenna, the integration of the miniature pressure sensor and the overall packaging and protection; S5. Visual verification and closed-loop traceability of the entire cabinet after wiring is completed; S6. In-depth application of digital quality archives.

2. The error-proof wiring method for the purifier electrical cabinet according to claim 1, characterized in that: The wiring data is parsed and converted into a structured list of wiring tasks, each of which contains the following field: Task Number T ID Cable unique identification code W ID The system includes starting point information, ending point information, cable attributes, and expected wiring status markers, and automatically generates a wiring task sequence. The sorting criteria for the wiring task sequence include: spatial order of the wire harness path, electrical safety priority, and terminal density.

3. The error-proof wiring method for the purifier electrical cabinet according to claim 1, characterized in that: W the cable of the encoding ring ID It binds to tasks in the wiring task list and automatically detects the match between cable type and task requirements. If the types do not match, it issues a warning.

4. The error-proof wiring method for the purifier electrical cabinet according to claim 1, characterized in that, In step S3, the step of achieving spatial positioning through a visual SLAM algorithm and overlaying the virtual 3D annotation information of each terminal position in the electrical cabinet onto the real-world image includes: S31. The starting terminal is visually highlighted. In the augmented reality interface, the device and specific terminal position of the starting terminal are highlighted with a flashing green outline. At the same time, the device name, terminal number and cable connection diagram of the terminal are displayed. S32. Cable connection confirmation: The operator places the coded ring within the camera's field of view, and the system automatically identifies the cable W. ID The system extends the virtual model of the cable from the current hand position to the target terminal position in the form of a trailing light effect. When the cable end enters the preset area of ​​interest of the terminal position, the system triggers an audio prompt "in position". S33. Connection action detection: After the operator completes the wiring operation, the system automatically detects whether the terminal has been reliably connected to the cable through the terminal status monitoring unit. If the detection is successful, the current wiring task is automatically marked as "completed" and the next wiring task is automatically loaded. The highlight display of the starting terminal is transferred to the starting terminal position of the next task. S34. Repeated guidance for the terminal block: Repeat the above process to guide the operator to complete the connection of the other end of the cable.

5. The error-proof wiring method for the purifier electrical cabinet according to claim 1, characterized in that: The terminal body is a standard DIN rail type terminal block with a width of 5.2mm, a rated voltage of 800V, and a rated current of 24A. The micro switch is embedded in a mounting hole with a diameter of 2.5mm, located below the terminal screw and at the top of the clamping frame. The micro switch is embedded in this hole, with the contact of the micro switch extending 0.3mm. When the operator tightens the screw, the bottom of the screw presses against the micro switch contact. When the contact travel reaches 0.2mm, the switch closes and outputs a "connected" signal.

6. The error-proof wiring method for the purifier electrical cabinet according to claim 1, characterized in that: The miniaturized layout of the RFID antenna involves embedding a flexible PCB antenna within the insulating shell of the terminal block. The antenna is connected to the terminal block bus via conductive adhesive. The RFID antenna operates at a frequency of 13.56MHz and has a read distance of 5-12mm. A miniature passive RFID tag is embedded in the insulation of the cable end, approximately 8mm from the cable end. When the cable end is inserted to the bottom of the terminal, the RFID tag is positioned directly above the antenna. The integrated miniature pressure sensor is a thin-film pressure sensor with a range of 0-50N and an accuracy of ±1N, attached to the inside of the conductive clamping arm of the terminal. The sensor lead extends along the wiring groove of the clamping arm and connects to the signal acquisition module via the terminal block bus. The sensor outputs a pressure value when the clamping arm presses the cable, used to determine the crimping quality. The overall encapsulation and protection consist of the terminal body, the embedded installation of the micro switch, the miniaturized layout of the RFID antenna, and the integrated miniature pressure sensor all being encased in the terminal block shell. The shell is made of polyamide material with a flame retardant rating of V0 and an IP20 protection rating.

7. The error-proof wiring method for the purifier electrical cabinet according to claim 1, characterized in that: The foolproof interlocking includes: If the access detection module does not trigger the "connected" signal, the system will prevent the task status from being updated to "completed" and will display a message in the augmented reality interface that reads "Wiring not completed, please check if the terminal screws are tightened". If the authentication module outputs "Authentication failed", the system will immediately issue an audible and visual alarm and mark the current terminal position and cable coding ring with a red flashing outline on the augmented reality interface, prompting "Cable error, please remove the current cable, check the wire number and reconnect it"; If the crimping force value is lower than the threshold, the system marks the terminal as "to be re-inspected" and automatically includes it in the re-inspection task queue. The re-inspection will be carried out uniformly after the wiring of the entire cabinet is completed. The system will only automatically mark the current connection task as "completed" and jump to the next task when the access detection and authentication are successful.

8. The error-proof wiring method for the purifier electrical cabinet according to claim 1, characterized in that, In step S5, the visual verification and closed-loop traceability of the entire cabinet after the wiring is completed includes: S51. Automatic cruise scanning: The mobile or track-type visual inspection device automatically traverses all wiring areas in the electrical cabinet along a preset trajectory, and captures wiring images of each terminal block with a high-resolution camera. S52. Image recognition and comparison: Based on a deep learning-based target detection model, the acquired images are analyzed in real time to identify the cable connection status, cable color, and coding ring information of each terminal in the image, and are compared item by item with the expected configuration in the wiring task list to identify the abnormal type. S53. Anomaly location and rework guidance: For detected anomalies, the system automatically associates the terminal positions and equipment coordinates involved in the anomaly, generates an anomaly list, and marks the spatial location of the abnormal terminal with a bright red ghost image in the augmented reality interface, and displays rework operation guidance. S54. Quality file generation: The system binds all data in this wiring process with the unique serial number of the purifier equipment to generate an "Electrical Wiring Digital Quality File", which serves as part of the equipment's factory quality certificate.

9. The error-proof wiring method for the purifier electrical cabinet according to claim 1, characterized in that, In step S6, the further application of the digital quality archive includes: S61. Full lifecycle traceability: the records are stored in a cloud database. After the device leaves the factory, customers can query the records through the device serial number to verify the wiring quality. S62. Based on big data, predictive maintenance is implemented by compiling wiring records for all devices and establishing a historical database of crimping force values. S63. Continuous process optimization: By statistically analyzing the wiring quality data of different operators and different batches, we can identify the process links or personnel with poor consistency in crimping force values, and provide data basis for process improvement and personnel training.

10. A visually guided assembly system for preventing wiring errors in a purifier electrical cabinet, characterized in that, The system for implementing the error-proof wiring method for the purifier electrical cabinet according to any one of claims 1-9, the system comprising: Wiring task management unit: includes electrical design software interface, wiring data parsing module, and task sequence generation module, used to convert electrical design drawings into a structured wiring task list; Cable identification coding unit: includes coding ring prefabrication device, QR code / Data Matrix code laser engraving module, and coding ring scanning and binding module, used to uniquely visually encode and register the identity of each cable; Visual guidance assembly unit: includes augmented reality glasses or mobile terminal, visual SLAM positioning module, virtual annotation overlay module, and access motion recognition module, used to highlight terminal positions in the operator's field of vision and provide wiring guidance; Terminal status monitoring unit: includes access detection module, RFID authentication module, crimping quality detection module and terminal block bus, used to monitor the wiring status, cable identity and crimping force value of each terminal in real time; The whole cabinet visual inspection unit includes a mobile or track-mounted visual inspection device, a deep learning image recognition module, and an anomaly location and rework guidance module, which are used for automatic detection of the whole cabinet and anomaly closed-loop processing after wiring is completed. Data Management and Traceability Unit: Includes a central control system, database server, and production execution system interface, used for storing, associating, tracing, and generating quality records of wiring data.

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