A harness electrical measurement and appearance detection integrated device

Abstract

The present application relates to the technical field of wire harness detection, and discloses a wire harness electrical measurement and appearance detection integrated device, which comprises a rack, a bearing assembly arranged on the rack and used for bearing a wire harness connector to be measured, an electrical measurement assembly arranged on the rack and below the bearing assembly, the electrical measurement assembly comprising an electrical measurement contact array and a probe assembly corresponding to the electrical measurement contact array, the probe assembly being used for electrically contacting a terminal of the wire harness connector and conducting an electrical signal to the electrical measurement contact array, and a lifting driving mechanism connected with the bearing assembly. The present application integrates appearance detection and electrical performance detection in the same station, and the wire harness connector only needs to be clamped once to complete appearance detection and electrical measurement in turn, without flowing between different stations, so as to avoid terminal damage risk caused by manual plugging and transfer, greatly improve detection efficiency, and reduce equipment occupation and labor cost.

Description

Technical Field

[0001] This invention relates to the field of wire harness testing technology, and more specifically, to a device that integrates wire harness electrical performance testing with wire harness connector end face appearance defect testing, which is particularly suitable for wire harness products with extremely high safety and reliability requirements, such as high-voltage wire harnesses for new energy vehicles and aerospace wire harnesses. Background Technology

[0002] With the booming development of the new energy vehicle industry, high-voltage wiring harnesses, as a crucial component connecting core parts such as power batteries, motor controllers, and power distribution units, are directly related to the safety of the entire vehicle due to their quality and reliability. Factory testing of high-voltage wiring harnesses typically includes two main categories: electrical performance testing (conductivity resistance, insulation withstand voltage, contact resistance, interlocking function, etc.) and appearance defect testing (insulation layer scratches / indentations / bulges, terminal oxidation / deformation / burrs, connector housing damage, integrity of wiring markings, etc.).

[0003] Currently, the above two types of testing items are typically performed in industry practice in the following ways: Electrical performance testing station: The operator inserts the connectors at both ends of the wire harness into the dedicated probe holders. The spring probes in the holders contact each terminal (power terminal, signal terminal, shield terminal) in the connectors one by one. The electrical parameters are measured by connecting to instruments such as withstand voltage testers and micro-ohmmeters. After the test is passed, the operator pulls the wire harness out of the holders. Visual inspection station: The wire harness that has completed the power-on test is transferred to another area, where it is visually inspected by a person with the help of a magnifying light, or placed on the platform of the vision inspection equipment, where an industrial camera takes pictures of the connector end face, terminals, wire body and other parts for identification.

[0004] The above process has the following technical problems: First, during power-on testing, the insertion and removal of the connectors and probe clamps at both ends of the wire harness rely on manual operation, which is inefficient. Furthermore, manual insertion and removal may involve tilting angles, which can easily cause physical damage to the connector terminals and affect the contact reliability of the terminals. Secondly, during appearance inspection, manual visual inspection and conventional visual inspection equipment can only inspect the outer surface of the wire harness. The connector terminal face (i.e. the end face area of ​​the terminal) is not easy to be effectively inspected and is prone to being missed. If there are tiny burrs on the terminal surface, these burrs may cause tip discharge during power-on testing, further burning the terminal and causing the defect to worsen. At this time, it is difficult to determine whether the defect is inherent before leaving the factory or caused by the inspection process itself, which brings trouble to the quality judgment. Third, power-on testing and appearance testing are conducted at different workstations, requiring the wire harness to be plugged in, unplugged, and transported multiple times. This not only reduces the overall testing efficiency but also increases the risk of terminal damage. Furthermore, the results of the two tests are difficult to trace back one by one, which is not conducive to closed-loop quality management. Summary of the Invention

[0005] To address the technical problems existing in the background art, the present invention proposes an integrated device for wire harness electrical testing and appearance inspection.

[0006] The present invention proposes an integrated device for electrical testing and appearance inspection of wire harnesses, comprising: frame; A support component, mounted on the frame, is used to support the connector of the wire harness to be tested; An electrical testing component is disposed on the frame and located below the support component. The electrical testing component includes an electrical testing contact array and a probe component corresponding to the electrical testing contact array. The probe component is used to make electrical contact with the terminals of the wire harness connector and conduct electrical signals to the electrical testing contact array. A lifting drive mechanism, connected to the bearing assembly, is used to drive the bearing assembly to reciprocate in the vertical direction, so that the terminals of the wire harness connector switch between positions close to and far from the probe assembly; A visual inspection component is disposed on the carrier component and located below the terminals of the wire harness connector. The visual inspection component is used to acquire images of the terminal surface of the wire harness connector. A linkage mechanism is connected to the carrier component and the vision detection component respectively. Driven by the lifting movement of the carrier component, the linkage mechanism drives the vision detection component to reciprocate in the horizontal direction, so that the vision detection component is located directly below the terminal when the carrier component is in the first position, and avoids the contact area between the terminal and the probe component when the carrier component is in the second position.

[0007] As a further optimized solution of the present invention, the frame includes a mounting base plate and fixed columns disposed on the mounting base plate, the bearing component is slidably sleeved on the fixed columns, and the electrical testing component is disposed on the mounting base plate and located between the fixed columns; Preferably, there are two fixing columns, symmetrically distributed on both sides of the mounting base plate, each fixing column is vertically arranged and parallel to each other; the mounting base plate is a flat plate structure, used to fix the entire device on the workbench; the fixing columns are hollow inside, which can be used to accommodate the components of the lifting drive mechanism.

[0008] As a further optimization of the present invention, the supporting component includes a movable plate and a positioning cylinder disposed on the movable plate. The positioning cylinder is used to accommodate and position the wire harness connector, and the lower end of the positioning cylinder extends to the bottom of the movable plate. Preferably, the movable plate is horizontally arranged, with sleeve holes at both ends that are adapted to the fixed post. The movable plate is slidably sleeved onto the fixed post through the sleeve holes. The positioning cylinder is a vertical cylindrical shape with openings at both the top and bottom. The positioning cylinder is fixedly installed on the upper end face of the movable plate. The energized end of the wire harness connector is inserted into the inner cavity of the positioning cylinder from the upper opening. The terminal face of the wire harness connector extends from the lower opening of the positioning cylinder to the bottom of the movable plate.

[0009] As a further optimization of the present invention, a limiting sleeve is installed on the upper part of the inner cavity of the positioning cylinder, and the inner cavity shape of the limiting sleeve is adapted to the outer shape of the wire harness connector for positioning the wire harness connector; a limiting plate is installed on the lower part of the inner cavity of the positioning cylinder, and the limiting plate is used to limit the insertion depth of the wire harness connector so that the terminal face extends to a predetermined position. Preferably, the inner wall of the limiting sleeve is a rough surface, which is an anti-slip texture or a silicone layer, used to improve the insertion friction between the wire harness connector and the limiting sleeve; the limiting plate is an annular plate, the inner ring of which is adapted to the outer circumference of the terminal surface of the wire harness connector, and the insertion is complete when the outer shell end of the wire harness connector abuts against the upper end surface of the limiting plate.

[0010] As a further optimized embodiment of the present invention, the probe assembly includes a substrate, a conductive probe, and an elastic element. The conductive probe is fixedly mounted on the substrate. The upper end of the conductive probe is used to contact the terminal, and the lower end is used to contact the electrical contact array. The elastic element is sleeved on the conductive probe and is used to provide a reset force to the conductive probe. Preferably, the substrate is arranged parallel above the fixing plate, and there are multiple conductive probes that correspond one-to-one with the contacts of the electrical contact array. The upper end of each conductive probe extends to the upper part of the substrate, and the lower end of each conductive probe is slidably inserted into a pre-reserved through hole on the fixing plate and extends to the lower part of the fixing plate. The elastic element is a spring, and each spring is respectively fitted onto the corresponding conductive probe. The two ends of the spring abut against the lower end surface of the substrate and the upper end surface of the fixing plate, respectively. The surface of the spring is covered with insulating material.

[0011] As a further optimization of the present invention, the electrical contact array is disposed on a fixed base, the fixed base is mounted on the mounting base plate, and the contacts of the electrical contact array correspond one-to-one with the conductive probes; Preferably, the fixed base is fixedly installed at the center of the upper surface of the mounting base plate, the electrical contact array is embedded in the upper surface of the fixed base, and the bottom of each contact is electrically connected to the external testing instrument through the internal circuit of the fixed base. The substrate and the electrical contact array are both made of beryllium copper plated with gold.

[0012] As a further optimization of the present invention, the visual inspection component includes a cantilever, a boom, and a visual inspection camera. One end of the cantilever is connected to the linkage mechanism, and the other end extends toward the terminal and is mounted on the boom. The visual inspection camera is mounted on the boom, and its lens faces the terminal surface. Preferably, the number of the visual inspection components is two sets, symmetrically distributed on both sides below the terminal; the cantilever is horizontally arranged below the movable slot, one end of which is fixedly connected to the output end of the linkage mechanism, and the other end extends horizontally below the wire harness connector; the rod is vertically arranged and fixedly installed on the extension end of the cantilever; the visual inspection camera is installed on the lower part of the rod, and its lens is horizontally facing the terminal surface.

[0013] As a further optimization of the present invention, the visual inspection component also includes a supplementary light, which is mounted on the boom and located above the visual inspection camera. The supplementary light has a semi-enclosed structure and is used to provide supplementary lighting to the terminal surface during image acquisition. Preferably, the supplementary light has a U-shaped structure, with evenly distributed LED beads installed on its inner wall, and the illumination direction of the LED beads is tilted towards the terminal surface; when the two sets of the visual detection components approach each other to the detection position, the openings of the two supplementary lights face each other and together surround the periphery of the terminal surface, forming an annular supplementary lighting area.

[0014] As a further optimization of the present invention, the linkage mechanism includes a driving component and a motion conversion component. The driving component converts the lifting motion of the bearing component into rotational motion, and the motion conversion component converts the rotational motion into horizontal reciprocating movement of the visual detection component. Preferably, the driving component is disposed in the movable slots at both ends of the movable plate, and the motion conversion component is disposed in the movable slots and connected to the driving component and the vision detection component respectively.

[0015] As a further optimization of the present invention, the driving component includes a driving gear and a driving rack. The driving rack is fixedly mounted on the frame and extends in a vertical direction. The driving gear is rotatably mounted on the bearing component and meshes with the driving rack. The motion conversion component includes a lead screw and a nut sleeved on the lead screw. The lead screw is coaxially connected to the driving gear or driven by a bevel gear set. The nut is connected to the vision detection component. Preferably, the drive rack is fixedly mounted on the long side of the L-shaped mounting arm, the short side of the mounting arm is fixedly connected to the upper side of the fixed column, and the long side of the mounting arm extends vertically downward and passes through the movable groove on the movable plate. The drive gear is rotatably mounted in the movable slot via a shaft, and the axis of the drive gear is perpendicular to the axis of the fixed column; one end of the lead screw is rotatably connected to the inner wall of the movable slot away from the mounting arm, and the other end of the lead screw is directly connected to the shaft of the drive gear via a coupling or is driven by a bevel gear set; a connecting rod is fixedly mounted on the nut, and the connecting rod extends downward and connects to the vision inspection component.

[0016] As a further optimization of the present invention, a linear guide rail is installed on the side wall of the movable groove. The linear guide rail extends along the moving direction of the vision detection component. The connecting rod passes through the guide rail groove on the linear guide rail and slides in cooperation with the guide rail groove to guide the horizontal movement of the vision detection component. Preferably, the linear guide rail is arranged parallel to the bottom of the lead screw, and a guide rail groove that runs vertically through the middle of the linear guide rail is provided. The guide rail groove is the same length as the lead screw. The end of the connecting rod away from the nut passes vertically downward through the guide rail groove and extends to the bottom of the movable plate. The connecting rod can slide freely along the length direction of the guide rail groove.

[0017] As a further optimized solution of the present invention, the positioning cylinder is rotatably mounted on the movable plate via a bearing, a transmission ring is provided on the lower outer periphery of the positioning cylinder, and a driving unit is provided on the vision inspection component. When the vision inspection component moves to the inspection position, the driving unit frictionally engages with the transmission ring to drive the positioning cylinder and the wire harness connector to rotate around the vertical axis. Preferably, the movable plate has a large-diameter circular hole in the middle, and the lower end of the positioning cylinder is rotatably connected to the circular hole through a bearing; the transmission ring is fixedly fitted onto the outer periphery of the positioning cylinder located below the movable plate; the drive unit is installed on the upper cantilever of one of the vision inspection components, and the drive unit is an electric motor with its output end facing upward and equipped with a drive wheel; when the two sets of vision inspection components approach each other to the detection position, the drive wheel abuts against the outer circular surface of the transmission ring and forms a friction transmission engagement; the drive wheel is a hard metal wheel, and the transmission ring is an aluminum alloy ring with its outer periphery covered with a polyurethane or rubber layer.

[0018] As a further optimization of the present invention, the lifting drive mechanism is a cylinder, a hydraulic cylinder, or an electric lead screw mechanism. Preferably, the lifting drive mechanism is a cylinder or hydraulic cylinder mounted on the upper surface of the mounting base plate, with its piston rod extending vertically upward and connected to the lower end surface of the movable plate; or, the lifting drive mechanism is an electric screw mechanism mounted inside the fixed column, with a vertical sliding groove provided on the side of the fixed column, and the nut end of the electric screw mechanism extending to the outside of the vertical sliding groove and fixedly connected to the inner wall of the sleeve hole of the movable plate.

[0019] The integrated wire harness electrical testing and appearance inspection device proposed in this invention has the following beneficial effects: 1. This invention integrates appearance inspection and electrical performance inspection into the same workstation. The wire harness connector can complete appearance inspection and electrical testing in one clamping, without having to be transferred between different workstations. This avoids the risk of terminal damage caused by manual insertion and removal and transportation, greatly improves inspection efficiency, and reduces equipment footprint and labor costs.

[0020] 2. This invention utilizes the lifting motion of the supporting component to synchronously drive the translation of the vision inspection component through a linkage mechanism, thereby realizing the automatic switching between appearance inspection and power-on inspection. No additional power source is required to drive the movement of the vision inspection component, which simplifies the structure, reduces costs, and ensures accurate and reliable timing of actions.

[0021] 3. The visual inspection component of the present invention can perform appearance inspection on the terminal surface both before and after electrical testing. By comparing and analyzing the two images, it can accurately determine whether the defect is inherent before leaving the factory or caused during the inspection process, providing a reliable basis for quality judgment.

[0022] 4. The present invention, through a rotatable positioning cylinder and a rotation drive unit, can drive the wire harness connector to rotate during visual inspection, realize multi-angle imaging of the terminal surface, avoid blind spots in inspection, and improve the comprehensiveness and accuracy of appearance inspection.

[0023] 5. The conductive probe of the present invention adopts a spring floating structure, which can adaptively form reliable contact with the terminal and the electrical test contact during electrical testing, while the insulating wrapping on the surface of the spring ensures electrical safety.

[0024] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the appearance inspection status of the terminal surface of the wire harness connector of the present invention; Figure 2 This is a schematic diagram of the electrical testing state of the wire harness connector of the present invention; Figure 3 For the present invention Figure 1 A schematic diagram of a partial cross-sectional structure; Figure 4 For the present invention Figure 2 A schematic diagram of a partial cross-sectional structure; Figure 5 This is a schematic diagram of the probe assembly of the present invention; Figure 6 For the present invention Figure 4 Enlarged structural schematic diagram of the drive assembly and transmission mechanism; Figure 7 This is a schematic diagram of the supplementary lighting structure of the present invention from a low angle; Figure 8 This is a bottom view of the positioning cylinder structure of the present invention.

[0026] 1. Mounting base plate; 2. Fixed base; 3. Electrical contact array; 4. Fixed column; 5. Fixed plate; 6. Movable plate; 7. Lifting mechanism; 8. Probe assembly; 81. Base plate; 82. Conductive probe; 83. Spring; 9. Positioning cylinder; 10. Wire harness connector; 11. Vision inspection assembly; 111. Cantilever; 112. Hanging rod; 113. Vision inspection camera; 114. Supplementary light; 12. Mounting arm; 13. Drive assembly; 131. Drive gear; 132. Drive rack; 133. Bevel gear set; 14. Motion conversion component; 141. Lead screw assembly; 142. Connecting rod; 143. Linear guide rail; 15. Movable groove; 16. Limit sleeve; 17. Limit plate; 18. Bearing; 19. Drive unit; 20. Transmission ring; 21. Guide block. Detailed Implementation

[0027] Embodiments of the present invention are described in detail below. Examples of these embodiments are illustrated in the accompanying drawings, wherein the same or similar symbols denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0028] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0029] Please see Figures 1 to 4 The integrated device for electrical testing and appearance inspection of wire harnesses proposed in this invention includes a mounting base plate 1 and a fixing column 4 serving as a frame.

[0030] A fixed base 2 is installed at the center of the upper end of the mounting base 1. An electrical test contact array 3 is embedded on the upper surface of the fixed base 2. The electrical test contact array 3 has multiple contacts, and the number of contacts is consistent with the number of terminals of the wire harness connector 10 under test and corresponds one-to-one. The bottom of each contact is electrically connected to an external testing instrument (such as a withstand voltage tester, micro ohmmeter, etc.) through the internal circuit of the fixed base 2.

[0031] There are two fixed columns 4, which are symmetrically distributed on both sides of the fixed base 2. They are both vertically set and parallel to each other, and are fixedly installed on the upper surface of the mounting base plate 1.

[0032] Fixed plates 5 and movable plates 6 are installed on the two fixed columns 4.

[0033] The fixed plate 5 is horizontally positioned above the electrical contact array 3, and its two ends are fixedly connected to the adjacent fixed posts 4 respectively. The movable plate 6 is horizontally positioned above the fixed plate 5, and its two ends are provided with sleeve holes. It is slidably sleeved onto the fixed posts 4 through the sleeve holes and can slide back and forth along the fixed posts 4 in the vertical direction.

[0034] The movable plate 6 is driven to rise and fall by the lifting mechanism 7. The lifting mechanism 7 can be a cylinder or oil cylinder installed on the upper end face of the mounting base plate 1, and its piston rod is connected to the lower end face of the movable plate 6; or it can be an electric screw mechanism installed inside the fixed column 4. The inner wall of the fixed column 4 is provided with a vertical sliding groove, and its nut end is slidably assembled in the vertical sliding groove and fixedly connected to the inner wall of the sleeve hole of the movable plate 6.

[0035] A probe assembly 8 is installed on the upper end of the fixed plate 5. The probe assembly 8 is located below the movable plate 6. A positioning cylinder 9 is installed on the upper end of the movable plate 6. The energized end of the wire harness connector 10 is inserted into the inner cavity of the positioning cylinder 9 from the upper end. The terminal face of the wire harness connector 10 extends to the lower part of the movable plate 6, and multiple terminals of the terminal face are one-to-one with multiple conductive probes 82 of the probe assembly 8. A vision inspection assembly 11 is installed on the bottom of the movable plate 6, symmetrically distributed on both sides below the terminals of the wire harness connector 10, for image acquisition of the terminal face.

[0036] When the lifting mechanism 7 drives the movable plate 6 to descend, the wire harness connector 10 moves down accordingly, and the terminal gradually approaches the conductive probe 82. At the same time, the vision inspection component 11 moves horizontally away from the terminal under the drive of the linkage mechanism, making room for electrical testing. When the movable plate 6 descends to the end point, the terminal contacts the conductive probe 82, and the lower end of the conductive probe 82 contacts the electrical test contact array 3, so that power-on detection can be performed. When the lifting mechanism 7 drives the movable plate 6 to rise, the wire harness connector 10 moves upward, the terminal disengages from the conductive probe 82, and at the same time, the vision inspection component 11 moves horizontally to directly below the terminal under the drive of the linkage mechanism to collect the appearance image of the terminal surface.

[0037] Please see Figure 3 and Figure 4 The positioning cylinder 9 is a vertical cylindrical shape with openings at both the top and bottom, and is fixedly installed on the upper surface of the movable plate 6.

[0038] A limiting sleeve 16 is installed on the upper part of the inner cavity of the positioning cylinder 9. The inner cavity shape of the limiting sleeve 16 is adapted to the outer shape of the wire harness connector 10 to be tested, and is used to accurately position the wire harness connector 10.

[0039] The inner wall of the limiting sleeve 16 is rough, for example, with anti-slip texture or coated with silicone layer, to increase the insertion friction between the wire harness connector 10 and the limiting sleeve 16, and prevent the wire harness connector 10 from falling off during the test. Clamps and buckles can also be added for auxiliary fixation.

[0040] A limiting plate 17 is installed at the lower part of the inner cavity of the positioning cylinder 9 near the opening. The limiting plate 17 is an annular plate, and its inner ring shape is adapted to the outer circumferential shape of the terminal surface of the wire harness connector 10. When the wire harness connector 10 is inserted into the limiting sleeve 16, the end of its outer shell contacts the upper end face of the limiting plate 17, which indicates that it is inserted in place. At this time, the terminal surface passes through the limiting plate 17 and extends to a predetermined position below the positioning cylinder 9.

[0041] Please see Figure 5 The probe assembly 8 includes a substrate 81, a conductive probe 82, and a spring 83.

[0042] The substrate 81 is arranged parallel above the fixing plate 5. There are multiple conductive probes 82, which are fixedly installed on the substrate 81. The upper end of each conductive probe 82 extends to the upper part of the substrate 81 for contacting the terminal of the wire harness connector 10. The lower end of each conductive probe 82 slides into the through hole reserved on the fixing plate 5 and extends to the lower part of the fixing plate 5 for contacting the contact of the electrical contact array 3.

[0043] Each conductive probe 82 is fitted with a spring 83, and the two ends of the spring 83 abut against the lower end surface of the substrate 81 and the upper end surface of the fixing plate 5, respectively.

[0044] When the conductive probe 82 is subjected to downward pressure, it will compress the spring 83 and move downward, so that the lower end of the conductive probe 82 can reliably contact the contacts of the electrical contact array 3. The surface of the spring 83 is covered with insulating material (such as insulating rubber sleeve or insulating varnish) to avoid the risk of electric shock. The substrate 81 and the electrical contact array 3 are preferably made of beryllium copper plated with gold to ensure good conductivity and wear resistance.

[0045] Please see Figure 1 and Figure 6 The visual inspection component 11 includes a cantilever 111, a boom 112, a visual inspection camera 113, and a supplementary light 114.

[0046] There are two sets of vision inspection components 11, symmetrically distributed on both sides below the terminals of the wire harness connector 10. The cantilever 111 is horizontally set below the movable slot 15. One end of the cantilever 111 is fixedly connected to the output end (link 142) of the linkage mechanism, and the other end extends horizontally below the wire harness connector 10. The suspension rod 112 is vertically fixedly installed on the extension end of the cantilever 111. The vision inspection camera 113 is installed on the lower part of the suspension rod 112, with its lens horizontally or tilted towards the terminal surface. The supplementary light 114 is installed on the upper part of the suspension rod 112, located above the vision inspection camera 113.

[0047] Please see Figure 7 The supplementary light 114 has a U-shaped semi-enclosed structure, with evenly distributed LED beads installed on its inner wall. The illumination direction of the LED beads is tilted towards the terminal surface. When the two sets of vision inspection components 11 approach each other to the inspection position, the openings of the two supplementary lights 114 face each other and together surround the periphery of the terminal surface, forming a ring-shaped supplementary light area, providing uniform and sufficient illumination for the vision inspection camera 113.

[0048] Please see Figure 3 , Figure 4 and Figure 6 The linkage mechanism is used to convert the lifting motion of the movable plate 6 into the horizontal reciprocating movement of the vision detection component 11. Both ends of the movable plate 6 are provided with vertically penetrating movable slots 15. The movable slots 15 are located between the positioning cylinder 9 and the fixed column 4. An L-shaped mounting arm 12 is fixedly installed on the upper part of the side of the fixed column 4 near the positioning cylinder 9. The short side of the mounting arm 12 is horizontal and fixedly connected to the upper side of the fixed column 4, and its long side extends vertically downward and passes through the movable slots 15.

[0049] The linkage mechanism includes a drive component 13 and a motion conversion component 14.

[0050] The drive assembly 13 includes a drive gear 131 and a drive rack 132. The drive rack 132 is fixedly installed on the long side of the mounting arm 12 and extends in the vertical direction. The drive gear 131 is rotatably installed in the movable groove 15 through a wheel axle, and its axis is perpendicular to the axis of the fixed column 4. The drive gear 131 and the drive rack 132 are meshed and connected.

[0051] The motion conversion component 14 includes a lead screw assembly 141, a connecting rod 142, and a linear guide rail 143. The lead screw assembly 141 includes a lead screw and a nut threaded onto the lead screw. One end of the lead screw is rotatably connected to the inner wall of the movable groove 15 away from the mounting arm 12. The other end of the lead screw is connected to the axle of the drive gear 131 via a coupling or a bevel gear set 133. The connecting rod 142 is fixedly installed at the lower end of the nut and extends vertically downward. The linear guide rail 143 is installed on the inner wall of the movable groove 15 and is arranged parallel to the lower part of the lead screw. The linear guide rail 143 has a guide rail groove that runs vertically through the middle. The guide rail groove is the same length as the lead screw. The connecting rod 142 passes through the guide rail groove and extends to the lower part of the movable plate 6. The connecting rod 142 can slide along the length direction of the guide rail groove. The lower end of the connecting rod 142 is fixedly connected to one end of the cantilever 111.

[0052] When the lifting mechanism 7 drives the movable plate 6 to rise and fall, the drive gear 131 rises and falls synchronously with the movable plate 6. Since the drive rack 132 is fixed, the drive gear 131 rolls and rotates along the drive rack 132 during the lifting and falling process, thereby driving the lead screw to rotate. The rotation of the lead screw drives the nut to move horizontally along the lead screw axis. The nut drives the vision detection component 11 to move horizontally through the connecting rod 142. In this way, the lifting and falling motion of the movable plate 6 is converted into the horizontal reciprocating movement of the vision detection component 11.

[0053] Specifically, when the movable plate 6 is at its highest position (first position, i.e., initial position), the visual inspection components 11 on both sides move closer to each other and horizontally to directly below the terminals of the wire harness connector 10, at which point visual inspection can be performed before electrical testing. When the movable plate 6 descends for electrical testing, the visual inspection components 11 on both sides move away from each other until the movable plate 6 is at the end of its descent stroke (the second position, i.e., the electrical testing position). At this point, the distance between the visual inspection components 11 on both sides is the largest, avoiding the contact area between the terminal and the probe assembly 8. At this time, power-on testing can be performed. When the electrical test is completed and the movable plate 6 rises, the visual inspection components 11 on both sides move closer to each other again. When the movable plate 6 returns to its highest position, it is positioned directly below the terminal again, and the appearance inspection after the electrical test can be performed. In addition, a guide block 21 is installed on the inner wall of the movable groove 15 near the mounting arm 12. The guide block 21 has a U-shaped guide groove that runs vertically through it. The U-shaped opening faces the drive gear 131. The long side of the mounting arm 12 slides vertically into the guide groove to play a limiting and guiding role, thereby improving the stability of the movable plate 6 lifting.

[0054] Please see Figure 1 , Figure 2 , Figure 6 and Figure 8 In order to achieve multi-angle imaging of the terminal face and avoid missed detection, the positioning cylinder 9 is rotatably mounted on the movable plate 6 via the bearing 18.

[0055] Specifically, a large-diameter circular hole is opened in the middle of the movable plate 6, and the lower end of the positioning cylinder 9 is rotatably connected to the circular hole through the bearing 18. The outer periphery of the positioning cylinder 9 located below the movable plate 6 is fixedly fitted with a transmission ring 20. A drive unit 19 is installed on the upper part of the cantilever 111 of one of the vision inspection components 11. The drive unit 19 is an electric motor with its output end facing upward and equipped with a drive wheel.

[0056] When the two sets of vision inspection components 11 approach each other to the inspection position, the drive wheel of the drive unit 19 contacts and presses against the outer circular surface of the transmission ring 20, forming a friction transmission engagement.

[0057] The drive wheel of the drive unit 19 is a hard metal wheel, and the transmission ring 20 is an aluminum alloy ring with a polyurethane or rubber layer covering its outer circumference to ensure stable frictional torque transmission between the two.

[0058] After the drive unit 19 is started, the drive wheel drives the transmission ring 20 to rotate through friction. The transmission ring 20 drives the positioning cylinder 9 and the wire harness connector 10 inserted therein to rotate around the vertical axis, so that the vision inspection camera 113 below can collect images of the terminal surface from multiple angles, fully covering all areas of the terminal surface.

[0059] The complete testing process for this device is as follows: The first step is to insert the connector 10 of the wire harness to be tested into the limiting sleeve 16 of the positioning cylinder 9 until the end of the outer shell abuts against the limiting plate 17. At this time, the terminal surface extends to a predetermined position below the movable plate 6.

[0060] In the second step, the lifting mechanism 7 drives the movable plate 6 to the highest position, and the visual inspection components 11 on both sides move closer to each other under the drive of the linkage mechanism to the bottom of the terminal. The drive unit 19 is started to rotate the positioning cylinder 9. At the same time, the visual inspection camera 113 collects the appearance image before electrical testing and records the initial state of the terminal surface (including possible inherent burrs, scratches, oxidation and other defects).

[0061] The third step, after the appearance inspection before electrical testing is completed, the lifting mechanism 7 drives the movable plate 6 to descend, and the visual inspection components 11 on both sides move away from each other under the drive of the linkage mechanism; when the movable plate 6 descends to the end point, the terminal contacts the conductive probe 82, the conductive probe 82 compresses the spring 83 and moves down to contact the electrical test contact array 3, and the external testing instrument performs the power-on performance test.

[0062] Fourth step: After the power-on test is completed, the lifting mechanism 7 drives the movable plate 6 to rise and reset. The two visual inspection components 11 are driven by the linkage mechanism to move closer to each other again to the bottom of the terminal. The visual inspection camera 113 collects the appearance image after the electrical test and records the state of the terminal surface after the electrical test.

[0063] The fifth step is to compare the appearance images before and after electrical testing. If there is a defect before electrical testing, the defect is an inherent defect from the factory. If there is no defect before electrical testing but a defect appears after electrical testing (such as burn marks), the defect is caused by the testing process. Based on this, quality judgment and process improvement are carried out.

[0064] It should be noted that in actual use, the device is usually installed in pairs on the testing workbench, corresponding to the electrical tests at both ends of the wire harness. In addition, a vision camera is set above the workbench to inspect the overall appearance, which can perform visual inspection of the overall exterior of the wire harness.

[0065] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. An integrated device for electrical testing and appearance inspection of wire harnesses, characterized in that, include: frame; A support component, mounted on the frame, is used to support the connector of the wire harness to be tested; An electrical testing component is disposed on the frame and located below the support component. The electrical testing component includes an electrical testing contact array and a probe component corresponding to the electrical testing contact array. The probe component is used to make electrical contact with the terminals of the wire harness connector and conduct electrical signals to the electrical testing contact array. A lifting drive mechanism, connected to the bearing assembly, is used to drive the bearing assembly to reciprocate in the vertical direction, so that the terminals of the wire harness connector switch between positions close to and far from the probe assembly; A visual inspection component is disposed on the carrier component and located below the terminals of the wire harness connector. The visual inspection component is used to acquire images of the terminal surface of the wire harness connector. A linkage mechanism is connected to the carrier component and the vision detection component respectively. Driven by the lifting movement of the carrier component, the linkage mechanism drives the vision detection component to reciprocate in the horizontal direction, so that the vision detection component is located directly below the terminal when the carrier component is in the first position, and avoids the contact area between the terminal and the probe component when the carrier component is in the second position.

2. The integrated device for wire harness electrical testing and appearance inspection according to claim 1, characterized in that, The frame includes a mounting base plate and fixed columns disposed on the mounting base plate. The load-bearing component is slidably sleeved on the fixed columns, and the electrical testing component is disposed on the mounting base plate and located between the fixed columns.

3. The integrated device for wire harness electrical testing and appearance inspection according to claim 1, characterized in that, The support assembly includes a movable plate and a positioning cylinder disposed on the movable plate. The positioning cylinder is used to accommodate and position the wire harness connector, and the lower end of the positioning cylinder extends below the movable plate.

4. The integrated wire harness electrical testing and appearance inspection device according to claim 3, characterized in that, A limiting sleeve is installed on the upper part of the inner cavity of the positioning cylinder. The inner cavity shape of the limiting sleeve is adapted to the outer shape of the wire harness connector and is used to position the wire harness connector. A limiting plate is installed on the lower part of the inner cavity of the positioning cylinder. The limiting plate is used to limit the insertion depth of the wire harness connector so that the terminal face extends to a predetermined position.

5. The integrated device for wire harness electrical testing and appearance inspection according to claim 1, characterized in that, The probe assembly includes a substrate, a conductive probe, and an elastic element. The conductive probe is fixedly mounted on the substrate. The upper end of the conductive probe is used to contact the terminal, and the lower end is used to contact the electrical test contact array. The elastic element is sleeved on the conductive probe and is used to provide a reset force to the conductive probe.

6. The integrated device for wire harness electrical testing and appearance inspection according to claim 5, characterized in that, The electrical contact array is mounted on a fixed base, which is installed on the mounting plate. The contacts of the electrical contact array correspond one-to-one with the conductive probes.

7. The integrated device for wire harness electrical testing and appearance inspection according to claim 1, characterized in that, The visual inspection assembly includes a cantilever, a boom, and a visual inspection camera. One end of the cantilever is connected to the linkage mechanism, and the other end extends toward the terminal and is mounted on the boom. The visual inspection camera is mounted on the boom, and its lens faces the terminal surface.

8. The integrated wire harness electrical testing and appearance inspection device according to claim 7, characterized in that, The visual inspection component also includes a supplementary light, which is mounted on the boom and located above the visual inspection camera. The supplementary light has a semi-enclosed structure and is used to provide supplementary lighting to the terminal surface during image acquisition.

9. The integrated device for wire harness electrical testing and appearance inspection according to claim 1, characterized in that, The linkage mechanism includes a drive component and a motion conversion component. The drive component converts the lifting motion of the bearing component into rotational motion, and the motion conversion component converts the rotational motion into horizontal reciprocating movement of the vision detection component.

10. The integrated device for wire harness electrical testing and appearance inspection according to claim 9, characterized in that, The drive assembly includes a drive gear and a drive rack. The drive rack is fixedly mounted on the frame and extends vertically. The drive gear is rotatably mounted on the bearing assembly and meshes with the drive rack. The motion conversion component includes a lead screw and a nut sleeved on the lead screw. The lead screw is coaxially connected to the drive gear or driven by a bevel gear set. The nut is connected to the vision inspection assembly.

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