New energy automobile wire harness detection system
Through the design of the bracket assembly and lifting structure, the high-efficiency integration of the new energy vehicle wiring harness testing system is achieved, solving the problems of inconvenient handling and maintenance during cable testing, and improving production efficiency and testing convenience.
Patent Information
- Application Number
- CN202520333994.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-02-28
- Publication Date
- 2026-01-30
- Estimated Expiration
- 2035-02-28
AI Technical Summary
In the current process of testing wiring harnesses for new energy vehicles, the handling, laying out and connecting of cables takes a long time, resulting in low production efficiency and inconvenience in repairing after problems are detected.
Design a new energy vehicle wiring harness testing system, including a bracket assembly, a lifting structure and a wire frame assembly. The bracket assembly fixes the tooling plate, and the lifting structure adjusts the height and position of the wire frame assembly, realizing the integration of cable fabrication and testing in one workstation, eliminating the steps of handling and repositioning.
It improved production efficiency, simplified cable inspection and repair processes, reduced cable handling and repositioning time, and enhanced the convenience of inspection and repair.
Smart Images
Figure CN223857323U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of new energy vehicle testing technology, specifically a new energy vehicle wiring harness testing system. Background Technology
[0002] With the rapid development of the new energy vehicle industry, the safety and reliability of new energy vehicles have received much attention. As a key component of the electrical system of new energy vehicles, the quality of wiring harnesses directly affects the performance and safety of the entire vehicle. In order to improve the installation efficiency and aesthetics of cables, most new energy vehicles are now equipped with dedicated integrated vehicle cables according to the vehicle body structure. This means that most of the electrical components of a car are connected by a single cable. The process of manufacturing integrated vehicle cables is called single-board assembly process. Specifically, one or more people work on a tooling board in a fixed area to assemble materials such as wires, sheaths, fuses, and cable ties into a complete assembly according to process documents. After the finished wiring harness and vehicle integrated cable are manufactured, they must be tested to avoid incorrect or missing connections and poor signal contact. Currently, the vehicle integrated cable is first removed from the tooling plate and then transported to a dedicated testing bench for testing. However, because the vehicle integrated cable has many branching joints and is quite heavy, it takes a lot of time to re-lay it out and find the joints to be tested and connect them to the testing system. During this process, the handling, laying out, and connecting of the cables all take time, resulting in low production efficiency. Furthermore, if a problem is detected, the cable must be fixed again before repairs can be carried out, which is very inconvenient. Utility Model Content
[0003] (a) Technical problems to be solved
[0004] To address the shortcomings of existing technologies, this utility model provides a new energy vehicle wiring harness testing system, which solves the problems mentioned in the background section.
[0005] (II) Technical Solution
[0006] To achieve the above objectives, this utility model provides the following technical solution: a new energy vehicle wiring harness testing system, comprising a bracket assembly, a rotatable tooling plate mounted at the front of the bracket assembly, a lifting structure mounted at the middle of the rear of the bracket assembly, testing control boxes mounted on both sides of the lifting structure at the rear of the bracket assembly, a vertically movable crossbeam mounted at the front of the lifting structure, a rotatable wire frame assembly mounted above the crossbeam, the wire frame assembly comprising a slider, a screw fixedly mounted below the slider, a nut mounted on the screw, a steel pipe inserted inside the slider, a Torx head screw for locking the steel pipe mounted above the slider, a gland head mounted at the front end of the steel pipe, and a signal connection wire mounted inside the wire frame assembly.
[0007] Preferably, the support assembly comprises a rectangular base frame, triangular frames fixedly installed on both sides of the rectangular base frame, a sleeve ring installed on the top of the triangular frame, a rotating shaft installed between the sleeve rings, a lower plum blossom head screw installed on the top of the sleeve ring and capable of locking the rotating shaft, and a tool plate installed on the rotating shaft and capable of adjusting the angle through the tightness of the lower plum blossom head screw.
[0008] Preferably, the lifting structure mainly comprises a servo motor, a screw rod, a linear guide rail, and a floating plate installed on the linear guide rail, and a cross beam is installed in front of the floating plate, and the servo motor drives the cross beam to move up and down through the screw rod when working.
[0009] Preferably, a plurality of through holes with a slightly larger spacing size than the width size of the sliding block are formed on the cross beam, a screw rod is inserted into the through hole, and one nut is arranged above and below the screw rod, and the height of the sliding block installation can be changed through the two nuts, and the sliding block is installed with a height offset to rotate the steel pipe.
[0010] Preferably, the length size of the cross beam is slightly larger than the length size of the tool plate, the length size of the steel pipe is the same as the width size of the tool plate, the steel pipe is gap-fitted with the sliding block, and the length of the steel pipe extending forward can be changed by adjusting the tightness of the upper plum blossom head screw.
[0011] Preferably, the whole vehicle integrated cable is made on the tool plate, the front end of different signal connection lines is provided with different connectors capable of being connected with the whole vehicle integrated cable, the length of the front end of the signal connection line falling downward can be changed through the tightness of the gran head, and the rear end of the signal connection line is connected to the detection electric control box and is reserved with a certain length to realize the up and down movement and avoid pulling.
[0012] The utility model provides a new energy automobile wire harness detection system has the following beneficial effects:
[0013] 1. The new energy automobile wire harness detection system is set through the cooperation of the support assembly, the lifting structure and the wire rack assembly, the new energy automobile wire harness detection system has the effect of improving production efficiency, the support assembly is fixed to the tool plate and the detection electric control box, the lifting structure and the wire rack assembly are adjusted to the signal connection line, the cable manufacturing and the detection system are reasonably integrated in one station, the just finished cable does not need to be transported to other stations and can be directly detected, the time spent on cable transportation and repositioning can be saved, and the production efficiency is improved.
[0014] 2. The new energy automobile wire harness detection system is set through the cooperation of the support assembly, the detection electric control box and the wire rack assembly, the new energy automobile wire harness detection system has the effect of facilitating cable maintenance, the support assembly, the detection electric control box and the wire rack assembly integrate the cable manufacturing and the cable detection in one station, and the cable does not need to be separated from the tool plate during detection, so if the cable has a problem, it can be directly maintained, and the steps of labeling, handing over to the manufacturing staff, fixing and then maintaining can be saved, so that the maintenance is more convenient. Attached Figure Description
[0015] Fig. 1 This is a structural schematic diagram of the three-dimensional view of this utility model;
[0016] Fig. 2 This is a structural schematic diagram of the left view of this utility model;
[0017] Fig. 3 This is a schematic diagram of the structure of the bracket assembly of this utility model;
[0018] Fig. 4 This is a structural schematic diagram of the wire frame assembly of this utility model.
[0019] In the diagram: 1. Bracket assembly; 101. Rectangular base frame; 102. Tripod frame; 103. Collar; 104. Rotating shaft; 105. Lower Torx head screw; 2. Tooling plate; 3. Lifting structure; 4. Detection control box; 5. Crossbeam; 6. Cable tray assembly; 601. Slider; 602. Screw; 603. Nut; 604. Steel pipe; 605. Upper Torx head screw; 606. Gland head; 7. Signal connection cable. Detailed Implementation
[0020] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments.
[0021] Please see Figs. 1 to 4The utility model provides a technical scheme: a new energy automobile wire harness detection system, including support assembly 1, support assembly 1's front is installed rotatable tooling plate 2, support assembly 1 includes rectangular chassis 101, support assembly 1 passes through rectangular chassis 101 and is fixed with ground, the upper fixed mounting of both sides of rectangular chassis 101 is installed tripod 102, and tripod 102 structure is stable, and the top of tripod 102 is installed thimble 103, and thimble 103 between installation has the pivot 104, and thimble 103 top installs the lower plum blossom head screw 105 of lockable pivot 104, tooling plate 2 is installed on pivot 104 and is adjusted angle through the tightness of lower plum blossom head screw 105, namely after loosening lower plum blossom head screw 105, pivot 104 can rotate in thimble 103, contrarily, after tightening lower plum blossom head screw 105, avoid pivot 104 to rotate in thimble 103, support assembly 1 rear side's middle position is installed lifting structure 3, and the both sides of support assembly 1 rear side are installed detection electric cabinet 4 in lifting structure 3, and the front of lifting structure 3 is provided with the transverse beam 5 of up and down movement, and the upper of transverse beam 5 is installed rotatable wire stand assembly 6, and wire stand assembly 6 includes sliding block 601, and the lower fixed mounting of sliding block 601 is installed screw rod 602, and screw rod 602 is provided with nut 603, and the inside of sliding block 601 is inserted with steel pipe 604, and the upper of sliding block 601 is installed upper plum blossom head screw 605 of lockable steel pipe 604, and the front end of steel pipe 604 is installed gran head 606, and a plurality of through -holes with the width size slightly greater than sliding block 601 of spacing size are set up on transverse beam 5, and screw rod 602 is inserted into the through -hole and is provided with a nut 603 up and down, and the height of sliding block 601 installation can be changed through the up and down two nuts 603, namely after loosening nut 603, the height of screw rod 602 is adjusted and then is locked to make the height of sliding block 601 change, and sliding block 601 is installed with the height of alternately arranged rotatable steel pipe 604, and signal connecting wire 7 is set up in wire stand assembly 6, and the length size of transverse beam 5 is slightly greater than the length size of tooling plate 2, and the length size of steel pipe 604 is same with the width size of tooling plate 2, and steel pipe 604 is matched with the clearance of sliding block 601, and the length of steel pipe 604 that stretches out to the front can be changed through the tightness of upper plum blossom head screw 605, and the length of steel pipe 604 that stretches out to the front can make signal connecting wire 7 front end when falling down can be connected to each position of tooling plate 2, and lifting structure 3 mainly is by servo motor, screw rod, linear guide and the floating plate of installation on linear guide, and transverse beam 5 is installed in the front of floating plate, and servo motor works through screw rod drive transverse beam 5 up and down movement, and then changes the height of all signal connecting wire 7 to change the distance with tooling plate 2, namely when needing detection, signal connecting wire 7 moves down and then is connected with the integrated cable of whole car, when needing to assemble the integrated cable of whole car, signal connecting wire 7 moves up and lets the working space, and the integrated cable of whole car is made on tooling plate 2, and the front end of different signal connecting wire 7 is installed different connector that can be connected with the integrated cable of whole car, and the length of signal connecting wire 7 front end that falls down can be changed through the tightness of gran head 606,The rear end of the signal connection cable 7 is connected to the detection control box 4, and a certain length is reserved to allow for vertical movement without pulling. Therefore, the integrated vehicle cable fabricated on the tooling plate 2 does not need to be transported to a specialized testing facility and can be tested on-site.
[0022] In use, workers first fabricate cables on fixture plate 2 according to traditional manufacturing processes. During this process, the operator can adjust the tilt angle of fixture plate 2 according to the cable condition and their own operating habits. At the same time, lifting structure 3 raises the cable frame assembly 6 to its highest point to prevent the downward-hanging signal connection cable 7 from interfering with the operator's operation. After the cable fabrication is completed, all the clips securing the cable harness should not be loosened. Only the plugs facing the fixture plate 2 should be loosened to facilitate connection with the signal connection cable 7. The height of the cable frame assembly 6 is further adjusted by lifting structure 3 so that the operator can directly touch the cable frame assembly 6. Then, the connectors at the front end of the signal connection cable 7 are connected one by one to the connectors on the cable. All signal connection cables 7 should be vertically downwards to be directly connected to the cable connectors that need to be connected. If they cannot be directly connected, they should be loosened. Open nuts 603, gland 606, and screws 605 to change the downward position of the signal connection cable 7. If it still cannot be directly connected, the tilt angle of the tooling plate 2 can be adjusted to make it more horizontal, or the cable frame assembly 6 can be removed and its installation position on the crossbeam 5 can be changed. The number and position of the cable frame assembly 6, the downward distance of the signal connection cable 7 and the connector at the front end, and the wiring inside the control box 4 are all arranged in advance according to the produced circuit. After all the lines and connectors that need to be tested are connected to the signal connection cable 7, the continuity, withstand voltage, current and other data of the circuit can be tested. If all are qualified, the test is completed. Then disconnect all connections, raise the cable frame assembly 6 and remove the cable. If the test fails, stop the test and repair directly.
[0023] In summary, this new energy vehicle wiring harness testing system integrates cable fabrication and testing into a single workstation by fixing the tooling plate 2 and the testing control box 4 to the bracket assembly 1 and adjusting the signal connection line 7 to the lifting structure 3 and the wire frame assembly 6. This allows newly fabricated cables to be directly tested for quality without needing to be moved to other workstations, saving time spent on cable handling and repositioning, thus improving production efficiency. Since the bracket assembly 1, the testing control box 4, and the wire frame assembly 6 integrate cable fabrication and testing into one workstation, and the cable does not need to be removed from the tooling plate 2 during testing, any cable problems can be repaired directly, eliminating the need for labeling, handing over to the fabrication staff, fixing, and then repairing, making repairs more convenient.
[0024] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.
Claims
1. A new energy vehicle wire harness detection system, comprising a support assembly (1), characterized in that: A rotatable tooling plate (2) is installed in front of the bracket assembly (1). A lifting structure (3) is installed in the middle of the rear of the bracket assembly (1). Detection control boxes (4) are installed on both sides of the lifting structure (3) behind the bracket assembly (1). A horizontal beam (5) that can move up and down is set in front of the lifting structure (3). A rotatable wire frame assembly (6) is installed above the horizontal beam (5). The wire frame assembly (6) includes a slider (601). A screw (602) is fixedly installed below the slider (601). A nut (603) is set on the screw (602). A steel pipe (604) is inserted into the slider (601). A Torx head screw (605) that can lock the steel pipe (604) is installed above the slider (601). A gland head (606) is installed at the front end of the steel pipe (604). A signal connection wire (7) is set inside the wire frame assembly (6).
2. The new energy vehicle wire harness detection system according to claim 1, characterized in that: The bracket assembly (1) includes a rectangular base frame (101), a tripod (102) is fixedly installed on the upper sides of both sides of the rectangular base frame (101), a collar (103) is installed on the top of the tripod (102), a rotating shaft (104) is installed between the collars (103), and a lower Torx head screw (105) that can lock the rotating shaft (104) is installed on the top of the collar (103). The tooling plate (2) is installed on the rotating shaft (104) and the angle is adjusted by tightening the lower Torx head screw (105).
3. The new energy vehicle wire harness detection system of claim 1, wherein: The lifting structure (3) is mainly composed of a servo motor, a lead screw, a linear guide rail and a floating plate installed on the linear guide rail. The crossbeam (5) is installed in front of the floating plate. When the servo motor is working, it drives the crossbeam (5) to move up and down through the lead screw.
4. The new energy vehicle wire harness detection system of claim 1, wherein: The crossbeam (5) has multiple through holes with a spacing slightly larger than the width of the slider (601). The screw (602) is inserted into the through holes and a nut (603) is set at the top and bottom. The installation height of the slider (601) can be changed by the two nuts (603). The slider (601) is installed with a rotatable steel pipe (604) at a staggered height.
5. The new energy vehicle wire harness detection system of claim 1, wherein: The length of the crossbeam (5) is slightly larger than the length of the tooling plate (2). The length of the steel pipe (604) is the same as the width of the tooling plate (2). The steel pipe (604) and the slider (601) are fitted with a clearance. The length of the steel pipe (604) extending forward can be changed by adjusting the tightness of the upper Torx head screw (605).
6. The new energy vehicle wire harness detection system of claim 1, wherein: The vehicle integrated cable is made on the tooling plate (2). Different connectors that can be connected to the vehicle integrated cable are installed at the front end of different signal connection lines (7). The length of the front end of the signal connection line (7) hanging down can be changed by tightening and loosening the gland (606). The rear end of the signal connection line (7) is connected to the detection control box (4) and a certain length is reserved to achieve up and down movement to avoid pulling.