Intelligent detection fault early warning wire harness

Abstract

The utility model relates to the technical field of wire harnesses, in particular to an intelligent detection fault early warning wire harness, which comprises an insulating sheath and wires, a plurality of groups of wires are arranged inside the insulating sheath, polyvinyl chloride insulating layers are wrapped outside the wires, and buffer materials are filled between the polyvinyl chloride insulating layers and the insulating sheath. The intelligent detection module is arranged at the top of the insulating sheath, a miniature circuit board is fixedly connected in the intelligent detection module, a control processing unit is arranged in the intelligent detection module, a fault diagnosis algorithm program is arranged in the intelligent detection module, and a communication interface is arranged in the intelligent detection module; and the output ends of the temperature sensor, the current sensor and the voltage sensor are sleeved on the lead. The beneficial effects of the utility model lie in that the intelligent detection module integrates a plurality of sensors, can comprehensively monitor the temperature, current, voltage and other key parameters of the wire harness in real time, can obtain the running state information of the wire harness in time, and greatly improves the operation quality and the use efficiency compared with a traditional device.

Description

Technical Field

[0001] This utility model relates to the field of wire harness technology, and in particular to intelligent fault detection and early warning wire harness. Background Technology

[0002] Wiring harnesses are suitable for use in automobiles, industrial automation equipment, power transmission systems, and other fields.

[0003] The fault warning harness can monitor the harness's operating status in real time, promptly detect potential faults and issue warnings, ensuring the safe and stable operation of the equipment.

[0004] Traditional wire harnesses rely primarily on periodic manual inspections to detect faults, which presents several problems. Firstly, manual inspections cannot provide real-time updates on the harness's operational status, and faults often occur suddenly, making it difficult to detect potential problems in advance. Once a fault occurs, it can lead to equipment downtime, affecting production schedules and even causing safety accidents. Secondly, the causes of wire harness faults are complex and diverse, such as open circuits, short circuits, and poor connections. Manual troubleshooting is difficult, inefficient, and consumes a significant amount of manpower and time. Although some existing wire harnesses have introduced simple detection methods, most can only detect a single type of fault, lacking comprehensiveness and intelligence, and failing to meet the high reliability and safety requirements of modern equipment.

[0005] To address the above issues, we have launched an intelligent fault detection and early warning harness. Utility Model Content

[0006] This utility model discloses an intelligent fault detection and early warning wiring harness, which aims to solve the technical problems in the background art.

[0007] To achieve the above objectives, the present invention adopts the following technical solution:

[0008] The intelligent fault detection and early warning wiring harness includes an insulating sheath and conductors. Multiple sets of conductors are disposed inside the insulating sheath, and each conductor is wrapped with a polyvinyl chloride (PVC) insulation layer. A cushioning material is filled between the PVC insulation layer and the insulating sheath. The harness also includes an intelligent detection module, which is located on top of the insulating sheath and has a micro-circuit board fixedly connected inside. The module contains a control processing unit, a built-in fault diagnosis algorithm, and a communication interface. Temperature, current, and voltage sensors are respectively disposed on the bottom of the micro-circuit board. The output terminals of the temperature, current, and voltage sensors are all sleeved on the conductors. A data transmission line, made of shielded twisted-pair cable, is connected at one end to the micro-circuit board of the intelligent detection module and at the other end to the control processing unit.

[0009] In automated production lines in large factories, temperature sensors, current sensors, and voltage sensors monitor the temperature, current, and voltage data of conductors in real time. The data is transmitted to the control processing unit via data transmission lines, and the fault diagnosis algorithm analyzes the data to detect abnormalities in advance.

[0010] In a preferred embodiment, an audible and visual alarm is fixedly connected to the intelligent detection module. When the control processing unit determines that a fault has occurred in the wiring harness, the audible and visual alarm emits sound and light warning signals.

[0011] If the control processing unit detects an abnormal current in a certain section of the wiring harness and determines that there is a risk of short circuit, it will immediately trigger the sound and light alarm on the intelligent detection module to quickly remind maintenance personnel to check and repair the fault by sound and flashing lights, thus preventing the fault from escalating.

[0012] In a preferred embodiment, a wireless communication module is fixedly connected to the intelligent detection module, and the wireless communication module sends fault information to a mobile terminal or a monitoring center.

[0013] If a widely distributed wiring harness fails, the wireless communication module will send information such as the specific location and type of the fault to the mobile terminal of the maintenance personnel and the monitoring center in real time. This allows staff to grasp the situation immediately without going to the site, quickly formulate a repair plan, and improve maintenance efficiency.

[0014] In a preferred embodiment, both ends of multiple sets of conductors are fixedly connected with connectors.

[0015] Multiple intelligent fault detection and early warning wiring harnesses can be quickly connected using connectors, making installation convenient. At the same time, the connectors ensure the stability of the connection and do not affect the real-time monitoring of the wires by the intelligent detection module, ensuring the safe operation of the entire electrical system.

[0016] In a preferred embodiment, the control processing unit analyzes and processes data using a fault diagnosis algorithm to determine the type and severity of the wiring harness fault.

[0017] When the temperature sensor detects a sudden temperature rise, the control processing unit combines current and voltage data and uses a fault diagnosis algorithm to determine whether the overheating is caused by poor contact or aging of the circuit, and at the same time assesses the severity of the fault, providing an accurate basis for subsequent maintenance.

[0018] In a preferred embodiment, all the wires are constructed with a high-purity oxygen-free copper structure.

[0019] High-purity oxygen-free copper conductors can reduce resistance, decrease power loss and heat generation, and ensure stable equipment operation.

[0020] The intelligent fault detection and early warning wiring harness provided by this utility model has the following advantages:

[0021] In this utility model:

[0022] 1. The intelligent detection module integrates multiple sensors, which can monitor key parameters such as temperature, current and voltage of the harness in real time and comprehensively, and obtain harness operating status information in a timely manner;

[0023] 2. The control processing unit has a built-in fault diagnosis algorithm, which can intelligently analyze the monitoring data, accurately determine the fault type and severity, and issue timely audible, visual and wireless warning signals through the early warning device to achieve early warning of faults and avoid accidents.

[0024] 3. Compared with manual inspection, this wiring harness can quickly and accurately locate faults, greatly shortening the troubleshooting time, improving equipment maintenance efficiency, reducing equipment downtime, and reducing production losses;

[0025] 4. Remote early warning and data interaction are achieved through the wireless communication module, allowing staff to monitor the wiring harness operation status anytime and anywhere, facilitating remote monitoring and management, improving the convenience and intelligence of management, and greatly improving the quality of operation and efficiency compared to traditional devices. Attached Figure Description

[0026] Figure 1 This is a first-view perspective three-dimensional schematic diagram of the intelligent fault detection and early warning wiring harness proposed in this utility model.

[0027] Figure 2 This is a second-view perspective three-dimensional schematic diagram of the intelligent fault detection and early warning wiring harness proposed in this utility model.

[0028] Figure 3 This is a schematic diagram of the conductor structure of the intelligent fault detection and early warning harness proposed in this utility model.

[0029] Figure 4 This is a schematic diagram of the intelligent detection module structure of the intelligent fault detection and early warning harness proposed in this utility model.

[0030] Figure 5 This is an exploded structural diagram of the intelligent fault detection and early warning wiring harness proposed in this utility model.

[0031] Figure 6 This is a side sectional view of the intelligent fault detection and early warning harness proposed in this utility model.

[0032] Figure 7 for Figure 6 Enlarged view of point A in the middle.

[0033] In the attached diagram: 1. Insulating sheath; 2. Wire; 3. Polyvinyl chloride insulation layer; 4. Buffer material; 5. Intelligent detection module; 6. Micro circuit board; 601. Temperature sensor; 602. Current sensor; 603. Voltage sensor; 7. Data transmission line; 8. Audible and visual alarm; 9. Wireless communication module; 10. Connecting connector. Detailed Implementation

[0034] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. The components of the embodiments of this application described and marked in the accompanying drawings can be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely represents selected embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0035] The intelligent fault detection and early warning wiring harness disclosed in this utility model is mainly applied to wiring harness scenarios.

[0036] Reference Figures 1-7 The intelligent fault detection and early warning wiring harness includes an insulating sheath 1 and conductors 2. Multiple sets of conductors 2 are arranged inside the insulating sheath 1. The conductors 2 are all wrapped with a polyvinyl chloride insulation layer 3. A buffer material 4 is filled between the polyvinyl chloride insulation layer 3 and the insulating sheath 1. The harness also includes an intelligent detection module 5, which is located on the top of the insulating sheath 1 and has a micro circuit board 6 fixedly connected inside. It also has a control processing unit, a built-in fault diagnosis algorithm program, and a communication interface. Temperature sensor 601, current sensor 602, and voltage sensor 603 are respectively arranged on the bottom of the micro circuit board 6. The output terminals of temperature sensor 601, current sensor 602, and voltage sensor 603 are all sleeved on the conductors 2. A data transmission line 7 is a shielded twisted pair cable. One end of the data transmission line 7 is connected to the micro circuit board 6 of the intelligent detection module 5, and the other end is connected to the control processing unit.

[0037] In this embodiment, in an automated production line of a large factory, temperature sensor 601, current sensor 602, and voltage sensor 603 monitor the temperature, current, and voltage data of wire 2 in real time and transmit them to the control processing unit through data transmission line 7. After analysis by a fault diagnosis algorithm, abnormal situations are detected in advance.

[0038] In a preferred embodiment, an audible and visual alarm 8 is fixedly connected to the intelligent detection module 5. When the control processing unit determines that the wiring harness has a fault, the audible and visual alarm 8 emits sound and light warning signals.

[0039] In this embodiment: if the control processing unit detects an abnormal current in a certain section of the wiring harness and determines that there is a risk of short circuit, it immediately triggers the sound and light alarm 8 on the intelligent detection module 5, which quickly reminds maintenance personnel to check and repair by means of sound and flashing light, so as to avoid the fault from escalating.

[0040] In a preferred embodiment, a wireless communication module 9 is fixedly connected to the intelligent detection module 5, and the wireless communication module 9 sends fault information to a mobile terminal or a monitoring center.

[0041] In this embodiment, if a widely distributed wiring harness fails, the wireless communication module 9 will send the specific location and type of the fault to the mobile terminal of the maintenance personnel and the monitoring center in real time, so that the staff can grasp the situation immediately without going to the site, quickly formulate a maintenance plan, and improve maintenance efficiency.

[0042] In a preferred embodiment, both ends of the multiple sets of wires 2 are fixedly connected to connectors 10.

[0043] In this embodiment, multiple intelligent fault detection and early warning wire harnesses can be quickly connected through the connector 10, which is convenient to install. At the same time, the connector 10 ensures the stability of the connection and does not affect the real-time monitoring of the wire 2 by the intelligent detection module 5, thus ensuring the safe operation of the entire electrical system.

[0044] In a preferred embodiment, the control processing unit analyzes and processes the data using a fault diagnosis algorithm to determine the type and severity of the wiring harness fault.

[0045] In this embodiment: when the temperature sensor 601 detects a sudden temperature rise, the control processing unit combines current and voltage data and uses a fault diagnosis algorithm to determine whether the overheating is caused by poor contact or by aging of the circuit, and at the same time assesses the severity of the fault, providing an accurate basis for subsequent maintenance.

[0046] In a preferred embodiment, all wires 2 are provided with a high-purity oxygen-free copper structure.

[0047] In this embodiment, the high-purity oxygen-free copper wire 2 can reduce resistance, reduce power loss and heat generation, and ensure stable operation of the equipment.

[0048] Working principle: When using this wire harness, multiple sets of conductors 2 are all equipped with high-purity oxygen-free copper structures to ensure conductivity. The conductors 2 are wrapped with a polyvinyl chloride insulation layer 3, and a buffer material 4 is filled between the polyvinyl chloride insulation layer 3 and the insulation sheath 1 to ensure the insulation and buffering performance of the wire harness. The intelligent detection module 5 has a micro circuit board 6 fixedly connected inside. The micro circuit board 6 has a built-in control processing unit with a built-in fault diagnosis algorithm program and a communication interface. Temperature sensor 601, current sensor 602, and voltage sensor 603 are respectively set on the bottom of the micro circuit board 6, and the output ends of all of them are sleeved on the conductors 2 to monitor the temperature, current, and voltage data of the wire harness in real time. The data transmission line 7 uses shielded twisted pair cable, one end of which is connected to the intelligent detection module 5. The micro circuit board 6 of the detection module 5 is connected to the control processing unit at the other end, transmitting the monitoring data to the control processing unit. The control processing unit analyzes and processes the data using a fault diagnosis algorithm to determine the type and severity of the wiring harness fault. When the control processing unit determines that a wiring harness fault has occurred, the sound and light alarm 8 fixedly connected to the intelligent detection module 5 emits sound and light warning signals to remind the user of the wiring harness fault. The wireless communication module 9 sends the fault information to a mobile terminal or monitoring center to achieve remote monitoring and early warning. Both ends of the multiple sets of wires 2 are fixedly connected to connectors 10 to ensure the electrical continuity of the wiring harness. This achieves intelligent detection, fault early warning, and remote monitoring functions for the wiring harness, ensuring the safety and reliability of the wiring harness in complex environments.

[0049] The above description is merely a preferred embodiment of this utility model, but the protection scope of this utility model is not limited thereto. The substitutions may be replacements of some structures, devices, or method steps, or they may be complete technical solutions. Equivalent substitutions or modifications made based on the technical solution and inventive concept of this utility model should all be covered within the protection scope of this utility model.

Claims

1. An intelligent fault detection and early warning harness, comprising an insulating sheath (1) and a conductor (2), characterized in that, Multiple sets of the aforementioned conductors (2) are all disposed inside the insulating sheath (1), and the exterior of each conductor (2) is wrapped with a polyvinyl chloride insulation layer (3). A cushioning material (4) is filled between the polyvinyl chloride insulation layer (3) and the insulating sheath (1), and the structure also includes: The intelligent detection module (5) is set on the top of the insulating sheath (1), and a micro circuit board (6) is fixedly connected inside and a control processing unit is set inside. It has a built-in fault diagnosis algorithm program and a communication interface. Temperature sensor (601), current sensor (602) and voltage sensor (603) are respectively set on the bottom of the micro circuit board (6). The output terminals of temperature sensor (601), current sensor (602) and voltage sensor (603) are all sleeved on the wire (2). The data transmission line (7) is a shielded twisted pair cable. One end is connected to the micro circuit board (6) of the intelligent detection module (5), and the other end is connected to the control processing unit.

2. The intelligent fault detection and early warning harness according to claim 1, characterized in that, The intelligent detection module (5) is fixedly connected to an audible and visual alarm (8). When the control processing unit determines that the wiring harness has a fault, the audible and visual alarm (8) emits sound and light warning signals.

3. The intelligent fault detection and early warning wiring harness according to claim 1, characterized in that, The intelligent detection module (5) is fixedly connected to a wireless communication module (9), which sends fault information to a mobile terminal or monitoring center.

4. The intelligent fault detection and early warning harness according to claim 1, characterized in that, Both ends of the multiple sets of conductors (2) are fixedly connected with connectors (10).

5. The intelligent fault detection and early warning harness according to claim 1, characterized in that, The control processing unit analyzes and processes data using a fault diagnosis algorithm to determine the type and severity of wiring harness faults.

6. The intelligent fault detection and early warning harness according to claim 1, characterized in that, The conductors (2) are all made of high-purity oxygen-free copper.

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