Plug-in harness mechanism for vehicle lamp assembly test

Abstract

The utility model discloses a kind of plug-in wiring harness mechanisms for vehicle light assembly test, comprising: assembly test rack, the fixed square plate for being turned over after being fixed to vehicle light is evenly equipped in the middle position of two side walls inside assembly test rack, the fixed square plate on the one side of assembly test rack is equipped with turnover drive mechanism, the turnover drive mechanism is used to turn over positioning for the vehicle light after being placed positioning, through the synergistic effect of pneumatic positioning clamp seat A, B and top tight seat, it can be realized to the multi-dimensional accurate positioning of vehicle light shell, avoid millimeter level positioning error produced by artificial operation, prevent wiring harness plug and interface misplacement damage;The clamping and positioning groove cooperation clamping mode, ensure that vehicle light is not deviated during plug-in wiring harness, effectively guarantee the reliability of electrical connection, reduce the product damage rate caused by assembly error.

Description

Technical Field

[0001] This utility model belongs to the field of vehicle lamp assembly technology, specifically relating to a plug-in harness mechanism for vehicle lamp assembly testing. Background Technology

[0002] In automotive lighting manufacturing, the precision and stability of wiring harness assembly are crucial for ensuring electrical safety. Traditional methods face multiple bottlenecks: manual positioning errors often lead to millimeter-level deviations, causing misalignment and damage to the wiring harness plug and interface; fixed fixtures lack flexibility, requiring frequent tooling changes when changing vehicle models, resulting in low efficiency and a tendency to develop micro-cracks due to incompatibility with curved lamp housings; insufficient stress control of the wiring harness, with redundant or taut conditions easily causing terminal fatigue wear; and the lack of integrated flipping and positioning functions, with manual operation easily damaging aligned components, significantly impacting assembly efficiency and reliability. Utility Model Content

[0003] The purpose of this utility model is to provide a plug-in harness mechanism for vehicle lamp assembly and testing, so as to solve the problems mentioned in the background art.

[0004] To achieve the above objectives, this utility model provides the following technical solution: a plug-in harness mechanism for vehicle lamp assembly and testing, comprising:

[0005] An assembly test frame is provided, with a fixing square plate in the middle of both sides of the inner side wall of the assembly test frame for flipping the vehicle light after it is fixed. A flipping drive mechanism is provided on the fixing square plate on one side of the assembly test frame. The flipping drive mechanism is used to flip and position the vehicle light after it has been placed and positioned.

[0006] The assembled flip light frame has a "W" shaped support structure. The front and rear sides of the middle of the assembled flip light frame are respectively provided with a pneumatic positioning clamp A for positioning one side of the middle of the headlight housing and a clamping seat for tightening the headlight housing after positioning. The four corners on both sides of the end of the assembled flip light frame are provided with a pneumatic positioning clamp B for positioning each side of the headlight housing.

[0007] Preferably, the bottom of the pneumatic positioning clamp B is provided with a fixing seat fixed to the four sides of the end of the assembled flip lamp holder, and an elastic telescopic top rod is provided at equal intervals through the inner side of one end of the assembled flip lamp holder.

[0008] Preferably, the assembled flip lamp holder has a cylinder on the side of its end. The cylinder is fixed to one side of the pneumatic positioning clamp A and pneumatic positioning clamp B, and is fixed to one side of the end of the fixed seat. It is used to cooperate in positioning and clamping the vehicle lamp. The top of the piston rod of the cylinder is movably connected to a semi-circular arc-shaped clamping plate through a hinge seat.

[0009] Preferably, a fixed block is provided on one side of the piston rod at the end of the cylinder, the fixed block is used to position the stroke of the clamping plate during the clamping movement; a guide positioning groove is provided on one side of the fixed block, the guide positioning groove is open at both ends, and is used to move the clamping plate inside it to clamp the vehicle light.

[0010] Preferably, the inner side of the guide positioning groove has an L-shaped structure, and the piston rod of the cylinder moves vertically up and down in the guide positioning groove, driving the clamping plate to be movably connected in the guide positioning groove through the hinge seat, and using the cylinder thrust to move to one side of the positioning groove end of the pneumatic positioning clamping seat A and the pneumatic positioning clamping seat B to clamp the vehicle light.

[0011] Preferably, the pneumatic positioning clamps B and A at the four corners of the assembled flip lamp holder are provided with positioning grooves that are the same shape as the positioning position of the vehicle lamp. The clamping plate enters from one side of the positioning groove under the push of the cylinder and clamps the vehicle lamp in the positioning groove by cooperating with the positioning groove.

[0012] Preferably, the flipping drive mechanism includes a servo motor disposed outside a fixed square plate on one side inside the assembly and testing frame. The shaft of the servo motor rotates through the fixed square plate and is fixed at the center position of one end of the assembly flipping lamp holder. A central spindle is fixed at the center point of the surface of the other end of the assembly flipping lamp holder. The central spindle is positioned in a groove opened in the fixed square plate on the other side inside the assembly and testing frame. When the servo motor drives the assembly flipping lamp holder to flip, the central spindle provides support and assists in rotation.

[0013] Preferably, the end of the clamping seat is provided with a positioning clamping groove with one side open, and a clamping cylinder is provided on the outer side of the clamping seat. The clamping cylinder is used to clamp the headlight position located in the positioning clamping groove.

[0014] Compared with the prior art, the technical effects and advantages of this utility model are as follows:

[0015] Through the coordinated action of pneumatic positioning clamps A and B and the clamping seat, multi-dimensional precise positioning of the headlight housing can be achieved, avoiding millimeter-level positioning errors caused by manual operation and preventing damage from misalignment of the wiring harness plug and interface; the clamping method of the clamping plate and the positioning groove ensures that the headlight is stable and does not shift during the wiring harness connection process, effectively ensuring the reliability of the electrical connection and reducing the product damage rate caused by assembly errors.

[0016] The "W"-shaped structure and flexible telescopic top rod design of the assembled flip-up light bracket can be adapted to the curved light housings of different vehicle models, reducing the frequency of tooling changes and significantly improving production efficiency. The integrated flip-up drive mechanism is driven by a servo motor, replacing manual flip-up operations, avoiding damage to aligned components, and realizing automatic flip-up positioning of the vehicle lights. Combined with the cylinder clamping function, it greatly improves the automation level of the assembly process and effectively solves problems such as insufficient wire harness stress control and lack of flip-up positioning function in traditional methods. Attached Figure Description

[0017] Figure 1 This is a front view of the plug-in harness mechanism for vehicle lamp assembly and testing according to this utility model;

[0018] Figure 2 This is a schematic diagram of assembling the flip lamp holder according to the present invention;

[0019] Figure 3 This is a schematic diagram of the pneumatic positioning clamp A of this utility model;

[0020] Figure 4 This is an exploded view of the pneumatic positioning clamp A of this utility model;

[0021] Figure 5 This is a schematic diagram of the clamping seat of this utility model.

[0022] In the diagram: 1. Assembly test frame; 2. Fixed square plate; 3. Tilting drive mechanism; 4. Assembly tilting lamp holder; 5. Pneumatic positioning clamp A; 6. Tightening seat; 7. Pneumatic positioning clamp B; 8. Fixed seat; 9. Cylinder; 10. Clamping plate; 11. Fixed block; 12. Guide positioning groove; 13. Positioning groove; 14. Servo motor; 15. Central spindle; 16. Positioning and tightening groove; 17. Push rod; 18. Tightening cylinder. Detailed Implementation

[0023] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0024] Please see Figure 1-5 This utility model provides a technical solution: a plug-in harness mechanism for vehicle lamp assembly and testing, comprising:

[0025] The assembly and testing frame 1 serves as the foundational support frame for the entire mechanism, supporting all core components and providing a stable working platform. Two fixing plates 2 are symmetrically distributed on the inner side walls of the assembly and testing frame 1, positioned at the midpoint of each side wall. These plates are perpendicularly fixed to the side walls of the assembly and testing frame 1, and their stability is ensured through bolt connections or welding. A flipping drive mechanism 3 is installed on one side of the fixing plate 2 of the assembly and testing frame 1. This mechanism flips and positions the positioned vehicle light, thus meeting the requirements of different processes for the light's posture.

[0026] The assembled flip-up light bracket 4 features a "W"-shaped support structure. This unique design provides multi-directional support points for the headlight, adapting to the shape and size of various car headlight models. The front and rear sides of the assembled flip-up light bracket 4 are equipped with pneumatic positioning clamps A5 for positioning one side of the headlight housing, and clamping seats 6 for securing the headlight housing after positioning. The pneumatic positioning clamps A5, through built-in pneumatic components, can quickly position and clamp the headlight housing upon receiving a control signal. After the initial positioning by the pneumatic positioning clamps A5, the clamping seats 6 are activated by an external control unit to trigger a clamping cylinder, firmly clamping the headlight housing in a preset position. At the four corners on both sides of the assembled flip-up light bracket 4, pneumatic positioning clamps B7 are located for positioning each side of the headlight housing. These pneumatic positioning clamps B7 work in conjunction with the pneumatic positioning clamps A5 to accurately position the headlight housing from multiple directions, ensuring the headlight remains stable during assembly and testing.

[0027] The bottom of the pneumatic positioning clamp B7 is equipped with four fixing seats 8 that are fixed to the four sides of the end of the assembled flip lamp holder 4. The fixing seats 8 are tightly connected to the end of the assembled flip lamp holder 4 by welding or high-strength bolts, providing a stable installation base for the pneumatic positioning clamp B7. Elastic telescopic top rods 17 are equidistantly inserted through the inner side of one end of the assembled flip lamp holder 4. The top rods 17 use springs or other elastic elements as the driving source, and can automatically extend and retract according to the curvature of the lamp surface during lamp placement, providing flexible support and avoiding damage to the lamp surface.

[0028] A cylinder 9 is installed on the side of the end of the assembled flip-up lamp holder 4. The cylinder 9 is fixed to one side of the pneumatic positioning clamp A5 and pneumatic positioning clamp B7, and also to one side of the end of the fixed seat 8. It is connected to the fixed seat 8 through a specially designed mounting bracket to ensure a firm installation. The cylinder 9 is used to position and clamp the vehicle lamp. The top of its piston rod is movably connected to a semi-circular clamping plate 10 through a hinge seat. The design of the hinge seat allows the clamping plate 10 to rotate flexibly to adapt to clamping requirements at different angles.

[0029] A stationary block 11 is provided on one side of the piston rod at the end of cylinder 9. The stationary block 11 is fixed to the side of cylinder 9 by bolts and is used to position the clamping plate 10 during the clamping movement. A guide positioning groove 12 is provided on one side of the stationary block 11. The guide positioning groove 12 is open at both ends and is used to allow the clamping plate 10 to move inside it to clamp the vehicle light. The guide positioning groove 12 provides a precise guide path for the movement of the clamping plate 10, ensuring that the clamping plate 10 moves stably and is accurately positioned during the clamping process.

[0030] The inner side of the guide positioning groove 12 has an L-shaped arc structure. This special shape design matches the movement trajectory of the clamping plate 10. The piston rod of the cylinder 9 moves vertically up and down within the guide positioning groove 12, causing the clamping plate 10 to move within the guide positioning groove 12 via a hinge seat. Using the thrust of the cylinder 9, it moves to one side of the positioning groove end of the pneumatic positioning clamp A5 and pneumatic positioning clamp B7 to clamp the vehicle light. During the clamping process, the piston rod of the cylinder 9 pushes the clamping plate 10 along the trajectory of the guide positioning groove 12 until the vehicle light is firmly clamped.

[0031] The pneumatic positioning clamps B7 and A5 at the four corners of the assembled flip lamp holder 4 have positioning grooves 13 with the same shape as the positioning position of the car lamp. This precise shape matching design can effectively improve the positioning accuracy. The clamping plate 10 enters from one side of the end of the positioning groove 13 under the push of the cylinder 9. By cooperating with the positioning groove 13, it clamps the car lamp in the positioning groove 13 to ensure that the car lamp will not move when clamped.

[0032] The drive mechanism 3 includes a servo motor 14 mounted on the outside of a fixed square plate 2 inside the assembly and testing frame 1. The servo motor 14 is fixed to the fixed square plate 2 via a motor mount, and its shaft rotates through the fixed square plate 2 and is fixed at the center of one end of the assembly flip lamp holder 4. Power is reliably transmitted through a coupling and other transmission components. A central spindle 15 is fixed at the center point of the surface of the other end of the assembly flip lamp holder 4. The central spindle 15 is positioned in a groove on the fixed square plate 2 inside the assembly and testing frame 1. The size of the groove is precisely matched with the central spindle 15. When the servo motor 14 drives the assembly flip lamp holder 4 to flip, the central spindle 15 provides support and assists in rotation, ensuring a smooth and stable flipping process.

[0033] The clamping seat 6 has a positioning clamping groove 16 with an open structure on one side at its end. The opening design of the positioning clamping groove 16 facilitates the placement and removal of the vehicle lamp. A clamping cylinder 18 is provided on the outer side of the clamping seat 6. The clamping cylinder 18 is connected to the clamping seat 6 through a mounting bracket and is used to clamp the vehicle lamp positioned in the positioning clamping groove 16. When the vehicle lamp is placed in the positioning clamping groove 16, the clamping cylinder 16 operates, pushing the clamping seat 6 to firmly clamp the vehicle lamp, ensuring that the vehicle lamp remains stable in subsequent processes.

[0034] Considering the need for rapid and stable clamping and positioning of vehicle lights, while adapting to the clamping force requirements of different sized lights, a FESTO DNC series standard cylinder, specifically model DNC-50-50-PPV-A, was selected. This cylinder has a 50mm bore and 50mm stroke, with a maximum theoretical output force of 981N, sufficient to meet the clamping force requirements of vehicle lights. Its double-acting design, combined with a pneumatic control system, enables rapid response. The built-in magnetic ring structure facilitates the installation of an inductive switch to detect piston position, ensuring accurate clamping action. Furthermore, this cylinder possesses corrosion and wear resistance, making it suitable for long-term stable operation in industrial environments.

[0035] To meet the requirements of precision, stability, and response speed for the 3rd stage of the flip drive mechanism, a Mitsubishi HG-KN series servo motor, specifically model HG-KN23J-S100, was selected. This servo motor has a rated power of 200W and a rated speed of 3000r / min, providing stable torque output to drive the assembled flip lamp holder to achieve a 180° flip. Its encoder resolution reaches 262144 pulses / revolution, ensuring the flip angle control accuracy is within ±0.0014°. It supports three control modes: position, speed, and torque, and the flip speed and angle can be flexibly adjusted via PLC programming. The motor is equipped with a braking device that can quickly lock the shaft in case of power failure or emergency, preventing accidental rotation of the assembled flip lamp holder and ensuring the safety of equipment and personnel.

[0036] Specifically, in use, the multi-dimensional positioning and clamping principle is as follows: The headlight is placed on the "W"-shaped structure of the assembled flip-up headlight bracket 4. The pneumatic positioning clamps A5 and B7 initially position the center and sides of the headlight housing through the positioning groove 13. Subsequently, the clamping cylinder 18 of the clamping seat 6 drives the positioning clamping groove 16 to further fix the headlight. At the same time, the cylinder 9 pushes the clamping plate 10 to move along the guide positioning groove 12 (L-shaped structure) of the fixed block 11, entering from one side of the end of the positioning groove 13 and clamping the headlight in accordance with the shape of the groove, forming a multi-dimensional precise positioning and stable clamping to ensure no deviation when plugging in the wiring harness.

[0037] Adaptive flexible support principle: The elastic telescopic top rod 17 at the end of the assembled flip lamp holder 4 provides elastic support when the lamp is placed, which can adapt to the contour of the curved lamp housing of different models and avoid damage to the lamp housing caused by rigid contact. At the same time, the cylinder 9 on the fixing seat 8 works in concert with the clamping plate 10 to achieve flexible clamping of lamps of different sizes by adjusting the cylinder thrust, eliminating the need for frequent tooling changes and significantly improving the versatility and production efficiency of the mechanism.

[0038] Integrated flip-up drive principle: Servo motor 14 drives the rotating shaft to rotate the assembled flip-up lamp holder 4 around the central spindle 15, achieving a 180° flip-up positioning of the vehicle lamp (e.g., from the wiring harness insertion station to the testing station). The central spindle 15 rolls in the groove of the fixed square plate 2, providing stable support and auxiliary rotation to ensure a smooth and precise flip-up process. This integrated design avoids component misalignment caused by manual flipping. Combined with the positioning and clamping mechanism, it can maintain the precise position of the vehicle lamp after flipping, achieving efficient connection between the wiring harness insertion and testing processes.

[0039] Finally, it should be noted that the above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Although the present utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A connector harness mechanism for vehicle headlight assembly and testing, characterized in that, include: Assembly test frame (1), the middle of the two inner side walls of the assembly test frame (1) is provided with a fixed square plate (2) for fixing the car lamp and driving it to rotate. The fixed square plate (2) on one side of the assembly test frame (1) is provided with a rotating drive mechanism (3). The rotating drive mechanism (3) is used to drive the positioned car lamp to rotate and position it after rotating. Assemble the flip lamp holder (4), which has a "W" shaped support structure. The rear side of the middle part of the assembled flip lamp holder (4) is provided with a pneumatic positioning clamp A (5) for positioning one side of the middle part of the lamp housing, and the front side is provided with a clamping seat (6) for clamping the lamp housing after positioning. Pneumatic positioning clamps B (7) are provided at the two corners of both ends of the assembled flip lamp holder (4) for positioning each side of the lamp housing.

2. The plug-in wiring harness mechanism for vehicle lamp assembly testing according to claim 1, characterized in that: The pneumatic positioning clamp B (7) has a fixed seat (8) at the bottom that is fixed to the four sides of the end of the assembled flip lamp holder (4). The inner side of one end of the assembled flip lamp holder (4) is provided with elastic telescopic top rods (17) that are equidistantly inserted.

3. The plug-in wiring harness mechanism for testing an assembly of a vehicle lamp according to claim 1, characterized in that: The assembled flip lamp holder (4) is provided with a cylinder (9) on the side of its end. The cylinder (9) is fixed on one side of the pneumatic positioning clamp A (5) and the pneumatic positioning clamp B (7), and is also fixed on one side of the end of the fixed seat (8). It is used to cooperate in positioning and clamping the car lamp. The piston rod of the cylinder (9) is movably connected to a semi-circular arc-shaped clamp plate (10) through a hinge seat.

4. The plug-in wiring harness mechanism for testing an assembly of a vehicle lamp according to claim 3, characterized in that: The piston rod at the end of the cylinder (9) is provided with a fixed block (11) on one side. The fixed block (11) is used to position the clamping plate (10) during the clamping movement. The fixed block (11) has a guide positioning groove (12) on one side. The guide positioning groove (12) is open at both ends and is used to move the clamping plate (10) inside it to clamp the vehicle light.

5. The plug-in harness mechanism for vehicle lamp assembly and testing according to claim 4, characterized in that: The inner side of the guide positioning groove (12) has an L-shaped structure, and the piston rod of the cylinder (9) moves vertically up and down in the guide positioning groove (12), driving the clamping plate (10) to move in the guide positioning groove (12) through the hinge seat. The cylinder (9) moves to the end of the positioning groove of the pneumatic positioning clamp A (5) and the pneumatic positioning clamp B (7) to clamp the car lamp.

6. The plug-in wiring harness mechanism for testing an assembly of a vehicle lamp according to claim 5, characterized in that: The pneumatic positioning clamps B (7) and A (5) at the four corners of the assembled flip lamp holder (4) are provided with positioning grooves (13) with the same shape as the positioning position of the car lamp. The clamping plate (10) enters from one side of the end of the positioning groove (13) under the push of the cylinder (9) and clamps the car lamp in the positioning groove (13) by cooperating with the positioning groove (13).

7. The plug-in wiring harness mechanism for testing an assembly of a vehicle lamp according to claim 1, characterized by: The flipping drive mechanism (3) includes a servo motor (14) located outside a fixed square plate (2) on one side inside the assembly test frame (1). The rotating shaft of the servo motor (14) rotates through the fixed square plate (2) and is fixed at the center of one end of the assembly flipping lamp holder (4). A central spindle (15) is fixed at the center point of the surface of the other end of the assembly flipping lamp holder (4). The central spindle (15) is positioned in a groove opened on the fixed square plate (2) on the other side inside the assembly test frame (1). When the servo motor (14) drives the assembly flipping lamp holder (4) to flip, the central spindle (15) provides support and assists in rotation.

8. The plug-in wiring harness mechanism for testing an assembly of a vehicle lamp according to claim 1, characterized by: The end of the clamping seat (6) is provided with a positioning clamping groove (16) with an open structure on one side, and a clamping cylinder (18) is provided on the outer side of the clamping seat (6). The clamping cylinder (18) is used to clamp the headlight position located in the positioning clamping groove (16).

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