High-voltage wire harness mistake-proofing tool

Abstract

The utility model discloses a kind of high-voltage wiring harness mistake-proof tool, including the plug-in module on substrate, pneumatic lock module, alarm module and control module.The plug-in module has connector installation groove, probe and pilot lamp, probe detects the installation in place condition of wiring harness terminal and connector, back pull confirmation operation and plug-in sequence correctness, pilot lamp corresponding display these states;The lock bolt of pneumatic lock module can lock or unlock connector, terminal sequence error is kept locked;Alarm module shows plug-in sequence error;Control module is electrically connected each module.This high-voltage wiring harness mistake-proof tool, by setting plug-in module, pneumatic lock module, alarm module and control module cooperation, terminal plug-in state can be effectively detected and forced to guide staff to carry out effective back pull confirmation, guarantee terminal plug-in state qualified, avoid the emergence of terminal falling adverse phenomenon, for the assembly of automobile battery pack Use to exclude safety hazard.

Description

Technical Field

[0001] This utility model relates to the field of wire harness processing and manufacturing technology, and in particular to a high-voltage wire harness error prevention tooling. Background Technology

[0002] In recent years, my country's new energy vehicle industry has developed rapidly. By 2025, the industry will usher in new opportunities through technological breakthroughs, market expansion, and international competition, promoting high-quality and sustainable development and accelerating the construction of a strong automotive nation. China's new energy vehicle industry is experiencing strong growth, with rapid development in vehicle matching, technology research and development, and the new energy vehicle consumer market. As an emerging field, with continuous improvements in technology research and development, the three-electric system (battery, motor, and electronic control system) occupies a primary position in new energy vehicles, and the battery pack has become the foundation. As a major component of new energy vehicles, the electrical performance of the battery pack is a key performance indicator to ensure a stable working environment. Since there are many connectors in the battery pack, the effectiveness of the mating contact between the female and male connector terminals becomes crucial.

[0003] In a battery pack, if either the female or male terminal is partially inserted, poor contact will occur after assembly due to the terminal coming loose, preventing the battery pack from supplying power and affecting the vehicle's starting and operation. If the terminal is completely detached, the vehicle will not start, severely impacting its use. Furthermore, detached terminals can also cause short circuits or open circuits, increasing safety hazards during vehicle operation. Short circuits can lead to serious consequences such as fires or explosions, threatening passenger and vehicle safety. For equipment, detached terminals prevent the battery from supplying power, causing electronic devices in the vehicle to malfunction or even be damaged. Currently, most wiring harness manufacturers use traditional manual connector insertion, relying solely on operators to check for proper insertion by pulling back the connector. This over-reliance on employee experience and technique, coupled with high production volumes, makes it possible to overlook this check. If a terminal is not properly inserted and the check is missed, it is difficult to detect, often resulting in the risk of some terminals becoming detached. Utility Model Content

[0004] This utility model provides a high-voltage wiring harness error prevention tooling to overcome the above-mentioned problems.

[0005] To achieve the above objectives, the technical solution of this utility model is as follows:

[0006] A high-voltage wiring harness error prevention tooling includes a plug-in module, a pneumatic lock module, an alarm module, and a control module mounted on a base plate;

[0007] The plug-in module includes a connector mounting slot, a probe, and an indicator light. The probe is located at the bottom of the connector mounting slot, and the indicator light is located outside the connector mounting slot, with its position corresponding to the position of the probe. When the connector is installed in the connector mounting slot, the probe is located inside the connector's insertion hole. The probe is used to detect whether the wire harness terminals and the connector are installed in place, whether the wire harness has been pulled back for confirmation after the two are connected, and whether the insertion sequence of the wire harness terminals in the insertion hole is correct. The indicator light is used to display whether the wire harness terminals and the connector are installed in place, whether the wire harness has been pulled back after the two are connected, and whether the insertion sequence of the wire harness terminals is correct.

[0008] The pneumatic lock module includes a locking tongue disposed on one side of the connector mounting slot. One end of the locking tongue is a free end, which can extend to the upper side of the connector mounting slot to lock the connector inside the connector mounting slot. The free end can also move away from the connector mounting slot until it disengages from the upper area of ​​the connector, at which point the connector is in an unlocked state. When the wiring harness terminals are inserted into the plug hole in the wrong order, the locking tongue automatically remains in the locked state.

[0009] The alarm module is used to display whether the insertion sequence of the wire harness terminals in the plug hole is incorrect;

[0010] The control module is electrically connected to the alarm module, the probe, the indicator light, and the latch.

[0011] Furthermore, the probe includes a first probe and a second probe, and the indicator light includes a first indicator light and a second indicator light; when the connector is installed in the connector mounting slot, the first probe and the second probe are respectively located in the first insertion hole and the second insertion hole of the connector, the first indicator light is located next to the first probe, the second indicator light is located next to the second probe, and the insertion sequence of the wire harness terminals is that one wire harness terminal is first inserted into the first insertion hole, and the other wire harness terminal is then inserted into the second insertion hole.

[0012] Furthermore, the pneumatic lock module also includes a lock body and a pneumatic drive device disposed within the lock body;

[0013] The connecting end of the latch is disposed on the lock body and can slide outward or inward within the slide groove of the lock body. The connecting end of the latch is connected to the pneumatic drive device, and the free end of the latch can be driven by the pneumatic drive device to move towards or away from the connector mounting groove.

[0014] Furthermore, the pneumatic lock module also includes a manual unlocking module disposed on the base plate. The manual unlocking module is connected to the pneumatic lock module and is used to manually unlock the lock tongue.

[0015] Furthermore, the pneumatic lock module also includes a pneumatic lock detection probe, which is located on the edge of the connector mounting groove and on the side close to the lock tongue.

[0016] Furthermore, the alarm module is an alarm indicator light.

[0017] Furthermore, the pneumatic drive device is a cylinder, and the piston end of the cylinder is fixedly connected to the connecting end of the locking tongue.

[0018] Furthermore, the substrate is provided with an air passage, one end of which is connected to the cylinder and the other end is connected to an air source, and an electromagnetic valve is provided on the air passage.

[0019] The beneficial effects of this utility model are:

[0020] This utility model discloses a high-voltage wiring harness error prevention tooling. Through the cooperation of a plug-in module, a pneumatic lock module, an alarm module, and a control module, it can effectively detect the terminal plug-in status and force employees to pull back and confirm it. This ensures that only semi-finished products with qualified plug-in status can be taken out from the detection device, thereby ensuring that the terminal plug-in status is qualified and avoiding the defective phenomenon of terminal falling off. This eliminates safety hazards for the assembly and use of automotive battery packs. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 This is a schematic diagram of a high-voltage wire harness error-proof tooling structure disclosed in an embodiment of this utility model (showing part of the connector);

[0023] Figure 2 This is a schematic diagram of a high-voltage wire harness error-proof tooling plug-in module disclosed in an embodiment of the present utility model;

[0024] Figure 3 This is a schematic diagram illustrating the use of a high-voltage wire harness error-proofing tool disclosed in this utility model embodiment. Figure 1 (Full connector shown);

[0025] Figure 4This is a schematic diagram illustrating the use of a high-voltage wire harness error-proofing tool disclosed in this utility model embodiment. Figure 2 ;

[0026] Figure 5 This is a schematic diagram illustrating the use of a high-voltage wire harness error-proofing tool disclosed in this utility model embodiment. Figure 3 .

[0027] In the picture:

[0028] 1. Substrate;

[0029] 2. Plug-in module; 21. Connector mounting slot; 22. First probe; 23. Second probe; 24. First indicator light; 25. Second indicator light;

[0030] 3. Pneumatic lock module; 31. Lock tongue; 32. Lock body; 33. Manual unlocking module; 34. Pneumatic lock detection probe;

[0031] 4. Alarm module;

[0032] 5. Control module;

[0033] 6. Connector; 61. First insertion hole; 62. Second insertion hole;

[0034] 7. Wire harness terminals;

[0035] 8. Wiring harness. Detailed Implementation

[0036] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0037] like Figure 1 The image shows a high-voltage wiring harness error prevention tooling provided in this embodiment, including a plug-in module 2, a pneumatic lock module 3, an alarm module 4, and a control module 5 disposed on a base plate 1;

[0038] The plug-in module 2 includes a connector mounting slot 21, a probe, and an indicator light. The probe is located at the bottom of the connector mounting slot 21, and the indicator light is located outside the connector mounting slot 21 with its position corresponding to the probe position. When the connector 6 is installed in the connector mounting slot 21, the probe is located in the connector's plug hole. The probe is used to detect whether the wire harness terminal 7 and the connector are installed in place, whether the wire harness 8 has been pulled back for confirmation after the two are connected, and whether the plugging sequence of the wire harness terminals in the plug hole is correct. The indicator light is used to display whether the wire harness terminal and the connector are installed in place, whether the wire harness has been pulled back after the two are connected, and whether the plugging sequence of the wire harness terminals is correct.

[0039] The pneumatic lock module 3 includes a locking tongue 31, which is disposed on one side of the connector mounting slot 21. One end of the locking tongue 31 is a free end, which can extend to the upper side of the connector mounting slot 21 to lock the connector inside the connector mounting slot 21. The free end can also move away from the connector mounting slot 21 until it is disengaged from the upper area of ​​the connector, at which point the connector is in an unlocked state. When the wiring harness terminals are inserted into the plug hole in the wrong order, the locking tongue 31 automatically remains in a locked state.

[0040] The alarm module 4 is used to display whether the insertion sequence of the wire harness terminals in the plug hole is incorrect;

[0041] The control module 5 is electrically connected to the alarm module 4, the probe, the indicator light, and the latch 31.

[0042] This utility model discloses a high-voltage wiring harness error-proofing fixture. Through the coordinated use of a plug-in module, a pneumatic lock module, an alarm module, and a control module, it can effectively detect the terminal plug-in status and forcefully guide employees to pull back the terminals for confirmation. This ensures that only semi-finished products with qualified plug-in connections can be removed from the detection device, thereby guaranteeing the qualified terminal plug-in status and preventing terminal detachment. This eliminates safety hazards for the assembly and use of automotive battery packs. This error-proofing fixture is simple and reliable to operate, easy to master, convenient to use, has high detection accuracy, and a mistake-proof function.

[0043] In a specific embodiment, such as Figure 2As shown, the probes include a first probe 22 and a second probe 23, and the indicator lights include a first indicator light 24 and a second indicator light 25. When the connector is installed in the connector mounting slot 21, the first probe 22 and the second probe 23 are respectively located in the first insertion hole 61 and the second insertion hole 62 of the connector. The first indicator light 24 is located next to the first probe 22, and the second indicator light 25 is located next to the second probe 23. The insertion sequence of the wire harness terminals is that one wire harness terminal is first inserted into the first insertion hole 61, and then the other wire harness terminal is inserted into the second insertion hole 62.

[0044] The first probe 22 and the second probe 23 respectively detect whether the wire harness terminal 7 in the nearby plug holes (first plug hole 61 and second plug hole 62) is plugged in properly, and the two probes, together with the first indicator light 24 and the second indicator light 25, can improve the correctness of the order of operation of plugging the two wire harness terminals 7 (the first probe 22 and the second probe 23 are both contact probes, and both are existing technologies).

[0045] The operating steps for this tooling are as follows:

[0046] like Figure 3-5 As shown, the connector to be inserted is first placed in the connector mounting slot 21. At this time, the controller drives the free end of the locking tongue 31 to move upward to the connector mounting slot 21 by controlling the solenoid valve and the pneumatic rod and other driving components, thereby locking the connector in the connector mounting slot 21.

[0047] Then, a wire harness terminal is inserted into the first insertion hole 61 of the connector 6. When the wire harness terminal is inserted into place, the terminal will press against the first probe 22. After the first probe 22 detects that the wire harness terminal is in place, it sends an arrival signal to the control module 5. After receiving the arrival signal, the control module 5 controls the first indicator light 24 to be constantly lit. Due to process requirements (in order to further ensure the connection stability between the wire harness terminal and the connector), after the wire harness terminal 7 is in place, the wire harness needs to be pulled back. When the wire harness has completed the pull-back operation and the pull-back force meets the set value, the wire harness is pulled back. When the value (set to be not less than 15N in this embodiment) is reached, the first probe 22 will detect the pull-back operation and then send a signal indicating that the pull-back is complete to the control module 5. The control module 5 controls the first indicator light 24 to change from a constantly lit state to an off state. At this time, the control module 5 controls the second indicator light 25 to change from an off state to a rapidly flashing state, prompting the operator that the next operation is to insert another wire harness terminal 7 into the second insertion hole 62 of the connector. Then, the operator inserts the terminal of the other wire into the second insertion hole 62 of the connector corresponding to the second indicator light 25. Once in position, the terminal will press against the second probe 23. The second probe 23 detects that the wire harness terminal 7 is in position and sends an arrival signal to the control module 5. After receiving the arrival signal, the control module 5 controls the second indicator light 25 to remain constantly lit. After the wire harness terminal is in position, a pull-back force needs to be applied to the wire harness (pull-back operation). When the wire harness completes the pull-back operation and the pull-back force meets the set value (in this embodiment, the force is not less than 15N), the second probe 23 detects the pull-back operation and sends a pull-back completion signal to the control module 5. 5. Control the second indicator light 25 to change from a constantly lit state to an off state. At this time, the control module 5 controls the air circuit to depressurize by controlling the solenoid valve. The cylinder drives the locking tongue 31 to move away from the connector mounting slot 21, thereby unlocking the connector. If there is no pull-back confirmation or the pull-back force is less than 15N, the indicator light will not turn off, and the locking tongue 31 of the pneumatic lock module 3 will not unlock. The connector and wire harness cannot be removed. The connector with the wire harness inserted can be removed from the connector mounting slot 21, which facilitates the insertion of the next connector with the wire harness. At this point, the entire insertion operation is completed.

[0048] In a specific embodiment, the pneumatic lock module 3 further includes a lock body 32 and a pneumatic drive device disposed in the lock body;

[0049] The connecting end of the latch 31 is disposed on the lock body and can slide outward or inward within the slide groove of the lock body. The connecting end of the latch 31 is connected to the pneumatic drive device, and the free end of the latch 31 can be driven by the pneumatic drive device to move towards or away from the connector mounting groove 21. When the free end of the latch 31 is driven to the upper side of the connector mounting groove 21, it is positioned above the connector, thus locking the connector. When the free end of the latch 31 is driven from the upper side of the connector mounting groove 21 to completely leave the connector mounting groove 21, the connector is unlocked.

[0050] In a specific embodiment, the pneumatic lock module 3 further includes a manual unlocking module 33 disposed on the base plate 1. The manual unlocking module 33 is connected to the pneumatic lock module 3 and is used to manually unlock the lock tongue 31.

[0051] When the wire harness is inserted into the connector in the wrong order, the pneumatic lock module 3 will automatically remain locked. At this time, the pneumatic lock needs to be unlocked by the manual unlocking module 33 to remove the connector from the connector mounting slot 21.

[0052] The manual unlocking module 33 includes a manual lock cylinder, a cam structure, and a linkage structure. Figure 1-2 (Not shown in the image) The cam structure is connected to the manual lock cylinder and the solenoid valve at both ends, and the linkage structure is connected to the manual lock cylinder and the latch 31 at both ends. When the wiring harness is inserted incorrectly into the connector's socket, the control module 5 receives a detection signal from the second probe. The control module 5 controls the solenoid valve to keep the latch 31 locked, preventing the operator from removing the connector from the connector mounting slot 21. Only someone with the manual lock cylinder key can drive the lock cylinder to rotate, switching the solenoid valve state via the cam structure. This first cuts off the air supply to the cylinder, and then pushes the latch 31 back to its original position via the linkage structure, thus achieving manual unlocking. The manual lock cylinder, cam structure, and linkage structure of the manual unlocking module are conventional designs, and their connection to the latch and cylinder is also existing technology. Therefore, their specific structure and working principle will not be described in detail here.

[0053] In a specific embodiment, the pneumatic lock module 3 further includes a pneumatic lock detection probe 34, which is located on the edge of the connector mounting groove 21 and on the side close to the latch 31. The pneumatic lock detection probe 34 is electrically connected to the control module and is used to detect the locking or unlocking status of the pneumatic lock.

[0054] In a specific embodiment, the alarm module 4 is an alarm indicator light. When the wiring harness terminals are inserted in the wrong order, that is, the wiring harness terminals are not inserted into the first insertion hole first, but are directly inserted into the second insertion hole instead of the first insertion hole, the control module 5 receives a signal from the second probe and controls the alarm indicator light to light up, indicating that the wiring harness terminals are inserted in the wrong order in the insertion holes. At the same time, the control module 5 controls the solenoid valve to adjust the air path to a pressure-holding state, that is, the cylinder keeps the free end of the locking tongue 31 extended to the upper side of the connector mounting groove 21, so that the locking tongue 31 is kept in a locked state. At this time, the control module 5 cannot change the locking tongue 31 from the locked state to the unlocked state. Therefore, it can prevent the operator from reworking after the incorrect insertion operation and avoid affecting the product quality.

[0055] In a specific embodiment, the pneumatic drive device is a cylinder, and the piston end of the cylinder is fixedly connected to the connecting end of the locking tongue 31. The cylinder has the characteristics of stable output force, fast response speed and high repeatability of action, which can ensure that the locking tongue 31 accurately completes the locking or unlocking action during the high-voltage wire harness insertion detection process.

[0056] In a specific embodiment, the substrate 1 is provided with an air passage, one end of which is connected to the cylinder and the other end to an air source. An electromagnetic valve is provided on the air passage. The electromagnetic valve has a short switching response time (typically milliseconds), enabling it to quickly feedback detection signals and drive the cylinder to operate. This ensures that the locking tongue 31 immediately performs a locking or releasing action after the terminal insertion state is determined, preventing defective products from flowing into subsequent stages during the detection gap. Controlling the cylinder's action by using a controller to regulate the electromagnetic valve is existing technology; its more specific structure and principle will not be elaborated here.

[0057] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this utility model.

Claims

1. A high-voltage wiring harness error prevention tooling, characterized in that, It includes a plug-in module (2), a pneumatic lock module (3), an alarm module (4), and a control module (5) disposed on the base plate (1); The plug-in module (2) includes a connector mounting slot (21), a probe, and an indicator light. The probe is located at the bottom of the connector mounting slot (21), and the indicator light is located outside the connector mounting slot (21) with its position corresponding to the position of the probe. When the connector (6) is installed in the connector mounting slot (21), the probe is located in the plug hole of the connector. The probe is used to detect whether the wire harness terminal (7) and the connector (6) are installed in place, whether the wire harness (8) has been pulled back to confirm the connection after the two are connected, and whether the plug-in sequence of the wire harness terminal in the plug hole is correct. The indicator light is used to display whether the wire harness terminal and the connector are installed in place, whether the wire harness has been pulled back after the two are connected, and whether the plug-in sequence of the wire harness terminal is correct. The pneumatic lock module (3) includes a locking tongue (31), which is disposed on one side of the connector mounting slot (21). One end of the locking tongue (31) is a free end, which can extend to the upper side of the connector mounting slot (21) to lock the connector in the connector mounting slot (21). The free end can also move away from the connector mounting slot (21) until it is removed from the upper area of ​​the connector. At this time, the connector is in an unlocked state. When the wiring harness terminals are inserted into the plug hole in the wrong order, the locking tongue (31) automatically remains in a locked state. The alarm module (4) is used to display whether the insertion sequence of the wire harness terminals in the plug hole is incorrect; The control module (5) is electrically connected to the alarm module (4), the probe, the indicator light, and the latch (31).

2. The high-voltage wiring harness error prevention tooling according to claim 1, characterized in that, The probes include a first probe (22) and a second probe (23), and the indicator lights include a first indicator light (24) and a second indicator light (25). When the connector (6) is installed in the connector mounting slot (21), the first probe (22) and the second probe (23) are respectively located in the first insertion hole (61) and the second insertion hole (62) of the connector. The first indicator light (24) is located next to the first probe (22), and the second indicator light (25) is located next to the second probe (23). The insertion sequence of the wire harness terminals is that one wire harness terminal is first inserted into the first insertion hole (61), and the other wire harness terminal is then inserted into the second insertion hole (62).

3. The high-voltage wiring harness error prevention tooling according to claim 1, characterized in that, The pneumatic lock module (3) also includes a lock body (32) and a pneumatic drive device disposed in the lock body; The connecting end of the latch (31) is disposed on the lock body (32) and can slide outward or inward in the groove of the lock body (32). The connecting end of the latch (31) is connected to the pneumatic drive device. The free end of the latch (31) can be driven by the pneumatic drive device to move towards or away from the connector mounting groove (21).

4. The high-voltage wiring harness error prevention tooling according to claim 3, characterized in that, The pneumatic lock module (3) also includes a manual unlocking module (33) disposed on the base plate (1). The manual unlocking module (33) is connected to the pneumatic lock module (3) and is used to manually unlock the lock tongue (31).

5. The high-voltage wiring harness error prevention tooling according to claim 1, characterized in that, The pneumatic lock module (3) also includes a pneumatic lock detection probe (34), which is located on the edge of the connector mounting groove (21) and on the side close to the lock tongue (31).

6. The high-voltage wiring harness error prevention tooling according to claim 1, characterized in that, The alarm module (4) is an alarm indicator light.

7. The high-voltage wire harness error prevention tooling according to claim 3, characterized in that, The pneumatic drive device is a cylinder, and the piston end of the cylinder is fixedly connected to the connecting end of the locking tongue (31).

8. The high-voltage wire harness error prevention tooling according to claim 7, characterized in that, The base plate (1) is provided with an air passage. One end of the air passage is connected to the cylinder, and the other end is connected to the air source. An electromagnetic valve is provided on the air passage.

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