New energy harness flaw detection and anti-damage sensor

Abstract

The utility model discloses a new energy wire harness flaw detection and anti -damage sensor, including aluminium alloy shell, aluminium alloy shell inside fixedly connected with development board, is provided with the capacitance charge -discharge module, signal acquisition and processing module and communication module in development board, the capacitance charge -discharge module can charge to the capacitor before the skinning machine under the knife, signal acquisition and processing module are electrically connected with the capacitance charge -discharge module, are used for gathering the discharge signal of capacitor and generate discharge process curve, communication module is connected with signal acquisition and processing module and external PLC system respectively, the utility model discloses the pre -flaw detection unit can recognize the insulation layer breakage wire harness before peeling, avoids breakage wire harness to enter subsequent process and leads to short circuit risk, based on 16 high -speed ADC and the high accuracy detection logic of processor, can accurate identification cutter and the touch moment of wire core, through the real -time control cutter action of PLC, thoroughly solve the problem of traditional skinning machine " cut the wire core " or " insulation layer residual ".

Description

Technical Field

[0001] This utility model relates to the field of sensor technology, specifically a sensor for detecting and preventing damage to new energy wiring harnesses. Background Technology

[0002] With the rapid development of the new energy vehicle industry, the processing accuracy of high-voltage wiring harnesses is crucial to the safety of the entire vehicle. However, current new energy wiring harness stripping and inspection technologies suffer from several drawbacks: insufficient detection accuracy and stability; the widespread use of 8-bit ADC chips and ordinary MCUs; low sampling rates; difficulty in capturing instantaneous changes in capacitor discharge; single-point or two-point probe contact; wire core misalignment leading to poor contact; high false positive rate; frequent instances of wire core damage or incomplete stripping; poor adaptability and low changeover efficiency; fixed capacitor capacity and charging circuit parameters; changing wire diameter requires sensor replacement or hardware adjustment, resulting in long changeover times; unsuitable for multi-variety, small-batch production; weak communication and anti-interference capabilities; often supporting only single RS485 communication, unable to interface with workshop MES systems; untraceable inspection data; and lack of interface isolation design, making communication interruptions easily caused by electromagnetic interference. Therefore, those skilled in the art have provided a new energy wiring harness flaw detection and damage prevention sensor to address the problems mentioned in the background. Utility Model Content

[0003] The purpose of this invention is to provide a sensor for detecting and preventing damage to new energy wiring harnesses, 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 new energy wire harness flaw detection and damage prevention sensor includes an aluminum alloy shell and a probe detection module. A development board is fixedly connected inside the aluminum alloy shell. The development board houses a capacitor charging / discharging module, a signal acquisition and processing module, and a communication module. The capacitor charging / discharging module charges the capacitor before the stripper cuts and forms a discharge circuit with the cutter through the probe detection module when the cutter touches the wire core. The signal acquisition and processing module is electrically connected to the capacitor charging / discharging module and is used to acquire the capacitor's discharge signal and generate a discharge process curve. It can also judge the discharge process to determine whether the cutter has touched the wire core. The communication module is connected to both the signal acquisition and processing module and an external PLC system, and is used to send the judgment result of the signal acquisition and processing module to the PLC system via the Modbus communication protocol to control the stripper's cutting action.

[0005] Furthermore, a probe module is fixedly connected to the surface of the aluminum alloy shell. The probe module is used to form an electrical connection with the end of the core of the new energy wiring harness.

[0006] Furthermore, the probe detection module includes at least three sets of elastic beryllium copper probes, which are arranged in a 120° ring.

[0007] Furthermore, the probe detection module also includes a pre-flaw detection unit, which is located at the front end of the elastic beryllium copper probe and is used to detect whether there is any damage to the insulation layer of the new energy wiring harness before stripping.

[0008] Furthermore, the capacitor charging and discharging module includes an adjustable film capacitor and a charging circuit. The adjustable film capacitor has a capacitance range of 0.1-10μF, and the charging circuit uses DC5V / 12V constant voltage charging and is connected in series with a precision adjustable resistor of 1k-100kΩ.

[0009] Furthermore, the signal acquisition and processing module includes a 16-bit high-speed ADC chip and a processor. The 16-bit high-speed ADC chip has a sampling rate of 1kHz and a resolution of 0.1mV.

[0010] Furthermore, the judgment logic of the signal acquisition and processing module is as follows: when the capacitor discharge voltage drops by ≥50% within 10ms, it is determined that the cutter has touched the wire core; when the capacitor discharge voltage drops by ≤10% within 10ms, it is determined that the cutter has not touched the wire core.

[0011] Furthermore, the communication module adopts the Modbus RTU protocol and connects to the PLC system via an RS485 interface, with an adjustable communication rate of 9600-115200bps.

[0012] Furthermore, the communication module is also equipped with a ModbusTCP interface for communicating with the workshop MES system, and the interface of the communication module is equipped with optocoupler isolation with an isolation voltage of 2500Vrms.

[0013] Furthermore, it also includes a human-computer interaction module, which includes an LCD screen and buttons. The LCD screen is used to display the discharge curve, wire diameter parameters and detection status, and the buttons are used to adjust the capacitance and discharge threshold.

[0014] By adopting the above technical solution Compared with the prior art, the beneficial effects of this utility model are: 1. The pre-detection unit can identify wire harnesses with damaged insulation before stripping, preventing damaged wire harnesses from entering subsequent processes and causing short circuit risks. At the same time, based on the high-precision detection logic of the 16-bit high-speed ADC and processor, it can accurately identify the moment of contact between the cutter and the wire core. The PLC controls the cutter action in real time, completely solving the problems of "cutting the wire core" or "insulation residue" in traditional stripping machines. The 0.1-10μF adjustable film capacitors paired with 1k-100kΩ precision adjustable resistors can be adapted to new energy wire harnesses with different wire diameters of 0.5-10mm². Multi-specification wire harness detection can be completed without changing the sensor, improving the efficiency of changeover. The 120° ring-shaped distribution of elastic beryllium copper probes solves the problem of poor contact caused by wire core misalignment, resulting in high detection stability.

[0015] 2. The communication interface features a 2500Vrms optocoupler isolation design, which can resist electromagnetic interference generated by workshop motors, frequency converters, and other equipment, reducing the communication failure rate. The dual interface design of Modbus RTU and Modbus TCP enables real-time control of the peeling machine and uploads test data to the MES system, facilitating production quality traceability and process optimization in the workshop. The LCD screen intuitively displays key test parameters, and the button-type parameter adjustment requires no professional programming skills. Ordinary operators can learn to use it after simple training. The real-time discharge curve display function can also help technicians quickly troubleshoot abnormalities and shorten the fault handling time. Attached Figure Description

[0016] Fig. 1 This is a schematic diagram of the overall structure of a new energy wire harness flaw detection and damage prevention sensor. Fig. 2 This is a schematic diagram of the development board in a new energy wiring harness flaw detection and damage prevention sensor. Fig. 3 This is a flowchart illustrating the operation of a new energy wiring harness flaw detection and damage prevention sensor.

[0017] In the diagram: 1. Aluminum alloy casing; 2. Development board; 3. Capacitor charging and discharging module; 4. Signal acquisition and processing module; 5. Communication module; 6. Probe detection module; 7. Human-computer interaction module. Detailed Implementation

[0018] To make the technical means, creative features, achieved objectives and effects of this utility model easier to understand, the present utility model is further described below in conjunction with specific embodiments. In the description of this utility model, it should be noted that the terms "upper," "lower," "inner," "outer," "front end," "rear end," "both ends," "one end," and "the other end," etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the accompanying drawings and are only for the convenience of describing this utility model and simplifying the description. For those skilled in the art, the specific meaning of the above terms in this utility model can be understood according to the specific circumstances.

[0019] Please see Figs. 1-3This utility model provides an embodiment of a new energy wire harness flaw detection and damage prevention sensor, including an aluminum alloy shell 1 and a probe detection module 6. A development board 2 is fixedly connected inside the aluminum alloy shell 1. The development board 2 contains a capacitor charging / discharging module 3, a signal acquisition and processing module 4, and a communication module 5. The capacitor charging / discharging module 3 can charge the capacitor before the stripper cuts, and when the cutter touches the wire core, it forms a discharge circuit with the cutter through the probe detection module 6. The signal acquisition and processing module 4 is electrically connected to the capacitor charging / discharging module 3, used to acquire the capacitor's discharge signal and generate a discharge process curve, and can judge the discharge process. To determine whether the cutter touches the wire core, the communication module 5 is connected to both the signal acquisition and processing module 4 and the external PLC system. It sends the judgment result from the signal acquisition and processing module 4 to the PLC system via the Modbus communication protocol to control the cutting action of the stripper. A probe module is also fixedly connected to the surface of the aluminum alloy housing 1. This probe module forms an electrical connection with the end of the wire core of the new energy harness. The probe detection module 6 includes at least three sets of elastic beryllium copper probes arranged in a 120° ring. The probe detection module 6 also includes a pre-flaw detection unit, which is located at the front end of the elastic beryllium copper probes and is used to detect whether the wire core is touching the wire core during stripping. The pre-detection system checks for insulation damage in new energy vehicle wiring harnesses. The capacitor charging / discharging module 3 includes an adjustable film capacitor and a charging circuit. The adjustable film capacitor has a capacitance range of 0.1-10μF. The charging circuit uses DC 5V / 12V constant voltage charging and is connected in series with a 1k-100kΩ precision adjustable resistor. The signal acquisition and processing module 4 includes a 16-bit high-speed ADC chip and a processor. The 16-bit high-speed ADC chip has a sampling rate of 1kHz and a resolution of 0.1mV. The judgment logic of the signal acquisition and processing module 4 is as follows: when the capacitor discharge voltage drops by ≥50% within 10ms, it is determined that the cutter has touched the wire core; when… If the capacitor discharge voltage drops by ≤10% within 10ms, it is determined that the cutter did not touch the wire core. After the new energy harness enters the inspection station, the end of its wire core forms an electrical connection with the probe module on the surface of the aluminum alloy shell 1. The probe module has 3 sets of elastic beryllium copper probes distributed in a 120° ring, which can ensure the connection stability of the wire core through multi-point contact. At the same time, the pre-flaw detection unit at the front end of the probe detection module 6 first detects the bundle insulation layer. If the insulation layer is found to be damaged, an early warning signal is directly triggered. Before the stripping machine starts the cutting program, the capacitor charging and discharging module 3 in the development board 2 starts to work: it adopts a DC5V / 12V constant voltage charging circuit with a capacity of 0.The adjustable film capacitor charging circuit, ranging from 1-10μF, uses a 1k-100kΩ precision adjustable resistor connected in series to adjust the charging current according to the wire diameter, adapting to the testing requirements of different wire harness specifications. When the stripping machine's cutter moves towards the wire harness, if the cutter touches the wire core, the wire core forms a closed discharge circuit with the probe detection module 6 through the elastic beryllium copper probe, and the adjustable film capacitor begins to discharge. At this time, the signal acquisition and processing module 4 starts, acquiring the capacitor discharge voltage signal in real time and transmitting the data to the processor. The processor generates a discharge process curve and judges according to preset logic: if the capacitor discharge voltage drops by ≥50% within 10ms, it is determined that the cutter has touched the wire core; if the drop is ≤10%, it is determined that there has been no contact. The pre-flaw detection unit can then proceed with the stripping process. This system identifies damaged insulation in wire harnesses before they are stripped, preventing them from entering subsequent processes and causing short circuits. Simultaneously, based on a 16-bit high-speed ADC and high-precision detection logic from the processor, it accurately identifies the moment the cutter touches the wire core. Real-time PLC control of the cutter's movement completely solves the problems of "cutting the wire core" or "insulation residue" found in traditional wire stripping machines. Adjustable 0.1-10μF film capacitors paired with 1k-100kΩ precision adjustable resistors adapt to new energy wire harnesses with different diameters (0.5-10mm²), allowing for multi-specification wire harness inspection without sensor replacement, improving changeover efficiency. The 120° annular distribution of elastic beryllium copper probes solves the problem of poor contact caused by wire core misalignment, ensuring high detection stability.

[0020] In this embodiment, the communication module 5 uses the Modbus RTU protocol and connects to the PLC system via an RS485 interface. The communication rate is adjustable from 9600 to 115200 bps. The communication module 5 also has a Modbus TCP interface for communication with the workshop MES system. The interface of the communication module 5 is optically isolated with an isolation voltage of 2500 Vrms. It also includes a human-machine interface module 7, which includes an LCD screen and buttons. The LCD screen displays the discharge curve, wire diameter parameters, and detection status. The buttons are used to adjust the capacitance and discharge threshold. The communication module 5 transmits the judgment result to the external PLC system via the Modbus RTU protocol (RS485 interface, adjustable communication rate 9600-115200 bps). The PLC controls the stripping machine's cutting action based on the result (e.g., immediately stopping the cutting when the wire core is touched to avoid damage). Simultaneously, the communication module 5 communicates with the workshop MES system via the Modbus TCP interface to achieve detection... The system allows for the uploading and traceability of test data (discharge curve, wire diameter parameters, and detection status), and features an interface with 2500Vrms optocoupler isolation to resist electromagnetic interference in the workshop. The LCD screen of the human-machine interface module 7 displays the discharge curve, wire diameter parameters, and detection status in real time. Operators can adjust the capacitor capacity (to adapt to different wire diameters) and discharge threshold (to optimize judgment accuracy) via buttons, lowering the professional operation threshold. The 2500Vrms optocoupler isolation design of the communication interface can resist electromagnetic interference generated by workshop motors, frequency converters, and other equipment, reducing the communication failure rate. The dual interface design of Modbus RTU and Modbus TCP enables both real-time control of the peeling machine and uploading of test data to the MES system, facilitating production quality traceability and process optimization in the workshop. The LCD screen intuitively displays key test parameters, and button-based parameter adjustment requires no professional programming skills; ordinary operators can learn to operate the system after simple training. The real-time discharge curve display function also helps technicians quickly troubleshoot test anomalies, shortening fault handling time.

[0021] After the new energy wiring harness enters the inspection station, the end of its wire core forms an electrical connection with the probe module on the surface of the aluminum alloy shell 1. Three sets of elastic beryllium copper probes arranged in a 120° ring within the probe module ensure the stability of the wire core connection through multi-point contact. Simultaneously, the pre-flaw detection unit at the front end of the probe inspection module 6 first inspects the bundle insulation layer. If insulation damage is detected, a warning signal is directly triggered. Before the stripping machine starts its cutting procedure, the capacitor charging and discharging module 3 in the development board 2 begins operation: it uses a DC 5V / 12V constant voltage charging circuit to charge an adjustable film capacitor with a capacity of 0.1-10μF. The 1k-100kΩ precision adjustable resistor connected in series in the circuit can adjust the charging current according to the wire diameter of the harness, adapting to the inspection requirements of different specifications of wiring harnesses. When the stripping machine's cutter moves towards the wiring harness, if the cutter touches the wire core, the wire core forms a closed discharge circuit with the probe inspection module 6 through the elastic beryllium copper probe, and the adjustable film capacitor begins to discharge. At this time, the signal acquisition and processing module 4 starts, acquiring the capacitor discharge voltage signal in real time and transmitting the data. The data is sent to the processor, which generates a discharge process curve and judges according to preset logic: if the capacitor discharge voltage drops by ≥50% within 10ms, it is determined that the cutter has touched the wire core; if the drop is ≤10%, it is determined that there has been no contact. The communication module 5 transmits the judgment result to the external PLC system via the Modbus RTU protocol (RS485 interface, communication rate adjustable from 9600-115200bps). The PLC controls the stripping machine's cutting action according to the result (if the cutter touches the wire core, it stops immediately to avoid damage). At the same time, the communication module 5 communicates with the workshop MES system through the Modbus TCP interface to realize the uploading and traceability of detection data (discharge curve, wire diameter parameters, detection status). The interface is equipped with 2500Vrms optocoupler isolation to resist electromagnetic interference in the workshop. The LCD screen of the human-machine interaction module 7 displays the discharge curve, wire diameter parameters and detection status in real time. Operators can adjust the capacitor capacity (to adapt to different wire diameters) and discharge threshold (to optimize judgment accuracy) through buttons, reducing the professional operation threshold.

[0022] The pre-detection unit can identify wire harnesses with damaged insulation before stripping, preventing damaged wire harnesses from entering subsequent processes and causing short circuit risks. Simultaneously, based on a 16-bit high-speed ADC and high-precision detection logic from the processor, it can accurately identify the moment the cutter touches the wire core. The PLC controls the cutter's movement in real time, completely solving the problems of "cutting the wire core" or "insulation residue" in traditional stripping machines. 0.1-10μF adjustable film capacitors paired with 1k-100kΩ precision adjustable resistors can adapt to new energy wire harnesses with different wire diameters of 0.5-10mm², completing multi-specification wire harness inspection without sensor replacement, improving changeover efficiency. The 120° annular distribution of elastic beryllium copper probes solves... The system effectively addresses contact issues caused by wire core misalignment, ensuring high detection stability. Its 2500Vrms optocoupler isolation design for the communication interface resists electromagnetic interference from workshop motors, frequency converters, and other equipment, reducing communication failure rates. The dual Modbus RTU and Modbus TCP interface design enables real-time control of the stripping machine and uploads detection data to the MES system, facilitating production quality traceability and process optimization in the workshop. The LCD screen intuitively displays key detection parameters, and button-based parameter adjustment requires no professional programming skills; ordinary operators can learn quickly with simple training. The real-time discharge curve display function also helps technicians quickly troubleshoot abnormalities, shortening fault handling time.

[0023] This specification describes embodiments, but not every embodiment contains only one independent technical solution. This way of describing the specification is only for clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A sensor for flaw detection and damage prevention in new energy wiring harnesses, characterized in that, The device includes an aluminum alloy shell (1) and a probe detection module (6). A development board (2) is fixedly connected inside the aluminum alloy shell (1). The development board (2) is equipped with a capacitor charging and discharging module (3), a signal acquisition and processing module (4), and a communication module (5). The capacitor charging and discharging module (3) can charge the capacitor before the peeling machine cuts, and can form a discharge circuit with the cutter through the probe detection module (6) when the cutter touches the wire core. The signal acquisition and processing module (4) is electrically connected to the capacitor charging and discharging module (3) and is used to collect the discharge signal of the capacitor and generate a discharge process curve. It can also judge the discharge process to determine whether the cutter touches the wire core. The communication module (5) is connected to the signal acquisition and processing module (4) and an external PLC system respectively. It is used to send the judgment result of the signal acquisition and processing module (4) to the PLC system through the Modbus communication protocol to control the cutting action of the peeling machine.

2. The new energy wiring harness flaw detection and damage prevention sensor according to claim 1, characterized in that, The aluminum alloy shell (1) is also fixedly connected to a probe module, which is used to form an electrical connection with the end of the core of the new energy harness.

3. The new energy wiring harness flaw detection and damage prevention sensor according to claim 2, characterized in that, The probe detection module (6) includes at least 3 sets of elastic beryllium copper probes, which are arranged in a 120° ring.

4. The new energy wiring harness flaw detection and damage prevention sensor according to claim 2, characterized in that, The probe detection module (6) also includes a pre-flaw detection unit, which is set at the front end of the elastic beryllium copper probe and is used to detect whether the insulation layer of the new energy wire harness is damaged before stripping.

5. A new energy wiring harness flaw detection and damage prevention sensor according to claim 1, characterized in that, The capacitor charging and discharging module (3) includes an adjustable film capacitor and a charging circuit. The adjustable film capacitor has a capacitance range of 0.1-10μF. The charging circuit uses DC5V / 12V constant voltage charging and is connected in series with a precision adjustable resistor of 1k-100kΩ.

6. The new energy wiring harness flaw detection and damage prevention sensor according to claim 1, characterized in that, The signal acquisition and processing module (4) includes a 16-bit high-speed ADC chip and a processor. The sampling rate of the 16-bit high-speed ADC chip is 1kHz and the resolution is 0.1mV.

7. A new energy wiring harness flaw detection and damage prevention sensor according to claim 1, characterized in that, The judgment logic of the signal acquisition and processing module (4) is as follows: when the capacitor discharge voltage drops by ≥50% within 10ms, it is determined that the cutter touches the wire core; when the capacitor discharge voltage drops by ≤10% within 10ms, it is determined that the cutter does not touch the wire core.

8. A new energy wiring harness flaw detection and damage prevention sensor according to claim 1, characterized in that, The communication module (5) adopts the Modbus RTU protocol and is connected to the PLC system through the RS485 interface. The communication rate is adjustable from 9600 to 115200 bps.

9. A new energy wiring harness flaw detection and damage prevention sensor according to claim 1, characterized in that, The communication module (5) is also equipped with a ModbusTCP interface for communicating with the workshop MES system, and the interface of the communication module (5) is equipped with optical isolation with an isolation voltage of 2500Vrms.

10. A new energy wiring harness flaw detection and damage prevention sensor according to claim 1, characterized in that, It also includes a human-computer interaction module (7), which includes an LCD screen and buttons. The LCD screen is used to display the discharge curve, wire diameter parameters and detection status, and the buttons are used to adjust the capacitance and discharge threshold.

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