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CN-121980683-A - Method for tracing crimping quality of automobile wire harness connector and actively inhibiting failure

CN121980683ACN 121980683 ACN121980683 ACN 121980683ACN-121980683-A

Abstract

The invention discloses a crimping quality tracing and failure active suppression method of an automobile wire harness connector, which comprises the steps of digitally modeling and parameter solidification in a crimping process, establishing a process parameter quality index mapping model through process trial production, determining a process parameter interval and a quality judgment threshold value of various products, digitally tracing the crimping quality in a whole batch, collecting crimping process data in real time, automatically judging quality grades, generating unique tracing source codes for each connector, realizing whole-flow tracing, actively regulating circuit loads to suppress corrosion and sending early warning when stage fretting corrosion is used, establishing a maintenance evaluation model based on precise maintenance of tracing source data, associating tracing source and early warning information, formulating a hierarchical maintenance strategy, and continuously optimizing the model and the threshold value through a data closed loop. The method has the advantages that the whole batch monitoring of the crimping quality and the active inhibition of failure risk and the accurate formulation of maintenance strategies are realized, and the reliability and the whole life cycle management efficiency of the electrical system are improved.

Inventors

  • XIE KE

Assignees

  • 乐清伟普汽车接插件有限公司

Dates

Publication Date
20260505
Application Date
20260120

Claims (10)

  1. 1. The method for tracing the crimping quality and actively inhibiting the failure of the automobile wire harness connector is characterized by comprising the following steps of: S1, digitally modeling and parameter curing in a crimping process, dividing product types according to core attributes of connectors, collecting a plurality of groups of process parameters and corresponding quality index data through process trial production, constructing a process parameter-quality index mapping model, determining process parameter intervals and quality judgment thresholds of the product types based on the mapping model, and distributing unique process codes for the product types; S2, carrying out sensing integration reconstruction on crimping equipment, collecting crimping process data of each connector in real time, comparing the crimping process data with an optimal technological parameter interval and a quality judgment threshold value in the mapping model, automatically judging the quality grade of each connector, generating and marking a unique tracing code containing a product type, a technological code, crimping time, the quality grade and an equipment number for each connector, and storing the tracing data into a cloud database to realize full-flow tracing; S3, actively suppressing fretting corrosion in the using stage, presetting the critical vibration frequency of fretting corrosion based on the vibration characteristic of the mounting position of the connector, collecting vibration data of the mounting position of the connector in real time through a vehicle-mounted sensing device, comparing the vibration data with the critical vibration frequency, and adjusting the output of a corresponding circuit load through a vehicle-mounted control unit to suppress fretting corrosion and simultaneously send risk early warning information when the vibration data exceeds a critical value; and S4, based on accurate maintenance of the traceable data, constructing a maintenance evaluation model by associating the traceable data of the connector with vibration risk early warning information sent by the vehicle-mounted system, classifying maintenance grades based on the maintenance evaluation model, formulating a corresponding maintenance strategy, and recording maintenance related data into a cloud database after executing maintenance operation to complete data closed loop so as to optimize a mapping model and a critical vibration frequency threshold.
  2. 2. The method for tracing the crimping quality and actively suppressing the failure of the automobile wire harness connector according to claim 1, wherein the core properties of the connector in the step S1 comprise a terminal material and a wire cross-sectional area, the terminal material comprises at least one of brass, phosphor bronze and titanium copper, the process parameters comprise at least wire stripping length, crimping pressure and crimping speed, and the quality indexes comprise at least contact resistance and drawing force.
  3. 3. The method for tracing the crimping quality and actively inhibiting the failure of the automobile wire harness connector according to claim 1 is characterized in that the implementation mode of the process trial production in S1 is that for each product type, a plurality of groups of different parameter combinations are selected in a preset process parameter range for crimping trial production, contact resistance and drawing force data are detected for each group of trial produced connectors respectively, each group of process parameters and corresponding detection data are associated to form a sample data set, and a process parameter-quality index mapping model is built by adopting a data fitting method based on the sample data set.
  4. 4. The method for tracing the crimping quality and actively inhibiting the failure of the automobile wire harness connector according to claim 1 is characterized in that the specific content of the sensing integration modification of the crimping equipment in S2 is that a high-definition industrial camera, a pressure sensor and a displacement sensor are integrated on the automatic crimping equipment, wherein the high-definition industrial camera is used for collecting wire stripping length image data, the pressure sensor is used for collecting crimping pressure curve data, the displacement sensor is used for collecting crimping displacement data, and the crimping process data is the collection of the image data, the pressure curve data and the displacement data.
  5. 5. The method for tracing the crimping quality and actively suppressing the failure of the automobile wire harness connector according to claim 1 is characterized in that the judging rule of the quality grade in the step S2 is that crimping process data completely accords with an optimal process parameter interval and the quality index meets a quality judging threshold, the quality grade is judged to be grade A, crimping process data has slight deviation but the quality index still meets the quality judging threshold, the quality grade is judged to be grade B, crimping process data exceeds the optimal process parameter interval or the quality index does not meet the quality judging threshold, the quality grade is judged to be grade C, and when the tracing data is stored, tracing data corresponding to the grade C connector is required to be marked and a rejection process is triggered.
  6. 6. The method for tracing the crimping quality and actively inhibiting the failure of the automobile wire harness connector according to claim 1 is characterized in that the marking mode of the tracing code in S2 is laser coding, the coding position is the surface of the connector sheath, the original structure and performance parameters of the connector are not changed in the coding process, and the cloud database adopts an encryption storage mode to support the realization of unique query and call of tracing data through the tracing code.
  7. 7. The method for tracing the crimping quality and actively inhibiting the failure of the automobile wire harness connector according to claim 1 is characterized in that the preset mode of the critical vibration frequency in the step S3 is that based on classification of the installation positions of the connector, micro-corrosion degree data of the connector under different vibration frequencies are collected through a bench vibration test, the vibration frequency corresponding to the micro-corrosion degree reaching a preset degradation standard is used as the critical vibration frequency, the installation positions of the connector at least comprise an engine cabin, a cockpit and a chassis, and the different installation positions correspond to different critical vibration frequencies.
  8. 8. The method for tracing the crimping quality and actively inhibiting the failure of the automobile wire harness connector according to claim 1 is characterized in that the specific mode of adjusting the load output of the corresponding circuit in S3 is that the load of the corresponding circuit is temporarily reduced by 10% -20% on the premise of not affecting the operation of the core functions of a vehicle so as to reduce the current density of the contact position of the terminal, the risk early warning information is sent to the background of an automobile enterprise through a vehicle-mounted remote information processing terminal, and the early warning information comprises tracing codes, the installation position and real-time vibration data of the connector.
  9. 9. The method for tracing the crimp quality and actively suppressing failure of an automotive harness connector according to claim 1, wherein the classification rule and the corresponding maintenance policy of the maintenance level in S4 are: (1) The first-level maintenance, namely, the quality grade of the connector is A grade and vibration risk early warning information is avoided, and the maintenance strategy is to clean impurities on the surface of the connector and check the locking state; (2) The second-level maintenance, wherein the quality grade of the connector is B-level, the vibration risk early warning information frequency is 1-3 times, the maintenance strategy is to re-detect the contact resistance of the connector, if the contact resistance meets the preset use threshold, the connector is used continuously, otherwise, the crimping process is re-executed; (3) And (3) three-stage maintenance, wherein the quality grade of the connector is B-stage, the vibration risk early warning information frequency is not lower than 4 times, or the quality grade is C-stage, and the maintenance strategy is to replace the connector integrally.
  10. 10. The method for tracing the crimping quality and actively suppressing the failure of the automobile wire harness connector according to claim 1, wherein the implementation process of the data closed loop in the step S4 is that maintenance grade, maintenance operation content, maintenance effect verification data and failure cause analysis data in a maintenance process are input into a cloud database, parameter correction is carried out on a technological parameter-quality index mapping model based on newly added data every interval preset period, and meanwhile, inching corrosion critical vibration frequency thresholds of connectors at different installation positions are optimized.

Description

Method for tracing crimping quality of automobile wire harness connector and actively inhibiting failure Technical Field The invention relates to the technical field of automobile wire harness manufacturing and maintenance, in particular to a method for tracing the crimping quality and actively inhibiting failure of an automobile wire harness connector. Background The automobile wire harness is a core connecting component of the automobile electrical system, the connector is used as a key node for transmitting signals and electric energy through the wire harness, and the crimping quality of the connector directly determines the stability, reliability and safety of the automobile electrical system. Along with the rapid development of automobiles in the intelligent and electric directions, the number of vehicle-mounted electrical equipment is greatly increased, the use scene of the wire harness connector is more complex, the wire harness connector is required to bear severe environments such as vibration, temperature change and the like in the running process of the automobile, and the high-precision requirement of high-frequency signal transmission is met, so that higher standards are provided for the crimping quality and the reliability of the whole life cycle of the wire harness connector. In the prior art, the crimping quality control of the automobile wire harness connector is mostly dependent on sampling detection after process test, a process parameter range is determined by detecting quality indexes such as contact resistance, drawing force and the like, and then mass production is carried out based on fixed process parameters. However, the control mode has the defects that on one hand, the sampling detection cannot cover the whole batch of products, the crimping quality defect of individual connectors is difficult to find, the accurate record of the crimping process parameters of each connector is lacked, when the quality problem occurs later, the whole process tracing cannot be realized, the problem root is difficult to locate, on the other hand, the determination of the existing process parameters is accumulated depending on experience, the accurate mapping model of the process parameters and the quality index is not constructed, the process parameters are optimized, the data support is lacked, and the connector product requirements of different core properties such as terminal materials and wire cross sections are difficult to adapt. In the use stage of the connector, vibration generated in the running process of the vehicle easily causes fretting abrasion at the joint of the connector terminal and the lead, thereby causing fretting corrosion, causing the problems of increased contact resistance, unstable signal transmission and the like, and causing circuit breaking when serious, and affecting the core function operation of the vehicle. At present, a passive maintenance strategy is adopted for solving the failure problem in the industry, namely, the failure connector is replaced or maintained after the failure occurs, active early warning and suppression cannot be carried out before the failure occurs, and the safety risk in the running process of the vehicle is increased. Meanwhile, most of the existing maintenance strategies are regularly and prophylactically maintained, and the problems of inaccurate maintenance opportunity judgment, unreasonable maintenance resource allocation and excessive maintenance or insufficient maintenance are caused by the fact that the historical data of the crimping quality of the connector and the actual working condition information in the using process are not combined. In addition, in the prior art, crimping quality data, using working condition data and maintenance data are mutually isolated, a complete data closed loop is not formed, crimping process parameters and failure early warning thresholds cannot be reversely optimized through subsequent maintenance data, and therefore iteration optimization capacity of a technical scheme is insufficient. Disclosure of Invention The invention aims to provide a crimping quality tracing and failure active suppression method for an automobile wire harness connector, which aims to solve the problems in the background technology. In order to achieve the purpose, the invention provides the technical scheme that the method for tracing the crimping quality and actively inhibiting the failure of the automobile wire harness connector comprises the following steps: S1, digitally modeling and parameter curing in a crimping process, dividing product types according to core attributes of connectors, collecting a plurality of groups of process parameters and corresponding quality index data through process trial production, constructing a process parameter-quality index mapping model, determining process parameter intervals and quality judgment thresholds of the product types based on the mapping model, and distributing unique proces