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CN-121983828-A - Quick assembly and accurate adaptation method for segmented wire harness connector

CN121983828ACN 121983828 ACN121983828 ACN 121983828ACN-121983828-A

Abstract

The invention relates to the technical field of electrical connection, in particular to a rapid assembly and accurate adaptation method of a segmented wire harness connector, which comprises the following steps of constructing a core algorithm module and outputting algorithm support data; the method comprises the steps of performing modularized parallel pre-assembly, outputting material verification qualified signals, compression joint quality detection data and functional module preassembly positioning data, combining algorithm support data to complete accurate adapting and butting, outputting butting precision data and multi-source error-proofing signals, fusing the algorithm support data, performing full-dimension segmentation calibration optimization, outputting calibration qualified data, collecting the compression joint quality detection data, the butting precision data and the calibration qualified data, and combining the algorithm support data to complete intelligent traceability and predictive maintenance. According to the invention, four large core algorithm modules are constructed to form algorithm support data, a closed-loop technical system is established, the assembly precision and the qualification rate are improved, the maintenance cost is reduced, and the requirements of a high-end electrical system are adapted.

Inventors

  • WU SHANSHAN
  • XIONG GUIRONG

Assignees

  • 乐清市精密电子电器有限公司

Dates

Publication Date
20260505
Application Date
20260129

Claims (10)

  1. 1. The rapid assembly and accurate adaptation method for the segmented wire harness connector is characterized by comprising the following steps of: Building a core algorithm module, and outputting algorithm support data comprising a parameter library, a model and a decision rule; based on the algorithm support data, performing modularized parallel pre-assembly, and outputting a material verification qualification signal, crimping quality detection data and functional module preassembly positioning data; based on the material verification qualified signal and the functional module preassembly positioning data, the algorithm supporting data is combined to finish accurate adapting and butting, and butting precision data and a multi-source error-proofing signal are output; Based on the docking precision data, fusing algorithm support data, executing full-dimension segmentation calibration optimization, and outputting calibration qualified data; and collecting crimping quality detection data, docking precision data and calibration qualified data, combining algorithm support data, completing intelligent traceability and predictive maintenance, outputting a unique traceability code and a fault prediction result, and triggering maintenance early warning.
  2. 2. The method for rapid assembly and precise adaptation of a segmented harness connector according to claim 1, wherein the specific steps of generating algorithm support data are as follows: Building a core algorithm system consisting of a visual guidance accurate positioning algorithm, a dynamic error compensation algorithm, an intelligent crimping parameter optimization algorithm and a multi-mode error-proofing adaptation algorithm; Collecting pixel coordinates of guide key feature points and corresponding mechanical coordinate training data, generating a visual positioning parameter library comprising filtering parameters, feature point matching threshold values and coordinate conversion coefficients after the pixel coordinates and the corresponding mechanical coordinate training data are processed by a visual guide accurate positioning algorithm, and outputting visual positioning parameter library data; Collecting environmental temperature, vibration acceleration, docking depth and corresponding error data in the assembly process as a sample set, inputting a BP neural network of a dynamic error compensation algorithm for training to obtain a weight matrix and offset, constructing an error prediction model, and outputting model parameter data; recording pressure and depth parameters corresponding to qualified crimping through segmented crimping tests of different cable specifications and terminal materials, optimizing and forming an intelligent crimping parameter library stored in a classified mode based on an intelligent crimping parameter optimization algorithm and combining engineering experience values, and outputting crimping parameter library data; based on the qualification judgment standard of mechanical alignment fit degree, visual feature point matching success rate and electrical on-resistance, a confidence threshold value, a conflict coefficient threshold value and decision logic of multi-mode signal fusion are formulated through a multi-mode error-proofing adaptation algorithm, an error-proofing decision rule is formed, and rule data is output; integrating the visual positioning parameter library data, the model parameter data, the crimping parameter library data and the rule data, verifying the consistency and the effectiveness of each part of data through a data verification algorithm, and removing abnormal data to form complete algorithm supporting data.
  3. 3. The method for quickly assembling and accurately adapting the segmented wire harness connector according to claim 2, wherein the multi-mode error-proofing adaptation algorithm adopts a D-S evidence theory to perform multi-source signal fusion decision, and specifically comprises the following steps: Acquiring a mechanical alignment signal, a visual matching signal and an electrical conduction signal which are generated in a precise matching and matching process, and outputting three types of original signal data; Based on three types of original signal data, respectively calculating a corresponding basic probability distribution function of each signal, calculating a distribution value of a mechanical alignment signal based on the fitting degree of a guide key, calculating a distribution value of a visual matching signal based on the matching success rate of characteristic points, calculating a distribution value of an electrical conduction signal based on the detection result of on-resistance, and outputting basic probability distribution data; Based on the basic probability distribution data, carrying out fusion operation by adopting a Dempster combination rule, and outputting comprehensive probability distribution data; Based on the comprehensive probability distribution data, comparing the comprehensive probability value of the adaptive lattice hypothesis proposition with a preset threshold value in algorithm support data, outputting an adaptive lattice judgment result, outputting the butt joint precision data and the multi-source error prevention signal if the adaptive lattice judgment result is qualified, triggering an alarm and terminating the subsequent flow if the adaptive lattice judgment result is unqualified.
  4. 4. The rapid assembly accurate adaptation method of a segmented wire harness connector according to claim 2, wherein the coordinate conversion coefficient is obtained in the process of executing coordinate conversion calibration operation through a vision-guided accurate positioning algorithm, the coordinate conversion calibration uses a hand-eye calibration algorithm to construct a mapping relation between pixel coordinates and mechanical coordinates, and the mapping formula is as follows: , Wherein, the 、 、 Respectively the pixel coordinates of the feature points of the guide key in the image, 、 、 Respectively the mechanical coordinates of the corresponding feature points, To the point of For calibrating the attitude conversion coefficients in the matrix, 、 、 And the calibration matrix is obtained by acquiring at least 10 groups of characteristic point pixel coordinates and corresponding mechanical coordinates at different positions and fitting the characteristic point pixel coordinates and the corresponding mechanical coordinates by a least square method, and the fitted attitude conversion coefficient and translation coefficient are directly used as core coordinate conversion data of a visual positioning parameter library.
  5. 5. The rapid assembly and accurate adaptation method of the segmented wire harness connector according to claim 2, wherein the core calculation logic for constructing the error prediction model is realized by an error compensation amount formula of a dynamic error compensation algorithm, and the specific formula is as follows: , Wherein, the In order to compensate for the amount of dynamic error, Is an input vector, comprising three parameters of ambient temperature, vibration acceleration and docking depth, For the input layer to hidden layer weight matrix, To conceal the layer-to-output layer weight matrix, For the correction weights of the output layer, For the input layer bias vector, In order to conceal the layer bias vector, In order to output the layer offset amount, Activating the function by Sigmoid, and expressing as And training and optimizing the weight matrix and the offset through the collected sample set, and forming error prediction model parameter data after training is completed.
  6. 6. The rapid assembly accurate adapting method of the segmented wire harness connector according to claim 2, wherein the parameter determination and the dynamic optimization of the intelligent crimping parameter library are realized by a PID adjustment formula of an intelligent crimping parameter optimization algorithm, and the specific formula is as follows: , Wherein, the For the crimping pressure adjustment amount at the present time, Is a coefficient of proportionality and is used for the control of the power supply, As an integral coefficient of the power supply, As a result of the differential coefficient, Is the deviation between the actual value and the target value of the crimping pressure at the current moment, Is an integrated value of the deviation amount, Dynamic correction is performed by collecting force and displacement curves in the crimping process in real time for the change rate of the deviation 、 、 The pressure is ensured to be stabilized in an adaptive range, and the corrected proportional coefficient, integral coefficient, differential coefficient and the corresponding pressure target value are included in an intelligent pressure parameter library according to the cable specification and the terminal material classification.
  7. 7. The method for rapid assembly and precise fitting of a segmented harness connector according to claim 2, characterized in that said specific steps of performing modular parallel pre-assembly are as follows: Reading material label information by adopting a wireless radio frequency identification technology, matching the material label information with a preset bill of materials one by one, outputting a material verification qualification signal or an alarm signal, and terminating preassembly when the alarm signal is triggered; Based on the material verification qualified signal, performing cable stripping treatment by an automatic stripping device and a visual detection unit, monitoring the stripping length in real time and controlling the stripping length in a preset error interval, removing a conductor oxide layer by a plasma cleaning device after stripping, and outputting a treated cable assembly; Based on the processed cable assembly, an intelligent crimping parameter optimization algorithm is called, a target pressure value of a conductor crimping area and an insulation crimping area is output, a servo crimping tool is driven to execute segmented crimping, a force and displacement curve is synchronously acquired, curve characteristic parameters are compared with preset qualified standards through a quality prejudging algorithm, and crimping quality detection data are output; Based on crimping quality detection data, the sealing ring is pressed and assembled to the shell preset sealing groove by adopting a special pressing tool, the high-voltage interlocking module and the shielding ring are fixed through the positioning structure, and the functional module is output to preassemble positioning data.
  8. 8. The method for quickly assembling and precisely fitting the segmented wire harness connector according to claim 2, wherein the specific steps of completing the precise fitting and docking are as follows: based on the material verification qualified signal and the functional module preassembly positioning data, acquiring a shell guide key image through an industrial camera, calling a visual guide accurate positioning algorithm to output a positioning deviation compensation value, calling a dynamic error compensation algorithm to acquire environment temperature, vibration acceleration and docking depth parameters and outputting an error compensation amount; Based on the positioning deviation compensation value and the error compensation amount, driving the servo tool to adjust the gesture and pushing the shell segments to butt joint, completing secondary locking through a buckle type or rotary type mechanism, and outputting a shell butt joint locking confirmation signal; Receiving a shell butt joint locking confirmation signal, guiding a terminal to be aligned with a jack based on terminal positioning coordinates output by a visual guiding accurate positioning algorithm, dynamically adjusting the inserting speed according to rule data of algorithm supporting data, collecting inserting force in real time, comparing the inserting force with a preset threshold value, outputting inserting detection data, and returning and alarming if the inserting force exceeds the threshold value; based on the insertion detection data, performing pull-back test and conduction detection, and outputting a pull-back qualified signal and a conduction detection signal; Based on the pull-back qualified signal and the conduction detection signal, the shell is combined with the butt joint locking confirmation signal, and the butt joint precision data and the multi-source error prevention signal are output through the multi-mode error prevention adaptation algorithm.
  9. 9. The method for rapid assembly and precise adaptation of a segmented harness connector according to claim 2, wherein the specific steps of performing full-dimensional segmented calibration optimization are as follows: Based on the butting precision data, testing contact resistance through a high-precision conduction detector, calibrating signal response performance of the high-voltage interlocking module, applying preset direct-current voltage according to set parameters to execute insulation performance test, applying preset alternating-current voltage to execute withstand voltage test, and outputting electrical calibration data; Based on the electrical calibration data, detecting the butt joint gap of the shell through a laser range finder, executing a locking mechanism circulation opening and closing test according to set times, executing a vibration simulation test according to a set frequency range and acceleration, and outputting mechanical calibration data; Based on the mechanical calibration data, performing a waterproof test according to a set protection level, performing a high-low temperature cyclic test according to a set temperature range and cyclic times, and outputting environment calibration data; Based on the electrical calibration data, the mechanical calibration data and the environmental calibration data, comprehensively evaluating according to a preset qualification judgment standard, outputting calibration qualification data or calibration disqualification signals, re-executing accurate adaptive matching when the disqualification signals are triggered, and outputting calibration qualification data when the calibration qualification signals are qualified.
  10. 10. The method for quickly assembling and precisely adapting a segmented wire harness connector according to claim 9, wherein the specific steps of completing the intelligent traceability and predictive maintenance are as follows: Integrating the material model, the production batch, the operator information and the equipment number through a production execution system based on the crimping quality detection data, the docking precision data and the calibration qualified data to generate a unique traceability code, and outputting traceability code data and full-flow integrated data; based on the whole process integration data, combining the historical assembly data with the fault data to construct a fault sample library, wherein the sample library comprises normal and fault working condition data and corresponding labels, and outputting fault sample library data; Constructing an algorithm training model through a fault prediction model based on the fault sample library data, and outputting a fault prediction model after training; based on the assembled, calibrated and running state parameters of the trained fault prediction model and the current connector, the residual service life and the potential fault type are prejudged, a fault prediction result is output, and a maintenance early warning is triggered when a set early warning threshold is reached.

Description

Quick assembly and accurate adaptation method for segmented wire harness connector Technical Field The invention relates to the technical field of electrical connection, in particular to a rapid assembly and accurate adaptation method of a segmented wire harness connector. Background The sectional type wire harness connector is a core component in the high-end fields of a new energy automobile high-voltage system, an industrial robot is precisely connected, aerospace electrical equipment and the like due to the advantages of convenience in modularized maintenance and flexible space adaptation, the existing assembly technology mainly surrounds mechanical structure positioning and basic automation operation expansion, the positioning of a connector shell and a terminal is achieved specifically through mechanical structures such as a positioning pin and a guide groove, cable pretreatment and terminal crimping are completed through automatic wire stripping and crimping equipment controlled by a PLC, a basic visual detection module is introduced in a part of scheme for material appearance defect identification or simple positioning assistance, crimping parameters are preset with fixed values based on manual experience, whether a product is qualified or not is judged through single index detection in a calibration link after the butt joint, and a technical mode with 'mechanical positioning + fixed parameter automation + single point calibration' as a core is integrally formed. The method is characterized in that the method comprises the steps of carrying out a positioning mode, namely, a positioning mode, a fixed preset mode, a pressing parameter, a dynamic adjustment mode and a basic visual detection, wherein the positioning mode is caused by overlapping short plates of multiple technologies, the logic is extremely strong, firstly, the positioning mode depends on rigid constraint of a mechanical structure, abrasion and deformation are easy to occur when a mechanical guide member is used for a long time, meanwhile, the thermal expansion and cold contraction of a part are easy to occur when the environment temperature changes, the static positioning precision is damaged by vibration interference, the problems of unstable contact resistance, signal transmission interference and the like are caused by the fact that the prior art lacks algorithm support capable of sensing the interference in real time, positioning deviation is accumulated, secondly, the pressing parameter adopts a fixed preset mode, the individual differences of different cable specifications and terminal materials are not considered, the dynamic adjustment cannot be carried out according to the real-time pressing feedback, the problem of loose or tight pressing easily occurs, the subsequent butt joint precision is indirectly influenced, furthermore, the basic visual detection only can provide static positioning reference, closed loop control is not formed between the basic visual detection and a mechanical execution mechanism, the positioning error cannot be converted into an adjustment instruction in real time, finally, the positioning precision after the connector is assembled is difficult to meet the requirements of sub-millimeter positioning of a high-end electrical system, the problem of causing unstable contact resistance, signal transmission interference and the like, the equipment operation reliability is influenced, the reliability is increased, the later maintenance frequency and the cost are increased. Disclosure of Invention Aiming at the technical defects in the background technology, the invention provides a rapid assembly and accurate adaptation method of a segmented wire harness connector, which solves the technical problems and meets the actual requirements, and the specific technical scheme is as follows: a rapid assembly and accurate adaptation method of a segmented wire harness connector comprises the following steps: Building a core algorithm module, and outputting algorithm support data comprising a parameter library, a model and a decision rule; based on the algorithm support data, performing modularized parallel pre-assembly, and outputting a material verification qualification signal, crimping quality detection data and functional module preassembly positioning data; based on the material verification qualified signal and the functional module preassembly positioning data, the algorithm supporting data is combined to finish accurate adapting and butting, and butting precision data and a multi-source error-proofing signal are output; Based on the docking precision data, fusing algorithm support data, executing full-dimension segmentation calibration optimization, and outputting calibration qualified data; and collecting crimping quality detection data, docking precision data and calibration qualified data, combining algorithm support data, completing intelligent traceability and predictive maintenance, outputting a unique tra