CN-122023249-A - Machining parameter monitoring method and system for wire harness terminal production

CN122023249ACN 122023249 ACN122023249 ACN 122023249ACN-122023249-A

Abstract

The invention relates to the technical field of image data processing, in particular to a processing parameter monitoring method and a processing parameter monitoring system for wire harness terminal production, wherein the method comprises the steps of obtaining continuous multi-frame images in a wire harness terminal crimping process; the method comprises the steps of calculating initial sectional areas of a wire harness conductor and a crimping wing in a crimping area of any image, respectively carrying out temperature compensation and vibration compensation on the initial sectional areas of the wire harness conductor and the crimping wing to obtain actual sectional areas of the wire harness conductor and the crimping wing, calculating a compression ratio of a wire harness terminal of the crimping area based on the actual sectional areas of the wire harness conductor and the crimping wing, adjusting the crimping force according to the compression ratio by utilizing a PID control model, and evaluating the crimping quality of the wire harness terminal based on the compression ratio. According to the invention, temperature compensation and vibration intensity are introduced to dynamically calibrate the sectional area, so that quality misjudgment caused by only depending on pressure data is avoided, the crimping force is adjusted in real time through a PID control model, the pressure output is dynamically optimized according to the crimping state, and the stable and accurate crimping process is ensured.

Inventors

LIU XIAOMING
Ding Zhenbiao
LI XUEREN
TANG ZHIXIONG

Assignees

东莞市捷信机电设备有限公司

Dates

Publication Date: 20260512
Application Date: 20251224

Claims (10)

1. A process parameter monitoring method for wire harness terminal production, comprising: acquiring continuous multi-frame images in the crimping process of the wire harness terminal; Acquiring a crimping area of any image; calculating initial sectional areas of the wire harness conductors and the crimping wings in the crimping area; The method comprises the steps of calculating the actual sectional areas of a wire harness conductor and a crimping wing, wherein the actual sectional areas comprise the step of performing temperature compensation on the initial sectional areas of the wire harness conductor and the crimping wing to obtain the sectional area of the wire harness conductor after temperature compensation and the sectional area of the crimping wing; Calculating a compression ratio of a harness terminal of the crimping region based on actual sectional areas of the harness conductor and the crimping wings; adjusting the crimping force according to the compression ratio of the wire harness terminal by using a PID control model; And crimping the wire harness terminal by adopting the crimping force to obtain a crimping formed wire harness terminal, and evaluating the crimping quality of the crimping formed wire harness terminal based on the compression ratio of the crimping formed wire harness terminal.
2. The method for monitoring processing parameters for wire harness terminal production according to claim 1, wherein the correcting the sectional area of the temperature-compensated wire harness conductor in combination with the vibration intensity of the wire harness conductor to obtain the actual sectional area of the wire harness conductor comprises: Normalizing the vibration intensity of the wire harness conductor to obtain a normalized conductor vibration value; multiplying the normalized conductor vibration value by a preset conductor vibration influence factor and adding the multiplied conductor vibration influence factor to 1 to obtain a conductor vibration correction coefficient; multiplying the conductor vibration correction coefficient by the sectional area of the wire harness conductor after temperature compensation to obtain the actual sectional area of the wire harness conductor.
3. The method for monitoring processing parameters for wire harness terminal production according to claim 1, wherein the correcting the sectional area of the temperature-compensated crimping wing in combination with the vibration intensity of the crimping wing to obtain the actual sectional area of the crimping wing comprises: Normalizing the vibration intensity of the crimping wing to obtain a normalized crimping wing vibration value; Subtracting the product of the normalized crimping wing vibration value and a preset crimping wing vibration influence factor from 1 to obtain a crimping wing vibration correction coefficient; and multiplying the vibration correction coefficient of the crimping wing by the sectional area of the crimping wing after temperature compensation to obtain the actual sectional area of the crimping wing.
4. The method for monitoring processing parameters for wire harness terminal production according to claim 1, wherein the acquisition of the vibration intensity of the wire harness conductor comprises: Acquiring a wire harness conductor region in the crimping region; Performing Fourier transform on the wire harness conductor region to obtain a frequency domain signal; separating high frequency components of the frequency domain signal using wavelet transform; The vibration intensity of the harness conductor is the main frequency amplitude of the high frequency component.
5. The method for monitoring processing parameters for wire harness terminal production according to claim 1, wherein the acquisition of the vibration intensity of the crimping wings comprises: Acquiring a crimping wing area in the crimping area; performing Fourier transform on the crimping wing area to obtain a frequency domain signal; separating low frequency components of the frequency domain signal using wavelet transform; The vibration intensity of the crimp wings is the dominant frequency amplitude of the low frequency component.
6. The method for monitoring processing parameters for wire harness terminal production according to claim 1, wherein the calculation of the PID control model includes an error signal calculated from a compression ratio error of a wire harness terminal of a crimping region, the compression ratio error being a difference between a target compression ratio of the wire harness terminal of the crimping region and a compression ratio of the wire harness terminal of the crimping region.
7. The process parameter monitoring method for wire harness terminal production of claim 1, wherein the PID control model comprises PID parameter tuning, the PID parameter tuning comprising: calculating the torsion degree of the wire harness terminal of the crimping area of the continuous multi-frame images; and when the torsion degree of the wire harness terminal of the continuous multi-frame images is larger than a preset torsion degree threshold, performing PID parameter setting by adopting a Ziegler-Nichols method.
8. The process parameter monitoring method for wire harness terminal production according to claim 7, wherein the degree of torsion of the wire harness terminal of the crimping region is a difference absolute value of a compression ratio of the wire harness terminal of a region on the left side of the axis of symmetry of the crimping region and a compression ratio of the wire harness terminal of a region on the right side of the axis of symmetry of the crimping region.
9. The method for monitoring processing parameters for wire harness terminal production according to claim 1, wherein the temperature compensating the initial sectional areas of the wire harness conductor and the crimping wing to obtain the sectional area of the wire harness conductor after temperature compensation and the sectional area of the crimping wing comprises: Calculating a difference value between the operation temperature of the crimping equipment and a preset standard temperature to obtain a temperature difference value; Multiplying the surface expansion coefficient of the wire harness conductor by the temperature difference value and adding the multiplied surface expansion coefficient and the temperature difference value to 1 to obtain a conductor compensation coefficient; And multiplying the surface expansion coefficient of the crimping wing by the temperature difference value and adding the multiplied surface expansion coefficient and the temperature difference value to 1 to obtain a crimping wing compensation coefficient, and recording the ratio of the initial sectional area of the crimping wing to the crimping wing compensation coefficient as the sectional area of the crimping wing after temperature compensation.
10. A process parameter monitoring system for wire harness terminal production, characterized in that the process parameter monitoring system comprises a processor and a memory, the memory storing computer program instructions which, when executed by the processor, implement a process parameter monitoring method for wire harness terminal production according to any one of claims 1-9.

Description

Machining parameter monitoring method and system for wire harness terminal production Technical Field The invention relates to the technical field of image data processing, in particular to a processing parameter monitoring method and system for wire harness terminal production. Background The automobile wire harness system is used as a neural network for transmitting electric power and signals of a vehicle, and is a key infrastructure for guaranteeing stable operation of electronic equipment of the vehicle. The wire harness terminal is used as a core component for electric connection, the compression joint quality of the wire harness terminal and a wire harness conductor directly determines core performance indexes such as contact resistance, mechanical strength and the like, and plays a decisive role in the reliability and safety of a vehicle electric system. Currently, with the acceleration of the intelligent and electric trend of automobiles, the number of vehicle-mounted electronic devices is increased, the complexity of a wire harness system is increased continuously, and the requirements on the stability and consistency of a wire harness terminal crimping process are severe. Although the production of automobile wire harness terminals is moving towards automation and standardization, the problem of crimping quality still frequently occurs, and the terminal becomes a bottleneck for restricting the high-quality development of the industry. The problems of contact failure, abnormal signal transmission and the like caused by poor crimping of the wire harness terminal can not only lead to the failure of vehicle-mounted electronic equipment, but also possibly threaten driving safety in serious cases. On one hand, the traditional quality monitoring means have obvious limitations that destructive sampling inspection is carried out by adopting a profile analyzer after crimping or initial crimping parameters are optimized based on historical data, the production process cannot be monitored on line in real time, abnormal conditions are difficult to intervene in time, and the crimping quality is uncontrollable. On the other hand, the monitoring technology relies on the pressure sensor to collect the pressure curve, and the quality is judged by comparing the pressure curve with the preset standard waveform, so that the pressure quality is easy to misjudge by only single pressure data, the production efficiency is reduced, and the long-term reliability and safety of the vehicle electrical system are more seriously affected. Disclosure of Invention In order to solve the technical problems of uncontrollable and erroneous judgment of the crimp quality detection in the crimping process, the invention provides the following aspects. In a first aspect, the present invention provides a process parameter monitoring method for wire harness terminal production, the method comprising: The method comprises the steps of obtaining continuous multi-frame images in a wire harness terminal crimping process, obtaining a crimping area of any image, calculating initial sectional areas of a wire harness conductor and a crimping wing in the crimping area, calculating actual sectional areas of the wire harness conductor and the crimping wing, wherein the calculation comprises the steps of carrying out temperature compensation on the initial sectional areas of the wire harness conductor and the crimping wing to obtain a sectional area of the wire harness conductor after temperature compensation and a sectional area of the crimping wing, correcting the sectional area of the wire harness conductor after temperature compensation according to vibration intensity of the wire harness conductor to obtain the actual sectional area of the wire harness conductor, correcting the sectional area of the crimping wing according to vibration intensity of the crimping wing to obtain the actual sectional area of the crimping wing, calculating compression ratio of the wire harness terminal of the crimping area based on the actual sectional areas of the wire harness conductor and the crimping wing, adjusting the crimping force according to the compression ratio of the wire harness terminal by using a PID control model, crimping the wire harness terminal to obtain the wire harness terminal after crimping molding, and evaluating crimping quality based on the compression ratio of the crimping molded terminal. According to the invention, the actual sectional areas of the wire harness terminal and the crimping wing are calculated through temperature and vibration compensation, so that the actual sizes of the wire harness conductor and the crimping wing under complex working conditions can be accurately reflected, a reliable data base is provided for subsequent analysis, and the problem of misjudgment caused by pressure data only in the prior art is avoided. Meanwhile, the compression ratio is calculated according to the actual sectional area, the pressure force