R&D Of Wire Harness Automatic Winding Machine And Station Identification

In view of the current problems in the wire harness manufacturing enterprises,most of the tape winding in wire harnesses is done manually.Due to the uncertainty of human beings,the efficiency is reduced,and the qualified rate of products is difficult to stabilize.Therefore,the harness automatic tape winding machine was developed.The equipment improves the degree of enterprise automation and lays a good foundation for enterprise industry 4.0.Firstly,According to the harness tape winding process,the working procedure of the equipment is formulated.Combining the research of winding machine at home and abroad,the automatic tape winding of multi-branch harnesses is designed.Meanwhile,it is modeled by Solidworks software,and the layout of the winding machine is completed.In order to simulate the functions of the manual twisting line,the beam line,and the cutting tape,a twisting line mechanism,a cable line mechanism,a tape cutting mechanism,and a harness end clamp are designed.Second,in order to achieve the identification of the station,the image processing method is introduced to obtain the coordinates of the branch points and the end points of the wire harness.The type of camera,lens,and light source needed for this system are selected.At the same time,the CCD camera is modeled.This is the basis for HALCON's calibration of the camera.The collected images are processed using the operator in HALCON and the coordinates of the endpoints and the branch points are obtained.The results are analyzed.The relative error of the coordinate value is controlled at 0.1%~5.5%.The absolute error is controlled at 0.3mm~5mm.The error is in accordance with the requirements of the winding process of the harness tape.Finally,a geometric parameter model of the wire winding process is established.According to the mechanical structure of the winding machine and the process parameter model,a device motion model is established for the three sections of the near end point L1,the middle section of the wire harness L2 and the branch point L3.The establishment of the movement model of the harness tape winding machine provides a theoretical basis for the implementation of PLC control.