Design And Research Of Automatic Production Line For High-voltage Wire Harness Of New Energy Vehicles

With the continuous expansion of the new energy vehicle market,the demand for highvoltage wiring harnesses is also growing rapidly.At present,most domestic and foreign automobile wire harness enterprises are still in the stage of semi automated production using some equipment,and the productivity level can not meet market requirements,and automated manufacturing is still far from being achieved.Starting from the actual needs of enterprises,this project conducts research on existing wire harness equipment,aiming to develop a production line that can fully automate the wire harness processing process and solve the processing quality and efficiency problems faced in the field of high-voltage wire harnesses for new energy vehicles.The main research content is as follows:(1)Overall scheme design.Clarify the functional requirements and technical indicators of the production line.Based on this,analyze the unwinding,feeding,cutting,peeling,and offline processes,determine the design plan,and complete the overall mechanical design.In response to the phenomenon of wire core damage,three real-time detection schemes are proposed: current method,dipole antenna method,and micro capacitance method.After comparing the advantages and disadvantages,the micro capacitance method is determined to be used for the design of the damage detection scheme.The control methods of each execution component were analyzed,and a control scheme centered on industrial tablet computer and PLC was determined.(2)Mechanical structure design.Analyze the action modes during the wire harness machining process,and carry out modular design for unwinding,processing,offline,and other auxiliary links during the wire harness machining process.Through mutual cooperation between modules,achieve automation of wire harness production.Select and verify the key components in the production line to verify the reliability of the design.(3)Structural stability analysis.First of all,use Ansys to carry out statics analysis on support and shaft parts with more load,analyze their structural strength and load distribution,and verify the rationality of structural design.Secondly,based on sensitivity theory,lightweight structural design is carried out for supporting components to improve their mechanical performance.Then,a dynamic analysis of the cutting process of the wire harness is conducted,analyzing the force and deformation of the cutting tool to ensure the safety of the cutting process.Finally,modal analysis was conducted using the tool holder and active shaft as examples to avoid resonance phenomena.By simulating and analyzing the mechanical structure,performance analysis and optimization design of the structure are achieved to improve equipment stability and usability.(4)Design of wire core damage detection and control system.Research is conducted on the detection method based on the principle of micro capacitance,design a detection circuit,and conduct simulation analysis of wire core cutting damage to verify the feasibility of this method.The electrical control system is designed with PLC as the control core,analyzing control requirements,implementing hardware design and selection,software design,and enabling the production line to have real-time monitoring of operating status,human-machine interaction,fault alarm and other functions.(5)Prototype construction and functional experiments.The mechanical structure and electrical control system of the prototype of the high-voltage wire harness automation production line for new energy vehicles will be constructed.Using this prototype as the main body,the unwinding test,peeling processing test,core damage detection test,offline test,and whole machine processing test of the wire harness were carried out,proving that the production line can achieve automation of various processes,meet the functional requirements of wire harness processing,and improve production efficiency and quality.