1. An ultrasonic welding inspection process method is characterized by comprising the following steps:

s1, firstly, introducing the good product image into an X-ray detector as a reference image;

s2, placing the sensor wire harness terminal to be detected and the connecting piece assembly into an objective table;

s3, moving the objective table on the horizontal plane until the sensor wire harness terminal and the connecting piece assembly to be detected are moved to the position right below the detector;

s4, adjusting the defocusing amount and the exposure of the X-ray detector, and then shooting the sensor wire harness terminal to be detected and the connecting piece assembly by using a detector;

s5, transmitting the image shot by the detector into an X-ray detector, comparing the image with a reference image, judging the similarity between the image shot by the detector and the reference image, and outputting an inspection report;

and S6, uploading the inspection report to a traceability system and/or storing the inspection report locally.

2. An ultrasonic welding inspection process as set forth in claim 1, wherein in step S3, the focusing is performed by adjusting the position of the probe in the vertical direction until the probe is adjusted to the quasi-focus.

3. The ultrasonic welding inspection process of claim 1, wherein the adjustment of the exposure level is performed by adjusting the position of the light pipe in the vertical direction in step S3.

4. An ultrasonic welding inspection process as claimed in claim 1, wherein in step S5, when the similarity between the image captured by the probe and the reference image is greater than or equal to 90%, the output inspection report is good.

5. An ultrasonic welding inspection process as claimed in claim 1, wherein in step S5, when the similarity between the image captured by the detector and the reference image is greater than or equal to 50% and less than 90%, the inspection report is output as a suspicious product.

6. An ultrasonic weld inspection process as set forth in claim 5 wherein the sensor harness terminals and connector tab assemblies which output inspection reports as suspect are manually inspected.

7. An ultrasonic welding inspection process as claimed in claim 1, wherein in step S5, when the similarity between the image captured by the probe and the reference image is less than 50%, the output inspection report is a defective product.

8. An ultrasonic welding inspection process as claimed in claim 1, wherein in step S5, the inspection report is displayed on the display, and the display simultaneously displays the image captured by the probe and the reference image.

9. An ultrasonic welding inspection process as set forth in claim 8 wherein said display displays primarily defect location and defect detail images of the images taken by the detector.

10. An ultrasonic weld inspection system comprising the ultrasonic weld inspection process of any one of claims 1-9, further comprising: module M1: leading the good product image into an X-ray detector as a reference image; module M2: placing a sensor wire harness terminal to be detected and a connecting piece assembly into an objective table; module M3: moving the objective table on a horizontal plane until the sensor wire harness terminal to be detected and the connecting piece assembly are moved to the position right below the detector; module M4: adjusting the defocusing amount and the exposure of the X-ray detector, and then shooting a sensor wire harness terminal to be detected and the connecting piece assembly by using the detector; module M5: the image shot by the detector is transmitted into the X-ray detector and is compared with the reference image, the similarity between the image shot by the detector and the reference image is judged, and an inspection report is output; module M6: the inspection report is uploaded to a traceability system and/or stored locally.

Background

The temperature sensor is a semiconductor device which converts non-electrical physical quantity into electrical quantity by utilizing the characteristic that the resistance value of the NTC changes along with the temperature, thereby being capable of carrying out accurate temperature measurement and automatic control. In recent years, the rapid growth of new energy industry and lithium ion battery industry drives the rapid growth of the demand of temperature sensors in China. With the increase of energy density and the reduction of safety margin of lithium batteries, the core problem is to know the temperature of the lithium battery cell itself. Therefore, the reliability of the temperature sensor is important.

A plurality of battery cells form a battery module in a series or parallel mode through a connecting sheet, and a temperature sensor can be installed on the connecting sheet between the batteries under the normal condition.

Ultrasonic welding is performed by transmitting a high-frequency vibration wave to the surfaces of two objects to be welded, and rubbing the surfaces of the two objects against each other under pressure to form a fusion between the molecular layers. Compared with a bare copper wire, the tinned copper wire has the advantages of corrosion resistance, oxidation resistance and weldability, so that the sensor wire harness is mostly made of the tinned copper wire, but the tinned copper wire is fragile in texture compared with the bare copper wire, and the wire harness has the possibility of breakage under the high-frequency vibration of ultrasonic welding equipment.

The prior Chinese patent with publication number CN209946350U discloses a sensor harness detection device, which comprises a shell, a display component and a power supply, wherein the shell is provided with a first BNC interface and a second BNC interface which are matched with a BNC connector of a sensor harness to be detected and a four-core interface which is matched with a four-pin connector of a three-way acceleration sensor harness to be detected, the first BNC interface is connected with the power supply, the display component and the second BNC interface in series, and the first BNC interface is also connected with the power supply, the display component and the four-core interface in series.

The inventor thinks that the prior art adopts the current on-off mode to detect the sensor pencil, but does not consider the situation that the current still can conduct when the pencil part breaks, and the test result is still qualified, exists the place to be improved.

Disclosure of Invention

Aiming at the defects in the prior art, the invention aims to provide an ultrasonic welding inspection process method and system.

The ultrasonic welding inspection process method provided by the invention comprises the following steps: s1, firstly, introducing the good product image into an X-ray detector as a reference image; s2, placing the sensor wire harness terminal to be detected and the connecting piece assembly into an objective table; s3, moving the objective table on the horizontal plane until the sensor wire harness terminal and the connecting piece assembly to be detected are moved to the position right below the detector; s4, adjusting the defocusing amount and the exposure of the X-ray detector, and then shooting the sensor wire harness terminal to be detected and the connecting piece assembly by using a detector; s5, transmitting the image shot by the detector into an X-ray detector, comparing the image with a reference image, judging the similarity between the image shot by the detector and the reference image, and outputting an inspection report; and S6, uploading the inspection report to a traceability system and/or storing the inspection report locally.

Preferably, in step S3, focusing is performed by adjusting the position of the probe in the vertical direction until the probe is adjusted to be in focus.

Preferably, in step S3, the adjustment of the exposure level is performed by adjusting the position of the light pipe in the vertical direction.

Preferably, in step S5, when the similarity between the image captured by the detector and the reference image is greater than or equal to 90%, the output inspection report is good.

Preferably, in step S5, when the similarity between the image captured by the detector and the reference image is greater than or equal to 50% and less than 90%, the output inspection report is a suspicious product.

Preferably, the sensor harness terminals and connector piece assemblies that output the test report as suspect are manually tested.

Preferably, in step S5, when the similarity between the image captured by the detector and the reference image is less than 50%, the output inspection report is a non-defective product.

Preferably, in step S5, the inspection report is displayed and output by the display, and the display also displays the image captured by the detector and the reference image at the same time.

Preferably, the display mainly displays the defect position and defect detail image of the image shot by the detector.

According to the present invention, there is provided an ultrasonic welding inspection system including the ultrasonic welding inspection process of any one of claims 1 to 9, further comprising: module M1: leading the good product image into an X-ray detector as a reference image; module M2: placing a sensor wire harness terminal to be detected and a connecting piece assembly into an objective table; module M3: moving the objective table on a horizontal plane until the sensor wire harness terminal to be detected and the connecting piece assembly are moved to the position right below the detector; module M4: adjusting the defocusing amount and the exposure of the X-ray detector, and then shooting a sensor wire harness terminal to be detected and the connecting piece assembly by using the detector; module M5: the image shot by the detector is transmitted into the X-ray detector and is compared with the reference image, the similarity between the image shot by the detector and the reference image is judged, and an inspection report is output; module M6: the inspection report is uploaded to a traceability system and/or stored locally.

Compared with the prior art, the invention has the following beneficial effects:

1. according to the invention, the sensor wire harness terminal and the connecting piece assembly are shot by the X-ray detector, the shot pictures are compared with good pictures, then the similarity between the pictures shot by the X-ray detector and the good pictures is judged, and then the inspection report is output, so that the accuracy of inspecting the sensor wire harness terminal and the connecting piece assembly is improved, and the convenience of screening unqualified products is improved.

2. According to the invention, the sensor wire harness terminal to be detected with the similarity of more than or equal to 50% and less than 90% and the connecting sheet assembly are manually detected, so that the detection accuracy is improved.

3. According to the invention, the inspection data are uploaded to the tracing system and locally stored, so that convenience of calling, storing and counting the inspection data by workers is improved, and the workers are helped to obtain the yield and the reject ratio of welding the sensor wire harness terminal and the connecting piece assembly.

Drawings

Other features, objects and advantages of the invention will become more apparent upon reading of the detailed description of non-limiting embodiments with reference to the following drawings:

FIG. 1 is a schematic flow diagram of a process embodying the invention;

FIG. 2 is a good image of the present invention, which is introduced into an X-ray detector;

fig. 3 is an image of a defective product photographed by a detector according to the present invention.

Detailed Description

The present invention will be described in detail with reference to specific examples. The following examples will assist those skilled in the art in further understanding the invention, but are not intended to limit the invention in any way. It should be noted that it would be obvious to those skilled in the art that various changes and modifications can be made without departing from the spirit of the invention. All falling within the scope of the present invention.

As shown in fig. 1, 2 and 3, an ultrasonic welding inspection process method according to the present invention includes the steps of:

s1, firstly, introducing the good product image into an X-ray detector as a reference image;

s2, placing the sensor wire harness terminal to be detected and the connecting sheet assembly on an objective table and fixedly installing;

s3, moving the objective table on the horizontal plane until the sensor wire harness terminal and the connecting piece assembly to be detected are moved to the position right below the detector;

s4, focusing is carried out by adjusting the position of the detector in the vertical direction until the detector is adjusted to be in focus; adjusting the exposure degree by adjusting the position of the light pipe in the vertical direction until the detector can shoot a clear image, and then shooting a sensor wire harness terminal to be detected by using the detector;

s5, automatically transmitting the image shot by the detector into an X-ray detector, comparing the image with a reference image, judging the similarity between the image shot by the detector and the reference image, and outputting an inspection report; when the similarity between the image shot by the detector and the reference image is more than or equal to 90%, the output inspection report is good; when the similarity between the image shot by the detector and the reference image is more than or equal to 50% and less than 90%, the output inspection report is a suspicious product; and when the similarity between the image shot by the detector and the reference image is less than 50%, the output inspection report is an unqualified product, and the unqualified product is eliminated.

The inspection report is displayed and output by the display, and the display also simultaneously displays the images of the defect positions and defect details of the image shot by the detector and the reference image, so that a worker can visually observe the defect positions and defect details of the sensor wire harness terminal and the connecting sheet assembly through the display, and the worker can further judge and know the sensor wire harness terminal and the connecting sheet assembly.

Further, the sensor harness terminal and the connecting piece assembly which output the inspection report as a suspicious product are manually inspected, workers comprehensively judge through images displayed by the display and real object observation of the sensor harness terminal and the connecting piece assembly, and products judged to be unqualified are eliminated.

And S6, uploading the inspection report to a traceability system and storing the inspection report locally. Through long-term the tracing system and local save of passing to the inspection report, improved the staff and transferred, preserved and statistics inspection data's convenience to help the staff to obtain sensor pencil terminal and connection piece subassembly welded yields and defective rate.

According to the present invention, there is provided an ultrasonic welding inspection system comprising: module M1: leading the good product image into an X-ray detector as a reference image; module M2: placing a sensor wire harness terminal to be detected and a connecting piece assembly into an objective table; module M3: moving the objective table on a horizontal plane until the sensor wire harness terminal to be detected and the connecting piece assembly are moved to the position right below the detector; module M4: adjusting the defocusing amount and the exposure of the X-ray detector, and then shooting a sensor wire harness terminal to be detected and the connecting piece assembly by using the detector; module M5: the image shot by the detector is transmitted into the X-ray detector and is compared with the reference image, the similarity between the image shot by the detector and the reference image is judged, and an inspection report is output; module M6: the inspection report is uploaded to a traceability system and/or stored locally.

The X-ray detector comprises an object stage, a detector, a light pipe and a display screen, wherein the object stage is positioned below the detector and the light pipe, the object stage is horizontally arranged, the object stage can horizontally move in a horizontal plane where the object stage is positioned, and the detector and the light pipe can move in the vertical direction. And the ultrasonic welding inspection device detects cracks of the sensor wire harness terminal and the connecting piece assembly which are welded into a whole by ultrasonic welding through the method.

Compared with a bare copper wire, the tinned copper wire has the advantages of corrosion resistance, oxidation resistance and weldability, so that the sensor wire harness is mostly made of the tinned copper wire, but the tinned copper wire is fragile in texture compared with the bare copper wire, and the wire harness has the possibility of breakage under the high-frequency vibration of ultrasonic welding equipment. Conventionally, a current on-off mode is used for detecting the sensor wire harness, but the current can still be conducted when the wire harness is partially broken, and the test result is still qualified. The defective products of the sensor wire harness can be suddenly and completely broken in the using process, so that signal acquisition is abnormal, equipment is stopped, or a vehicle cannot normally run.

The image detection technology of the application judges whether the sample to be detected is qualified or not through the similarity data by comparing the similarity of the image of the sample to be detected after ultrasonic welding detected by the X-ray detector with the contour of a non-defective standard image, and outputs a detection report, so that the accuracy of detection of the sensor wire harness is improved.

Principle of operation

During inspection, a worker guides a good product image into an X-ray detector as a reference image, then puts a sensor harness terminal to be detected and a connecting piece assembly into an object stage, moves the sensor harness terminal to be detected and the connecting piece assembly to be under a detector through movement, then adjusts the positions of the detector and a light pipe in the vertical direction to complete focusing and exposure adjustment, then shoots the sensor harness terminal and the connecting piece assembly by using the detector, judges the similarity between the image shot by the detector and the reference image and outputs an inspection report, and then uploads the inspection report to a tracing system and stores the inspection report locally.

Those skilled in the art will appreciate that, in addition to implementing the system and its various devices, modules, units provided by the present invention as pure computer readable program code, the system and its various devices, modules, units provided by the present invention can be fully implemented by logically programming method steps in the form of logic gates, switches, application specific integrated circuits, programmable logic controllers, embedded microcontrollers and the like. Therefore, the system and various devices, modules and units thereof provided by the invention can be regarded as a hardware component, and the devices, modules and units included in the system for realizing various functions can also be regarded as structures in the hardware component; means, modules, units for performing the various functions may also be regarded as structures within both software modules and hardware components for performing the method.

In the description of the present application, it is to be understood that the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", and the like indicate orientations or positional relationships based on those shown in the drawings, and are only for convenience in describing the present application and simplifying the description, but do not indicate or imply that the referred device or element must have a specific orientation, be constructed in a specific orientation, and be operated, and thus, should not be construed as limiting the present application.

The foregoing description of specific embodiments of the present invention has been presented. It is to be understood that the present invention is not limited to the specific embodiments described above, and that various changes or modifications may be made by one skilled in the art within the scope of the appended claims without departing from the spirit of the invention. The embodiments and features of the embodiments of the present application may be combined with each other arbitrarily without conflict.