CN114186430A - Method for calculating bundled conductor current carrying value based on digital analog simulation three-dimensional wire harness - Google Patents
Method for calculating bundled conductor current carrying value based on digital analog simulation three-dimensional wire harness Download PDFInfo
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Abstract
The invention discloses a method for calculating a bundled conductor current-carrying value based on a digital analog simulation three-dimensional wire harness, which relates to the technical field of electrical design. The invention avoids the problem that the cable is pulled by a big horse in the using process, effectively improves the utilization rate of the cable, adopts the digital analog simulation technology in the equipment development process, standardizes the cable laying process, accurately calculates, reasonably selects the type, saves unnecessary cable waste and reduces the production cost.
Description
Technical Field
The invention belongs to the technical field of cable calculation electrical design, and particularly relates to a method for calculating a bundled conductor current carrying value based on a digital analog simulation three-dimensional wire harness.
Background
As is known to all, when the current carrying value of a wire is greater than the rated current, the wire generates a heating phenomenon due to temperature rise, a plurality of wires are bound into a wire harness, and under the condition of long-term electrification, the heat dissipation performance is poor, so that the accumulative temperature rise is caused, the insulating layer of the wire is aged and falls off too early, and the safety of equipment and personnel is seriously damaged, so that the current carrying value correction coefficient K of the wire is difficult to determine in the initial design stage by the prior art meansshTo reduce the impact of the wire with currents higher than the rated current, only excessively high safety assessments can be generally used.
On the other hand, with the vigorous development of test simulation equipment and intelligent equipment, the upgrading of industrial structure is promoted, the annual output value of departments is gradually improved from ten million to billions, the production scale is stably improved, the demand for cables is increased year by year, the data of the cables consumed by the long-term electric fitting production of the electric control module in the department is collected, the conclusion is drawn that the actual effective utilization rate of the cables is less than 60 percent, the waste phenomenon in the design and production process is very common, in order to realize the requirements of saving the production cost, improving the product benefit and strengthening the market competitiveness, the digital analog simulation electrical process technology is adopted, the method can simulate the cable laying condition in advance to obtain complete process data, not only can optimize cable type selection, but also can standardize the cable laying path, and avoids the phenomenon of 'strip large-channel communication Roman' with non-uniform routing paths and various styles due to the technical level difference of a line worker, thereby fundamentally solving the problem of easily generating irregular electromagnetic compatibility.
The prior art method has thousands of wires for a few devices and tens of thousands of wires for many devices, each wire is analyzed to belong to a wire harness group, a wiring path is established, and huge data volume is calculated under the condition of continuously adding or reducing the number of the wires to the wire harness. According to the standard of a cable use manual, influence of other factors is removed, the effective current carrying value of each added wire of the bundled cable is reduced by 0.017%, the effective current carrying value of each added wire of a group of 30 wires of the wire harness group is reduced by 0.51% by calculation, and the reduction value is half, so that the influence of the wire harness group on the current carrying value is reflected greatly.
For single piece customization equipment, specification designation cannot be made on the design of hundreds of cable routing paths of a whole machine, and the length and model of a cable can be accurately grasped, and the method of evaluation calculation is adopted, so that the cost of the cable is saved, the cable is a source of cable waste, the specification selection of the cable is too large, the length data of the cable is lost, and the safety coefficient evaluation is too high, and the cable is a source of cable waste.
Disclosure of Invention
The technical problem solved by the invention is as follows: the method is characterized in that the cable laying form in the whole machine is simulated through a digital simulation technology, key data are analyzed and calculated, and the actual cable consumption of the whole machine equipment is obtained, so that the electric fitting cost of the whole machine is reduced.
The purpose of the invention is realized by the following technical scheme: a method for calculating a bundled conductor current carrying value based on a digitalized analog simulation three-dimensional wire harness comprises the following steps: the method comprises the following steps: creating a digital three-dimensional model library and a parameterized database; the digital three-dimensional model library comprises a mechanical structure model, an electrical element model and a connector model; step two: assembling the electrical component model and the connector model in the mechanical structure model based on the mechanical structure model and in an actual assembly relationship; step three: providing logic parameter data according to a parameterization database, automatically judging the positions of ports of access devices at two ends of the wires, automatically interconnecting hundreds of wires according to a specified planning path, and generating a three-dimensional wire harness group; step four: obtaining current-carrying value correction coefficient K of single lead in three-dimensional wire harness groupshAnd calculating a wire current carrying value I, finishing wire type selection according to the wire current carrying value I, acquiring wire length data, and acquiring the actual offline length according to the wire length data.
In the method for calculating the current carrying value of the bundled conductor based on the digitalized analog simulation three-dimensional wire harness, in the step one, the parameterized database comprises a parameterized 2D electrical schematic diagram, initial parameters, operation rules and identifications of extracted parameters.
In the method for calculating the current carrying value of the bundled conductors based on the digitalized analog simulation three-dimensional wire harness, in the third step, the wiring harness laying path is planned, a plurality of wiring harness groups are set, and signal types with different intensities, frequencies and functions are classified into groups.
In the above method for calculating the current carrying value of the bundled conductor based on the digitized analog simulation three-dimensional wire harness, in the third step, the logic parameter data includes: port information of the wire connecting device, color, line type, bending radius, line diameter and manufacturer.
In the method for calculating the current carrying value of the bundled conductors based on the digitalized analog simulation three-dimensional wire harness, in the third step, the three-dimensional wire harness group is a wire harness formed by arranging n conductor groups along the circumferential direction, and then the cabling of the digitalized prototype cable network is completed by the n wire harness groups.
In the method for calculating the current carrying value of the bundled conductor based on the digital analog simulation three-dimensional wire harness, in the fourth step, the current carrying value I of the conductor is obtained by the following formula:
I＝(((P/U*cosφ)*Ksh)*Kg)*β；
wherein I is a wire current carrying value; p is the power of the equipment; u is a voltage; cos phi is the power factor; beta is the peak current safety coefficient; kshA current carrying value correction coefficient; kgTo represent an altitude correction factor.
In the method for calculating the current carrying value of the bundled conductor based on the digital analog simulation three-dimensional wire harness, in the fourth step, the actual offline length is obtained by the following formula:
L0＝L+L2；
wherein L is0Representing the actual downline length; l is wire length data; l is2Is the stress relief length.
Compared with the prior art, the invention has the following beneficial effects:
(1) the invention realizes a complete digital complete machine and successfully solves the technical difficulty that the current-carrying value of the bundled cable cannot be calculated and analyzed in the design stage by the prior art. The design method has the advantages that the short board caused by production is made up for the traditional 2D electrical design drawing, the phenomenon that digital three-dimensional design is heavy mechanical and light electrical is improved for a long time, the digital three-dimensional cable design is an important component for making up the electrical part of a digital complete machine, the traditional structure and electrical serial design mode can be pulled to a unified digital design platform, the coordination of the structure and the electrical control design is enhanced, and the design defects of the product can be corrected at the beginning of the drawing design through the evaluation of a complete digital prototype.
(2) According to the invention, through the transmission of the logical parameters of the 2D electrical schematic diagram, the uniqueness of reading and calling data sources is realized, and the basic database of both design data and production data is obtained, so that the uniformity of the data sources is fundamentally ensured, the purpose of generating a data table without checking is achieved, the artificial statistical errors in the product research and development link are eliminated, the real-time exchange of data can be realized, when the top-level data needs to be changed, only the bottom-level data source needs to be modified, the data chain related to the back-end data source is automatically associated and changed, and the design accuracy is improved.
(3) The invention realizes the purpose of obtaining the length L of each wire and the correction coefficient K of the current carrying value of the wire through digital analog simulation by collecting parameters in statistics and calculationshAnd calculating to obtain a wire current carrying value I, looking up a table to obtain the specification and model of the selected wire, and compared with the prior art, the utilization rate of the cable can be improved by 99 percent. Meanwhile, the actual cable consumption of the electric device of the whole machine can be obtained at the initial stage of design, and cost accounting is facilitated.
Drawings
Various other advantages and benefits will become apparent to those of ordinary skill in the art upon reading the following detailed description of the preferred embodiments. The drawings are only for purposes of illustrating the preferred embodiments and are not to be construed as limiting the invention. Also, like reference numerals are used to refer to like parts throughout the drawings. In the drawings:
FIG. 1 is a flow chart of a method for calculating bundled conductor current carrying values based on a digitized analog simulation three-dimensional wire harness according to an embodiment of the invention;
FIG. 2 is a schematic diagram of a digital three-dimensional wiring harness space laying state provided by an embodiment of the invention;
fig. 3 is a cross-sectional view of one branch of the digitized three-dimensional wire harness provided by the embodiment of the invention, and a schematic diagram of the number of the wires of the digitized three-dimensional wire harness is shown.
Detailed Description
Exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings. While exemplary embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure may be embodied in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. It should be noted that the embodiments and features of the embodiments may be combined with each other without conflict. The present invention will be described in detail below with reference to the embodiments with reference to the attached drawings.
Fig. 1 is a flowchart of a method for calculating a bundled conductor current-carrying value based on a digitized analog simulation three-dimensional wire harness according to an embodiment of the present invention. As shown in fig. 1, the method comprises the steps of:
the method comprises the following steps: creating a digital three-dimensional model library (comprising a mechanical structural part model, an electrical element model, a connector model and the like) and a parametric database (comprising a parametric 2D electrical schematic diagram, setting initial parameters, operation rules and extracting parameter identifiers).
Step two: the method comprises the steps of simulating the whole machine assembly through a digital three-dimensional virtual environment, assembling an electric element model and a connector model in a mechanical structural member based on a mechanical structural member model and an actual assembly relation, and reasonably and separately arranging strong-current devices, high-frequency devices, weak-current devices and low-frequency devices according to the technical requirement of electromagnetic compatibility to determine the relative positions of the devices.
Step three: planning a wiring harness laying path, setting a plurality of wiring harness groups, and classifying signal types such as different intensities, frequencies and functions into groups.
Step four: and importing logic parameter data (including port information, color, line type, bending radius, line diameter, manufacturers and the like) of a parameterized 2D electrical schematic diagram, providing the logic parameter data according to the 2D electrical schematic diagram in a digital three-dimensional environment, automatically judging the positions of ports of devices connected to two ends of a wire, automatically interconnecting hundreds of wires according to a specified planning path, and generating a three-dimensional wire harness group.
Step five: by analyzing the wiring harness information of the laying path, the detection point position is arranged to extract the data of the number, the root number and the like of the wires passing through the point, and the data are used for analyzing and calculating the correction coefficient K of the current carrying value of the wiresshAnd calculating the corrected current carrying value, automatically finishing the wire model selection, acquiring wire length data and generating a data statistical table.
Information acquisition of a digital three-dimensional model library, a parametric database and the like can be counted and sorted by third-party software and transmitted through a data channel, and can also be established and completed by the software; the three-dimensional wire harness group grouping and connection data transmission are controlled by the 2D electrical schematic diagram.
The main cable path, the branch routing path and the branch bundle group are created by attaching to the outer surface or the inner cavity of the mechanical structural part model in a three-dimensional environment; the section shape of the wire harness is a wire harness formed by arranging n wires along the circumferential direction, and then the digital prototype cable net laying is completed by n wire harness groups.
The shielding layer grounding of the shielding cable is controlled by the 2D electrical schematic diagram, and an access electrical model grounding port is automatically generated.
After the virtual assembly of the whole machine is completed, hundreds of conductors are accurately connected with logic parameter information in the device port and are obtained by transmitting a parameterized 2D electrical schematic diagram, and the number of the generated conductors is n to n multiplied by 10nAnd the root wires can be automatically generated and can be automatically connected with ports on the electric element model.
Generating virtual three-dimensional wire harnesses, obtaining the number of wires distributed in each wire harness group, and inquiring an attenuation table to obtain a current carrying value correction coefficient KshAnd calculating an accurate wire current carrying value I, wherein the expression is as follows:
I＝(((P/U*cosφ)*Ksh)*Kg)*β；
wherein, IIs the current carrying value of the wire; p is the power of the equipment; u is a voltage; cos phi is the power factor; beta is the peak current safety coefficient; kshA current carrying value correction coefficient; kgTo represent an altitude correction factor.
The virtual wire harness is simulated to obtain the accurate length L, and the stress release length L is added to the actual offline length2The expression is as follows;
L0＝L+L2
wherein L is0Representing the actual downline length;
through calculation and analysis, data such as the offline length of the wire, the current carrying value of the wire and the like are obtained, and a chart is automatically generated through statistics of a BOM (Bill of material) table without manual intervention.
Specifically, 1, creating a three-dimensional digital mechanical structure model: modeling according to design 1:1, and carrying out a complete machine execution mechanism module, a digital three-dimensional electrical appliance model and a framework of a three-dimensional wire harness for the complete machine execution mechanism module, and providing protection and fixing positions for the complete machine execution mechanism module;
2. creating a three-dimensional digitalized electrical element model library: establishing a model according to the appearance of the physical device according to a 1:1 ratio, wherein the model has parameters such as external color, model, manufacturer, weight, wiring port position and the like; the device layout is distributed in the mechanical structural part model according to a rule that the input and output distances of the two related elements are shortest and the electromagnetic compatibility is optimal;
3. digital parameter library: the data support is a basic database for implementing an algorithm, provides a read and called data source for a data group formed by grouping according to types and algorithm rules, can be butted with an external software data channel to transmit data, is a data support for generating a three-dimensional wire harness by the data wire harness, and provides a data source for reading analysis, calculation and statistics;
4. parametric 2D electrical schematic plan view: the method mainly comprises the key steps of dividing one part into two parts, namely a drawn logic relation graph of electrical interconnection, and the other part into a bottom-layer parameterized device, a device and a cable data set, and communicating and transmitting the relation with a three-dimensional digital virtual parameter library for data, providing electrical logic parameter information for a three-dimensional environment, and driving automatic wiring;
5. IIIMaintaining a digitized virtual environment; the method is characterized by comprising the steps of assembling a combined structural part, a model library, a parameter library and electrical principle logic parameters, and automatically generating and finishing laying according to a preset path and a wire harness group. The number of the wires contained in the bundled wire harness is calculated through analysis to obtain a current value correction coefficient KshCalculating an accurate wire current-carrying value (as shown in fig. 2 and 3);
(1) in this embodiment, step 1 describes: the creation of the three-dimensional digital virtual structural part is that after the structural engineer finishes, the three-dimensional digital virtual structural part is transmitted to the electrical engineer, and after the electrical apparatus and cable protection fixing measures are designed by the electrical engineer, the structural change part feeds back the structural engineer for further improvement.
(2) In this embodiment, step 2 describes: the establishment of the three-dimensional digital virtual electrical appliance model base is completed by electrical engineers, and each electrical appliance model needs a name set according to fixed regulations as a material code and is used for searching conveniently, distinguishing functions, reading and filtering parameters.
(3) In this embodiment, the steps 3 to 5 are as follows: the three-dimensional digital virtual parameter library has huge amount of bottom layer data, is filled by software capable of being in butt joint with a data channel, and imports data in batches, wherein the parameters are all variables transmitted directionally, and if the top layer data needs to be changed, only the bottom layer data needs to be modified, and the parameters are all changed on the data chain.
(4) In this embodiment, the modeling in the above steps is completed to obtain a complete digital prototype, which can be used for review, cost accounting, and improving the compatibility of each functional module, and the design of the functional modules is performed by digital assembly, analysis and interference check, and the design defects of the drawing are corrected by the internal space and the heat dissipation conditions, so as to improve the mutual connection compatibility of the functional modules.
(5) Preferred cabling paths are as follows;
the cable laying path is driven by reasonable layout of devices, according to the principle that the routing is shortest and the distance is closest, the axis of the cable laying path and the reference surface of the side wall are kept horizontal and vertical, and the arc radius of the cable laying path at a turning angle is larger than the bending radius of the cable and is positioned on the same reference surface; the planned path avoids acute angles, heating elements,Electrical elements of strong magnetic field and moving structure position. Customizing and presetting wiring paths of different wire harness groups and vertical spacing L of strong and weak signals1The size is more than or equal to 500mm, the vertical cross cannot be avoided, the coupling interference of the wire harness signals is reduced, and the electromagnetic compatibility of the whole machine is improved.
(6) Preferred calculation value selection scheme
Calculating the correction coefficient K of the obtained current carrying valueshObtaining an expression of a current carrying value of the accurate wire as follows;
I＝(((P/U*cosφ)*β)*Ksh)*Kg
wherein cos phi takes a value of 0.8, and beta takes a value of 0.7;
the actual length of the lower line is added with the stress release length L2The expression is as follows;
L0＝L+L2
wherein L is0The value is 35mm, when the sectional area of the wire is more than 10mm2Taking a value of 0;
(7) in this embodiment, the above steps are completed: and calculating and counting the data of each wire, adding an operation rule by adopting the expression, automatically filling simulation parameters, counting an operation result list, establishing a database by selecting the type of the cable based on a cable use manual, and quickly counting by adopting judgment statements to generate a cable specification table.
The invention realizes a complete digital complete machine and successfully solves the technical difficulty that the current-carrying value of the bundled cable cannot be calculated and analyzed in the design stage by the prior art. The design method has the advantages that the short board caused by production is made up for the traditional 2D electrical design drawing, the phenomenon that the digitalized three-dimensional design is heavy mechanical and light electrical is improved for a long time, the digitalized three-dimensional cable design is an important component for making up the electrical part of the digitalized complete machine, the traditional structure and electrical serial design mode can be pulled to a unified digitalized design platform, the coordination of the structure and the electrical control design is enhanced, and the product design defect can be corrected at the beginning of the drawing design through the evaluation of a complete digitalized prototype; the invention realizes the uniqueness of reading and calling data sources, designs a basic database of which both data and production data are sourced, and carries out root-to-root conversion by the logic parameter transmission of the 2D electrical schematic diagramThe data source uniformity is ensured, the aim of generating a data table without checking is fulfilled, the artificial statistical error in the product research and development link is eliminated, the real-time exchange of data can be realized, when the top-layer data needs to be changed, only the bottom-layer data source needs to be modified, the data chain related to the back-end data chain is automatically associated and changed, and the design accuracy is improved; the invention realizes the purpose of obtaining the length L of each wire and the correction coefficient K of the current carrying value of the wire through digital analog simulation by collecting parameters in statistics and calculationshAnd calculating to obtain a wire current carrying value I, looking up a table to obtain the specification and model of the selected wire, and compared with the prior art, the utilization rate of the cable can be improved by 99 percent. Meanwhile, the actual cable consumption of the electric device of the whole machine can be obtained at the initial stage of design, and cost accounting is facilitated.
Although the present invention has been described with reference to the preferred embodiments, it is not intended to limit the present invention, and those skilled in the art can make variations and modifications of the present invention without departing from the spirit and scope of the present invention by using the methods and technical contents disclosed above.
Claims (7)
1. A method for calculating a current carrying value of a bundled wire based on a digitalized analog simulation three-dimensional wire harness is characterized by comprising the following steps:
the method comprises the following steps: creating a digital three-dimensional model library and a parameterized database; the digital three-dimensional model library comprises a mechanical structure model, an electrical element model and a connector model;
step two: assembling the electrical component model and the connector model in the mechanical structure model based on the mechanical structure model and in an actual assembly relationship;
step three: providing logic parameter data according to a parameterization database, automatically judging the positions of ports of access devices at two ends of the wires, automatically interconnecting hundreds of wires according to a specified planning path, and generating a three-dimensional wire harness group;
step four: the method comprises the steps of obtaining a current carrying value correction coefficient of a single wire in a three-dimensional wire harness group, calculating a wire current carrying value, completing wire type selection according to the wire current carrying value, obtaining wire length data, and obtaining the actual offline length according to the wire length data.
2. The method of claim 1 for calculating bundled wire current-carrying values based on digitized analog simulation of a three-dimensional wire harness, characterized in that: in step one, the parameterization database comprises an identification of a parameterization 2D electrical schematic diagram, initial parameters, operation rules and extraction parameters.
3. The method of claim 1 for calculating bundled wire current-carrying values based on digitized analog simulation of a three-dimensional wire harness, characterized in that: and in the third step, planning a wiring harness laying path, setting a plurality of wiring harness groups, and classifying the signal types with different intensities, frequencies and functions into groups.
4. The method of claim 1 for calculating bundled wire current-carrying values based on digitized analog simulation of a three-dimensional wire harness, characterized in that: in step three, the logic parameter data includes: port information of the wire connecting device, color, line type, bending radius, line diameter and manufacturer.
5. The method of claim 1 for calculating bundled wire current-carrying values based on digitized analog simulation of a three-dimensional wire harness, characterized in that: in the third step, the three-dimensional wire harness group is a wire harness formed by arranging n wire groups along the circumferential direction, and the digital prototype cable network laying is completed by the n wire harness groups.
6. The method of claim 1 for calculating bundled wire current-carrying values based on digitized analog simulation of a three-dimensional wire harness, characterized in that: in step four, the wire current carrying value I is obtained by the following formula:
I＝(((P/U*cosφ)*Ksh)*Kg)*β；
wherein I is a wire current carrying value; p is the power of the equipment; u is a voltage; cos phi is the power factor; beta is the peak current safety coefficient; kshA current carrying value correction coefficient; kgTo represent an altitude correction factor.
7. The method of claim 1 for calculating bundled wire current-carrying values based on digitized analog simulation of a three-dimensional wire harness, characterized in that: in step four, the actual length of the lower line is obtained by the following formula:
L0＝L+L2；
wherein L is0Representing the actual downline length; l is wire length data; l is2Is the stress relief length.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN116451509A (en) * | 2023-06-15 | 2023-07-18 | 天津有容蒂康通讯技术有限公司 | Method and system for assembling complex cable assembly |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN116451509A (en) * | 2023-06-15 | 2023-07-18 | 天津有容蒂康通讯技术有限公司 | Method and system for assembling complex cable assembly |
| CN116451509B (en) * | 2023-06-15 | 2023-08-22 | 天津有容蒂康通讯技术有限公司 | Method and system for assembling complex cable assembly |
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