Twisted pair crimping system and twisted pair crimping method

Abstract

The invention discloses a twisted pair crimping system and a twisted pair crimping method. The twisted pair crimping system comprises a cable clamp used for clamping and fixing a twisted pair; the moving device is used for moving the twisted pair; the artificial intelligence visual device can simulate human eyes to identify the actual positions of the geometric centers of the two conductor cores of the twisted pair moved to the detection station and the actual distance between the geometric centers of the two conductor cores; the position calibration device is suitable for calibrating the crimping position of the twisted pair according to the position deviation between the actual position and the preset ideal position when the actual distance is not smaller than the preset safety distance, so as to eliminate the position deviation; and the crimping device is arranged at the crimping station and is used for crimping the conductor core onto the terminal. When the conductor core is moved to a predetermined crimping position, a geometric center of the conductor core is located on a centerline of the terminal. According to the invention, the crimping position of the conductor core of the twisted pair can be calibrated according to the identified position deviation, and the crimping precision and quality of the twisted pair are improved.

Description

Technical Field

[0001] This invention relates to a twisted-pair wire crimping system and a twisted-pair wire crimping method. Background Technology

[0002] In existing technology, in order to crimp the cores of a twisted pair to a terminal, it is necessary to first strip off a section of the outer sheath of the twisted pair to expose the two cores, then unwind and straighten the exposed two cores, and finally strip off a section of the outer insulation layer of the two cores to expose the conductor core. The conductor core of a twisted pair typically consists of multiple conductive wires twisted together, such as multiple copper wires twisted together.

[0003] In existing technologies, errors in the processing of twisted-pair cables can cause the conductor cores to be difficult to position in the intended ideal location, resulting in a positional deviation between the actual and intended positions. This prevents the conductor cores from being accurately positioned for crimping. Current technologies typically employ a guiding structure in the crimping device to guide the conductor cores to the correct crimping position. However, this guiding structure cannot reliably guide the conductor cores to the correct crimping position, leading to inconsistent crimping quality.

[0004] Furthermore, in existing technologies, due to the small diameter of the conductive wires in the conductor core of twisted-pair cables, there is a risk that some conductive wires will be cut or broken during the processing of the twisted-pair cables. This can result in the actual number of conductive wires in the conductor core being less than the intended number. However, in existing technologies, it is impossible to identify and determine the actual number of conductive wires in the conductor core, which reduces the quality of twisted-pair cable products. Summary of the Invention

[0005] The purpose of this invention is to solve at least one aspect of the aforementioned problems and defects existing in the prior art.

[0006] According to one aspect of the present invention, a twisted-pair crimping system is provided. The twisted-pair crimping system includes: a cable clamp for clamping and securing a twisted pair; a moving device for moving the cable clamp and the twisted pair in a horizontal direction perpendicular to the axis of the twisted pair; an artificial intelligence vision device disposed at a detection station, capable of mimicking human vision to identify the actual positions of the geometric centers of the two exposed conductor cores of the twisted pair moved to the detection station and the actual distance between the geometric centers of the two conductor cores in the horizontal direction; a position calibration device adapted to calibrate the crimping position of the twisted pair based on the positional deviation between the actual position and a predetermined ideal position, when the actual distance is not less than a predetermined safety distance, to eliminate the positional deviation; and a crimping device disposed at a crimping station for crimping the conductor cores to a terminal fixed at a predetermined crimping position. When the conductor cores are moved to the predetermined crimping position, the geometric center of the conductor cores is located on the centerline of the terminal fixed at the predetermined crimping position.

[0007] According to an exemplary embodiment of the present invention, the crimping device includes: a fixed mold fixed at the predetermined crimping position for fixing the terminal and guiding the conductor core into the terminal; and a movable mold located above the fixed mold and movable in a vertical direction perpendicular to the axis of the twisted pair for crimping the terminal onto the conductor core, wherein the predetermined safety distance is equal to half the width of the movable mold in the horizontal direction.

[0008] According to another exemplary embodiment of the present invention, the twisted pair crimping system further includes: a position adjustment device adapted to adjust the position of the conductor core at the crimping station when the actual spacing is less than the predetermined safety spacing, so as to prevent the two conductor cores of the twisted pair from being simultaneously crimped into the same terminal by the moving mold.

[0009] According to another exemplary embodiment of the present invention, when the actual spacing is less than the predetermined safety spacing, the position adjustment device adjusts the position of the two conductor cores of the twisted pair relative to the moving mold, such that one conductor core currently being crimped is located in the coverage area of ​​the moving mold in the vertical direction, and the other conductor core is located outside the coverage area of ​​the moving mold and close to the side of the coverage area.

[0010] According to another exemplary embodiment of the present invention, the artificial intelligence vision device includes: a recognition module capable of mimicking the human eye to recognize the geometric contours of the exposed core wires and the exposed conductor cores of the twisted pair; and a calculation module capable of calculating, based on the recognized geometric contours of the conductor cores, the positional deviation between the actual position and the predetermined ideal position, and the actual distance between the geometric centers of the two conductor cores.

[0011] According to another exemplary embodiment of the present invention, the identification module includes: a vertical camera for capturing images of the twisted pair in a vertical direction perpendicular to the axis of the twisted pair; and a vision processor for identifying the geometric contours of the core wires and conductor cores of the twisted pair based on the images captured by the vertical camera.

[0012] According to another exemplary embodiment of the present invention, each conductor core of the twisted pair includes multiple conductive wires twisted together, and the artificial intelligence vision device is also capable of mimicking the human eye to identify the actual number of conductive wires in each conductor core of the twisted pair. When the actual number of conductive wires in the conductor core identified by the artificial intelligence vision device is not equal to a predetermined number, the artificial intelligence vision device determines that the quality of the twisted pair is unqualified.

[0013] According to another exemplary embodiment of the present invention, the twisted pair crimping system further includes: a removal device disposed at the inspection station for removing substandard twisted pairs from the cable clamp.

[0014] According to another exemplary embodiment of the present invention, the artificial intelligence vision device includes: a recognition module capable of mimicking the human eye to recognize the end face contours of the two core wires of the twisted pair and the end face contours of the conductive wires of the two conductor cores; and a calculation module capable of calculating the actual number of conductive wires of the conductor core based on the recognized end face contours of the core wires and the end face contours of the conductive wires of the conductor cores.

[0015] According to another exemplary embodiment of the present invention, the identification module includes: a horizontal camera for capturing an image of the end face of the twisted pair along the axial direction of the twisted pair; and a vision processor capable of identifying the end face contours of the two core wires and the end face contours of the conductive wires of the two conductor cores of the twisted pair based on the end face image captured by the horizontal camera.

[0016] According to another aspect of the present invention, a method for crimping twisted-pair cables is provided. The method includes the following steps:

[0017] S10: Provides the aforementioned twisted-pair crimping system;

[0018] S20: Fix the twisted pair cable to be crimped onto the cable clamp and use the moving device to move the twisted pair cable fixed on the cable clamp to the testing station;

[0019] S30: Use the artificial intelligence vision device to identify the actual number of conductive wires in each conductor core of the twisted pair;

[0020] S40: Determine whether the quality of the twisted pair is qualified based on the actual number of conductive wires in the identified conductor core.

[0021] According to another exemplary embodiment of the present invention, if the determination result of the aforementioned step S40 is negative, then the following steps are performed:

[0022] S50: Remove the substandard twisted pair from the cable clamp using the removal device;

[0023] S51: Use a moving device to move the cable clamp to the loading station for loading the twisted pair cable;

[0024] S52: Return to the previous step S20.

[0025] According to another exemplary embodiment of the present invention, if the determination result of the aforementioned step S40 is yes, then the following steps are performed:

[0026] S60: Using the artificial intelligence vision device, identify the actual position of the geometric center of the two conductor cores of the twisted pair and the actual distance between the geometric centers of the two conductor cores in the horizontal direction perpendicular to the axis of the twisted pair;

[0027] S70: Determine whether the actual distance is not less than the predetermined safety distance.

[0028] According to another exemplary embodiment of the present invention, if the determination result of the aforementioned step S70 is negative, then the following steps are performed:

[0029] S80: The moving device is used to move the twisted pair to the crimping station along the horizontal direction and the position of the conductor core is adjusted by the position adjustment device to prevent the two conductor cores of the twisted pair from being simultaneously crimped into the same terminal by the moving mold of the crimping device.

[0030] S81: The conductor core is pressed onto the terminal fixed at a predetermined pressing position using the crimping device;

[0031] S82: The mobile device is used to move the twisted pair cable with crimped terminals to the inspection station and the artificial intelligence vision device is used to inspect whether the crimping quality of the twisted pair cable is qualified.

[0032] S83: Use a mobile device to move the twisted pair to the unloading station and unload the twisted pair with qualified crimping quality into the qualified product recycling bin, or unload the twisted pair with unqualified crimping quality into the unqualified product recycling bin.

[0033] S84: Use a moving device to move the cable clamp to the loading station for loading the twisted pair cable;

[0034] S85: Return to the previous step S20.

[0035] According to another exemplary embodiment of the present invention, if the determination result of the aforementioned step S70 is yes, then the following steps are performed:

[0036] S90: The moving device moves the twisted pair to the crimping station along the horizontal direction and the position calibration device calibrates the crimping position of the conductor core so that the geometric center of the conductor core is located on the center line of the terminal fixed at the predetermined crimping position.

[0037] S91: The conductor core is pressed onto the terminal fixed at the predetermined pressing position using the crimping device;

[0038] S92: The mobile device is used to move the twisted pair cable with crimped terminals to the inspection station and the artificial intelligence vision device is used to inspect whether the crimping quality of the twisted pair cable is qualified.

[0039] S93: Use a mobile device to move the twisted pair to the unloading station and unload the twisted pair with qualified crimping quality into the qualified product recycling bin, or unload the twisted pair with unqualified crimping quality into the unqualified product recycling bin.

[0040] S94: Use a moving device to move the cable clamp to the loading station for loading the twisted pair cable;

[0041] S95: Return to the previous step S20.

[0042] In the foregoing exemplary embodiments of the present invention, the artificial intelligence vision device is able to mimic the human eye in identifying the positional deviation between the actual position and the predetermined ideal position of the geometric center of the conductor core of the twisted pair. Therefore, the present invention can calibrate the crimping position of the conductor core of the twisted pair based on the identified positional deviation, enabling the conductor core to be accurately positioned at the predetermined crimping position, thereby improving the crimping accuracy and quality of the twisted pair.

[0043] Other objects and advantages of the invention will become apparent from the following description of the invention with reference to the accompanying drawings, and will help to provide a comprehensive understanding of the invention. Attached Figure Description

[0044] Figure 1 This diagram shows a perspective view of a processed twisted pair cable according to an exemplary embodiment of the present invention.

[0045] Figure 2 This diagram shows a perspective view of a twisted-pair crimping system according to an exemplary embodiment of the present invention.

[0046] Figure 3 A plan view of the crimping device of a twisted-pair crimping system according to an exemplary embodiment of the present invention is shown;

[0047] Figure 4 This diagram shows a plan view of a twisted-pair crimping system according to an exemplary embodiment of the present invention, wherein an ideal twisted-pair cable without positional deviation is shown and the twisted-pair cable is in a testing position.

[0048] Figure 5 This is a plan view of a twisted-pair crimping system according to an exemplary embodiment of the present invention, showing an actual manufactured twisted-pair cable with a positional deviation and the cable being inspected at a testing station.

[0049] Figure 6 A plan view of a twisted-pair crimping system according to an exemplary embodiment of the present invention is shown, wherein the moving die of the crimping device simultaneously covers both conductor cores of the twisted pair.

[0050] Figure 7 This diagram shows a plan view of a twisted-pair crimping system according to an exemplary embodiment of the present invention, wherein the moving die of the crimping device covers only one conductor core of the twisted pair.

[0051] Figure 8 This image shows an end face image of a qualified twisted pair cable according to an exemplary embodiment of the present invention.

[0052] Figure 9 This diagram shows a partially enlarged view of the conductor core of a qualified twisted pair cable according to an exemplary embodiment of the present invention.

[0053] Figure 10 This image shows an end face image of a substandard twisted pair cable according to an exemplary embodiment of the present invention. Detailed Implementation

[0054] The technical solution of the present invention will be further described in detail below through embodiments and in conjunction with the accompanying drawings. In this specification, the same or similar reference numerals indicate the same or similar components. The following description of the embodiments of the present invention with reference to the accompanying drawings is intended to explain the overall inventive concept of the present invention and should not be construed as a limitation thereof.

[0055] Furthermore, in the following detailed description, numerous specific details are set forth for ease of explanation to provide a thorough understanding of the embodiments disclosed herein. However, it will be apparent that one or more embodiments may be practiced without these specific details. In other instances, well-known structures and apparatuses are illustrated to simplify the figures.

[0056] According to a general technical concept of the present invention, a twisted-pair crimping system is provided. The twisted-pair crimping system includes: a cable clamp for clamping and fixing a twisted-pair cable; a moving device for moving the cable clamp and the twisted-pair cable in a horizontal direction perpendicular to the axis of the twisted-pair cable; an artificial intelligence vision device disposed at a detection station, capable of mimicking the human eye to identify the actual positions of the geometric centers of the two exposed conductor cores of the twisted-pair cable moved to the detection station and the actual distance between the geometric centers of the two conductor cores in the horizontal direction; a position calibration device adapted to calibrate the crimping position of the twisted-pair cable based on the positional deviation between the actual position and the predetermined ideal position, when the actual distance is not less than a predetermined safety distance, to eliminate the positional deviation; and a crimping device disposed at a crimping station for crimping the conductor cores to a terminal fixed at a predetermined crimping position. When the conductor cores are moved to the predetermined crimping position, the geometric center of the conductor cores is located on the centerline of the terminal fixed at the predetermined crimping position.

[0057] According to another general technical concept of the present invention, a twisted-pair crimping system is provided. The twisted-pair crimping system includes: a cable clamp for clamping and fixing a twisted-pair cable, wherein each conductor core of the twisted-pair cable comprises multiple conductive wires twisted together; a moving device for moving the cable clamp and the twisted-pair cable in a horizontal direction perpendicular to the axis of the twisted-pair cable; and an artificial intelligence vision device disposed at an inspection station, capable of mimicking the human eye to identify the actual number of conductive wires in each conductor core of the twisted-pair cable. When the actual number of conductive wires in the conductor core identified by the artificial intelligence vision device is not equal to a predetermined number, the artificial intelligence vision device determines that the quality of the twisted-pair cable is unqualified.

[0058] According to another general technical concept of the present invention, a method for crimping twisted-pair cables is provided. The method includes the following steps: providing the aforementioned twisted-pair crimping system; fixing the twisted-pair cable to be crimped onto the cable clamp and moving the cable fixed on the cable clamp to a detection station using a moving device; using the artificial intelligence vision device to identify the actual number of conductive wires in each conductor core of the twisted-pair cable; and determining whether the quality of the twisted-pair cable is qualified based on the identified actual number of conductive wires in the conductor core.

[0059] Figure 1A perspective view of a processed twisted-pair cable 10 according to an exemplary embodiment of the present invention is shown. Figure 2 This diagram shows a perspective view of a twisted-pair crimping system according to an exemplary embodiment of the present invention. Figure 3 A plan view of the crimping device 4 of a twisted-pair crimping system according to an exemplary embodiment of the present invention is shown; Figure 4 This diagram shows a plan view of a twisted-pair crimping system according to an exemplary embodiment of the present invention, wherein an ideal twisted-pair cable 10 without positional deviation is shown and the twisted-pair cable 10 is in a testing position. Figure 5 This diagram shows a plan view of a twisted-pair crimping system according to an exemplary embodiment of the present invention, wherein an actual manufactured twisted-pair cable 10 with a positional deviation is shown and the twisted-pair cable 10 is in the testing station. Figure 6 A plan view of a twisted-pair crimping system according to an exemplary embodiment of the present invention is shown, wherein the moving mold 42 of the crimping device 4 simultaneously covers the two conductor cores 12 of the twisted-pair cable 10; Figure 7 A plan view of a twisted-pair crimping system according to an exemplary embodiment of the present invention is shown, wherein the moving mold 42 of the crimping device 4 covers only one conductor core 12 of the twisted-pair cable 10; Figure 8 This image shows an end face of a qualified twisted pair cable 10 according to an exemplary embodiment of the present invention. Figure 9 This diagram shows a partially enlarged schematic of the conductor core 12 of a qualified twisted pair cable 10 according to an exemplary embodiment of the present invention. Figure 10 This image shows an end face of a substandard twisted pair cable 10 according to an exemplary embodiment of the present invention.

[0060] like Figures 1 to 10As shown, in an exemplary embodiment of the present invention, a twisted-pair crimping system is disclosed. The twisted-pair crimping system includes: a cable clamp 5, a moving device 6, an artificial intelligence vision device 3, a position calibration device (not shown), and a crimping device 4. The cable clamp 5 is used to clamp and fix a twisted-pair cable 10. The moving device 6 is used to move the cable clamp 5 and the twisted-pair cable 10 along a horizontal direction X perpendicular to the axial direction Y of the twisted-pair cable 10. The artificial intelligence vision device 3 is disposed at an inspection station, which is capable of mimicking the human eye to identify the actual positions P1', P2' of the geometric centers of the two exposed conductor cores 12 of the twisted-pair cable 10 moved to the inspection station, and the actual distance between the geometric centers of the two conductor cores 12 in the horizontal direction X. The position calibration device is adapted to calibrate the crimping position of the twisted-pair cable 10 based on the positional deviation between the actual positions P1', P2' and the predetermined ideal positions P1, P2, when the actual distance is not less than a predetermined safety distance, in order to eliminate the positional deviation. The crimping device 4 is installed at the crimping station and is used to crimp the conductor core 12 to the terminal 2 which is fixed at a predetermined crimping position. When the conductor core 12 is moved to the predetermined crimping position, the geometric center of the conductor core 12 is located on the center line of the terminal 2 which is fixed at the predetermined crimping position.

[0061] like Figures 1 to 10 As shown in the illustrated embodiment, the crimping device 4 includes a fixed mold 41 and a movable mold 42. The fixed mold 41 is fixed at a predetermined crimping position for fixing the terminal 2 and guiding the conductor core 12 into the terminal 2. The movable mold 42 is located above the fixed mold 41 and can move in a vertical direction Z perpendicular to the axial direction Y of the twisted pair 10 for crimping the terminal 2 onto the conductor core 12. In the illustrated embodiment, the predetermined safety distance is equal to half the width of the movable mold 42 in the horizontal direction X.

[0062] like Figures 1 to 10 As shown in the illustrated embodiment, the twisted pair crimping system further includes a position adjustment device (not shown). The position adjustment device is adapted to adjust the position of the conductor core 12 at the crimping station when the actual spacing is less than the predetermined safety spacing, so as to prevent the two conductor cores 12 of the twisted pair 10 from being crimped into the same terminal 2 simultaneously by the moving mold 42.

[0063] like Figures 1 to 10 As shown in the illustrated embodiment, when the actual spacing is less than the predetermined safety spacing, the position adjustment device adjusts the position of the two conductor cores 12 of the twisted pair 10 relative to the moving mold 42, so that one conductor core 12 currently being crimped is located in the coverage area of ​​the moving mold 42 in the vertical direction Z, and the other conductor core 12 is located outside the coverage area of ​​the moving mold 42 and close to the side of the coverage area.

[0064] like Figures 1 to 10As shown in the illustrated embodiment, the artificial intelligence vision device 3 includes a recognition module (not shown) and a calculation module (not shown). The recognition module is capable of mimicking the human eye in recognizing the geometric contours of the exposed core wires 11 and the exposed conductor cores 12 of the twisted pair 10. The calculation module is capable of calculating the actual positions P1' and P2' of the geometric centers of the conductor cores 12, the positional deviations between the actual positions P1' and P2' and the predetermined ideal positions P1 and P2, and the actual distance between the geometric centers of the two conductor cores 12, based on the recognized geometric contours of the conductor cores 12.

[0065] like Figures 1 to 10 As shown in the illustrated embodiment, the recognition module includes a vertical camera 31 and a vision processor (not shown). The vertical camera 31 is used to capture images of the twisted pair 10 along a vertical direction Z perpendicular to the axis Y of the twisted pair 10. The vision processor is capable of recognizing the geometric contours of the core wires 11 and conductor cores 12 of the twisted pair 10 based on the images of the twisted pair 10 captured by the vertical camera 31.

[0066] like Figures 1 to 10 As shown in the illustrated embodiment, each conductor core 12 of the twisted pair 10 includes multiple conductive wires 13 twisted together. The artificial intelligence vision device 3 is also able to mimic the human eye to identify the actual number of conductive wires 13 in each conductor core 12 of the twisted pair 10. When the actual number of conductive wires 13 in the conductor core 12 identified by the artificial intelligence vision device 3 is not equal to the predetermined number, the artificial intelligence vision device 3 determines that the quality of the twisted pair 10 is unqualified.

[0067] like Figures 1 to 10 As shown in the illustrated embodiment, the twisted-pair crimping system also includes a removal device (not shown) located at the inspection station for removing substandard twisted-pair cables 10 from the cable clamp 5.

[0068] like Figures 1 to 10 As shown in the illustrated embodiment, the artificial intelligence vision device 3 includes a recognition module (not shown) and a calculation module (not shown). The recognition module is capable of mimicking the human eye to recognize the end face contours of the two core wires 11 of the twisted pair 10 and the end face contours of the conductive wires 13 of the two conductor cores 12. The calculation module is capable of calculating the actual number of conductive wires 13 of the conductor core 12 based on the recognized end face contours of the core wires 11 and the end face contours of the conductive wires 13 of the conductor core 12.

[0069] like Figures 1 to 10As shown in the illustrated embodiment, the recognition module includes a horizontal camera 32 and a vision processor (not shown). The horizontal camera 32 is used to capture images of the end faces of the twisted pair 10 along the axial direction Y of the twisted pair 10. The vision processor is capable of recognizing the end face contours of the two core wires 11 and the end face contours of the conductive wires 13 of the two conductor cores 12 of the twisted pair 10 based on the end face images captured by the horizontal camera 32.

[0070] like Figures 1 to 10 As shown, in an exemplary embodiment of the present invention, a twisted-pair crimping system is disclosed. The twisted-pair crimping system includes: a cable clamp 5, a moving device 6, and an artificial intelligence vision device 3. The cable clamp 5 is used to clamp and fix a twisted-pair cable 10, wherein each conductor core 12 of the twisted-pair cable 10 includes multiple conductive wires 13 twisted together. The moving device 6 is used to move the cable clamp 5 and the twisted-pair cable 10 in a horizontal direction X perpendicular to the axial direction Y of the twisted-pair cable 10. The artificial intelligence vision device 3 is disposed at an inspection station, which is capable of mimicking the human eye to identify the actual number of conductive wires 13 in each conductor core 12 of the twisted-pair cable 10. When the actual number of conductive wires 13 in the conductor core 12 identified by the artificial intelligence vision device 3 is not equal to a predetermined number, the artificial intelligence vision device 3 determines that the quality of the twisted-pair cable 10 is unqualified.

[0071] like Figures 1 to 10 As shown in the illustrated embodiment, the twisted-pair crimping system also includes a removal device (not shown) located at the inspection station for removing substandard twisted-pair cables 10 from the cable clamp 5.

[0072] like Figures 1 to 10 As shown in the illustrated embodiment, the artificial intelligence vision device 3 includes a recognition module (not shown) and a calculation module (not shown). The recognition module is capable of mimicking the human eye to recognize the end face contours of the two core wires 11 of the twisted pair 10 and the end face contours of the conductive wires 13 of the two conductor cores 12. The calculation module is capable of calculating the actual number of conductive wires 13 of the conductor core 12 based on the recognized end face contours of the core wires 11 and the end face contours of the conductive wires 13 of the conductor core 12.

[0073] like Figures 1 to 10 As shown in the illustrated embodiment, the recognition module includes a horizontal camera 32 and a vision processor (not shown). The horizontal camera 32 is used to capture images of the end faces of the twisted pair 10 along the axial direction Y of the twisted pair 10. The vision processor is capable of recognizing the end face contours of the two core wires 11 and the end face contours of the conductive wires 13 of the two conductor cores 12 of the twisted pair 10 based on the end face images captured by the horizontal camera 32.

[0074] like Figures 1 to 10As shown in the illustrated embodiment, the artificial intelligence vision device 3 can also mimic the human eye to recognize the actual positions P1', P2' of the geometric centers of the two exposed conductor cores 12 of the twisted pair 10 moved to the inspection station, and the actual distance between the geometric centers of the two conductor cores 12 in the horizontal direction X. The twisted pair crimping system also includes: a position calibration device (not shown) and a crimping device 4. The position calibration device is adapted to calibrate the crimping position of the twisted pair 10 based on the positional deviation between the actual positions P1', P2' and the predetermined ideal positions P1, P2, when the actual distance is not less than a predetermined safety distance, so as to eliminate the positional deviation. The crimping device 4 is disposed at the crimping station and is used to crimp the conductor cores 12 to the terminal 2 fixed at the predetermined crimping position. When the conductor cores 12 are moved to the predetermined crimping position, the geometric center of the conductor cores 12 is located on the centerline of the terminal 2 fixed at the predetermined crimping position.

[0075] like Figures 1 to 10 As shown in the illustrated embodiment, the crimping device 4 includes a fixed mold 41 and a movable mold 42. The fixed mold 41 is fixed at a predetermined crimping position for fixing the terminal 2 and guiding the conductor core 12 into the terminal 2. The movable mold 42 is located above the fixed mold 41 and can move in a vertical direction Z perpendicular to the axial direction Y of the twisted pair 10 for crimping the terminal 2 onto the conductor core 12. The aforementioned predetermined safety distance is equal to half the width of the movable mold 42 in the horizontal direction X.

[0076] like Figures 1 to 10 As shown in the illustrated embodiment, the twisted pair crimping system further includes a position adjustment device (not shown), which is adapted to adjust the position of the conductor core 12 at the crimping station when the actual spacing is less than a predetermined safety spacing, so as to prevent the two conductor cores 12 of the twisted pair 10 from being simultaneously crimped into the same terminal 2 by the moving mold 42.

[0077] like Figures 1 to 10 As shown in the illustrated embodiment, when the actual spacing is less than the predetermined safety spacing, the position adjustment device adjusts the position of the two conductor cores 12 of the twisted pair 10 relative to the moving mold 42, so that one conductor core 12 currently being crimped is located in the coverage area of ​​the moving mold 42 in the vertical direction Z, and the other conductor core 12 is located outside the coverage area of ​​the moving mold 42 and close to the side of the coverage area.

[0078] like Figures 1 to 10As shown in the illustrated embodiment, the artificial intelligence vision device 3 includes a recognition module (not shown) and a calculation module (not shown). The recognition module is capable of mimicking the human eye in recognizing the geometric contours of the exposed core wires 11 and the exposed conductor cores 12 of the twisted pair 10. The calculation module is capable of calculating the actual positions P1' and P2' of the geometric centers of the conductor cores 12, the positional deviations between the actual positions P1' and P2' and the predetermined ideal positions P1 and P2, and the actual distance between the geometric centers of the two conductor cores 12, based on the recognized geometric contours of the conductor cores 12.

[0079] like Figures 1 to 10 As shown in the illustrated embodiment, the recognition module includes a vertical camera 31 and a vision processor (not shown). The vertical camera 31 is used to capture images of the twisted pair 10 along a vertical direction Z perpendicular to the axis Y of the twisted pair 10. The vision processor identifies the geometric contours of the core wires 11 and conductor cores 12 of the twisted pair 10 based on the images of the twisted pair 10 captured by the vertical camera 31.

[0080] like Figures 1 to 10 As shown, in another exemplary embodiment of the present invention, a method for crimping twisted-pair cables is also disclosed. This method includes the following steps:

[0081] S10: Provides the aforementioned twisted-pair crimping system;

[0082] S20: Fix the twisted pair 10 to be crimped onto the cable clamp 5 and use the moving device 6 to move the twisted pair 10 fixed on the cable clamp 5 to the inspection station.

[0083] S30: Use artificial intelligence vision device 3 to identify the actual number of conductive wires 13 in each conductor core 12 of twisted pair 10;

[0084] S40: Determine whether the quality of the twisted pair 10 is qualified based on the actual number of conductive wires 13 of the identified conductor core 12.

[0085] like Figures 1 to 10 As shown in the illustrated embodiment, if the determination result of the aforementioned step S40 is negative, then the following steps are performed:

[0086] S50: Remove the substandard twisted pair cable 10 from the cable clamp 5 using the removal device;

[0087] S51: The cable clamp 5 is moved to the loading station for loading the twisted pair cable 10 using the moving device 6;

[0088] S52: Return to the previous step S20.

[0089] like Figures 1 to 10As shown in the illustrated embodiment, if the determination result of the aforementioned step S40 is yes, then the following steps are performed:

[0090] S60: Using artificial intelligence vision device 3, identify the actual positions P1' and P2' of the geometric centers of the two conductor cores 12 of the twisted pair 10 and the actual distance between the geometric centers of the two conductor cores 12 in the horizontal direction X perpendicular to the axial direction Y of the twisted pair 10.

[0091] S70: Determine whether the actual distance is not less than the predetermined safety distance.

[0092] like Figures 1 to 10 As shown in the illustrated embodiment, if the determination result of the aforementioned step S70 is negative, then the following steps are performed:

[0093] S80: The moving device 6 moves the twisted pair 10 to the crimping station along the horizontal direction X and the position adjustment device adjusts the position of the conductor core 12 to prevent the two conductor cores 12 of the twisted pair 10 from being simultaneously crimped into the same terminal 2 by the moving mold 42 of the crimping device 4.

[0094] S81: The conductor core 12 is pressed into the terminal 2, which is fixed in a predetermined pressing position, using the crimping device 4;

[0095] S82: The twisted pair 10 with the crimped terminal 2 is moved to the inspection station using the moving device 6 and the crimping quality of the twisted pair 10 is inspected using the artificial intelligence vision device 3.

[0096] S83: Use the moving device 6 to move the twisted pair 10 to the unloading station and unload the twisted pair 10 with qualified crimping quality into the qualified product recycling box or unload the twisted pair 10 with unqualified crimping quality into the unqualified product recycling box.

[0097] S84: The cable clamp 5 is moved to the loading station for loading the twisted pair cable 10 using the moving device 6;

[0098] S85: Return to the previous step S20.

[0099] like Figures 1 to 10 As shown in the illustrated embodiment, if the determination result of the aforementioned step S70 is yes, then the following steps are performed:

[0100] S90: The twisted pair 10 is moved to the crimping station along the horizontal direction X using the moving device 6, and the crimping position of the conductor core 12 is calibrated using the position calibration device so that the geometric center of the conductor core 12 is located on the center line of the terminal 2 which is fixed at the predetermined crimping position.

[0101] S91: The conductor core 12 is pressed onto the terminal 2, which is fixed at a predetermined pressing position, using the crimping device 4;

[0102] S92: The twisted pair 10 with the crimped terminal 2 is moved to the inspection station using the moving device 6 and the crimping quality of the twisted pair 10 is inspected using the artificial intelligence vision device 3.

[0103] S93: Use the moving device 6 to move the twisted pair 10 to the unloading station and unload the twisted pair 10 with qualified crimping quality into the qualified product recycling box or unload the twisted pair 10 with unqualified crimping quality into the unqualified product recycling box.

[0104] S94: The cable clamp 5 is moved to the loading station for loading the twisted pair 10 using the moving device 6;

[0105] S95: Return to the previous step S20.

[0106] Those skilled in the art will understand that the embodiments described above are exemplary and can be improved upon. The structures described in the various embodiments can be freely combined without causing structural or principle conflicts, and these changes should fall within the protection scope of this invention.

[0107] Although the invention has been described in conjunction with the accompanying drawings, the embodiments disclosed in the drawings are intended to illustrate preferred embodiments of the invention and should not be construed as limiting the invention.

[0108] While some embodiments of the general concept of the invention have been shown and described, those skilled in the art will understand that changes may be made to these embodiments without departing from the principles and spirit of the general concept of the invention, the scope of which is defined by the claims and their equivalents.

[0109] It should be noted that the word "comprising" does not exclude other elements or steps, and the words "a" or "an" do not exclude multiple elements. Furthermore, any reference numerals in the claims should not be construed as limiting the scope of the invention.

Claims

1. A twisted pair wire crimping system, characterized by, Comprising: a cable clamp (5) for clamping and fixing a twisted pair (10); a moving device (6) for moving the cable clamp (5) and the twisted pair (10) along a horizontal direction (X) perpendicular to an axial direction (Y) of the twisted pair (10); an artificial intelligence vision device (3) arranged at a detection station, capable of simulating human eyes to identify actual positions (P1', P2') of geometric centers of two exposed conductor cores (12) of the twisted pair (10) moved to the detection station and an actual distance between the geometric centers of the two conductor cores (12) in the horizontal direction (X); a position calibration device adapted to calibrate a crimping position of the twisted pair (10) according to a position deviation between the actual positions (P1', P2') and predetermined ideal positions (P1, P2) when the actual distance is not less than a predetermined safe distance, so as to eliminate the position deviation; and a crimping device (4) arranged at a crimping station for crimping the conductor cores (12) to terminals (2) fixed at a predetermined crimping position, when the conductor cores (12) are moved to the predetermined crimping position, the geometric centers of the conductor cores (12) are located on a center line of the terminals (2) fixed at the predetermined crimping position.

2. The twisted pair crimping system according to claim 1, wherein: the crimping device (4) comprises: a fixed die (41) fixed at the predetermined crimping position for fixing the terminals (2) and guiding the conductor cores (12) into the terminals (2); and a moving die (42) located above the fixed die (41) and capable of moving along a vertical direction (Z) perpendicular to the axial direction (Y) of the twisted pair (10) for crimping the terminals (2) to the conductor cores (12), the predetermined safe distance is equal to half of a width of the moving die (42) in the horizontal direction (X).

3. The twisted pair wire crimping system of claim 2, wherein, Further comprising: a position adjusting device adapted to adjust the positions of the conductor cores (12) at the crimping station to prevent the two conductor cores (12) of the twisted pair (10) from being simultaneously crimped into the same terminal (2) by the moving die (42) when the actual distance is less than the predetermined safe distance.

4. The twisted pair crimping system according to claim 3, wherein: when the actual distance is less than the predetermined safe distance, the position adjusting device adjusts the positions of the two conductor cores (12) of the twisted pair (10) relative to the moving die (42) so that a conductor core (12) currently being crimped is located in a coverage area of the moving die (42) in the vertical direction (Z), and the other conductor core (12) is located outside the coverage area of the moving die (42) and close to a side edge of the coverage area.

5. The twisted pair crimping system according to claim 1, wherein: the artificial intelligence vision device (3) comprises: a recognition module capable of mimicking the human eye to recognize the geometric profile of the exposed core wire (11) and the geometric profile of the exposed conductor core (12) of the twisted pair cable (10); and a calculation module capable of calculating the actual position (P1', P2') of the geometric center of the conductor core (12) from the recognized geometric profile of the conductor core (12), the position deviation between the actual position (P1', P2') and the predetermined ideal position (P1, P2), and the actual distance between the geometric centers of the two conductor cores (12).

6. The twisted pair cable crimping system according to claim 5, characterized in that: the recognition module comprises: a vertical camera (31) for taking images of the twisted pair cable (10) along a vertical direction (Z) perpendicular to the axial direction (Y) of the twisted pair cable (10); and a visual processor capable of recognizing the geometric profile of the core wire (11) and the conductor core (12) of the twisted pair cable (10) from the images of the twisted pair cable (10) taken by the vertical camera (31).

7. The twisted pair cable crimping system according to any one of claims 1-6, characterized in that: each conductor core (12) of the twisted pair cable (10) comprises a plurality of conductive wires (13) twisted together, the artificial intelligence visual device (3) is further capable of mimicking the human eye to recognize the actual number of conductive wires (13) of each conductor core (12) of the twisted pair cable (10), when the actual number of conductive wires (13) of the conductor core (12) recognized by the artificial intelligence visual device (3) is not equal to the predetermined number, the artificial intelligence visual device (3) determines that the quality of the twisted pair cable (10) is unqualified.

8. The twisted pair wire crimping system of claim 7, wherein, further comprising: a removal device arranged at the detection station for removing the twisted pair cable (10) with unqualified quality from the cable clamp (5).

9. The twisted pair cable crimping system according to claim 7, characterized in that: the artificial intelligence visual device (3) comprises: a recognition module capable of mimicking the human eye to recognize the end face profile of the two core wires (11) and the end face profile of the two conductive wires (13) of the conductor core (12) of the twisted pair cable (10); and a calculation module capable of calculating the actual number of conductive wires (13) of the conductor core (12) from the recognized end face profile of the core wire (11) and the end face profile of the conductive wire (13) of the conductor core (12).

10. The twisted pair cable crimping system according to claim 9, characterized in that: the recognition module comprises: a horizontal camera (32) for taking end face images of the twisted pair cable (10) along the axial direction (Y) of the twisted pair cable (10); and a visual processor capable of recognizing the end face profile of the two core wires (11) and the end face profile of the two conductive wires (13) of the conductor core (12) of the twisted pair cable (10) from the end face images of the twisted pair cable (10) taken by the horizontal camera (32).

11. A method of crimping twisted pair wire, characterized by, comprising the following steps: S10: providing the twisted pair cable crimping system according to any one of claims 7-10; S20: Fix the twisted pair (10) to be crimped onto the cable clamp (5) and use the moving device (6) to move the twisted pair (10) fixed on the cable clamp (5) to the testing station; S30: Using the artificial intelligence vision device (3), identify the actual number of conductive wires (13) in each conductor core (12) of the twisted pair (10); S40: Determine whether the quality of the twisted pair (10) is qualified based on the actual number of conductive wires (13) of the identified conductor core (12).

12. The twisted-pair crimping method according to claim 11, characterized in that: If the result of the aforementioned step S40 is negative, then the following steps are executed: S50: Remove the substandard twisted pair (10) from the cable clamp (5) using the removal device; S51: The cable clamp (5) is moved to the loading station for loading the twisted pair (10) using the moving device (6); S52: Return to the previous step S20.

13. The twisted-pair crimping method according to claim 11, characterized in that: If the judgment result of the aforementioned step S40 is yes, then the following steps are executed: S60: Using the artificial intelligence vision device (3), identify the actual positions (P1', P2') of the geometric centers of the two conductor cores (12) of the twisted pair (10) and the actual distance between the geometric centers of the two conductor cores (12) in the horizontal direction (X) perpendicular to the axial direction (Y) of the twisted pair (10); S70: Determine whether the actual distance is not less than the predetermined safety distance.

14. The twisted-pair crimping method according to claim 13, characterized in that: If the judgment result of the aforementioned step S70 is negative, then the following steps are executed: S80: The moving device (6) moves the twisted pair (10) to the crimping station along the horizontal direction (X) and the position adjustment device adjusts the position of the conductor core (12) to prevent the two conductor cores (12) of the twisted pair (10) from being simultaneously crimped into the same terminal (2) by the moving mold (42) of the crimping device (4); S81: The conductor core (12) is pressed into the terminal (2) which is fixed at a predetermined pressing position using the crimping device (4); S82: Using the moving device (6), the twisted pair (10) with the crimped terminal (2) is moved to the inspection station and the artificial intelligence vision device (3) is used to detect whether the crimping quality of the twisted pair (10) is qualified. S83: Use the moving device (6) to move the twisted pair (10) to the unloading station and unload the twisted pair (10) with qualified crimping quality into the qualified product recycling box or unload the twisted pair (10) with unqualified crimping quality into the unqualified product recycling box. S84: Using the moving device (6), the cable clamp (5) is moved to the loading station for loading the twisted pair (10); S85: Return to the previous step S20.

15. The twisted-pair crimping method according to claim 13, characterized in that: If the judgment result of the aforementioned step S70 is yes, then the following steps are executed: S90: Using the moving device (6) along the horizontal direction (X), the twisted pair (10) is moved to the crimping station and the crimping position of the conductor core (12) is calibrated using the position calibration device so that the geometric center of the conductor core (12) is located on the center line of the terminal (2) fixed at the predetermined crimping position. S91: The conductor core (12) is pressed onto the terminal (2) fixed at the predetermined pressing position using the crimping device (4); S92: Using the moving device (6), the twisted pair (10) with the crimped terminal (2) is moved to the inspection station and the artificial intelligence vision device (3) is used to detect whether the crimping quality of the twisted pair (10) is qualified. S93: Use the moving device (6) to move the twisted pair (10) to the unloading station and unload the twisted pair (10) with qualified crimping quality into the qualified product recycling box or unload the twisted pair (10) with unqualified crimping quality into the unqualified product recycling box. S94: The cable clamp (5) is moved to the loading station for loading the twisted pair (10) using the moving device (6); S95: Return to the previous step S20.

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