CRIMPING MOLD HEALTH MONITORING AND MAINTENANCE OPTIMIZATION SYSTEM

Abstract

The invention relates to a system and method for monitoring the health condition of the moving and wear-prone components of dies used in industrial production lines, especially cable terminal crimping dies (10).

Description

1 TARIFF CRIMPING MOLD HEALTH MONITORING AND MAINTENANCE OPTIMIZATION SYSTEM Technical Area 5 The invention is primarily for industrial production, including cable terminal crimping dies. the health of the moving and wear-exposed components of the molds used in the production lines It relates to a system and method for monitoring the situation. The invention specifically addresses the wear of blades involved in cable terminal crimping dies. the amount, deformation, changes in cutting edge geometry and usage lifespan determination and real-time health status assessment, remaining usage enabling lifespan estimation and automatic optimization of maintenance decisions. It is related to a health monitoring and care optimization system. 15 State of the Art The wear condition of the blades used in cable terminal crimping dies is currently available. In industrial applications, tracking is mostly based on the number of cycles (prints). 20 This method, commonly used in production lines, involves molding based on a specific theoretical framework. It is based on the principle of maintenance or replacement when a certain number of copies are printed. For example, in many production lines, the blades require maintenance after approximately 5,000 print runs. is being taken or modified. This approach takes into account the actual physical condition of the pattern. It is an estimation method that does not take into account factors, but only relies on the number of uses. 25 In current systems, blade wear and deterioration of the cutting edge geometry occur. real-time detection of microcracks or deformations There is no structure in place for this. The health condition of the molds, operator observation or indirectly through quality problems that arise during production 30 This is being evaluated. Therefore, wear levels vary from mold to mold and production. This can vary greatly depending on the conditions. Mold material, heat treatment quality, the type of terminal used, the operator's method of application, the press machine settings and production Different wear levels at the same print count due to variables such as the environment. This can occur. This situation may lead to premature maintenance in some molds, 35 In some molds, excessive wear leads to delayed intervention. 2 Consequently, the scrap rate increases, product quality decreases, and unplanned shutdowns occur. As the number of spare parts increases, spare parts inventory management becomes more difficult, and maintenance costs rise. Current methods involve image processing, industrial camera technologies, or artificial intelligence. Since no base-based analyses are used, the physical condition of the mold cannot be objectively and continuously assessed. It cannot be evaluated. Furthermore, the remaining service life of the mold in current systems... predicts, creates a health score, or automatically makes care decisions. There is no mechanism in place. These deficiencies lead to maintenance in industrial production lines. This leads to the optimization of most processes through trial and error. This is happening and negatively impacting production efficiency. 10 In conclusion, the existence of the above problems and the inadequacy of the current solutions, This has made it necessary to make improvements in the technical field. Purpose of the Invention 15 The present invention eliminates the aforementioned disadvantages and contributes to the relevant technical field. Crimping mold health monitoring and care optimization system that brings new advantages. It is related to. The main purpose of the invention is to reduce the wear of the blades in cable terminal crimping dies. the amount, deformation, changes in cutting edge geometry and usage The goal is to create a system that allows for the determination of lifespan. The purpose of the invention is to determine the real-time health status of knives, with 25% remaining use. enabling lifespan estimation and automatic optimization of maintenance decisions. The goal is to establish a system. Another purpose of the invention is to determine the physical condition of the die blades based on the number of cycles. The goal is to establish a system that evaluates independently and objectively. 30 Another aim of the invention is to use image processing and artificial intelligence algorithms to define a knife. The goal is to develop a system that calculates the wear rate and the health score of the mold. Another aim of the invention is to automatically alert the operator when critical wear levels are reached. The goal is to establish a system that provides warnings and creates a maintenance plan. 3 Another purpose of the invention is to integrate all images, analysis results, health scores, and care. storing its history in a database allows for retrospective comparison. The goal is to create a system that provides this. Another purpose of the invention is to communicate with the production machine to control the cycle number and operation. automatically collects and analyzes this information and integrates the results into the production management system. The goal is to create a system for transmitting information. Another aim of the invention is to reduce unplanned downtime and prevent unnecessary maintenance procedures. and to create a system that improves product quality. 10 Another aim of the invention is to create a modular structure adaptable to different crimping molds. The goal is to create a system that is user-friendly and can be easily integrated into production lines. Another aim of the invention is to combine additional sensor data such as force, vibration, and temperature with 15 multiple that can be expanded and evaluate this data together with image processing results The goal is to establish a system suitable for analysis. To fulfill all the purposes mentioned above and those that can be derived from the detailed explanation. The invention is based on industrial production, primarily cable terminal crimping molds. the health of the moving and wear-exposed components of the molds used in the production lines It is a system that enables monitoring of the situation, - the mold positioned on the crimping die and the mold on the crimping die high resolution of the blades in each cycle or at specified periods The industrial camera that captured the image, 25 - an industrial camera placed on the crimping die to capture images. by providing constant and homogeneous light during the process, it standardizes image quality. lighting module, - a knife connected to the camera and captured by the camera's images. wear, cutting edge geometry, deformations, microcracks and 30 Image processing and artificial intelligence module that analyzes surface distortions, - image processing and artificial intelligence module related to image processing and Crimping mold health from images analyzed by artificial intelligence module health score that calculates wear rate and estimated remaining lifespan. score and remaining lifespan estimation module, 35 4 - linked to the health score and remaining lifespan estimation module, and health critical score and remaining service life estimation module calculated by Decision support systems that make decisions about maintenance, replacement, or continuing production based on thresholds. software, - related to decision support software and by decision support software 5 The determined crimping die's health condition, wear level, remaining Operator interface that displays service life and maintenance recommendations to the operator. - all image recordings captured by the camera, image processing and artificial intelligence the analysis results generated by the intelligence module, health score and remainder Health scores calculated with the lifespan estimation module, maintenance history 10 and a database that stores production data, - by communicating with the crimping press machine that activates the crimping die Production machine communication that collects cycle count and operating information. It is related to the fact that it includes the module. The invention is also applicable to industrial applications, particularly cable terminal crimping dies. the moving and wear-prone components of molds used in production lines It is a method that enables monitoring of health status, a) After the crimping process is completed, by industrial camera The image of the blades on the crimping die is illuminated by module 20. Automatic acquisition in cycles determined with support, b) Images captured by the industrial camera are displayed via the lighting module. Image processing is performed by conducting quality control under the provided standard lighting conditions. and transfer to the artificial intelligence module, c) Image processing and artificial intelligence module performs knife-like operations on images. wear, cutting edge geometry, microcracks, deformations and by analyzing surface deterioration, health score and wear rate are determined. The data is transmitted to the health score and remaining life expectancy estimation module, and Mold health by health score and remaining lifespan estimation module Calculation of score and wear rate, 30 d) Calculated by the health score and remaining lifespan estimation module health score and remaining lifespan, by decision support software comparison with predefined threshold values ​​and this comparison the decision as a result of which maintenance or mold change is required creation, 35 e) Critical wear alerts generated by decision support software and maintenance decisions are displayed to the operator via the operator interface, obtained all images, analysis results, health scores and care recording its history in the database and production machine communication. Sending the necessary notifications to the production system via the module 5 It includes the steps of the process. The structural and characteristic features and all the advantages of the invention are given in the figures below. And thanks to the detailed explanation written with references to these figures, it becomes clearer. This will be understood as such. Therefore, the evaluation should also include these forms and detailed explanations. This should be done taking this into consideration. 10 Figures that will help understand the invention. Figure 1: Schematic diagram of the system described in the invention. Explanation of Part References 10. Crimping mold 20. Industrial camera 30. Lighting module 20 40. Image processing and artificial intelligence module 50. Health score and remaining lifespan estimation module 60. Decision support software 70. Operator interface 80. Database 25 90. Production machine communication module Detailed Description of the Invention In this detailed description, the preferred alternatives to the system in question are only 30. to facilitate a better understanding of the subject and without creating any limiting effects. This is explained as follows. Figure 1 shows a schematic diagram of the system that is the subject of the invention. Accordingly, the system is the most In its basic form; it enables the mechanical connection of the cable to the cable terminal. 35 Crimping die (10) which performs the crimping process, crimping die (10) 6 the die blades on it have a high speed in each cycle or at specified periods. industrial camera (20) that captures the high-resolution image of the industrial camera (20) By providing constant and homogeneous light during image acquisition, it ensures standard image quality. lighting module (30) which makes it so, from the images taken by the camera (20) blade wear, cutting edge geometry, deformations, microcracks and 5 Image processing and artificial intelligence module (40) that analyzes surface distortions, image Crimping pattern from images analyzed with processing and artificial intelligence module (40) (10) calculates the health score, wear rate and estimated remaining service life health score and remaining lifespan estimation module (50), health score and remaining Maintenance, replacement 10 according to critical thresholds calculated with the service life estimation module (50). or decision support software that decides to continue production (60), decision support software Crimping mold (10) determined by (60) health status, wear level, remaining Operator interface (70) which shows the operator the service life and maintenance recommendations. All image recordings taken by the camera (20) are processed by image processing and artificial intelligence. Analysis results produced by module (40), health score and remaining service life 15 Health scores, care history and production calculated with the prediction module (50). The database (80) that stores the data communicates with the crimping press machine and cycles collecting the number and work data and analyzing the results for maintenance and production management. It includes a production machine communication module (90) that transfers to its processes. The system described in the invention is the wear of the blades on the crimping die (10). real-time monitoring and analysis of the condition and maintenance decisions an AI-powered crimping pattern that enables automatic generation (10) It is a health monitoring system. Crimping mold (10), cable terminal and mechanical cable. It ensures that they are joined together. Crimping process is performed by crimping 25 There are blades that are subject to wear on the mold (10). Crimping die (10) on which the physical condition of the blades can be monitored Industrial cameras (20) are positioned. The industrial cameras (20) are positioned on each high resolution of die blades in the cycle or at specified intervals It obtains images. The images taken by the camera (20) are used for analysis. In order to ensure that it is of suitable quality, during the image acquisition on the crimping mold (10) A lighting module (30) providing constant and homogeneous light is installed. Thus The brightness, contrast, and shadow structure of the images have been standardized. Images obtained by camera (20) are analyzed by camera 35, which is the analysis component of the system. to be processed by the image processing and artificial intelligence module (40) associated with (20) 7 is transferred to the system. Image processing and artificial intelligence module (40), in the images blade edge geometry, wear amount, deformation, microcracks, and surface It includes algorithms that can detect distortions and the crimping pattern (10) It generates numerical data regarding the physical condition of the blades. Analysis data obtained by the image processing and artificial intelligence module (40), health score and remaining associated with image processing and artificial intelligence module (40) The crimping mold is evaluated by the service life estimation module (50). (10) health score, wear rate and estimated remaining service life are calculated. Health score and remaining lifespan estimation module (50), analyzes data mathematically 10 by converting the current state of the crimping mold (10) into models numerically It produces an output that expresses this. Calculated by the health score and remaining lifespan estimation module (50) values ​​are linked to the health score and remaining lifespan estimation module (50) 15 The decision support software (60) is processed by the decision support software. (60), maintenance by interpreting the health condition of the crimping mold (10), such as changing the crimping mold (10) or continuing production making decisions and the component of the system that transmits information about these decisions to the user It is offered via the operator interface (70). 20 connected with the decision support software (60). operator interface (70), crimping die (10) health status, wear level, a user who visually displays the remaining service life and maintenance recommendations It is the interface. The system includes all image recordings, analysis results, health scores, care history, and 25 The production data is stored in the database (80). The database (80) has a history. by comparing data, monitoring wear curves, and verifying the accuracy of the system. It is a centralized registration structure that allows for the level to be increased. The system obtains... The information received is presented to the user visually via the operator interface (70), All analysis results and maintenance history are recorded in the database (80). is being received. The production machine communication module (90) activates the crimping mold (10). Communicating with the crimping press machine, it transmits cycle count and operating information. collecting and analyzing the results and integrating them into maintenance and production management processes. 35 It is able to transfer. Thanks to this structure, any fundamental element in the existing production line is eliminated. 8 Mold health status in real time without requiring process changes. It can be monitored, and maintenance decisions are optimized with AI-powered analyses. Unplanned downtime is reduced, and product quality and production efficiency are increased. The system is designed in a modular structure and can accommodate different types of crimping molds (10) and 5 Used in different production lines if suitable mechanical adaptations are made. It can be developed in a way that can be applied to similar pattern systems. Image processing and The algorithms of the artificial intelligence module (40) are updated with new data obtained during use. by updating it in a way that will allow the accuracy of the analysis to be improved It is configurable. 10 In an alternative design of the invention, the system may utilize force, vibration, temperature, or similar factors. It can be developed to work with data obtained from sensors. This The data is evaluated together with image processing and artificial intelligence analysis results, Crimping mold (10) allows for higher accuracy in determining health status. 15 It can provide opportunities. The system described in this invention reduces unplanned production downtime and unnecessary maintenance. and preventing premature part replacements, improving product quality, maintenance reducing costs, improving spare parts inventory management and production 20 Its efficiency has been increased. The operating principle of the system described in the invention is as follows: After the crimping process is completed or within the predetermined cycle 25 between them, industrial camera (20), lighting module (30) provided by High crimping die (10) blades under constant and homogeneous light conditions It automatically takes high-resolution images. Obtained by the camera (20) The images are transferred to the image processing and artificial intelligence module (40) for analysis. In the image processing and artificial intelligence module (40), image processing algorithms are transferred. The images show the blade edge geometry, wear amount, and deformations. It detects microcracks and surface defects. Artificial intelligence algorithms then perform this... image data along with cycle count, maintenance history and usage data. by evaluating health score and remaining lifespan estimation module (50) 35 It calculates the mold's health score, wear rate, and estimated remaining service life. 9 Health score and remaining lifespan values ​​are determined by decision support software (60). It is compared with predefined threshold values. As a result of this comparison... system; production continues, planned maintenance is carried out, crimping mold (10) planning the replacement or when critical wear levels are reached by the operator It automatically generates a decision to be alerted. 5 Analysis results and maintenance recommendations generated by decision support software (60), It is presented to the user visually via the operator interface (70). However All images taken by the camera (20) are processed by the image processing and artificial intelligence module. Analysis results produced by (40) health score and remaining lifespan estimate 10 health scores, care records and production data database calculated with module (50) (80) are stored within. These records allow comparison with past data and It enables continuous improvement of system performance. Production machine communication module (90), cycle information from production equipment and 15 It automatically retrieves relevant production data, transfers it to analysis processes, and provides decision support. the results generated by the software (60) are transferred to the maintenance and production management systems This ensures that the information is transmitted. Thanks to this method, maintenance decisions are made only during the cycle (printing). not depending on the number, but the actual physical wear condition of the crimping die (10) and This is provided based on AI-powered analysis results. Thus, unnecessary maintenance is eliminated. 20 Processes are reduced, unplanned downtimes are prevented, product quality is improved, and mold usage is reduced. Its lifespan is managed more effectively.

Claims

REQUESTS 1. Industrial production, especially cable terminal crimping molds (10). molds used in production lines are mobile and exposed to wear It is a system that enables monitoring of the health status of its components, and its feature is; 5 - positioned on the crimping die (10) and the crimping die (10) the die blades on it in each cycle or at specified periods industrial camera that takes high resolution image (20), - placed on the crimping die (10) and the industrial camera (20) by providing constant and homogeneous light during image acquisition 10 lighting module (30) that standardizes image quality, - connected to camera (20) and received by camera (20) From the images, we can observe blade wear, cutting edge geometry, analyzing deformations, microcracks and surface defects Image processing and artificial intelligence module (40), 15 - image related to image processing and artificial intelligence module (40) from images analyzed with the processing and artificial intelligence module (40) Crimping mold (10) health score, wear rate and estimated remaining health score that calculates lifespan and remaining lifespan prediction module (50), 20 - linked to health score and remaining lifespan estimation module (50) health score and remaining lifespan estimation module (50) Maintenance, replacement, or production based on critical thresholds calculated by [company name]. Decision support software that makes the decision to continue (60), - decision support software (60) and decision support software 25 Crimping pattern determined by (60) (10) health status, wear level, remaining service life and maintenance recommendations It includes the operator interface (70) which shows the operator.

2. It is a system that complies with Claim 1, and its feature is that it is controlled by the camera (20) mentioned 30 All the image recordings taken are processed by the image processing and artificial intelligence module (40) analysis results, health score and remaining lifespan produced by Health scores, care history and production calculated with the prediction module (50). It contains a database (80) that stores its data. 35 11 3. It is a system that conforms to Claim 1, and its feature is that it uses the mentioned crimping pattern (10) By communicating with the crimping press machine that activates it, the number of cycles and Production machine communication module (90) that collects working information It includes.

4. Industrial production, especially cable terminal crimping molds (10). molds used in production lines are mobile and exposed to wear It is a method that enables monitoring the health status of its components, feature; a) After the crimping process is completed, industrial camera (20) 10 The image of the blades on the crimping die (10) by Automatically in the cycles determined with the support of the lighting module (30) taking, b) Images taken by the industrial camera (20), lighting module Image 15 was quality controlled by performing quality control under standard lighting conditions provided by (30). transfer to the processing and artificial intelligence module (40), c) Image processing and artificial intelligence module (40) on images blade wear, cutting edge geometry, microcracks, health score by analyzing deformations and surface defects and data on wear rate, health score and remaining service life 20 transmitting to the prediction module (50) and mold health by this module Calculation of the score and wear rate, d) Health score and remaining lifespan estimation module (50) calculated health score and remaining lifespan, decision support 25 with threshold values ​​predefined by the software (60). comparison and, as a result of this comparison, maintenance or mold replacement. making a decision as to whether it is necessary or not e) Critical wear warnings generated by decision support software (60) and maintenance decisions are sent to the operator via the operator interface (70). 30 shown It includes the steps of the process.

5. A method that conforms to claim 4, and its characteristic is that it is obtained in the aforementioned step (e). all images, analysis results, health scores and care This includes the step of recording the history into the database (80). 35 12 6. A method that complies with claim 4, and its characteristic is that production occurs in the mentioned (e) process step. The machine communicates with the production system via the communication module (90) This includes the process of sending notifications.

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