System and method for determining termination quality of electrical wire using thermal characteristics
By using thermal sensors to monitor and analyze the thermal characteristics of terminals and wires during wire termination, the problem of accurately identifying termination quality in existing technologies is solved, enabling precise monitoring and evaluation of wire terminations.
Patent Information
- Application Number
- CN202480024973.0
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2023-04-14
- Filing Date
- 2024-04-04
- Publication Date
- 2025-11-11
AI Technical Summary
Existing wire termination quality monitoring systems struggle to accurately identify defective crimped connections, especially when using manual tools. Traditional force- and size-based monitoring methods are prone to misjudgment and cannot effectively monitor changes in thermal properties.
Thermal sensors are used to monitor the termination thermal data from the terminal to the wire and compare it with stored thermal data to determine the termination quality. This includes using thermal sensors to collect thermal energy, transferred and reflected thermal energy from the terminal and the wire, and combining data analysis techniques such as convolutional neural networks for feature extraction and quality assessment.
It enables precise monitoring of wire termination quality, identifies defects that are difficult to detect using traditional methods, improves the reliability and accuracy of termination connections, and is applicable to various termination methods and materials.
Smart Images
Figure CN120937199A_ABST
Abstract
Description
Technical Field
[0001] This article relates to methods and systems for monitoring the termination quality of wires using the thermal properties of the termination. Background Technology
[0002] Electrical wires are terminated using various methods, such as crimping, brazing, or soldering. For example, electrical terminals are typically crimped onto wires using a crimping device to form leads. A crimping device can be a stationary device or a hand tool. In operation, the terminal is placed in a fixed part of the stationary device or hand tool, and the end of the wire is inserted into the ferrule or sleeve of the terminal. The crimping head of the tool is moved toward the fixed part through a crimping stroke, thereby crimping the terminal onto the wire.
[0003] Systems for monitoring crimp quality have been developed. When a defective crimp is detected, the lead is discarded. Some known crimp quality monitoring systems measure crimp quality by measuring the crimp height. Typically, if the terminal is not crimped to the correct crimp height for a given terminal and wire combination, it will result in an unsatisfactory crimp connection. However, many unsatisfactory crimp connections will still exhibit a “correct” crimp height. Therefore, systems that monitor crimp quality based on crimp height may allow defective leads to pass through the crimping device. Additionally, variations in crimp height or other physical changes in the crimped terminal are not themselves the cause of a defective crimp connection, but can indicate another factor leading to a poor connection. These factors include using the wrong terminal or wire size, missing wire bundles, short brushes, insulation in the crimp, abnormal terminal placement, incorrect wire type, improper insulation stripping, etc. Such defective crimp connections often have the appearance of high-quality crimp connections and are therefore detectable upon inspection.
[0004] Other known crimp quality monitoring systems detect defective crimps by analyzing the crimping force applied to the terminals during actual crimping operations. For example, the system collects force and displacement data during the crimping stroke and compares this data with normalized data collected from known good crimps during a learning phase. This comparison is used to determine whether a particular crimp meets acceptable criteria. However, crimp quality monitoring systems based on force distribution are not without problems. The system is inaccurate when measuring certain types of defective crimps. For example, the system is susceptible to incorrectly identifying crimps with insulation in the barrel as good crimps. The system is also prone to incorrectly identifying some good crimps as defective. Furthermore, for various materials, such as aluminum wire, the force variation between crimping terminals with correctly inserted aluminum wire and crimping terminals without inserted aluminum wire is very small. Therefore, measuring force to determine whether a crimp is proper is ineffective.
[0005] Furthermore, measuring the crimp quality of crimped terminals is difficult when crimping is performed using hand tools. Due to the size, portability, and nature of hand tools, it is difficult to provide sufficient monitoring equipment or sensors to properly monitor the crimp quality.
[0006] Not only is a crimping quality monitoring system needed, but also a wire termination quality monitoring system is typically required. This system can be used to accurately monitor the termination quality of all types of wires and different types of terminations, whether the termination is done by a stationary device or by hand tools.
[0007] Therefore, it is advantageous to provide wire termination monitoring systems and methods that can be used to monitor different wire terminations, regardless of the device used to achieve the wire termination. Particularly advantageous are wire termination monitoring systems and methods that not only measure force or dimensions but also monitor the thermal characteristics of the termination. Summary of the Invention
[0008] This embodiment relates to a method for determining the quality of a terminal-to-wire termination. The method includes: positioning a terminal in a wire termination area of a wire termination device; positioning a wire in the wire termination area of the wire termination device; terminating the terminal to the wire; monitoring thermal data of the terminal-to-wire termination using one or more thermal sensors; and comparing the monitored thermal data with stored thermal data to determine if the terminal-to-wire termination is defective. If the terminal-to-wire termination is defective, the wire is discarded. Attached Figure Description
[0009] The invention will now be described by way of example with reference to the accompanying drawings, in which:
[0010] Figure 1 This is a perspective view of a first illustrative wire termination system with a handheld wire termination device and a thermal sensor located thereon to monitor the termination quality from the terminal to the wire.
[0011] Figure 2 It is along Figure 1 The line 2-2 cut Figure 1 An illustrative end view of a handheld wire termination device.
[0012] Figure 3 This demonstrates the use of thermal property monitoring. Figure 1 A flowchart illustrating the terminating quality of terminals to wires.
[0013] Figure 4 This is a perspective view of a second illustrative wire termination system, having an illustrative wire termination device and an illustrative thermal sensor located near the wire termination device to monitor the termination quality from the terminal to the wire. The illustrative wire termination device is a crimping device.
[0014] Figure 5This demonstrates the use of thermal property monitoring. Figure 4 A flowchart illustrating the terminating quality of terminals to wires.
[0015] Figure 6 This is a perspective view of a third illustrative wire termination system, featuring an illustrative wire termination device and an illustrative thermal sensor located near the wire termination device to monitor the termination quality from the terminal to the wire. The illustrative wire termination device is a heating device.
[0016] Figure 7 This demonstrates the use of thermal property monitoring. Figure 6 A flowchart illustrating the terminating quality of terminals to wires. Detailed Implementation
[0017] Illustrative wire termination systems 2, 102, 202 with wire termination devices or apparatus 10, 110, 210 and methods for monitoring the wire termination process 300, 400 are shown in order to determine the termination quality by using thermal properties and characteristics.
[0018] Figure 1-2 Figures 4-5 show crimping devices 10 and 110, which use thermal properties and characteristics to determine the quality of the crimped termination. Figure 7 -8 illustrates heating device 210, such as, but not limited to, devices for heat shrinking, which use thermal properties and characteristics to determine the quality of heated terminations. However, the use of crimping devices 10, 110 and heating device 210 is illustrative and not limiting. As described below, using thermal data and analysis to monitor the termination of wires, conductors, or terminals has other uses beyond those related to crimping and heating terminations alone. For example, devices such as insulation displacement connector (IDC) devices, soldering devices, etc., can be used to attach connectors or terminals to wires using processes other than crimping or heat shrinking. Alternatively, crimping devices 10, 110 can be another type of crimping device, such as lead frame devices.
[0019] refer to Figure 1 and Figure 2The applicator 12 is coupled to the crimping device 10. In the illustrated embodiment, the crimping device 10 is a handheld wire termination device or tool that can be used in multiple locations. The applicator 12 can be removed and replaced with a different applicator, such as when the applicator 12 is worn or damaged, or when an applicator with a different configuration is desired. The applicator 12 has a wire termination area or crimping area 18 and includes a first crimp connector 20 and a second crimp connector 22 as a mechanical tool for crimping an electrical connector or terminal 24 to the end of a wire 26 in the crimping area 18. The second crimp connector 22 can be a stationary part of the applicator 12, and the first crimp connector 20 can be a movable part. Alternatively, both the second crimp connector 22 and the first crimp connector 20 can be movable. The crimping device 10 shown and described is illustrative because crimping devices can have different configurations.
[0020] One or more sensors 28 are mounted to the crimping device 10. Sensors 28 may include thermal sensors, vision sensors, or both. Additional types of sensors may be included within sensors 28. Alternatively, one sensor 28 may be a thermal sensor, and another sensor 28 located away from the thermal sensor may be a vision sensor. Sensors 28 may be mounted in or near various locations within or near the crimping area 18. Sensors 28 may be movably mounted by a removable device, such as, but not limited to, a magnet (not shown). Alternatively, sensors 28 may be held in place using mechanical fasteners, latches, adhesives, etc. The shape and positioning of sensors 28 are intended to be illustrative, as thermal sensors may have other configurations and may be positioned in other locations.
[0021] exist Figure 1 and Figure 2 In the illustrated embodiment, sensor 28 is a thermal sensor 28 positioned to have a field of view including the crimp region 18. Thermal sensor 28 is positioned to acquire thermal characteristics of the terminal 24 and / or wire 26 in the crimp region 18 in the form of heat dissipation data. In the illustrative embodiment, thermal sensor 28 is positioned in line with the longitudinal axis 30 of the terminal 24. This allows thermal sensor 28 to directly sense and collect thermal data from heat energy emitted directly from the terminal 24 and / or wire 26. In an alternative embodiment, thermal sensor 28 may be positioned offset or eccentrically from axis 30. If sensor 28 is positioned offset or eccentrically from axis 30, thermal sensor 28 may collect heat energy transferred through terminal 24 to wire 26 or another object, and / or thermal sensor 28 may collect heat energy reflected from terminal 24 and / or wire 26. In various illustrative embodiments, more than one thermal sensor 28 may be provided.
[0022] In various illustrative embodiments, the applicator may have protrusions located near the crimping area 18 and the terminals 24 and / or wires 26, configured to intentionally reflect or guide thermal energy from the sensed terminals 24 and / or wires 26. This allows a thermal sensor 28 offset or eccentric to the terminals 24 to read thermal data reflected from the protrusions. The protrusions may be made of a material with a known emissivity to enhance reflective imaging of the thermal properties of the terminals 24 and / or the terminated wires 26. This will allow for the ability to thermally "sensor" areas that are not easily observed or to observe a larger surface area of the terminals 24 and / or wires 26.
[0023] As previously mentioned, the thermal data collected by thermal sensor 28 can be one or a combination of three different components of energy. The first is thermal energy emitted directly from terminal 24 and / or wire 26. The second is thermal energy transferred through an object (heat from other places along the path), such as from terminal 24 to wire 26. The third is thermal energy reflected from terminal 24 and / or wire 26.
[0024] In one exemplary embodiment, thermal data is captured by multiple sensors 28 arranged in a matrix (e.g., a charge-coupled device network). This allows the thermal data to be captured and arranged in rows and columns—similar to how the pixels of the data describe a visual image collected using a conventional visual energy camera. For example, one thermal sensor may be positioned in line with the longitudinal axis of the terminal, while other thermal sensors in the matrix may be positioned offset or eccentrically from the axis. Due to the number of data points, techniques such as, but not limited to, adapted convolutional neural networks are used to extract features from these data matrices to analyze the crimping process before, during, and after crimping. These features are evident in specific regions of interest on the terminal 24 and / or wire 26 and form the basis for terminating the termination.
[0025] The characteristics and features of the collected thermal data may include, but are not limited to: i) zone heating; ii) heat transfer time; iii) heat transfer patterns; iv) temperature increments; and v) physical properties and changes identified by thermal properties.
[0026] Furthermore, thermal data can be collected at various rates, resulting in time-varying images. Using analytical techniques, such as, but not limited to, artificial intelligence, the time-varying data can be analyzed.
[0027] In various illustrative examples, thermal sensor 28 has the ability to collect absolute temperature. Absolute temperature can be used not only to analyze the "relative" region of interest, but also to analyze the potential unique mechanical properties of the termination.
[0028] The display device 32 can be communicatively coupled to the thermal sensor 28 and configured to display the thermal characteristics acquired by the thermal sensor 28. The display device 32 can be integrated into the main controller or processor of the crimping device 10 or into the thermal sensor 28 itself, or it can be a separate controller or processor 34, such as a desktop computer, laptop computer, tablet computer, monitor, projector, head-up display glasses, etc. Optionally, the display device 32 can be a crimp quality monitor (CQM) device. The controller 34 and / or the display device 32 can be coupled to the thermal sensor 28 via cables or the like. Alternatively, the controller 34 and / or the display device 32 can communicate wirelessly via induction, radio frequency waves, Wi-Fi, etc., to transmit data between the thermal sensor 28 and the controller 34 and / or the display device 32.
[0029] The controller 34 and / or display device 32 may include a storage device or memory device 36, such as, but not limited to, a hard disk drive, RAM, ROM, and / or another internal data storage device. The memory device 36 may be configured to store data acquired by the thermal sensor 28. Such data can be used for subsequent quality reporting purposes.
[0030] In various illustrative embodiments, the crimping device 10 may include additional sensors (not shown), such as, but not limited to, force sensors or linear sensors, to provide additional data on the quality of the crimping.
[0031] Figure 3 A method 50 for determining termination quality is illustrated. During the crimping operation, the first crimp connector 20 and the second crimp connector 22 of the crimping device 10 are driven toward each other and eventually away from each other, thereby terminating the terminal 24 to the wire 26, as shown. Figure 3 As shown in 52.
[0032] The crimping of terminal 24 onto wire 26 occurs as the first crimp connector 20 and the second crimp connector 22 move toward each other. The first crimp connector 20 and the second crimp connector 22 engage terminal 24 and crimp terminal 24 onto wire 26 by compressing terminal 24 between the first crimp connector 20 and the second crimp connector 22. When this occurs, heat energy or heat is generated in and around terminal 24 and wire 26 within and near the crimp.
[0033] As previously described, the thermal sensor 28 (either directly from a thermal sensor 28 positioned in line with axis 30 or indirectly from a thermal sensor 28 positioned offset or eccentrically from axis 30) can acquire temperature measurements / data at specified intervals or continuously at the ends of terminals 24 and wires 26 located in the crimping area 18. The collected temperature measurements / data are transmitted to a display device 32, controller 34, or storage device 36 located on or outside the crimping device 10. The temperature measurements / data transmitted by the thermal sensor 28 are used by the operator of the crimping device 10 to determine whether the wire terminations meet appropriate criteria to provide the desired electrical and mechanical connection. The term "operator" is used herein to identify the equipment or personnel operating or controlling the crimping device 10.
[0034] The quality of the termination can be monitored by directly or indirectly monitoring the temperature of terminal 24. Other characteristics of the termination can be analyzed by directly or indirectly analyzing the temperature of terminal 24. For example, temperature can be used to calculate the force input to terminal 24, because the amount of force is related to the temperature of terminal 24 after termination.
[0035] In an exemplary embodiment, such as Figure 3 As shown in section 54, the thermal characteristics of the termination are measured directly or indirectly by one or more thermal sensors 28 during the termination process. Thermal characteristics are measured at predetermined intervals based on time or tool position. For example, a predetermined sampling time can be selected, and thermal characteristics can be measured at each point within a discrete sampling time. Alternatively or additionally, thermal characteristics can be measured when the crimping tool is at a predetermined crimping height position. The position of the crimping tool can be detected by a distance sensor (not shown), etc.
[0036] Controller 34 can create a measured temperature distribution for termination based on the measured thermal characteristics. The measured thermal distribution is then compared to an acceptable temperature distribution or range known for successful termination, such as... Figure 3 As shown in 56. Alternatively, the measured thermal characteristics can be compared to the known acceptable temperature characteristics or distribution of the specific material used. The acceptable temperature distribution or acceptable temperature distribution range can be pre-installed in the controller 34, or it can be developed and stored in the controller 34 by the user in the field. If the measured temperature distribution is within the acceptable temperature distribution range, the controller 34 will indicate that the termination is appropriate. If the measured temperature distribution is not within the acceptable temperature distribution range, the controller 34 will indicate that the termination is unacceptable and refuse the termination, such as... Figure 3 As shown in 58, data related to thermal characteristics, peak temperature, area under the temperature curve, shape of the temperature curve, or any combination thereof can be analyzed to determine if there are defects in the terminals.
[0037] refer to Figure 4The applicator 112 is coupled to the crimping device 110. In the illustrated embodiment, the crimping device 110 is a handheld wire termination device or tool that can be used in multiple locations. The applicator 112 can be removed and replaced with a different applicator, for example, when the applicator 112 is worn or damaged, or when an applicator with a different configuration is desired. The applicator 112 has a wire termination area or crimping area 118 and includes a first crimp connector 120 and a second crimp connector 122 as a mechanical tool for crimping an electrical connector or terminal 124 to the end of a wire 126 in the crimping area 118. The second crimp connector 122 can be a stationary part of the applicator 112, and the first crimp connector 120 can be a movable part. Alternatively, both the second crimp connector 122 and the first crimp connector 120 can be movable. The crimping device 110 shown and described is illustrative, as crimping devices can have different configurations.
[0038] One or more sensors 128 are located near the crimping device 110 but are removed from it. Sensors 128 may include thermal sensors, vision sensors, or both. Additional types of sensors may be included in sensor 128. Alternatively, one sensor 128 may be a thermal sensor, and another sensor 128 located away from the thermal sensor may be a vision sensor.
[0039] exist Figure 4 In the illustrative embodiment shown, sensor 128 is a thermal sensor 128 positioned on a wearable device on the operator's wrist. However, thermal sensor 128 may be mounted on other types of wearable devices or in other locations near the crimping device 110. The shape and positioning of thermal sensor 128 are intended to be illustrative, as thermal sensors may have other configurations and may be positioned in other locations.
[0040] The thermal sensor 128 is positioned to have a field of view including the crimping area 118. To facilitate the positioning of the thermal sensor 128, a positioning or calibration device 144 may be provided to provide guidance on the correct positioning of one or more thermal sensors 128 relative to the wire termination or crimping device 110 and to indicate whether the thermal sensor 128 is correctly positioned relative to the crimping area 118. The positioning device may be disposed on or away from the thermal sensor 128. The positioning device provides guidance on the correct positioning of one or more thermal sensors relative to the wire termination area of the wire termination device.
[0041] Thermal sensor 128 is positioned to acquire thermal characteristics of terminals 124 and / or wires 126 in the crimp region 118 in the form of heat dissipation data. Thermal sensor 128 may be positioned in line with the longitudinal axis 130 of terminals 124 to allow thermal sensor 128 to directly sense and collect thermal data from heat energy emitted directly from terminals 124 and / or wires 126. Alternatively, thermal sensor 128 may be positioned offset or eccentrically from axis 130, thereby allowing thermal sensor 128 to collect heat energy transferred through terminals 124 to wires 126 or another object and / or collect heat energy reflected from terminals 124 and / or wires 126. In various illustrative embodiments, more than one thermal sensor 128 may be provided.
[0042] In various illustrative embodiments, the applicator may have protrusions located near the crimping area 118 and the terminals 124 and / or wires 126, configured to intentionally reflect or guide thermal energy from the sensed terminals 124 and / or wires 126. This allows a thermal sensor 128, offset or eccentric to the terminals 124, to read thermal data reflected from the protrusions. The protrusions may be made of a material with a known emissivity to enhance reflective imaging of the thermal properties of the terminated terminals 124 and / or wires 126. This will allow for the ability to thermally "sensor" areas that are not easily observed or to observe a larger surface area of the terminals 124 and / or wires 126.
[0043] As previously described, the thermal data collected by thermal sensor 128 can be one or a combination of three different components of energy. The first is thermal energy emitted directly from terminal 124 and / or wire 126. The second is thermal energy transferred through an object (heat from other places along the path), such as from terminal 124 to wire 126. The third is thermal energy reflected from terminal 124 and / or wire 126.
[0044] The number and location of thermal sensors, as well as the characteristics of the thermal data, are similar to those regarding... Figure 1 and Figure 2 The embodiments shown are described.
[0045] Display device 132 can be communicatively coupled to thermal sensor 128 and configured to display the thermal characteristics acquired by thermal sensor 128. Display device 132 can be integrated into the main controller or processor of crimping device 110 or the thermal sensor 128 itself, or it can be a separate controller or processor 134, such as a desktop computer, laptop computer, tablet computer, monitor, projector, head-up display glasses, etc. Optionally, display device 132 can be a crimp quality monitor (CQM) device. Controller 134 and / or display device 132 can be coupled to thermal sensor 128 via cables, etc. Alternatively, controller 134 and / or display device 132 can communicate wirelessly via induction, radio frequency waves, Wi-Fi, etc., to transmit data between thermal sensor 128 and controller 134 and / or display device 132.
[0046] The controller 134 and / or display device 132 may include a storage or memory device 136, such as, but not limited to, a hard disk drive, RAM, ROM, and / or another internal data storage device. The memory device 136 may be configured to store data acquired by the thermal sensor 128. Such data can be used for subsequent quality reporting purposes.
[0047] In various illustrative embodiments, the crimping device 110 may include additional sensors (not shown), such as, but not limited to, force sensors or linear sensors, to provide additional data on the quality of the crimping.
[0048] Figure 5 A method 150 for determining termination quality using a remote thermal sensor 128 is illustrated. During the crimping operation, the thermal sensor 128 is appropriately positioned relative to the crimping area 118, such as... Figure 5 As shown in 152, this allows the thermal sensor 128 to make appropriate measurements when crimping occurs. Then, the first crimp connector 120 and the second crimp connector 122 of the crimping device 110 are driven toward each other and eventually away from each other, thereby terminating the terminal 124 to the wire 126, as... Figure 5 As shown in 154.
[0049] As the first crimp connector 120 and the second crimp connector 122 move toward each other, crimping of the terminal 124 to the wire 126 occurs. The first crimp connector 120 and the second crimp connector 122 engage the terminal 124 and crimp the terminal 124 to the wire 126 by compressing the terminal 124 between the first crimp connector 120 and the second crimp connector 122. When this occurs, heat energy or heat is generated in and around the terminal 124 and the wire 126 within and near the crimp.
[0050] As previously described, the thermal sensor 128 (either directly from a thermal sensor 128 positioned in line with axis 130 or indirectly from a thermal sensor 128 offset or eccentric to axis 130) can acquire temperature measurements / data at specified intervals or continuously at the ends of terminals 124 and wires 126 located in the crimping area 118. The collected temperature measurements / data are transmitted to a display device 132, controller 134, or memory device 136 located on or outside the crimping device 110. The temperature measurements / data transmitted by the thermal sensor 128 are used by the operator of the crimping device 110 to determine whether the wire terminations meet appropriate criteria to provide the desired electrical and mechanical connection.
[0051] The quality of the termination can be monitored by directly or indirectly monitoring the temperature of terminal 124. Other characteristics of the termination can be analyzed by directly or indirectly analyzing the temperature of terminal 124. For example, temperature can be used to calculate the force input to terminal 124, because the amount of force is related to the temperature of terminal 124 after termination.
[0052] In an exemplary embodiment, such as Figure 5 As shown in 156, the thermal characteristics of the termination are measured directly or indirectly by one or more thermal sensors 128 during the termination process. Thermal characteristics are measured at predetermined intervals based on time or tool position. For example, a predetermined sampling time can be selected, and thermal characteristics can be measured at each point within a discrete sampling time. Alternatively or additionally, thermal characteristics can be measured when the crimping tool is at a predetermined crimping height position. The position of the crimping tool can be detected by a distance sensor (not shown), etc.
[0053] The controller 134 can create a measured temperature profile for termination based on the measured thermal characteristics. The measured thermal profile is then compared to an acceptable temperature profile or acceptable temperature range known for successful termination, such as... Figure 5 As shown in 158. Alternatively, the measured thermal characteristics can be compared to the known acceptable temperature characteristics or distribution of the specific material used. The acceptable temperature distribution or acceptable temperature distribution range can be pre-installed in the controller 134, or it can be developed and stored in the controller 134 by the user in the field. If the measured temperature distribution is within the acceptable temperature distribution range, the controller 134 will indicate that the termination is appropriate. If the measured temperature distribution is not within the acceptable temperature distribution range, the controller 134 will indicate that the termination is unacceptable and refuse the termination, as shown in 158. Figure 5 As shown in 160, data related to thermal characteristics, peak temperature, area under the temperature curve, shape of the temperature curve, or any combination thereof can be analyzed to determine if there are defects in the terminals.
[0054] refer to Figure 6The wire termination system 202 includes a heating device 210. The heating device 210 has a heating element 212 in the wire termination area or heating zone 218. The heating device 210 is used to terminate and seal the connector or terminal 224 to the wire 226. However, other types of devices, such as insulation displacement connector (IDC) devices, soldering devices, etc., can be used, which use processes other than crimping or heat shrinking to attach the connector or terminal to the wire.
[0055] One or more thermal sensors 228 are located near the heating device 210, but are removed from it. In the illustrative embodiment shown, one thermal sensor 228 is located on a wearable device on the operator's wrist. However, the thermal sensor 228 may be mounted on other types of wearable devices or in other locations near the heating device 210. The shape and positioning of the thermal sensor 228 are intended to be illustrative, as the thermal sensor may have other configurations and may be positioned in other locations.
[0056] The thermal sensor 228 is positioned to have a field of view including the heating zone 218. To facilitate the positioning of the thermal sensor 228, a positioning or calibration device 244 may be provided to provide guidance on the correct positioning of one or more thermal sensors 228 relative to the wire termination or crimping device 210 and to indicate whether the thermal sensor 228 is correctly positioned relative to the heating zone 218. The positioning device may be located on or away from the thermal sensor 228.
[0057] Thermal sensor 228 is positioned to acquire the thermal characteristics of terminals 224 and / or wires 226 in the heated zone 218 in the form of heat dissipation data. Thermal sensor 228 may be positioned in line with the longitudinal axis 230 of terminals 224 and / or heat-shrink wrap 227 to allow thermal sensor 228 to directly sense and collect thermal data of heat energy emitted directly from terminals 224 and / or wires 226. Alternatively, thermal sensor 228 may be positioned offset or eccentrically from axis 230, thereby allowing thermal sensor 228 to collect heat energy transferred through terminals 224 to wires 226 or another object and / or collect heat energy reflected from terminals 224 and / or wires 226. In various illustrative embodiments, more than one thermal sensor 228 may be provided.
[0058] In various illustrative embodiments, the heating device 210 may have protrusions positioned near the heating zone 218 and the terminals 224 and / or wires 226, configured to intentionally reflect or guide thermal energy from the sensed terminals 224 and / or wires 226. This allows the thermal sensor 228, offset or eccentric to the terminals 224, to read thermal data reflected from the protrusions. The protrusions may be made of a material with known emissivity to enhance reflective imaging of the thermal properties of the terminated terminals 224 and / or wires 226.
[0059] As previously described, the thermal data collected by thermal sensor 228 can be one or a combination of three different components of energy. The first is thermal energy emitted directly from terminal 224 and / or wire 226. The second is thermal energy transferred through an object (heat from other places along the path), such as from terminal 224 to wire 226. The third is thermal energy reflected from terminal 224 and / or wire 226.
[0060] The number and location of thermal sensors, as well as the characteristics of the thermal data, are similar to those regarding... Figure 1 and Figure 2 The embodiments shown are described.
[0061] Display device 232 can be communicatively coupled to thermal sensor 228 and configured to display the thermal characteristics acquired by thermal sensor 228. Display device 232 can be integrated into the main controller or processor of heating device 210 or the thermal sensor 128 itself, or it can be a separate controller or processor 234, such as a desktop computer, laptop computer, tablet computer, monitor, projector, head-up display glasses, etc. Controller 234 and / or display device 232 can be coupled to thermal sensor 228 via cables or the like. Alternatively, controller 234 and / or display device 232 can communicate wirelessly via induction, radio frequency waves, Wi-Fi, etc., to transmit data between thermal sensor 228 and controller 234 and / or display device 232.
[0062] The controller 234 and / or display device 232 may include a storage or memory device 236, such as, but not limited to, a hard disk drive, RAM, ROM, and / or another internal data storage device. The memory device 236 may be configured to store data acquired by the thermal sensor 228. Such data can be used for subsequent quality reporting purposes.
[0063] Figure 7 A method 250 for determining termination quality using a remote thermal sensor 228 is illustrated. During heating operation, the thermal sensor 228 is appropriately positioned relative to the heating zone 218, such as... Figure 7 As shown in 252, this allows the thermal sensor 228 to make appropriate measurements when heating occurs. Heating is then initiated, thereby terminating terminal 224 to wire 226, as... Figure 7 As shown in 254. When this occurs, heat or heat is generated in and near the termination 224 and wire 226.
[0064] As previously described, the thermal sensor 228, positioned directly in line with axis 230 or indirectly offset or eccentrically from axis 230, can acquire temperature measurements / data at specified intervals or continuously at the ends of terminals 224 and wires 226 located in heating zone 218. The collected temperature measurements / data are transmitted to a display device 232, controller 234, or memory device 236 located on or outside the heating device 210. The temperature measurements / data transmitted by the thermal sensor 228 are used by the operator of the heating device 210 to determine whether the wire terminations meet appropriate standards to provide the desired electrical and mechanical connection. The quality of the terminals can be monitored by directly or indirectly monitoring the temperature of terminals 224.
[0065] In illustrative embodiments, such as Figure 7 As shown in 256, the thermal characteristics of the termination are measured directly or indirectly by one or more thermal sensors 228 during the termination process. Thermal characteristics are measured at predetermined intervals based on time or tool position. For example, a predetermined sampling time can be selected, and thermal characteristics can be measured at each point within a discrete sampling time. Alternatively or additionally, thermal characteristics can be measured when the heating tool is at a predetermined temperature.
[0066] The controller 234 can create a measured temperature distribution for termination based on the measured thermal characteristics. It then compares the measured thermal distribution with known acceptable temperature distributions or acceptable temperature ranges for successful terminations, such as... Figure 7 As shown in 258. Alternatively, the measured thermal characteristics can be compared to the known acceptable temperature characteristics or distribution of the specific material used. The acceptable temperature distribution or acceptable temperature distribution range can be pre-installed in the controller 234, or it can be developed and stored in the controller 234 by the user in the field. If the measured temperature distribution is within the acceptable temperature distribution range, the controller 234 will indicate that the termination is appropriate. If the measured temperature distribution is not within the acceptable temperature distribution range, the controller 234 will indicate that the termination is unacceptable and refuse termination, such as... Figure 5 As shown in 260, data related to thermal characteristics, peak temperature, area under the temperature curve, shape of the temperature curve, or any combination thereof can be analyzed to determine if there are defects in the terminals.
[0067] Using thermal data and analysis to monitor wire or conductor terminations has applications beyond just crimping and heat shrinkage-related applications. For example, thermal analysis of welding (ultrasonic, resistance, etc.), molding, stamping, thermoplastic welding, and thermal riveting (plastic riveting) helps determine whether a proper connection has been secured. In addition to collecting thermal data directly after termination has occurred to determine if proper termination has been affected, thermal sensors can be used to collect thermal data during the termination process, allowing the controller to continue the termination process until a good termination / connection is achieved.
[0068] By collecting thermal data during the termination process, either through non-contact methods such as thermal sensors or through direct contact with thermal sensors, or both, the data can be used to provide quality assessments without the need for destructive testing. The use of thermal data is beneficial in many applications, particularly where there are very small force variations between terminating terminals with wires and terminating terminals without wires, such as when terminating aluminum wires.
Claims
1. A method for determining the termination quality from terminals (24, 124, 224) to wires (26, 126, 226), the method comprising: Position the terminals (24, 124, 224) in the wire termination areas (18, 118, 218) of the wire termination devices (10, 110, 210); Position the wires (26, 126, 226) in the wire termination areas (18, 118, 218) of the wire termination devices (10, 110, 210); Connect terminals (24, 124, 224) to wires (26, 126, 226); The thermal data of the termination from the terminal (24, 124, 224) to the wire (26, 126, 226) is monitored using one or more thermal sensors (28, 128, 228); The monitored thermal data is compared with the stored thermal data to determine if there are any defects in the terminations from terminals (24, 124, 224) to wires (26, 126, 226); Therefore, if the termination from terminals (24, 124, 224) to wires (26, 126, 226) is defective, then wires (26, 126, 226) are discarded.
2. The method as described in claim 1, wherein, The one or more thermal sensors (28, 128, 228) are located on the wire termination device (10, 110, 210).
3. The method as described in claim 2, wherein, The one or more thermal sensors (28, 128, 228) are spaced apart from the wire termination areas (18, 118, 218) of the wire termination devices (10, 110, 210).
4. The method of claim 1, wherein, The one or more thermal sensors (28, 128, 228) are positioned away from the wire termination device (10, 110, 210).
5. The method of claim 4, wherein, The one or more thermal sensors (28, 128, 228) are positioned on the wearable device.
6. The method of claim 5, wherein, Positioning devices (144, 244) are provided on the wearable device, thereby providing guidance for the correct positioning of the one or more thermal sensors (28, 128, 228) relative to the wire termination area (18, 118, 218) of the wire termination device (10, 110, 210).
7. The method of claim 1, wherein, The termination of the terminals (24, 124, 224) to the wires (26, 126, 226) is a crimp termination.
8. The method of claim 1, wherein, The termination of the terminals (24, 124, 224) to the wires (26, 126, 226) is an ultrasonic welding termination.
9. The method of claim 1, wherein, The termination of the terminals (24, 124, 224) to the wires (26, 126, 226) is a resistance welded termination.
10. The method of claim 1, wherein, The termination of the terminals (24, 124, 224) to the wires (26, 126, 226) is a brazed termination.
11. The method of claim 1, wherein, The termination of the terminals (24, 124, 224) to the wires (26, 126, 226) is a heat-shrinkable termination.
12. The method of claim 1, wherein, The one or more thermal sensors (28, 128, 228) monitor thermal data of the termination from the terminals (24, 124, 224) to the wires (26, 126, 226) for a limited time.
13. The method of claim 1, wherein, The one or more thermal sensors (28, 128, 228) continuously monitor thermal data of the termination from the terminals (24, 124, 224) to the wires (26, 126, 226) within defined intervals.
14. The method of claim 1, comprising: Visual data of the termination of the terminals (24, 124, 224) to the wires (26, 126, 226) are monitored using one or more vision sensors.
15. The method of claim 1, comprising: Monitor other data of the terminals (24, 124, 224) in the wire termination areas (18, 118, 218) connected to the wires (26, 126, 226); Other data and thermal data are compared with the stored data to determine if there are defects in the terminations from terminals (24, 124, 224) to wires (26, 126, 226).
16. The method of claim 1, wherein, At least one of the one or more thermal sensors (28, 128, 228) monitors thermal data reflected from the termination of the terminal (24, 124, 224) to the wire (26, 126, 226).
17. The method of claim 1, wherein, At least one of the one or more thermal sensors (28, 128, 228) monitors thermal data of the termination of the terminal (24, 124, 224) to the wire (26, 126, 226) by means of the thermal properties transmitted via the wire (26, 126, 226).
18. A wire termination system (2, 102, 202) that allows determination of the termination quality from terminals (24, 124, 224) to wires (26, 126, 226), the wire termination system (2, 102, 202) comprising: Wire termination devices (10, 110, 210) with wire termination areas (18, 118, 218); Thermal sensors (28, 128, 228) are located near the wire termination areas (18, 118, 218) and are positioned to acquire thermal data of the termination from terminals (24, 124, 224) to wires (26, 126, 226). Among them, thermal sensors (28, 128, 228) monitor thermal data of the termination from terminals (24, 124, 224) to wires (26, 126, 226) to determine whether there is a defect in the termination from terminals (24, 124, 224) to wires (26, 126, 226).
19. The wire termination system (2, 102, 202) as described in claim 18, wherein, The wire termination devices (10, 110, 210) are handheld wire termination devices (10, 110, 210).
20. The wire termination system (2, 102, 202) as described in claim 19, wherein, The thermal sensor is located on the handheld wire termination device (10, 110, 210) near the wire termination area (18, 118, 218).
21. The wire termination system (2, 102, 202) as described in claim 20, wherein, The thermal sensors (28, 128, 228) are removably mounted to the handheld wire termination device (10, 110, 210).
22. The wire termination system (2, 102, 202) as described in claim 18, wherein, The thermal sensors (28, 128, 228) are located on a sensing device away from the handheld wire termination device (10, 110, 210).
23. The wire termination system (2, 102, 202) as described in claim 22, wherein, The sensing device is a wearable device.
24. The wire termination system (2, 102, 202) as described in claim 23, wherein, The sensing device has a positioning device (144, 244) that indicates when the thermal sensor is positioned in the field of view having the wire termination area (18, 118, 218).