Detection system for detecting an incorrectly installed plug connection of a plug connector, and data collection system for collecting measurement data for such a detection system

Abstract

In a detection system for detecting an incorrectly installed plug connection of a plug connector, the detection system comprises at least one plug-in attempt detection device for detecting a plug-in attempt, at least one measuring unit (3, 4, 6, 7, 8) for acquiring plug-in operation data and at least one verification device for verifying the plug connection using the data profile of acquired plug-in operation data.

Description

[0001] Detection system for detecting an incorrectly assembled plug connection of a connector and data collection system for collecting measurement data for such a detection system

[0002] The invention relates to a detection system for detecting an incorrectly mounted plug connection of a connector and a data collection system for collecting measurement data for such a detection system.

[0003] Detection systems for identifying incorrectly assembled plug connections in a connector, as well as data collection systems for collecting measurement data relating to the mating of connectors, are known in the art. During a mating process, the plug and coupling parts of a connector, or parts of them, are locked into one another, and during this locking process, a sound signal or acoustic signal in the form of a clicking noise is emitted. The assembly of such connectors is usually carried out manually. It is often not immediately apparent whether the connection has been made completely and correctly, i.e., whether the locking has been complete, secure, and proper. It is therefore not necessarily possible to determine immediately during the assembly of connectors whether the assembly was carried out completely and correctly, and thus whether the connection is secure.The assembly force is heavily influenced by the person performing the assembly, depending on the hand, hand position, movement sequence, and any possible misalignment of the components being assembled. Typically, an improper connection will be discovered during the end-of-line inspection at the latest. However, an incorrectly installed connection of such a connector requires complex and therefore expensive rework to correct the problem.

[0004] WO 2013 / 131632 A1 therefore discloses a control system and a method for controlling the assembly of a coupling device, comprising at least one plug connector, wherein a mobile sensor device is arranged in the immediate vicinity of the signal source of the plug connector. The signal is an electronic and / or acoustic or sound signal. The signal emitted during the plugging process is recorded and evaluated. If a sound signal, i.e. the characteristic sound of a plugging process, such as the characteristic sound of the locking or clicking of the retaining element of a plug connector, is emitted as a signal, this is recorded during the plugging process and evaluated in an evaluation unit. The recorded signal orNoise can be separated from interference signals, in particular interference noise, and then checked to determine whether proper locking has occurred, i.e. whether a secure plug-in connection has been achieved. The mobile sensor device is designed to detect a structure-borne and / or airborne sound signal. To detect structure-borne sound, the mobile sensor device is brought into vibratory contact with the coupling device and / or the at least one locking cam thereon. The mobile sensor device is arranged on or integrated into a carrier material, wherein the carrier material disclosed can be, for example, an assembly glove and / or an item of clothing and / or a device that can be worn on a person's body, such as a belt, a watch or a bracelet, into which the mobile sensor device can be or is integrated.The data collected by the mobile sensor device is evaluated in a nearby decentralized evaluation unit and / or in a central evaluation unit. The collected data is transmitted via Wi-Fi, Bluetooth, cable, one or more USB interfaces, or wirelessly.

[0005] WO 2016 / 070984 A1 discloses a device and a method for monitoring the assembly of two components using a click fastener for connecting the components. A sensor for detecting an assembly force and a sound receiver are provided. During the assembly of the two components, the force applied to at least one of the two components by means of a device used to connect the two components and the sound generated during the assembly of the two components are measured. The course of the measured force is recorded as a function of time and / or the course of the measured sound is recorded as a function of time.The curve of the force as a function of time and / or the curve of the sound as a function of time are evaluated and a signal is generated which indicates the quality of the assembly of the click fastener if the curve of the force as a function of time and / or the curve of the sound as a function of time corresponds to a predetermined criterion. Furthermore, the acceleration of a finger and / or a hand of an operator carrying out the assembly is measured during the assembly of the two components. Using the assembly force as a basis is only suitable to a limited extent, as this depends on the person carrying out the assembly. For example, misalignment of the two components during the plug-in process has a major influence on the assembly force. Furthermore, the assembly force is difficult to detect and requires complex measuring sensors. This makes the process prone to errors.The discriminatory power between a proper and improper connection is also difficult to determine with a force sensor. The acoustic sensor is susceptible to interference from distant background noise, such as the noise level in an assembly hall. While assessing a proper and improper connection using both an acoustic sensor and a motion sensor simultaneously increases reliability and discriminatory power, it requires rapid processing of the acquired data, which entails comparatively high complexity in terms of high performance of the electronic components and size.

[0006] WO 2015 / 053936 A1 discloses a system for ensuring the joining of a connector. A microphone is arranged near the joining zone of electrical connectors. The microphone is designed to detect an audible noise as soon as the electrical connector is joined. Furthermore, an output unit is provided, which is connected to the microphone and receives the audio signals from the microphone. The output unit processes the audio signals to ensure the joining connection. The output unit filters out background noise to amplify the audio signals. Due to the use of an acoustic sensor, the system is suitable for applications where low to medium selectivity is sufficient and / or in environments where little noise influences the measurement result.The evaluation results in a limitation in the discriminatory power between a proper plug connection and an improper one.

[0007] WO 2017 / 062124 A1 also discloses a system for ensuring a mating connection of a connector. This system comprises a user-worn sensor unit that is worn near or on the hand of the operator, wherein the sensor unit comprises an acoustic sensor that is arranged near a mating zone of electrical connectors. The acoustic sensor can detect an acoustic noise as soon as the electrical connector is mated. The system further comprises a user-worn controller that is connected to the acoustic sensor, wherein the controller receives the audio signals from the acoustic sensor and processes the audio signals to determine the mating status of a connector. The controller provides the operator with feedback regarding the mating status of the connector.Due to the use of an acoustic sensor, this system is also suitable for applications where low to medium selectivity is sufficient and / or in environments where only minimal noise influences the measurement result. Here, too, the evaluation results in a limitation in the selectivity between a proper plug connection and an improper one.

[0008] WO 2017 / 062122 A1 discloses another system for ensuring a mating connection of a connector. This system comprises an acoustic sensor arranged near a mating zone of electrical connectors, wherein the acoustic sensor is designed to detect audible noises as soon as the electrical connector is mated. Furthermore, a connector identification sensor is provided, which is arranged near the electrical connectors. The connector identification sensor is designed to identify the presence of electrical connectors. The system further comprises a controller connected to the acoustic sensor and the connector identification sensor, wherein the controller receives the connector identification signals from the connector identification sensor, as well as the acoustic signals from the acoustic sensor.The controller processes the connector identification signals and the acoustic signals to verify the safety of the mating connection. However, the connection identification sensor does not contribute to the evaluation of the plug connection, i.e., the question of whether it is correct or not, so here too there is a limitation in the discriminatory power between a correct and an incorrect plug connection.

[0009] Furthermore, FR 3 024 522 B1 discloses a system and a method for determining the locking of a manual connection of a latchable quick connector. Here, a carrier is fixed to an operator, wherein at least one acoustic sensor is provided for measuring acoustic signals emitted by the connection. The measured acoustic signal is detected. The detected acoustic signals are filtered and compared with acoustic reference signals that are representative of the locking state of the connector, wherein a result of this comparison is simultaneously obtained. A message is sent to the operator regarding whether or not a locked state has been achieved. Furthermore, the method comprises detecting a movement of a first hand of the operator in order to measure movements of this first hand that are representative of the attempt to connect the connector.Detecting the movements triggers the start of the measurement and recording of the acoustic signals. Furthermore, an auxiliary recording of the movements of the first hand measured during the recording of the movements is provided, an auxiliary filtering of the recorded movements of the first hand, and subsequently an auxiliary comparison of the recorded and filtered movements of the first hand with the reference movements that indicate a connection attempt. As soon as a movement of the user's first hand is detected, a recording is triggered. Acoustic signals are recorded over a period of time, and the filters and comparison devices process the signals at an interval that lasts from a few tenths of a second before a trigger condition to a few tenths of a second after.This results in a two-stage test in sequential order, with the assessment of the quality of the plug connection—i.e., whether it is correct or not—only taking place in the second step using the acoustic sensor. In the first step, the motion signal merely triggers the recording of the acoustic signal.

[0010] DE 10 2014 016 153 A1 discloses a device and method suitable for monitoring the assembly of two components to be connected by means of a clip fastening, wherein a sensor for detecting an assembly force and a sound receiver are present. The sensor for detecting an assembly force and / or the sound receiver are arranged on a glove. In the method for monitoring the assembly of two components to be connected by means of a clip fastening, wherein the two components are brought together in order to carry out the assembly by means of a clip fastening, the force exerted on at least one of the two components during the assembly of the two components is measured by means of a device used to connect the two components, and the sound generated during the assembly of the two components is measured.The course of the force as a function of time and / or the course of the sound as a function of time is evaluated and a signal is generated which indicates a quality of the assembly of the clip fastening if the course of the force as a function of time and / or the course of the sound as a function of time corresponds to a predetermined criterion.

[0011] The aforementioned devices and methods for monitoring assembly connections predominantly utilize acoustic detection, e.g., by detecting a click when a locking lug engages in a designated anchor or locking receptacle. Some of the devices and methods also incorporate pressure or acceleration sensors. These devices are generally limited to primarily detecting signals from a finger or thumb of the hand of an operator performing the plugging process. The present invention is therefore based on the object of providing a detection system that serves to ensure assembly and thus reliably detects incorrectly installed plug connections.

[0012] The problem is solved for a detection system for detecting an incorrectly assembled plug connection of a connector, wherein the detection system comprises at least one plug-in attempt detection device for detecting a plug-in attempt, at least one measuring unit for recording plug-in process data, and at least one verification device for verifying the plug connection using the data profile of recorded plug-in process data. The problem is also solved by a data collection system for collecting measurement data, wherein the data collection system comprises at least two measuring units, at least one data evaluation unit, and at least one flexible carrier, wherein the at least two measuring units and the data evaluation unit are arranged on the flexible carrier and in close proximity to one another, wherein the measuring units each comprise at least one acceleration sensor and at least one of the measuring units comprises at least one microphone.Further developments of the invention are defined in the dependent claims.

[0013] This creates a detection system and a data collection system for collecting measurement data, in particular for collecting measurement data for such a detection system, in which, on the one hand, a plug-in attempt is detected by at least one plug-in attempt detection device, on the other hand, measuring units for recording data of the respective plug-in processes and, furthermore, at least one verification device are provided, by means of which an assessment of the quality of a respective plug-in connection is made possible after completion of the plug-in process based on the recorded plug-in process data by evaluating the recorded or acquired data profile. Thus, in contrast to the prior art solutions, incorrectly mounted plug-in connections are detected and not simply a verification of correctly mounted plug-in connections.For this purpose, the plug-in attempt is already detected, and then verification is carried out using the data profile of the plug-in process data.

[0014] Advantageously, at least one first measuring unit for detecting hand gestures for a plug-in attempt and at least one second measuring unit for detecting the plug-in process are provided, in which data on acceleration and / or force absorption as well as the released energy are detected via the sound.

[0015] Due to the complexity of the trigger hand movements to be analyzed, which are recorded by the at least one first measuring unit and analyzed by the at least one plug-in attempt detection device for the presence of a plug-in attempt, rule-based data processing is usually not sufficient. The detection system therefore advantageously comprises at least one type of artificial intelligence, e.g., one or more artificial neural networks, with the aid of which all measuring unit inputs can be or are converted as inputs to a binary output to indicate the decision of a correct plug-in connection or an incorrect plug-in connection. With the aid of such an (artificial) neural network, all measuring unit or sensor inputs can be converted as inputs to a binary output, i.e., the decision "plug-in connection OK."

[0016] (= proper plug connection is present) or NOK (= there is no proper or correct plug connection).

[0017] The measuring units can be or will be arranged on at least one of the fingers and the thumb of at least one hand of an operator who carries out the plugging process. The measuring units can in particular be or will be arranged on or at at least one carrier, in particular a flexible carrier. Such a carrier can be or will be designed, for example, in the manner of a glove, partial glove or in another manner suitable for fastening to a hand of an operator. If at least one flexible carrier is provided, this can be designed, for example, as a glove, partial glove and / or in the form of at least two straps that connect at least two measuring units and the at least one wrist unit to one another.For example, three islands can be provided, two of which each have a measuring unit arranged on them and the wrist unit arranged on the third, and these islands can be connected to one another via straps or other connecting devices. Cables extending between the measuring units and the wrist unit can be fixed to the connecting devices. For example, two textile straps can be provided to which cables extending between the measuring units and the wrist unit are fixed. In order to be able to detachably fix straps in particular, but also individual areas of a glove or partial glove to one another in order to create a secure and good hold on the hand of an operator, at least one hook and loop fastener, at least one lacing or at least one other fastening device can be provided.

[0018] The detection system advantageously further comprises at least one wrist unit for placement on the wrist of an operator performing a plugging operation. The at least one wrist unit advantageously comprises at least one microphone for recording ambient noise and at least one microcontroller. In a sound data processing unit of the at least one microcontroller of the wrist unit, a comparison is made with the recorded data of a measuring unit that can be or is arranged on the thumb of a hand of an operator, which can also be referred to as a thumb unit, in order to improve the detection of the sound profile of the locking of the plug partners of the plug connector. As a result, the sound profile of the locking of the plug part and coupling part as plug partners of a plug connector can be detected more precisely in order to better detect this sound profile in the detected data.

[0019] The at least one wrist unit advantageously further comprises at least one gyroscope or a gyroscopic device, wherein the gyroscope or the gyroscopic device records movement data of a hand of an operator, which are used as an identification trigger for opening a measuring window, wherein the presence of data or signals characterizing a proper plugging process is checked within the measuring window.

[0020] The measuring units or sensors are preferably arranged on the fingers of one or both hands of an operator carrying out the plugging processes in such a way that they do not interfere with the operator's hands while working, but still record all relevant measured values. Therefore, in a preferred embodiment, the measuring units are or can be arranged intermedially or proximally on the fingers and / or thumb of at least one hand of an operator. In particular, when the measuring units are arranged on the thumb and index finger or between the thumb and index finger of at least one hand of an operator, the measuring units can be or will be arranged in the area of ​​the metacarpal bones of the hand. The sensors orMeasuring units, i.e. the sensory hardware units, are therefore not arranged in the area of ​​the distal phalanx of the finger, rarely distally in the area of ​​a middle phalanx, preferably intermedially, i.e. at the proximal phalanx, or proximally in the area of ​​the metacarpal bone, whereby the proximal arrangement is particularly preferred.

[0021] Further advantageously, the measuring units are arranged in a rotational or rotated manner on or around the middle or proximal phalanx of the finger. When arranged on a thumb of an operator's hand, the at least one measuring unit can be directed on the inside towards the index finger of the hand; when arranged on an index finger of an operator's hand, the at least one measuring unit can be arranged on the inside towards the thumb. In particular, an arrangement with a rotation in the direction of the top of the hand can be provided. When arranged on a middle finger and / or a ring finger and / or a little finger of an operator's hand, the arrangement in the direction of the top of the hand is particularly suitable.

[0022] A data collection system comprises at least two measuring units and at least one data evaluation unit, wherein the at least two measuring units and the data evaluation unit are mounted in close proximity to one another on a support, in particular a flexible support. The measuring units each contain at least one acceleration sensor and, in total across all measuring units, at least one microphone, i.e., at least one of the measuring units contains at least one microphone. Redundancy can be created by providing a respective acceleration sensor or acceleration sensor on each measuring unit. Furthermore, greater variability can be created by advantageously providing two microphones instead of just one.

[0023] Further advantageously, the at least one microphone of at least one of the measuring units is directed towards the fingertip or thumbtip of a hand of an operator wearing the measuring units. This enables particularly good and interference-free recording of the acoustic signals that occur during the plugging process. Furthermore, at least one opening can advantageously be arranged in a housing of the measuring unit, which opening is covered by at least one membrane to protect against dust and water. The measuring unit or its housing is advantageously sealed from the environment. The at least one microphone is arranged in the housing of the measuring unit such that it is arranged inside the housing in the region of the opening or directly adjacent to it.In order to protect the microphone and the other components of the measuring unit, which are arranged inside its housing, from dust and water, the at least one opening is provided with or covered by the at least one membrane. The opening is preferably aligned towards the fingertip of a finger on the hand of an operator wearing the measuring unit(s). In order to be able to record and evaluate the audio signals in the best possible quality, the microphone is arranged on the measuring unit, also referred to as the thumb unit, in the area of ​​the opening for sound transmission and the opening is provided with or covered with a membrane to protect the microphone in particular.The opening covered by the at least one membrane is advantageously oriented towards the tip of the thumb in order to be able to better record audio signals from the plugging process compared to ambient noise. To record ambient noise, the at least one wrist unit comprises at least one microphone. Since at least one of the at least two measuring units also comprises a microphone, the microphone of the wrist unit is at least a second microphone that records ambient noise. In the sound data processing of the at least one microcontroller of the wrist unit, a comparison is made with the data recordings from the measuring unit, which is / will be arranged on the thumb of one hand of an operator performing the plugging process, so that the sound profile of the locking process can be better recognized.

[0024] The at least one wrist unit further advantageously comprises at least one gyroscope or at least one gyroscopic device and a 3-axis acceleration sensor. This makes it particularly easy to capture acceleration signals and movement data from an operator's hand. As mentioned above, the latter are used as an identification trigger to open a measurement window, and the presence of data or signals characterizing a proper insertion process is checked within the measurement window.

[0025] The data evaluation unit can be mounted on the back of the hand of an operator performing a mating process to be assessed, as movement data can be captured more effectively there than on the wrist. The wrist can distort movements performed during connector assembly, or movements captured by a wrist unit on the wrist may be incorrectly evaluated.

[0026] Since operators perform delicate assembly tasks using a tweezer grip when plugging a connector, providing at least two measuring units proves particularly advantageous. The tweezer grip refers to holding the assembly piece or the connector parts, i.e., the plug part and the coupling part, between the index finger and thumb. Therefore, positioning the measuring units proximally on the thumb and index finger of one of the operator's hands proves particularly advantageous. Depending on the type of plugging process, it varies whether the plugging process is completed with the index finger or the thumb of one hand until a locking lug on the connector snaps into place.

[0027] More complex plugging tasks can be performed with the aid of additional fingers. The little finger can be particularly helpful when plugging the parts of a connector through narrow openings. This little finger is then advantageously equipped with a measuring unit to record and transmit the signals from the plugging process. Depending on the application of the detection system or data collection system, a different number of measuring units and a different arrangement of these can be provided on the fingers of at least one of the two hands of an operator performing the respective plugging process.

[0028] The at least one wrist unit can comprise at least one RFID unit, with which a respective assembly station from which the wrist unit is used, or RFID-tagged connectors, can be identified in the same IT system, or can be identified as plug connections verified via the data collection system. The wrist unit thus comprises at least one RFID unit, with which either the current assembly station from which the wrist unit is used can be identified, or RFID-tagged plug parts or connectors, which can be identified in the same IT system as the verified plug connections via the data collection system.

[0029] The data collection system can further advantageously be provided with or be equipped with at least one transmitting device for transmitting the collected data to a data transmitter via WLAN, LTE, Bluetooth, and / or radio technologies. The data transmitter can be a gateway, a server, or an edge device. Furthermore, at least one local or cloud-based database for storing the collected data, a cloud for performing analyses of the mating processes, and at least one graphical evaluation unit for displaying evaluation results are provided. The operators performing the mating processes wear the data collection system or the recognition system or their components on at least one hand or wrist during the assembly of the connectors. The data collection system, or in particular its wrist unit, can transmit data, for example, via WLAN, LTE, Bluetooth, or other radio technologies to a data transmitter, such as a gateway, a server, or an edge device.The data is stored in a local or cloud-based database. Analyses of the plug-in processes can be performed in an internal or external cloud and made available via graphical analysis.

[0030] In a method for checking and evaluating the quality of a plug connection of a connector that includes at least one locking stage, which method records a characteristic assembly movement pattern, a so-called "event" is first detected via the movement pattern of the hand of an operator performing the plugging process. In this case, such an event is understood to be a potential assembly attempt, i.e., a characteristic plugging movement that can be detected. The event activates acceleration sensors or

[0031] Accelerometer of one of the measuring units of the data collection system. If an increase is detected within a short period of time, the microphone is also switched on. It is also possible to have the accelerometers or accelerometers continuously record data (so-called streaming) and, in the event of an event, analyze the last specified n milliseconds or n seconds of the recording and switch on the microphones based on this. The same applies to the microphones; these can also record acoustic signals or stream the data and discard all data until an event occurs. If the event was not a plug-in attempt, the data is discarded again. This results in the advantage of an energy-saving process in which the recording of personal audio data is significantly reduced compared to state-of-the-art solutions.

[0032] The table below lists five different versions 1 to 5 of the data collection system. The general list of individual features of the data collection system can be found in the first column of the table above; the respective implementation of these features in the respective embodiments 1 to 5 of the data collection system can be found in their respective columns. In the first embodiment of the data collection system, a 1-axis acceleration sensor is provided on the wrist unit as a number of sensor or measuring unit inputs for detecting the gesture control of a hand of an operator who is performing a plug-in process that is being monitored. The arrangement point on the wrist unit is on the upper side of the wrist. Two measuring units are provided, which are arranged on a glove. The data connection between the measuring units and the wrist unit is realized by cable. The positions of the measuring units on the fingers or thumb and finger are intermediate.The acceleration sensors in the measuring units are single-axis accelerometers. Start / stop activation is achieved by pressing a switch on the device, i.e., the measuring units and / or the wrist unit.

[0033] In the second embodiment of the data collection system, a gyroscope with six channels, representing the number of sensor or measuring unit inputs, is provided on the wrist unit for detecting the gesture control of a hand of an operator performing a monitored mating process. The location on the wrist unit is on the top of the hand. Three measuring units are provided, which are arranged on two gloves. These are therefore placed on the two hands of an operator performing the mating process, i.e., the operator wears two appropriately equipped gloves while performing the mating processes during the assembly of the connectors. The data connection between the measuring units and the wrist unit is implemented via Bluetooth. The positions of the measuring units on the fingers or thumb and fingers are proximal. The acceleration sensors in the measuring units are designed as 3-axis acceleration sensors.Start / stop activation is achieved through geofencing. In the third embodiment of the data collection system, a gyroscope with nine channels (the number of sensor or measuring unit inputs) is provided on the wrist unit for detecting the gesture control of a hand of an operator performing a monitored plug-in process. Four measuring units are provided. The data connection between the measuring units and the wrist unit is implemented via Wi-Fi (WLAN). The positions of the measuring units on the fingers or thumb and fingers can be provided distally. The acceleration sensors in the measuring units are implemented in the form of a 6-axis gyroscope. Start / stop activation is achieved by reading an auto-ID.

[0034] The fourth embodiment of the data collection system features five measuring units and a proprietary radio link between the measuring units and the wrist unit. The acceleration sensors in the measuring units are implemented as a 9-axis gyroscope.

[0035] In the fifth embodiment of the data collection system, LTE is provided as the data connection between the measuring units and the wrist unit.

[0036] The five embodiments show examples of different embodiments that are possible for the data collection system with regard to the individual variable features listed in the first column. Further embodiments can be created, in particular, by combining each variant in one row of the table above with each variant in each of the other rows. Of course, any combination of the listed different embodiments is also possible.

[0037] To further explain the invention, exemplary embodiments are described in more detail below with reference to the drawings. These show: Figure 1 shows a plan view of an operator's right hand, which is provided with a partial glove with a detection system according to the invention and a data collection system according to the invention, comprising five measuring units according to the invention and a wrist unit according to the invention,

[0038] Figure 2 is a sketch of a right hand of an operator, on which a measuring unit according to the invention is arranged on the index finger and on the thumb of the hand, wherein the measuring unit arranged on the thumb is provided with an opening with a microphone arranged behind it, Figure 3 is a sketch of a left hand of an operator for

[0039] Illustration of the different arrangement possibilities of measuring units on the hand, here on the thumb and index finger of the hand,

[0040] Figure 4 is a schematic diagram of two measuring units according to the invention, Figure 5 is a schematic diagram of a wrist unit according to the invention, Figure 6 is a schematic diagram of the communication paths of a detection system according to the invention with a data collection system according to the invention, Figure 7 is a signal-time diagram illustrating a trigger cascade with a measurement or verification time window according to the invention, and

[0041] Figure 8 shows a flow chart with the individual steps of a data acquisition according to the invention.

[0042] Figure 1 shows a first embodiment of a data collection system 1 according to the invention for collecting measurement data. The data collection system 1 comprises a flexible carrier 2 in the form of a partial glove. In the embodiment shown in Figure 1, two measuring units 3, 4 and a data evaluation unit 5 are attached to the flexible carrier 2. Furthermore, Figure 1 shows further measuring units 6, 7, 8, which can also be formed either as part of the flexible carrier 2 or attached to it or arranged separately from it on a hand 10 of an operator who is performing a plug-in process of a connector (which, however, is not visible in Figure 1). One of the measuring units 3, 4, 6, 7, 8 can be arranged on each of the fingers 11, 12, 13, 14 and the thumb 15 of the hand 10.As can be further seen in Figure 1, the data evaluation unit 5 is arranged on the back of the right hand 10, attached to the flexible support 2 in the form of a partial glove. The data evaluation unit 5 comprises a motion sensor to capture movement data from the operator's hand. Since an arrangement on the wrist can distort assembly movements, arranging the data evaluation unit 5 on the back of the hand is particularly suitable. This is particularly feasible when arranging the data evaluation unit 5 on a glove or partial glove, since the positioning on the flexible support 2 can be highly variable.The provision of measuring unit 3 on the thumb 15 and measuring unit 4 on the index finger 11 of the operator's hand 10 allows the operator to perform the plugging process with a tweezer grip during delicate assembly tasks, with the respective assembly piece, i.e., the parts of a connector, held between the index finger and thumb. In order to be able to perform a plugging process, and in particular a successful plugging process, both unhindered and clearly detectable, the provision of a respective measuring unit on the thumb and index finger of the hand 10 is suitable.

[0043] In the embodiment shown in Figure 1, the two measuring units 3, 4 are each arranged intermedially on the thumb 15 and index finger 11. As can be seen from Figure 3, for example, there are various ways of arranging the measuring units on the hand, in this case on the left hand 16, of an operator. The respective measuring unit 4 is arranged here once distally, i.e. on the middle phalanx, with the distal arrangement being identified by the reference numeral 110, once intermedially, with this arrangement on the proximal phalanx being identified by the reference numeral 111, and once proximal, with the proximal arrangement being identified by the reference numeral 112. The proximal arrangement is provided in Figure 3 in the region of a metacarpal bone of the hand 16. The arrangement does not necessarily have to be above the metacarpal bone, but can also be slightly offset from it.In the illustration in Figure 3, the measuring unit 3 is arranged intermedially on the thumb 15, i.e. on the proximal phalanx of the thumb, which is identified by the reference numeral 113.

[0044] Corresponding arrangements of the respective measuring unit 6, 7, 8 can be provided not only on the index finger 11, but also on the other fingers 12, 13, 14 of the hand, if desired. If, for example, more complex plug-in tasks are carried out, the additional measuring units 6, 7, 8 can also be arranged on the other fingers 12, 13, 14 of the operator's hand 10. If, for example, it is necessary during the plug-in process that a plug part is inserted into a narrow opening of a coupling part of a connector to be joined, the little finger 14 can also be used to help push the plug part forward. Accordingly, for such a plug-in process, arranging the measuring unit 8 on the little finger 14 of the operator's hand 10 is suitable in order to be able to easily record signals from the plug-in process and forward them to the data evaluation unit.

[0045] As can be seen from Figure 2, an arrangement of the two measuring units 3, 4 on the index finger 11 and the thumb 15 of the right hand 10 of an operator is provided there, corresponding to Figure 1. The measuring unit 3, which is arranged on the person's thumb 15, comprises a microphone 30. This can also be seen from the sketched detailed view of the two measuring units 3, 4 in Figure 4. The measuring unit 3 comprises a housing 31 provided with an opening 32. The microphone 30 is arranged in the area of ​​the opening 32 in the interior 33 of the housing 31 of the measuring unit 3. The opening 32 is sealed to the outside by a membrane 34 in order to prevent the ingress of dirt and water. The passage of acoustic signals through the membrane 34 is still possible.In order to reliably record any click signal, which may indicate a correct plugging process, along with other data and signals, the opening 32 in the housing 31 of the measuring unit 3 is oriented toward the thumbtip 150 of the thumb 15 of the operator's hand 10. This is shown in Figure 2 and also indicated by the arrow P1 in Figure 4. The arrow P1 points in the direction of the thumbtip 150. Within its housing 31, the measuring unit 3 further comprises a first acceleration sensor 35 and a second acceleration sensor 36. Accelerations of the hand 10 can be recorded via the acceleration sensor(s) 35, 36. Thus, the measuring unit 3 records both acoustic signals and acceleration signals.In order to be able to indicate to the operator whether the plugging process has been carried out correctly or incorrectly, in this case optically, the measuring unit 3 further comprises an optical display in the form of an LED 37 within its housing 31.

[0046] The measuring unit 4, also shown in Figure 4, which is arranged on the index finger 11 of the hand 10 (see Figures 1 and 2), also comprises a housing 40. An acceleration sensor 41 as well as electronics or electronic components 42 are arranged within or in the interior 44 of the housing 40. Furthermore, the housing 40 of the measuring unit 4 also comprises an optical display device, shown here in the form of an LED 43. Of course, instead of the LEDs 37 and 43, another type of optical display and / or a haptic and / or an acoustic or other display can also be provided. The acceleration sensor 41 of the measuring unit 4 can thus detect accelerations of the index finger 11 during insertion processes.

[0047] Because the opening 32 in the housing 31 of the measuring unit 3 is aligned on the thumb 15 of the hand 10 of the operator in the direction of the thumb tip 150, audio signals of the plugging process can be captured very well despite ambient noise.

[0048] Figure 5 shows a wrist unit 9, which also includes a housing 90 provided with an opening 91. This opening 91 is also covered with a membrane 92 to reliably prevent dirt, dust, and liquid from penetrating the interior 93 of the housing 90. Within or inside 93 of the housing 90 of the wrist unit 9, a microphone 94 is also arranged in the region of the opening 91 in the housing 90 to detect ambient noise. These signals are combined in the sound data processing unit in a microcontroller 95, which is also arranged in the housing 90 of the wrist unit 9, with the acoustic signals generated by the measuring unit 3, which is arranged on the thumb 15 of the hand 10 of the operator.This makes it easier to identify the locking signal, which indicates whether a successful mating process was performed, from the acoustic signals recorded by the measuring unit 3. When the coupling part and the plug part, or the mating partners of a connector, lock together, a characteristic sound profile occurs, which can be filtered out from the acoustic signals recorded by the microphone 30 of the measuring unit 3 by comparing it with the acoustic signals recorded by the microphone 94 of the wrist unit 9.

[0049] The wrist unit 9 further includes an acceleration sensor 96 and a gyroscope or gyroscopic device 97 for recording general movement data, which serves as an identification carrier for opening a measurement window or verification window for verifying a proper or improper insertion process. The wrist unit and its structure correspond to the data evaluation unit 5, as shown arranged on the flexible carrier in Figure 1.

[0050] In order to be able to send the result of the data evaluation within the microcontroller 95 to a display device and / or to a device that externally monitors the plugging processes, the wrist unit 9 comprises a transmitter unit 99 in its housing 90, via which data can be sent wirelessly via WLAN and Bluetooth. Furthermore, the wrist unit 9 comprises an RFID antenna or gate 98 and a visual display, here in the form of an LED 100. A visual display of the quality of the plugging process—i.e., whether the plugging process was incorrect or correct—can thus be displayed directly on the wrist unit 9, namely via the LED 100.

[0051] Via the RFID antenna or the gate 98, it is possible to identify the current station from which the wrist unit or the measuring units and the wrist unit, i.e. the data collection system 1, are used. This is indicated in Figure 6. Here, the wrist unit 9 of the data collection system 1 is identified at a respective assembly station 200, 201, 202, at which connectors are mounted. The part of the data collection system 1 that is arranged on the operator 18 is thus identified here at the individual assembly stations 200, 201, 202. Furthermore, it is possible to use the RFID antenna or the gate 98 of the wrist unit 9 to make RFID-tagged connectors identifiable in the same system as the verified plug connections via the data collection system 1.

[0052] Figure 6 further shows that the data collection system 1 sends data, for example, via WLAN, LTE, Bluetooth, or other wireless technologies to a data transmitter, such as a gateway, a server, or an edge device. Figure 6 shows an example of a data transmitter 210. The data transmission is indicated by three arrows 211. The data is stored in a local or external cloud-based database. Such a database 212 is also indicated in Figure 6. Analyses of the plug-in processes are performed in an internal or external cloud 213. The results of the analyses can be made available to a wide variety of people via a graphical evaluation. A device for data processing or graphical processing in the form of a display 214 is also indicated in Figure 6.

[0053] Figure 7 shows a trigger cascade, which means that not just one trigger signal, but a cascade of triggers is used to initiate the check to determine whether a desired signal, such as a characteristic acoustic signal, is present within a verification time window. This check is only carried out after several trigger signals have been received. In the uppermost signal-time diagram, an event is detected due to the exceedance of a threshold value Si in the movement data of the hand 10 of the operator 18, thus a potential assembly attempt, i.e. a characteristic insertion movement of the hand. If the threshold value Si is exceeded in the movement data (the movement amplitude), an event trigger T is generated. EThis activates acceleration sensors 35, 36, 41, 96 of the measuring units 3, 4 and the wrist unit 9. If an increase in the acceleration of the hand is detected within a short period of time, the microphone 30, 94 is switched on. The acceleration signals are shown in the second signal-time diagram in Figure 7. By exceeding the acceleration signal or the amplitude of the acceleration signal of the threshold value S2 indicated there, an assembly attempt is triggered by the amplitude peak or assembly trigger T MV detected. This assembly trigger T MV is thus the second trigger that signals an assembly attempt. The microphone 30 of the measuring unit 3 and, if necessary, also the microphone 94 of the wrist unit 9 are switched on. If the acoustic signals also exceed a predetermined threshold value S3, which is shown in the third signal-time diagram in Figure 7, assembly is triggered by this assembly amplitude MA detected, the assembly verification is carried out. The acoustic signals that are recorded after the microphone is switched on to determine whether assembly verification has occurred are within a verification time window or measurement window M v . The existence of the assembly verification M A triggers the opening of the verification time window or measurement window M v Accordingly, there are two trigger signals T E and T MV before the verification time window or measurement window M v opens, within which the presence of the assembly verification M A is queried. This is therefore a trigger cascade.

[0054] It is also possible to have the acceleration sensors permanently record acceleration data, i.e. to operate a streaming, and only in the case of an event that is triggered by the occurrence of the event trigger T EIt is determined to analyze the last preset n milliseconds or n seconds of the recording and, based on this, to switch on the microphones, i.e. microphone 30 of the measuring unit 3 and microphone 94 of the wrist unit 9. The same can also be done for the microphones, i.e. acoustic signals are permanently recorded by them, which, however, all until the occurrence of an event, i.e. the presence of the event trigger T E and the trigger for the assembly attempt T MV save the recorded data only temporarily and after checking whether the mounting amplitude M A present, discard them. If the event was not a connection attempt, all data is discarded. This means that the procedure is energy-efficient and the recording of personal audio data can be reduced to the minimum necessary in accordance with the General Data Protection Regulation.

[0055] Figure 8 shows a flowchart with individual steps of data acquisition by the data collection system 1. In a first step 220, the data collection system 1 is switched on. In a second step 221, optical and haptic feedback is provided that the data collection system 1 is ready to carry out data collection and analysis. In a third step 222, a start button or a corresponding switch is pressed, which starts the data recording. In a fourth step 223, movement data is initially recorded. In a fifth step 224, a query is made as to whether an assembly attempt has occurred. In a sixth step 225, a query is made as to whether an event has been detected, i.e., whether an event trigger is present. If no event trigger is present, in a seventh step 226, the operator 18 presses a corresponding switch, which enables the recorded data to be overwritten.In an eighth step 227, the recorded data set is saved and sent to an artificial intelligence for training. The next step is to resume recording motion data, thus continuing the process with the fourth step 223.

[0056] In the event that an event was detected in the sixth step 225, a measurement window M vor verification window is opened and the recording of acceleration and acoustic data is started. In the tenth step 229, it is determined whether a predefined trigger time window has already been exceeded. If this is the case, the assembly attempt is ended in an eleventh step 230 and restarted with the fourth step 223, i.e., the recording of movement data. If the trigger time window has not yet been exceeded, a twelfth step 231 checks whether a stop has been activated, i.e., an abort of the data collection is intended. If this is the case, the process continues with the eleventh step 230, i.e., the termination of the assembly attempt, and the recording of movement data is started again in the fourth step 223. If no stop was activated, a thirteenth step 232 checks whether suitable recording profiles have been recorded, i.e., whether a proper plug-in process has been determined.If this is not the case, a corresponding NIO signal is output in the fourteenth step 233, i.e., the signal of an improper plugging process. This can be done haptically and / or visually, for example, by the aforementioned LED 37 of the measuring unit 3, LED 43 of the measuring unit 4, or LED 100 of the wrist unit 9. If a proper plugging process was detected, i.e., a suitable recording profile for a proper plugging process, the assembly results are saved in the next fifteenth step 234 so that they can be archived for quality assurance purposes. The recording of movement data, i.e., the fourth step 223, can then be started again. The same applies if a proper plugging process (see step 233) was not detected.

[0057] The extended data acquisition process, as outlined in the flowchart in Figure 8, is very efficient, and information is fed back to an artificial intelligence for continuous learning of the data collection system 1 . As an alternative to the manual operation of switches or buttons, the opening and closing of the measurement window or verification time window, as well as a signal for the next plugging process, can also be triggered automatically, for example by entering and exiting a geofence, e.g. in a real-time location system, or by reading an audio ID, a barcode, a data matrix code, or an RFID tag.

[0058] In addition to the embodiments of a data collection system for collecting measurement data described above and shown in the figures, in particular for a detection system for detecting an incorrectly assembled plug connection of a connector, as well as such a detection system, numerous others can be formed, in particular any combinations of the aforementioned features thereof, wherein at least two measuring units, at least one data evaluation unit and at least one flexible support for arranging the measuring units and the data evaluation unit, in particular in the form of a wrist unit, can be provided on a hand or wrist of an operator who carries out the plugging process. The at least two measuring units and the data evaluation unit are arranged in close proximity to one another.The measuring units each comprise at least one accelerometer or acceleration sensor and at least one of the measuring units comprises at least one microphone.

[0059] List of reference symbols

[0060] 1 data collection system

[0061] 2 flexible supports

[0062] 3 measuring unit

[0063] 4 measuring unit

[0064] 5 Data evaluation unit

[0065] 6 measuring unit

[0066] 7 measuring unit

[0067] 8 measuring unit

[0068] 9 Wrist unit

[0069] 10 (right) hand

[0070] 11 fingers / index finger

[0071] 12 fingers / middle finger

[0072] 13 fingers / ring finger

[0073] 14 fingers / little finger

[0074] 15 thumbs

[0075] 16 left hand

[0076] 18 Operator

[0077] 30 microphones

[0078] 31 housings

[0079] 32 Opening

[0080] 33 Interior of 31

[0081] 34 Membran

[0082] 35 first acceleration sensor

[0083] 36 second acceleration sensor

[0084] 37 LED

[0085] 40 housings

[0086] 41 Accelerometer

[0087] 42 Electronics

[0088] 43 LED

[0089] 44 Interior of 40

[0090] 90 housings

[0091] 91 Opening membrane

[0092] Interior of 90

[0093] microphone

[0094] Microcontroller Accelerometer Gyroscope

[0095] RFID antenna / gate transmitter unit LED distal arrangement intermedial arrangement proximal arrangement / in the metacarpal bone area intermedial arrangement thumb tip first assembly station second assembly station third assembly station data transmitter data transmission database cloud

[0096] Data processing / graphic processing device first step second step third step fourth step fifth step sixth step seventh step eighth step ninth step tenth step eleventh step twelfth step 232 thirteenth step

[0097] 233 fourteenth step

[0098] 234 fifteenth step

[0099] P1 Arrow

[0100] 51 Threshold

[0101] T E Event trigger

[0102] 52 Threshold

[0103] T MV assembly trigger / assembly attempt

[0104] 53Threshold

[0105] M A Assembly amplitude / assembly verification

[0106] M v Verification time window / measurement window

Claims

Claims 1. A detection system for detecting an incorrectly mounted plug connection of a connector, wherein the detection system comprises at least one plug-in attempt detection device for detecting a plug-in attempt, at least one measuring unit (3, 4, 6, 7, 8) for detecting plug-in process data, and at least one verification device for verifying the plug connection via the data profile of detected plug-in process data.

2. Detection system according to claim 1, characterized in that at least one first measuring unit for detecting hand gestures for a plug-in attempt and at least one second measuring unit for detecting the plug-in process are provided, in which data on acceleration and / or force absorption as well as the released energy are detected via the sound.

3. Detection system according to claim 1 or 2, characterized in that the detection system comprises at least one type of artificial intelligence, by means of which all measuring unit inputs are or are converted as inputs to a binary output for indicating the decision of a correct plug connection or an incorrect plug connection.

4. Detection system according to one of the preceding claims, characterized in that the measuring units can be arranged or are arranged on at least one of the fingers (11, 12, 13, 14) and the thumb (15) of at least one hand (10, 16) of an operator (18) who carries out a plugging operation, in particular by arranging the measuring units (3, 4, 6, 7, 8) on or on at least one carrier, in particular a flexible carrier (2).

5. Detection system according to one of the preceding claims, characterized in that the detection system comprises at least one wrist unit (9) for arranging on a wrist of an operator (18) performing a plugging operation, wherein the at least one wrist unit (9) comprises at least one microphone (94) for recording ambient noise and at least one microcontroller (95), wherein in a sound data processing of the at least one microcontroller (95) of the wrist unit (9) a comparison is carried out with the recorded data of a measuring unit (3) that can be arranged or is arranged on a thumb (15) of a hand (10, 16) of an operator (18) in order to improve the detection of the sound profile of the locking of the plug-in partners of the plug-in connector.

6. Recognition system according to claim 5, characterized in that the at least one wrist unit (9) comprises at least one gyroscope (97), wherein the gyroscope (97) records movement data of a hand (10, 16) of an operator (18), which serves as an identification trigger for opening a measurement window (M v ) can be used, whereby within the measurement window (M v ) the presence of data or signals characterising a proper mating process is checked.

7. Recognition system according to one of claims 4 to 6, characterized in that the measuring units (3, 4, 6, 7, 8) can be arranged or are arranged intermedially or proximally on the fingers (11, 12, 13, 14) and / or the thumb (15) of at least one hand (10, 16) of an operator (18), in particular when the measuring units (3, 4) are arranged on the thumb (15) and index finger (11) or between the thumb (15) and index finger (11) of at least one hand (10) of an operator (18), the measuring units (3, 4) can be arranged or are arranged in the region of the metacarpal bones of the hand (109).

8. Recognition system according to claim 7, characterized in that the measuring units (3, 4, 6, 7, 8) are arranged in a rotational or rotated manner on the middle or base of the finger, in particular when arranged on a thumb (15) of a hand (10) on the inside directed towards the index finger (11) of the hand (10), when arranged on an index finger (11) of a hand (10) on the inside directed towards the thumb (15), in particular with a rotation in the direction of the top of the hand (10), when arranged on a middle finger (12) and / or a ring finger (13) and / or a little finger (14) of a hand (10) are arranged in the direction of the top of the hand (10) of the operator (18).

9. Data collection system (1) for collecting measurement data, in particular for a recognition system according to one of the preceding claims, characterized in that the data collection system (1) comprises at least two measuring units (3, 4), at least one data evaluation unit (5) and at least one flexible carrier (2), wherein the at least two measuring units (3, 4) and the data evaluation unit (5) are arranged on the flexible carrier (2) and in close proximity to one another, wherein the measuring units (3, 4) each comprise at least one acceleration pickup or acceleration sensor (35, 36) and at least one of the measuring units (3, 4) comprises at least one microphone (30).

10. Data collection system (1) according to claim 9, characterized in that the at least one microphone (30) of the at least one of the measuring units (3, 4) is directed towards the fingertip or the thumbtip (150) of a thumb (15) of a hand (10) of an operator (18) carrying the measuring unit(s) (3, 4, 6, 7, 8).

11. Data collection system (1) according to claim 10, characterized in that in a housing (31) of the measuring unit (3) at least one opening (32) is arranged, which is covered by at least one membrane (34) for protection against dust and water.

12. Data collection system (1) according to one of claims 9 to 11, characterized in that at least one wrist unit (9) is provided, wherein the at least one wrist unit (9) comprises at least one gyroscope (97) and a 3-axis acceleration sensor (96).

13. Data collection system (1) according to claim 12, characterized in that the at least one wrist unit (9) comprises at least one microphone (94) for recording ambient noise.

14. Data collection system (1) according to claim 12 or 13, characterized in that the at least one wrist unit (9) comprises at least one RFID unit (98) with which a respective assembly station (200, 201, 202), from which the wrist unit (9) is used, or RFID-tagged plugs can be made recognizable in the same IT system as plug connections verified via the data collection system (1).

15. Data collection system (1) according to one of claims 9 to 14, characterized in that the data collection system (1) is provided or can be provided with at least one transmitting device (99) for transmitting the collected data via WLAN, LTE, Bluetooth and / or radio technologies to a data transmitter (210), in particular a gateway, a server or an edge device as a data transmitter, at least one local or cloud-based database (212) is provided for storing the collected data, a cloud (213) for carrying out analyses of the plugging processes and at least one graphic evaluation unit (214) for displaying evaluation results.

16. Data collection system (1) according to one of claims 9 to 15, characterized in that the at least one flexible carrier (2) is designed as a glove, as a partial glove and / or in the form of at least two bands which connect at least two measuring units (3, 4, 6, 7, 8) and the at least one wrist unit (9) to one another.

Images