System and method for determining the quality of wire termination sections using thermal properties
Thermal sensors are used to monitor and analyze wire termination quality by comparing thermal data with stored profiles, addressing inaccuracies in existing systems and ensuring reliable detection of defective connections.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2024-04-04
- Publication Date
- 2026-04-14
AI Technical Summary
Existing wire termination quality monitoring systems, such as those based on crimping height and force measurement, are inaccurate and fail to detect defective connections due to factors like incorrect terminal or wire size, missing strands, or insulator presence, especially when using manual tools.
A method and system that utilizes thermal sensors to monitor the thermal properties and signatures of wire terminations, comparing collected thermal data with stored data to determine the quality of the termination process.
Accurately identifies defective terminations by analyzing thermal characteristics, providing reliable quality assurance for various wire termination processes regardless of the equipment used, including manual tools, and reducing false positives/negatives.
Smart Images
Figure 2026512078000001_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to a method and a system for monitoring the quality of a terminal processing part of a wire by utilizing the thermal characteristics of the terminal processing part of the wire.
Background Art
[0002] Wires are terminally processed using various methods such as crimping, soldering, or welding. For example, generally, an electrical terminal is crimped to a wire by a crimping device to form a lead wire. This crimping device may be a fixed-type device or a manual tool. During operation, the terminal is placed in the fixing part of the fixed-type device or the manual tool, and the end of the wire is inserted into the ferrule or barrel of the terminal. The ram of the tool is moved toward the fixing part through the crimping stroke, whereby the terminal is crimped to the wire.
[0003] Systems for monitoring the quality of crimping have been developed. When a defective crimping is detected, the lead wire is discarded. Some known crimping quality monitoring systems measure the crimping quality by measuring the crimping height. Usually, when a terminal is not crimped with the correct crimping height for a specific combination of terminal and wire, an insufficient crimping connection results. However, many insufficient crimping connections nevertheless have an "accurate" crimping height. Therefore, a system for monitoring crimping quality based on the crimping height may pass defective lead wires from the crimping device as acceptable. Furthermore, variations in the crimping height or other physical variations in the crimped terminal may not be the cause of the defective crimping connection itself, but rather may indicate another factor causing the connection failure. Such factors include the use of incorrect terminal size or wire size, missing strands of the wire, insufficient brush length, insulation of the crimping part, abnormal position of the terminal, incorrect wire type, and inaccurate stripping of the insulator. Such defective crimping connections often exhibit the appearance of high-quality crimping connections and thus pass the inspection.
[0004] Other known crimp quality monitoring systems detect defective crimps by analyzing the crimping force applied to the terminal during the actual crimping process. For example, these systems collect force and displacement data during the crimping stroke and compare this data with normalized data collected from known good crimps during the learning phase. This comparison is used to determine whether a particular crimp meets the acceptable criteria. However, crimp quality monitoring systems that monitor crimp quality based on force profiles are not without their problems. These systems are inaccurate when it comes to measuring certain types of defective crimps. For example, these systems tend to inaccurately identify crimps with an insulator inside the barrel as good crimps. Furthermore, these systems tend to misidentify some good crimps as poor crimps. Moreover, in the case of various materials, such as aluminum wire, the force variation between crimping the terminal with the aluminum wire properly inserted and crimping the terminal without the aluminum wire inserted is very small. As a result, measuring the force to determine whether a crimp is good or bad is not effective.
[0005] Furthermore, measuring the crimping quality of crimp terminals becomes difficult when crimping is performed using manual tools. Due to the size, portability, and nature of manual tools, it is difficult to implement a monitoring device or sensor that is sufficient to properly monitor crimping quality. [Overview of the Initiative] [Problems that the invention aims to solve]
[0006] There is still a need for wire termination quality monitoring systems that can be used to accurately monitor the quality of wire terminations, not only for crimp quality monitoring systems, but for all types of wires and various types of terminations, regardless of whether such terminations are performed by fixed equipment or manual tools.
[0007] Therefore, it is beneficial to provide wire termination monitoring systems and methods that can be used to monitor various wire termination processes, regardless of the equipment used to perform the wire termination process. In particular, it is beneficial to provide wire termination monitoring systems and methods that monitor not only the force or dimensions of the termination process but also the thermal properties of the termination process. [Means for solving the problem]
[0008] One embodiment relates to a method for determining the quality of a terminal termination section for a wire. This method includes positioning a terminal in the wire termination zone of a wire termination processing device, positioning a wire in the wire termination zone of the wire termination processing device, terminating the terminal on the wire, monitoring thermal data of the terminal termination section for the wire using one or more thermal sensors, and comparing the monitored thermal data with stored thermal data to determine whether or not the terminal termination section for the wire is defective. If the terminal termination section for the wire is defective, the wire is discarded.
[0009] The present invention will be described below with reference to the attached drawings. [Brief explanation of the drawing]
[0010] [Figure 1] This is a perspective view of a first exemplary wire termination system, which has a handheld wire termination device with a thermal sensor positioned to monitor the quality of the terminal termination process for a wire. [Figure 2] This is an end view of the handheld wire termination device shown as an example in Figure 1, along line 2-2 in Figure 1. [Figure 3] This flowchart illustrates one example of a method for quality monitoring of the terminal termination section of a wire shown in Figure 1, utilizing its thermal properties. [Figure 4]This is a perspective view of a second exemplary wire termination system, comprising an exemplary wire termination device which is a crimping device, and an exemplary thermal sensor positioned near the wire termination device to monitor the quality of the terminal termination process on the wire. [Figure 5] This flowchart illustrates one example of a method for quality monitoring of the terminal termination section of a wire shown in Figure 4, utilizing its thermal properties. [Figure 6] This is a perspective view of a third exemplary wire termination system, comprising an exemplary wire termination processing device which is a heating device, and an exemplary thermal sensor positioned near the wire termination processing device to monitor the quality of the terminal termination processing on the wire. [Figure 7] This flowchart illustrates one example of a method for quality monitoring of the terminal termination section of a wire shown in Figure 6, utilizing its thermal properties. [Modes for carrying out the invention]
[0011] Exemplary wire termination systems 2, 102, 202 having wire termination devices or wire termination processing devices 10, 110, 210, and methods for monitoring wire termination processes 300, 400 to determine termination quality by utilizing thermal characteristics and signatures are also shown.
[0012] Figures 1-2 and 4-5 show crimping devices 10 and 110 that determine the quality of the crimped termination section using thermal characteristics and signatures. Figures 7-8 show a heating device 210, including but not limited to a heat shrinking device, that determines the quality of the heated termination section using thermal characteristics and signatures. However, the use of crimping devices 10 and 110 and heating device 210 is illustrative and not limiting. Monitoring wire, conductor, or terminal termination processes using thermal data and thermal analysis, as described below, is used not only for crimping and heat-based termination applications but also for other purposes. For example, devices such as insulated displacement connector (IDC) devices and welding devices may be used to attach connectors or terminals to wires using processes other than crimping or heat shrinking. Alternatively, the crimping devices 10, 110 may be other types of crimping devices, such as lead frame devices.
[0013] Referring to Figures 1 and 2, the applicator 12 is coupled to the crimping device 10. In the illustrated embodiment, the crimping device 10 is a handheld wire termination processing device or wire termination tool that can be used in multiple locations. The applicator 12 can be removed and replaced with another applicator, for example, if it becomes worn or damaged, or if an applicator with a different configuration is desired. The applicator 12 has a wire termination zone or crimping zone 18, and comprises a first crimping head 20 and a second crimping head 22 as a mechanical tool for crimping an electrical connector or terminal 24 to the end of a wire 26 in the crimping zone 18. The second crimping head 22 is a fixed component of the applicator 12, and the first crimping head 20 may be a movable component. Alternatively, both the second crimping head 22 and the first crimping head 20 may be movable. The crimping device 10 shown and described is illustrative and can have various configurations.
[0014] One or more sensors 28 are attached to the crimping device 10. These sensors 28 may consist of thermal sensors, visual sensors, or both. Other types of sensors may be included among these sensors 28. Alternatively, one sensor 28 may be a thermal sensor, and another sensor 28 located remotely from this thermal sensor may be a visual sensor. These sensors 28 can be attached at various locations within or near the crimping zone 18. The sensor 28 may be detachably attached by a detachable device, such as, but not limited to, a magnet (not shown). Alternatively, the sensor 28 may be held in place by the use of mechanical fasteners, latches, and adhesives. The shape and position of the sensor 28 are illustrative, and the thermal sensor may have other configurations and be positioned in other locations.
[0015] In the embodiments shown in Figures 1 and 2, the sensor 28 is a thermal sensor 28 positioned to have a field of view that includes the crimping zone 18. The thermal sensor 28 is positioned to acquire the thermal characteristics of the terminal 24 and / or wire 26 in the crimping zone 18 in the form of discrete thermal data. In one exemplary embodiment, the thermal sensor 28 is positioned in line with the longitudinal axis 30 of the terminal 24. This allows the thermal sensor 28 to directly sense the thermal energy emitted directly from the terminal 24 and / or wire 26 and collect thermal data from this thermal energy. In another embodiment, the thermal sensor 28 may be positioned off-axis or eccentrically from the axis 30. When the sensor 28 is positioned off-axis or eccentrically from the axis 30, the thermal sensor 28 can collect thermal energy transmitted to the wire 26 or other object via the terminal 24, and / or the thermal sensor 28 can collect thermal energy reflected from the terminal 24 and / or the wire 26. In various exemplary embodiments, two or more thermal sensors 28 may be provided.
[0016] In various exemplary embodiments, the applicator may have projections positioned near the crimping zone 18 and the terminal 24 and / or wire 26, which are configured to intentionally reflect or direct thermal energy from the terminal 24 and / or wire 26 to be sensed. This allows a thermal sensor 28 located away from or eccentrically from the terminal 24 to read thermal data reflected from these projections. These projections may be made from a material with known emissivity to improve the reflected image of the thermal properties of the terminal 24 and / or wire 26 being terminated. This allows for thermal "sensing" of areas that are not easily visible, or for viewing a wider surface area of the terminal 24 and / or wire 26.
[0017] As described above, the thermal data collected by the thermal sensor 28 may consist of one or a combination of three different energy components. The first component is the thermal energy directly emitted from the terminal 24 and / or the wire 26. The second component is the thermal energy transferred through an object, such as from the terminal 24 to the wire 26 (heat from other places it passes through). The third component is the thermal energy reflected from the terminal 24 and / or the wire 26.
[0018] In one exemplary embodiment, thermal data is acquired by a matrix of sensors 28 (e.g., a network of charge-coupled elements), thereby enabling the thermal data to be acquired and arranged in rows and columns, similar to how visual images collected by conventional visual energy cameras are represented by data pixels. For example, one thermal sensor may be positioned in line with the longitudinal axis of its terminals, while other thermal sensors in the matrix may be positioned off-axis or eccentrically. Depending on the number of data points, without limitation, techniques such as adaptive convolutional neural networks are used to extract features from these data matrices and analyze the crimping process before, during, and after the formation of the crimp. These features are found in specific regions of interest on the terminals 24 and / or the wires 26 and serve as criteria when classifying the termination processing section.
[0019] Examples of the characteristics and signatures of the thermal data collected include, but are not limited to, i) area heating, ii) heat transfer time, iii) heat transfer pattern, iv) temperature change, and v) physical properties and variations identified by thermal properties.
[0020] Furthermore, the thermal data can be collected at various speeds, resulting in a time-series image. By using analysis techniques such as, for example, artificial intelligence, it becomes possible to analyze the data that changes over time.
[0021] In various exemplary examples, the thermal sensor 28 has the ability to collect absolute temperature. The absolute temperature enables not only the analysis of "relative" regions of interest but also the analysis of potentially unique mechanical properties in the termination processing section.
[0022] The display device 32 can be communicatively coupled to the thermal sensor 28 and configured to display the thermal characteristics obtained by the thermal sensor 28. The display device 32 may be incorporated into the host controller or processor of the crimping device 10, or into the thermal sensor 28 itself, or it may be a separate controller or processor 34 such as, for example, a desktop computer, a laptop computer, a tablet computer, a monitor, a projector, and a head-up display glass. Optionally, the display device 32 may be a crimp quality monitor (CQM) device. The controller 34 and / or display device 32 may be coupled to the thermal sensor 28 via a cable or the like. Alternatively, the controller 34 and / or display device 32 may transmit data between the thermal sensor 28 and the controller 34 and / or display device 32 by wireless communication via inductive, radio frequency, and Wi-Fi or the like.
[0023] The controller 34 and / or display device 32 may include a storage device or memory device 36, such as a hard disk drive, RAM, ROM, and / or other internal data storage device, but is not limited to these. The memory device 36 may be configured to store data acquired by the thermal sensor 28. Such data may be used for subsequent quality reporting purposes.
[0024] In various exemplary embodiments, the crimping device 10 may include additional sensors (not shown), such as force sensors or linear sensors, to provide additional data relating to the quality of the crimping.
[0025] Figure 3 shows a method 50 for determining the quality of the termination process. During the crimping process, the first crimping head 20 and the second crimping head 22 of the crimping device 10 are driven toward each other and then toward each other so that the terminals 24 are terminated on the wire 26 as shown in Figure 3 52.
[0026] This crimping of the terminal 24 to the wire 26 is performed by the movement of a first crimping head 20 and a second crimping head 22 toward each other. The first crimping head 20 and the second crimping head 22 engage with the terminal 24 and crimp the terminal 24 to the wire 26 by compressing the terminal 24 between the first crimping head 20 and the second crimping head 22. When this crimping is performed, thermal energy or heat is generated in and near the crimped area of the terminal 24 and the wire 26.
[0027] As described above, the thermal sensor 28 can acquire temperature readings / data of the terminals 24 and wire ends 26 positioned in the crimping zone 18 at specified time intervals or continuously, either directly from a thermal sensor 28 positioned in line with the axis 30, or indirectly from a thermal sensor 28 positioned off-axis or eccentrically from the axis 30. The collected temperature readings / data are transmitted to a display device 32, controller 34, or storage device 36 located either 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 termination section meets the appropriate criteria for achieving the desired electrical and mechanical connection. In this specification, the term "operator" is used to refer to the device or person operating or controlling the crimping device 10.
[0028] The quality of the termination process can be monitored by directly or indirectly monitoring the temperature of terminal 24. Other characteristics of the termination process can be analyzed by directly or indirectly analyzing the temperature of terminal 24. For example, this temperature may be used to calculate the force applied to terminal 24, because the amount of this force is related to the temperature of terminal 24 after the termination process is performed.
[0029] In one exemplary embodiment, as shown by 54 in Figure 3, the thermal properties of the terminal section are measured directly or indirectly by one or more thermal sensors 28 during the crimping process. These thermal properties are measured at predetermined time intervals based on time or tool position. For example, a predetermined sample time may be selected, and the thermal properties may be measured at each of the individual sample times. Alternatively or additionally, the thermal properties may be measured when the crimping tool is at a predetermined crimping height position. This position of the crimping tool may be detected by a distance sensor (not shown) or the like.
[0030] The controller 34 can generate a measured temperature profile of the termination section based on the measured thermal characteristics. The measured thermal profile is then compared to a known allowable temperature profile or allowable temperature profile range for a normal termination section, as shown by 56 in Figure 3. Alternatively, the measured thermal characteristics may be compared to a known allowable temperature characteristics or allowable temperature profile for the specific material being used. The allowable temperature profile or allowable temperature profile range may be pre-installed in the controller 34 or may be created in the field by the user and stored in the controller 34. If the measured temperature profile is within the acceptable temperature profile range, the controller 34 indicates that the termination process is appropriate. If the measured temperature profile is outside the acceptable temperature profile range, the controller 34 indicates that the termination process is unacceptable and rejects the termination process as shown by 58 in Figure 3. Whether or not the termination process is defective can be determined by analyzing data on thermal characteristics, peak temperature, area under the temperature curve, shape of the temperature curve, or any combination thereof.
[0031] Referring to Figure 4, the applicator 112 is coupled to the crimping device 110. In the illustrated embodiment, the crimping device 110 is a handheld wire termination processing device or wire termination tool that can be used in multiple locations. The applicator 112 can be removed and replaced with another applicator, for example, if it is worn or damaged or if an applicator with a different configuration is desired. The applicator 112 has a wire termination zone or crimping zone 118 and comprises a first crimping head 120 and a second crimping head 122 as a mechanical tool for crimping an electrical connector or terminal 124 to the end of a wire 126 in the crimping zone 118. The second crimping head 122 may be a fixed component of the applicator 112, and the first crimping head 120 may be a movable component. Alternatively, both the second crimping head 122 and the first crimping head 120 may be movable. The crimping device 110 shown and described is illustrative and may have a different configuration.
[0032] One or more sensors 128 are positioned near the crimping device 110, but away from it. These sensors 128 may include thermal sensors, visual sensors, or both. Other types of sensors may be included in the sensors 128. Alternatively, one sensor 128 may be a thermal sensor, and another sensor 128 located remotely from the thermal sensor may be a visual sensor.
[0033] In the exemplary embodiment shown in Figure 4, the sensor 128 is positioned on a wearable device worn on the operator's wrist. However, the thermal sensor 128 may be mounted on other types of wearable devices or at other locations near the crimping device 110. The shape and positioning of the thermal sensor 128 are illustrative, and the thermal sensor may have other configurations and be positioned at other locations.
[0034] The thermal sensor 128 is positioned to have a field of view that includes the crimping zone 118. To facilitate the positioning of the thermal sensor 128, a positioning device or calibration device 144 may be provided to provide guidance regarding the proper positioning of one or more thermal sensors 128 relative to the wire termination processing device or crimping device 110, and to indicate whether the thermal sensor 128 is properly positioned relative to the crimping zone 118. This positioning device may be provided on the thermal sensor 128 or remotely from the thermal sensor 128. The positioning device provides guidance regarding the proper positioning of one or more thermal sensors relative to the wire termination processing zone of the wire termination processing device.
[0035] The thermal sensor 128 is positioned to acquire the thermal characteristics of the terminal 124 and / or wire 126 in the crimping zone 118 in the form of individual thermal data. The thermal sensor 128 may also be positioned in line with the longitudinal axis 130 of the terminal 124, so that the thermal sensor 128 can directly sense the thermal energy emitted directly from the terminal 124 and / or wire 126 and collect thermal data from this thermal energy. Alternatively, the thermal sensor 128 may be positioned off-axis or eccentrically from the axis 130, thereby enabling the thermal sensor 128 to collect thermal energy transmitted to the wire 126 or other object via the terminal 124, and / or to collect thermal energy reflected from the terminal 124 and / or the wire 126. In various exemplary embodiments, two or more thermal sensors 128 may be provided.
[0036] In various exemplary embodiments, the applicator may have projections positioned near the crimping zone 118 and the terminal 124 and / or wire 126, which are configured to intentionally reflect or direct thermal energy from the terminal 124 and / or wire 126 to be sensed. This allows a thermal sensor 128, located away from or eccentrically from the terminal 124, to read the thermal data reflected from these projections. These protrusions may be made from a material with a known emissivity to improve the reflective image of the thermal properties of the terminals 124 and / or wires 126 being terminated. This makes it possible to thermally "sens" areas that are not easily visible, or to visualize a wider surface area of the terminals 124 and / or wires 126.
[0037] As described above, the thermal data collected by the thermal sensor 128 may consist of one or a combination of three different energy components. The first component is the thermal energy directly emitted from terminal 124 and / or wire 126. The second component is the thermal energy transferred from terminal 124 to wire 126 via an object (heat from other places it passes through). The third component is the thermal energy reflected from terminal 124 and / or wire 126.
[0038] The number and positioning of the thermal sensors, as well as the characteristics of the thermal data, are the same as those described with respect to the embodiments shown in Figures 1 and 2.
[0039] The display device 132 may be communicatively coupled to the thermal sensor 128 and configured to display thermal characteristics acquired by the thermal sensor 128. The display device 132 may be integrated into the host controller or processor of the crimping device 110, or into the thermal sensor 128 itself, or it may be a separate controller or processor 134, such as a desktop computer, laptop computer, tablet computer, monitor, projector, or head-up display glasses. Optionally, the display device 132 may be a crimp quality monitor (CQM) device. The controller 134 and / or the display device 132 may be coupled to the thermal sensor 128 via a cable or the like. Alternatively, the controller 134 and / or the display device 132 may transmit data between the thermal sensor 128 and the controller 134 and / or the display device 132 by wireless communication via inductive, radio frequency, and Wi-Fi or the like.
[0040] The controller 134 and / or the display device 132 may include a storage device or memory device 136, such as a hard disk drive, RAM, ROM, and / or other internal data storage device, but is not limited to these. The memory device 136 may be configured to store data acquired by the thermal sensor 128. Such data may be used for subsequent quality reporting purposes.
[0041] In various exemplary embodiments, the crimping device 110 may include additional sensors (not shown), such as force sensors or linear sensors, to provide additional data relating to the quality of the crimping.
[0042] Figure 5 shows a method 150 for determining the quality of a terminal section using a remote thermal sensor 128. During the crimping process, the thermal sensor 128 is positioned appropriately relative to the crimping zone 118, shown by 152 in Figure 5, thereby enabling accurate measurements as crimping is performed. The first crimping head 120 and the second crimping head 122 of the crimping device 110 are then driven toward each other and finally toward each other, so that the terminal 124 is terminated relative to the wire 126, as shown by 154 in Figure 5.
[0043] This crimping of terminal 124 to wire 126 is performed by moving a first crimping head 120 and a second crimping head 122 toward each other. The first crimping head 120 and the second crimping head 122 engage with terminal 124 and crimp terminal 124 to wire 126 by compressing terminal 124 between the first crimping head 120 and the second crimping head 122. When this crimping is performed, thermal energy or heat is generated in and near the crimped area of terminal 124 and wire 126.
[0044] As described above, the thermal sensor 128 can acquire temperature readings / data of the terminals 124 and wire 126 positioned in the crimping zone 118 at specified time intervals or continuously, either directly from a thermal sensor 128 positioned in line with the axis 130, or indirectly from a thermal sensor 128 positioned off-axis or eccentrically from the axis 130. The collected temperature readings / data are transmitted to a display device 132, controller 134, or storage device 136, either 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 termination section meets the appropriate criteria for achieving the desired electrical and mechanical connection.
[0045] The quality of the termination process can be monitored by directly or indirectly monitoring the temperature of terminal 124. Other characteristics of the termination process can be analyzed by directly or indirectly analyzing the temperature of terminal 124. For example, this temperature may be used to calculate the force applied to terminal 124, because the amount of this force is related to the temperature of terminal 124 after the termination process is performed.
[0046] In one exemplary embodiment, as shown by 156 in Figure 5, the thermal properties of the termination section are measured directly or indirectly by one or more thermal sensors 128 during termination. These thermal properties are measured at predetermined intervals based on time or tool position. For example, a predetermined sample time may be selected, and the thermal properties may be measured at each of the individual sample times. Alternatively or additionally, the thermal properties may be measured when the crimping tool is at a predetermined crimping height. This position of the crimping tool may be detected by a distance sensor (not shown) or the like.
[0047] The controller 134 can generate a measured temperature profile of the termination section based on the measured thermal characteristics. The measured thermal profile is then compared to a known allowable temperature profile or allowable temperature profile range for a normal termination section, as shown in Figure 5, 158. Alternatively, the measured thermal characteristics may be compared to a known allowable temperature characteristics or allowable temperature profile for the specific material used. The allowable temperature profile or allowable temperature profile range may be pre-installed in the controller 134 or may be created on-site by the user and stored in the controller 134. If the measured temperature profile is within the acceptable temperature profile range, the controller 134 indicates that the termination is appropriate. If the measured temperature profile is outside the acceptable temperature profile range, the controller 134 indicates that the termination is unacceptable and rejects the termination unit as shown by 160 in Figure 5. Whether or not the termination unit is defective can be determined by analyzing data regarding thermal characteristics, peak temperature, area under the temperature curve, shape of the temperature curve, or any combination thereof.
[0048] Referring to Figure 6, the wire termination system 202 includes a heating device 210. The heating device 210 has heating elements 212 in the wire termination zone or heating zone 218. The heating device 210 is used to connect and seal the connector or terminal 224 to the wire 226. However, other types of devices may be used, such as insulated displacement connector (IDC) devices and welding devices, which attach the connector or terminal to the wire using processes other than crimping or heat shrinking.
[0049] One or more thermal sensors 228 are positioned near the heating device 210, but away from it. In the illustrated embodiment, one thermal sensor 228 is positioned on a wearable device worn on the operator's wrist. However, the thermal sensors 228 may be mounted on other types of wearable devices or at other locations near the heating device 210. The shape and positioning of the thermal sensors 228 are illustrative, and the thermal sensors may have other configurations and be positioned at other locations.
[0050] The thermal sensor 228 is positioned to have a field of view that includes 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 regarding the proper 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 properly positioned relative to the heating zone 218. This positioning device may be provided on the thermal sensor 228 or remotely from the thermal sensor 228.
[0051] The thermal sensor 228 is positioned to acquire the thermal characteristics of terminal 224 and / or wire 226 in the heated zone 218 in the form of individual thermal data. The thermal sensor 228 may also be positioned in line with the longitudinal axis 230 of terminal 224 and / or heat shrink wrap 227, so that the thermal sensor 228 can directly sense the thermal energy emitted directly from terminal 224 and / or wire 226 and collect thermal data from this thermal energy. Alternatively, the thermal sensor 228 may be positioned off-axis or eccentrically from the axis 230, thereby enabling the thermal sensor 228 to collect thermal energy transmitted to the wire 226 or other object via the terminal 224, and / or to collect thermal energy reflected from the terminal 224 and / or the wire 226. In various exemplary embodiments, two or more thermal sensors 228 may be provided.
[0052] In various exemplary embodiments, the heating device 210 may have projections positioned near the heating zone 218 and the terminals 224 and / or wires 226, which are configured to intentionally reflect or direct the thermal energy from the terminals 224 and / or wires 226 to be sensed. This allows a thermal sensor 228, positioned away from or eccentrically from the terminals 224, to read the thermal data reflected from these projections. These projections may be made from a material having a known emissivity to improve the reflected image of the thermal properties of the terminals 224 and / or wires 226 to be terminated.
[0053] As mentioned above, the thermal data collected by the thermal sensor 228 may consist of one or a combination of three different energy components. The first component is the thermal energy directly emitted from terminal 224 and / or wire 226. The second component is the thermal energy transferred through an object (heat from other places it passes through), such as from terminal 224 to wire 226. The third component is the thermal energy reflected from terminal 224 and / or wire 226.
[0054] The number and positioning of the thermal sensors, as well as the characteristics of the thermal data, are the same as those described with respect to the embodiments shown in Figures 1 and 2.
[0055] The display device 232 may be communicatively coupled to the thermal sensor 228 and configured to display thermal characteristics acquired by the thermal sensor 228. The display device 232 may be integrated into the host controller or processor of the heating device 210, or into the thermal sensor 128 itself, or it may be a separate controller or processor 234, such as a desktop computer, laptop computer, tablet computer, monitor, projector, or head-up display glasses. The controller 234 and / or the display device 232 may be coupled to the thermal sensor 228 via a cable or the like. Alternatively, the controller 234 and / or the display device 232 may transmit data between the thermal sensor 228 and the controller 234 and / or the display device 232 by wireless communication via inductive, radio frequency, and Wi-Fi or the like.
[0056] The controller 234 and / or the display device 232 may include a storage device or memory device 236, such as a hard disk drive, RAM, ROM, and / or other internal data storage device, but is not limited to these. The memory device 236 may be configured to store data acquired by the thermal sensor 228. Such data may be used for subsequent quality reporting purposes.
[0057] Figure 7 shows a method 250 for determining the quality of a termination section using a remote thermal sensor 228. During the heating operation, the thermal sensor 228 is positioned appropriately relative to the heating zone 218, as shown by 252 in Figure 7, to enable appropriate measurements as heating takes place. Subsequently, as heating begins, the terminal 224 is terminated relative to the wire 226, as shown by 254 in Figure 7. This termination process generates thermal energy or heat in and near the termination section of the terminal 224 and the wire 226.
[0058] As described above, the thermal sensor 228 can acquire temperature measurements / data of the terminals 224 and wire 226 positioned in the heating zone 218 at specified time intervals or continuously, either directly from the thermal sensor 228 positioned in line with the axis 230, or indirectly from the thermal sensor 228 positioned off-axis or eccentrically from the axis 230. The collected temperature readings / data are transmitted to a display device 232, controller 234, or storage device 236 located on or outside the heating device 210. The temperature readings / data transmitted by the thermal sensor 228 are used by the operator of the heating device 210 to determine whether the wire termination section meets the appropriate criteria for achieving the desired electrical and mechanical connection. The quality of the termination section can be monitored by directly or indirectly monitoring the temperature of the terminal 224.
[0059] In one exemplary embodiment, as shown by 256 in Figure 7, the thermal properties of the termination section are measured directly or indirectly by one or more thermal sensors 228 during the termination process. These thermal properties are measured at predetermined intervals based on time or tool position. For example, a predetermined sample time may be selected, and the thermal properties may be measured at each of the individual sample times. Alternatively or additionally, the thermal properties may be measured when the heated tool is at a predetermined temperature.
[0060] The controller 234 can generate a measured temperature profile of the termination section based on the measured thermal characteristics. The measured thermal profile is then compared to a known allowable temperature profile or allowable temperature profile range for a normal termination section, as shown by 258 in Figure 7. Alternatively, the measured thermal characteristics may be compared to a known allowable temperature characteristics or allowable temperature profile for the specific material being used. The allowable temperature profile or allowable temperature profile range may be pre-installed in the controller 234 or may be created on-site by the user and stored in the controller 234. If the measured temperature profile is within the allowable temperature profile range, the controller 234 indicates that the termination is appropriate. If the measured temperature profile is outside the acceptable temperature profile range, the controller 234 indicates that the termination process is unacceptable and rejects the termination process as shown by 260 in Figure 5. Whether or not the termination process is defective can be determined by analyzing data regarding thermal characteristics, peak temperature, area under the temperature curve, shape of the temperature curve, or any combination thereof.
[0061] Monitoring wire or conductor termination processes using thermal data and thermal analysis is used not only in crimping and heat shrinkage-related applications but also in other areas. For example, thermal analysis of welds (ultrasonic welds, resistance welds, etc.), molded parts, punched parts, thermoplastic welds, and heat-staking parts (plastic rivets) is useful for determining whether a proper connection is ensured. In addition to collecting thermal data immediately after termination to determine whether proper termination has been performed, thermal sensors may also 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.
[0062] By collecting thermal data during termination using non-contact methods such as thermal sensors, direct-contact thermal sensors, or a combination of both, this data can be used to perform quality evaluation without the need for destructive testing. The use of thermal data is beneficial in many applications, particularly in applications where the force variation between termination of terminals with wires and termination of terminals without wires is very small, such as when terminating aluminum wires.
Claims
1. A method for determining the quality of the termination processing section of terminals (24, 124, 224) for wires (26, 126, 226), - Positioning the terminals (24, 124, 224) in the wire termination zones (18, 118, 218) of the wire termination processing equipment (10, 110, 210), - Positioning the wires (26, 126, 226) in the wire termination zones (18, 118, 218) of the wire termination processing device (10, 110, 210), - Terminating the terminals (24, 124, 224) with respect to the wires (26, 126, 226), - Monitoring thermal data of the termination processing section of the terminals (24, 124, 224) for the wires (26, 126, 226) using one or more thermal sensors (28, 128, 228), - The monitored thermal data is compared with stored thermal data to determine whether or not there is a defect in the termination processing section of the terminals (24, 124, 224) for the wires (26, 126, 226). Includes, A method wherein, if the termination section of the terminal (24, 124, 224) for the wire (26, 126, 226) is defective, the wire (26, 126, 226) is discarded.
2. The method according to claim 1, wherein one or more thermal sensors (28, 128, 228) are positioned on the wire termination processing device (10, 110, 210).
3. The method according to claim 2, wherein the one or more thermal sensors (28, 128, 228) are located away from the wire termination zones (18, 118, 218) of the wire termination processing device (10, 110, 210).
4. The method according to claim 1, wherein the one or more thermal sensors (28, 128, 228) are positioned remotely from the wire termination processing equipment (10, 110, 210).
5. The method according to claim 4, wherein the one or more thermal sensors (28, 128, 228) are positioned on a wearable device.
6. The method according to claim 5, wherein positioning devices (144, 244) are provided on the wearable device, thereby providing guidance regarding the proper positioning of one or more thermal sensors (28, 128, 228) relative to the wire termination zones (18, 118, 218) of the wire termination processing equipment (10, 110, 210).
7. The method according to claim 1, wherein the termination processing section of the terminals (24, 124, 224) for the wires (26, 126, 226) is a crimp termination processing section.
8. The method according to claim 1, wherein the termination processing section of the terminals (24, 124, 224) for the wires (26, 126, 226) is an ultrasonic welding termination processing section.
9. The method according to claim 1, wherein the termination processing section of the terminals (24, 124, 224) for the wires (26, 126, 226) is a resistance welding termination processing section.
10. The method according to claim 1, wherein the termination processing section of the terminals (24, 124, 224) for the wires (26, 126, 226) is a solder termination processing section.
11. The method according to claim 1, wherein the termination processing portion of the terminals (24, 124, 224) for the wires (26, 126, 226) is a heat shrink termination processing portion.
12. The method according to claim 1, wherein one or more thermal sensors (28, 128, 228) monitor the thermal data of the termination processing unit of the terminals (24, 124, 224) for the wires (26, 126, 226) for a specified period of time.
13. The method according to claim 1, wherein one or more thermal sensors (28, 128, 228) continuously monitor the thermal data of the termination processing section of the terminals (24, 124, 224) with respect to the wires (26, 126, 226) over a predetermined time interval.
14. One or more visual sensors are used to monitor the visual data of the termination processing unit of the terminals (24, 124, 224) for the wires (26, 126, 226). The method according to claim 1, including the method described in claim 1.
15. Monitoring other data from the termination processing unit of the terminals (24, 124, 224) for the wires (26, 126, 226) in the wire termination processing zones (18, 118, 218), The other data and the thermal data are compared with stored data to determine whether there is a defect in the termination processing section of the terminals (24, 124, 224) for the wires (26, 126, 226). The method according to claim 1, including the method described in claim 1.
16. The method according to claim 1, wherein at least one of the one or more thermal sensors (28, 128, 228) monitors the thermal data of the termination processing section of the terminal (24, 124, 224) for the wire (26, 126, 226) that is reflected from the termination processing section of the terminal (24, 124, 224) for the wire (26, 126, 226).
17. The method according to claim 1, wherein at least one of the one or more thermal sensors (28, 128, 228) monitors the thermal data of the termination processing unit of the terminals (24, 124, 224) with respect to the wires (26, 126, 226) via thermal characteristics transmitted through the wires (26, 126, 226).
18. A wire termination system (2, 102, 202) capable of determining the quality of the termination processing section of terminals (24, 124, 224) for wires (26, 126, 226), A wire termination processing device (10, 110, 210) having wire termination processing zones (18, 118, 218), A thermal sensor (28, 128, 228) is positioned near the wire termination processing zone (18, 118, 218), and the thermal sensor (28, 128, 228) is positioned to acquire thermal data of the termination processing section of the terminal (24, 124, 224) for the wire (26, 126, 226), and Equipped with, A wire termination processing system (2, 102, 202) monitors the thermal data of the termination processing section of the terminals (24, 124, 224) for the wires (26, 126, 226) and determines whether or not there is a defect in the termination processing section of the terminals (24, 124, 224) for the wires (26, 126, 226).
19. The wire termination processing system (2, 102, 202) according to claim 18, wherein the wire termination processing device (10, 110, 210) is a handheld wire termination processing device (10, 110, 210).
20. The wire termination system (2, 102, 202) according to claim 19, wherein the thermal sensor is positioned in the vicinity of the wire termination zone (18, 118, 218) on the handheld wire termination processing device (10, 110, 210).
21. The wire termination system (2, 102, 202) according to claim 20, wherein the thermal sensors (28, 128, 228) are detachably attached to the handheld wire termination processing device (10, 110, 210).
22. The wire termination system (2, 102, 202) according to claim 18, wherein the thermal sensors (28, 128, 228) are positioned at a sensing device located remotely from a handheld wire termination processing device (10, 110, 210).
23. The wire termination processing system according to claim 22, wherein the sensing device is a wearable device (2, 102, 202).
24. The wire termination system (2, 102, 202) according to claim 23, wherein the sensing device has a positioning device (144, 244) that indicates when the thermal sensor is positioned to have the wire termination zone (18, 118, 218) within its field of view.