Crimping determination device, crimping determination method, crimping determination program, wire harness processing device, and wire harness processing method

Abstract

To provide a crimp determination device which can reduce the distribution of a wire harness having a crimp failure to a market.SOLUTION: A crimp determination device according to an embodiment for determining the quality of a crimp state of a wire harness in which a crimp terminal is crimped to an electric wire, comprises a drop part, an image acquisition part and a control part. The drop part drops inspection liquid to any of a first electric wire part and a second electric wire part in the wire harness having a crimp part to which the electric wire is crimped by the crimp terminal, the first electric wire part in which the electric wire is exposed on the tip side relative to the crimp part, and the second electric wire part in which the electric wire is exposed on a base end side relative to the crimp part. The image acquisition part acquires an image including the other of the first electric wire part and the second electric wire part. The control part determines the quality of the crimp state of the crimp part on the basis of the image.SELECTED DRAWING: Figure 4

Description

Technical Field

[0001] Embodiments of the present invention relate to a crimping determination device, a crimping determination method, a crimping determination program, a wire harness processing device, and a wire harness processing method.

Background Art

[0002] In the wiring of electronic devices, for connections at high-wattage parts such as the power supply system, a wire harness in which a crimp terminal is crimped to an electric wire is used. In such a wire harness, if the crimp terminal is not sufficiently crimped to the electric wire, oxidation of the electric wire or disconnection of the electric wire may occur during product operation, and there is a risk of an increase in the resistance value, resulting in heat generation and smoke generation.

[0003] Therefore, when manufacturing a wire harness, product management is required to prevent the shipment of wire harnesses with poor crimping. More specifically, for example, it is required to select wire harnesses with poor crimping by determining the quality of the crimping state, or to process wire harnesses with poor crimping to improve the crimping state.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] [[ID=�9]]The problem to be solved by the present invention is to provide a crimping determination device, a crimping determination method, a crimping determination program, a wire harness processing device, and a wire harness processing method that can reduce the market outflow of wire harnesses with poor crimping.

Means for Solving the Problems

[0006] The crimping determination device according to the embodiment is a device for determining the quality of the crimping state of a wire harness in which a crimp terminal is crimped to an electric wire, and comprises a dripping unit, an image acquisition unit, and a control unit. The dripping unit drops an inspection liquid onto either the first wire section or the second wire section of the wire harness, which has a crimped section in which the electric wire is crimped by the crimp terminal, a first wire section in which the electric wire is exposed on the tip side of the crimped section, and a second wire section in which the electric wire is exposed on the base end side of the crimped section. The image acquisition unit acquires an image including the other of the first wire section and the second wire section. The control unit determines the quality of the crimping state of the crimped section based on the image. [Brief explanation of the drawing]

[0007] [Figure 1] This is a schematic plan view showing a wire harness according to an embodiment. [Figure 2] Figures 2(a) to 2(c) are schematic cross-sectional views illustrating an example of a crimped section of a wire harness. [Figure 3] This is a block diagram representing a crimping determination device according to an embodiment. [Figure 4] Figures 4(a) and 4(b) are explanatory diagrams showing an example of a crimping determination device according to the embodiment. [Figure 5] Figures 5(a) and 5(b) are explanatory diagrams showing another example of a crimping determination device according to the embodiment. [Figure 6] This is a flowchart illustrating an example of a crimping determination method according to the embodiment. [Figure 7] This flowchart shows another example of the crimping determination method according to the embodiment. [Figure 8] Figures 8(a) to 8(c) are images showing the data from Experimental Example 1. [Figure 9] Figures 9(a) to 9(c) are images showing the data from Experimental Example 2. [Figure 10] Figures 10(a) to 10(c) are images showing the data from Experimental Example 3. [Figure 11]Figures 11(a) to 11(c) are images showing the data from Experimental Example 4. [Figure 12] Figures 12(a) and 12(b) are tables and graphs showing the data for Experimental Examples 1-4. [Figure 13] This is a block diagram representing a wire harness processing apparatus according to an embodiment. [Figure 14] Figures 14(a) and 14(b) are explanatory diagrams showing an example of a wire harness processing apparatus according to an embodiment. [Figure 15] Figures 15(a) and 15(b) are explanatory diagrams showing another example of a wire harness processing apparatus according to the embodiment. [Figure 16] This is a flowchart illustrating an example of a wire harness processing method according to the present invention. [Modes for carrying out the invention]

[0008] Each embodiment of the present invention will be described below with reference to the drawings. Drawings are schematic or conceptual, and the relationships between the thickness and width of each part, as well as the ratios of the sizes of different parts, are not necessarily identical to those of reality. Even when representing the same part, the dimensions and ratios may be depicted differently in different drawings. In this specification and in each figure, elements similar to those described above are denoted by the same reference numerals with respect to previously shown figures, and detailed explanations are omitted as appropriate.

[0009] Figure 1 is a schematic plan view showing a wire harness according to an embodiment. As shown in Figure 1, the wire harness 10 comprises an electric wire 1 and a crimp terminal 2 attached to the end of the electric wire 1.

[0010] The wire harness 10 has multiple electric wires 1. A portion of the electric wires 1 is covered with an insulating covering member 5. The electric wires 1 include, for example, metals such as aluminum, copper, and copper alloys. The crimp terminals 2 include, for example, metals such as aluminum, copper, and copper alloys, or those with plating on their surfaces.

[0011] The crimp terminal 2 has a first attachment portion 2a attached to the covering member 5 and a second attachment portion 2b attached to the electric wire 1. The first attachment portion 2a is attached so as to cover the periphery of the covering member 5 that covers the electric wire 1. That is, the first attachment portion 2a is attached to the portion of the electric wire 1 covered by the covering member 5. The first attachment portion 2a is fixed to the covering member 5 by crushing (crimping) the first attachment portion 2a so as to cover the periphery of the covering member 5.

[0012] The second attachment portion 2b is attached so as to cover the periphery of the electric wire 1. That is, the second attachment portion 2b is attached to the portion of the electric wire 1 not covered by the covering member 5. The second attachment portion 2b is fixed to the electric wire 1 by crushing (crimping) the second attachment portion 2b so as to cover the periphery of the electric wire 1. Thereby, the second attachment portion 2b is electrically connected to the electric wire 1. That is, the second attachment portion 2b is crimped to the electric wire 1. Thus, the wire harness 10 has a crimp portion 3 in which the crimp terminal 2 (second attachment portion 2b) is crimped to the electric wire 1. In other words, the crimp portion 3 is a portion where the electric wire 1 is crimped by the crimp terminal 2 (second attachment portion 2b) and bears the electrical connection.

[0013] The wire harness 10 further has a first wire portion 4a and a second wire portion 4b. The first wire portion 4a is a portion where the electric wire 1 is exposed on the tip side (i.e., the side opposite to the covering member 5) with respect to the crimp portion 3. The second wire portion 4b is a portion where the electric wire 1 is exposed on the base end side (i.e., the side of the covering member 5) with respect to the crimp portion 3. The first wire portion 4a and the second wire portion 4b are portions not crimped by the crimp portion 3. That is, the first wire portion 4a and the second wire portion 4b are portions not covered by the crimp portion 3.

[0014] Figs. 2(a) to 2(c) are cross-sectional views schematically showing an example of the crimp portion of the wire harness. Figs. 2(a) to 2(c) are cross-sectional views taken along the line A1 - A2 shown in Fig. 1. As shown in Figures 2(a) to 2(c), in the crimping section 3, the electric wire 1 is housed inside the crimp terminal 2 (second mounting section 2b). In other words, in the crimping section 3, the electric wire 1 is located in the space enclosed by the crimp terminal 2 (second mounting section 2b). Therefore, it is difficult to accurately determine the quality of the crimping from the appearance of the crimping section 3 alone.

[0015] As shown in Figure 2(a), when the crimping is done well, no large gap is created between the crimp terminal 2 and the wire 1. On the other hand, as shown in Figure 2(b), when the crimping is done poorly, a large gap is created between the crimp terminal 2 and the wire 1. In this way, the quality of the crimping can be estimated to some extent by observing the cross-section of the crimped portion 3.

[0016] However, as shown in Figure 2(c), for example, if there is a gap between the crimp terminal 2 and the wire 1, but that gap is small, it is difficult to determine whether the crimping is good or bad. In other words, it is difficult to accurately determine whether the crimping is good or bad simply by observing the cross-section of the crimped part 3 and qualitatively evaluating the condition of the cross-section.

[0017] (Crimping detection device) Figure 3 is a block diagram showing a crimping determination device according to an embodiment. As shown in Figure 3, the crimping determination device 100 according to the embodiment includes a holding unit 20, a dripping unit 30, an image acquisition unit 40, a control unit 50, and a display unit 60. The crimping determination device 100 determines whether the crimping state of the crimped portion 3 of the wire harness 10 is good or bad.

[0018] The holding part 20 holds the wire harness 10. In this example, the holding part 20 holds multiple wire harnesses 10. The number of wire harnesses 10 held by the holding part 20 may be one or two or more. The holding part 20 is, for example, a jig. The holding part 20 can be provided as needed and is optional.

[0019] The dropping section 30 drops an inspection liquid TS that does not corrode the metal onto either the first wire section 4a or the second wire section 4b. The dropping section 30 includes, for example, a pump. The inspection liquid TS preferably contains, for example, a coloring agent. The coloring agent includes, for example, at least one of a pigment, a dye, and a fluorescent coloring agent. The coloring agent is, for example, a color ink. The inspection liquid TS preferably contains, for example, an organic solvent. The organic solvent includes, for example, low-viscosity organic solvents such as acetone and ethanol. The inspection liquid TS may contain both a coloring agent and an organic solvent. The inspection liquid TS may also contain at least one of an oil, a resin, a phosphor, and a resin with fluorescent properties.

[0020] The dropping section 30 is electrically connected to the control unit 50. The dropping section 30 dispenses the test solution TS by driving a pump in response to a command signal from the control unit 50, for example. In other words, the control unit 50 controls the operation of the dropping section 30, for example.

[0021] The image acquisition unit 40 acquires an image that includes the other of the first wire section 4a and the second wire section 4b. In other words, the image acquisition unit 40 acquires an image that includes the wire section to which the inspection liquid TS is not dripped. More specifically, for example, if the dripping section 30 drips the inspection liquid TS onto the first wire section 4a, the image acquisition unit 40 acquires an image that includes the second wire section 4b. For example, if the dripping section 30 drips the inspection liquid TS onto the second wire section 4b, the image acquisition unit 40 acquires an image that includes the first wire section 4a. Note that the image acquired by the image acquisition unit 40 only needs to include the wire section to which the inspection liquid TS is not dripped. The image acquired by the image acquisition unit 40 may include the wire section to which the inspection liquid TS is dripped, or it may not include the wire section to which the inspection liquid TS is dripped. In other words, the image acquisition unit 40 may acquire an image that includes both the first wire section 4a and the second wire section 4b. The image acquisition unit 40 is, for example, a CCD (Charge Coupled Device) camera, an infrared camera, or a fluorescence microscope.

[0022] The image acquisition unit 40 is electrically connected to the control unit 50. The image acquisition unit 40 acquires images, for example, in response to command signals from the control unit 50. In other words, the control unit 50 controls the operation of the image acquisition unit 40, for example. The image acquisition unit 40 outputs the acquired image data to the control unit 50.

[0023] The control unit 50 determines the quality of the crimping state of the crimping section 3 based on the image output from the image acquisition unit 40. The control unit 50 determines the quality of the crimping state of the crimping section 3 based on, for example, whether or not the inspection liquid TS leaks out of the wire section on the side where the inspection liquid TS is not dripped. If the crimping shape is as shown in Figure 2(a), no leakage will occur, but if there is a gap in the crimping section 3 as shown in Figure 2(b) or Figure 2(c), the inspection liquid TS will leak out due to capillary action. The control unit 50 determines the quality of the crimping state of the crimping section 3 based on, for example, the leakage rate of the inspection liquid TS in the wire section on the side where the inspection liquid TS is not dripped. The control unit 50 determines the quality of the crimping state of the crimping section 3 based on, for example, the void ratio of the crimping section 3 estimated from the leakage rate. The control unit 50 may, for example, determine the void ratio of the crimping section 3 by AI analysis based on the image, and determine the quality of the crimping state of the crimping section 3 based on the void ratio.

[0024] The control unit 50 is electrically connected to the dripping part 30, the image acquisition unit 40, and the display unit 60. The control unit 50 controls the operation of the dripping part 30 by, for example, outputting a command signal to the dripping part 30. The control unit 50 controls the operation of the image acquisition unit 40 by, for example, outputting a command signal to the image acquisition unit 40. The control unit 50 outputs a judgment result regarding the quality of the crimping state of the crimping part 3 to the display unit 60.

[0025] The display unit 60 displays the judgment result regarding the quality of the crimping state of the crimping unit 3. The display unit 60 is electrically connected to the control unit 50. The display unit 60 displays the judgment result output from the control unit 50. The display unit 60 is, for example, a monitor. The display unit 60 can be provided as needed and is optional.

[0026] Figures 4(a) and 4(b) are explanatory diagrams showing an example of a crimping determination device according to the embodiment. As shown in Figures 4(a) and 4(b), the crimping determination device 100, for example, drops inspection liquid TS onto the first wire portion 4a at the tip end using the dropping device 30, and acquires an image including the second wire portion 4b at the base end using the image acquisition device 40.

[0027] Figure 4(a) is a schematic diagram showing the case when the crimping state of the crimping section 3 is good. Figure 4(b) is a schematic diagram showing the case when the crimping state of the crimping section 3 is poor. As shown in Figure 4(b), when the crimping state of the crimping section 3 is poor, when the inspection liquid TS is dropped onto the first wire section 4a, the inspection liquid TS passes through the crimping section 3 due to capillary action and flows out to the second wire section 4b. Therefore, after the inspection liquid TS is dropped onto the first wire section 4a, the inspection liquid TS is detected in the second wire section 4b. More specifically, for example, the inspection liquid TS is detected in the image (second image) which includes the second wire section 4b after the inspection liquid TS has been dropped onto the first wire section 4a.

[0028] In contrast, as shown in Figure 4(a), when the crimping state of the crimping section 3 is good, even if the inspection liquid TS is dropped onto the first wire section 4a, the inspection liquid TS does not pass through the crimping section 3 and does not flow into the second wire section 4b. Therefore, after dropping the inspection liquid TS onto the first wire section 4a, the inspection liquid TS is not detected in the second wire section 4b. More specifically, for example, in the image (second image) including the second wire section 4b after dropping the inspection liquid TS onto the first wire section 4a, the inspection liquid TS is not detected.

[0029] Based on the above, the control unit 50 can determine that the crimping state of the crimping section 3 is "good" if, for example, the inspection liquid TS is not detected in the image (second image) which includes the second wire section 4b after the inspection liquid TS has been dropped onto the first wire section 4a, and that the crimping state of the crimping section 3 is "bad" if the inspection liquid TS is detected in the second image.

[0030] Figures 5(a) and 5(b) are explanatory diagrams showing another example of a crimping determination device according to the embodiment. As shown in Figures 5(a) and 5(b), the crimping determination device 100 may, for example, drop the inspection liquid TS onto the second wire portion 4b at the base end using the dropping unit 30, and acquire an image including the first wire portion 4a at the tip end using the image acquisition unit 40.

[0031] Figure 5(a) is a schematic diagram showing the case where the crimping of the crimping section 3 is in good condition. Figure 5(b) is a schematic diagram showing the case where the crimping of the crimping section 3 is in poor condition. In this example as well as in Figures 4(a) and 4(b), if the crimping of the crimping section 3 is in poor condition, the inspection liquid TS will be detected in the first wire section 4a after dropping the inspection liquid TS onto the second wire section 4b (Figure 5(b)). In contrast, if the crimping of the crimping section 3 is in good condition, the inspection liquid TS will not be detected in the first wire section 4a after dropping the inspection liquid TS onto the second wire section 4b (Figure 5(a)).

[0032] Therefore, the control unit 50 can determine that the crimping state of the crimping section 3 is "good" if, for example, the inspection liquid TS is not detected in the image (second image) including the first wire section 4a after the inspection liquid TS has been dropped onto the second wire section 4b, and that the crimping state of the crimping section 3 is "bad" if the inspection liquid TS is detected in the second image.

[0033] As described above, the control unit 50 determines the quality of the crimping state of the crimping section 3 based on an image that includes at least the wire portion to which the inspection liquid TS is not applied after the inspection liquid TS has been dropped. Preferably, the control unit 50 determines the quality of the crimping state of the crimping section 3 based on an image taken before the inspection liquid TS is dropped and an image taken after the inspection liquid TS is dropped. In this case, the image acquisition unit 40 acquires a first image, which is an image taken before the inspection liquid TS is dropped, and a second image, which is an image taken after the inspection liquid TS is dropped. The first and second images each include the wire portion to which the inspection liquid TS is not applied. The first and second images are acquired, for example, at the same field of view.

[0034] Furthermore, it is preferable that the control unit 50, for example, determines the outflow rate of the inspection liquid TS in the other of the first wire section 4a and the second wire section 4b from the first image and the second image, and determines the quality of the crimping state of the crimping section 3 based on the outflow rate. The control unit 50 can, for example, generate a difference image showing the change from the first image to the second image, and determine the outflow rate of the inspection liquid TS based on the difference image. More specifically, for example, the outflow rate F is expressed as the ratio of the number of pixels P2 of the wire section to which the inspection liquid TS is not dripped (the other wire section) to the number of pixels P1 of the wire section to which the inspection liquid TS is dripped (one wire section) in the binarized difference image (F(%) = 100 × P2 / P1).

[0035] Furthermore, it is preferable that the control unit 50 determines the void ratio of the crimped portion 3 by AI analysis based on the outflow rate, and determines the quality of the crimped state of the crimped portion 3 based on the void ratio. In the AI ​​analysis, for example, the void ratio is calculated using a database in which data on good products and data on defective products are stored. The database stores, for example, data on the outflow rate and void ratio for good products and defective products.

[0036] In this specification, "AI analysis" refers to analysis using AI (Artificial Intelligence). In AI analysis, the porosity is calculated using a predetermined algorithm with data stored in a database. The "predetermined algorithm" here estimates and calculates the porosity from input image data showing the outflow shape and outflow rate data. In addition, AI analysis may calculate the porosity based on the outflow rate and data other than the outflow rate (for example, data on manufacturing conditions and materials).

[0037] In this embodiment, the void ratio of the crimped portion 3 may be determined by AI analysis based on an image using the following procedure, for example. First, wire harnesses crimped under various conditions are prepared as samples for training data. Next, an image (second image) is obtained of the sample wire harness, including the second wire portion 4b after the inspection liquid TS has been dropped onto the first wire portion 4a. A cross-sectional image of the crimped portion 3 is also obtained of the sample wire harness, and void ratio data is obtained from the cross-sectional image of the crimped portion 3. The cross-sectional image of the crimped portion 3 may be an image taken by actually cutting the wire harness at the crimped portion 3, or it may be an image taken non-destructively by X-ray CT (Computed Tomography). Next, the obtained second image and the void ratio data are linked, and machine learning is performed to create training data (judgment model) for AI analysis. When making a judgment, the second image of the wire harness to be judged is obtained, and the void ratio of the crimped portion 3 can be determined by AI analysis using the training data (judgment model) created as described above.

[0038] (Method for determining crimping) Figure 6 is a flowchart showing an example of a crimping determination method according to the embodiment. As shown in Figure 6, in the crimping determination method according to the embodiment, first, the image acquisition unit 40 acquires an image (first image) of the second wire section 4b before the inspection liquid TS is dropped onto the first wire section 4a (pre-dropping image acquisition step; step S101).

[0039] Next, the inspection liquid TS is dropped onto the first wire section 4a using the dropping section 30 (dropping step; step S102). In the dropping step, it is preferable to drop an inspection liquid TS containing a coloring agent or an inspection liquid TS containing an organic solvent. Alternatively, an inspection liquid TS containing both a coloring agent and an organic solvent may be dropped.

[0040] Next, the image acquisition unit 40 acquires an image (second image) of the second wire section 4b after the inspection liquid TS has been dropped onto the first wire section 4a (post-dropping image acquisition step; step S103).

[0041] Next, the outflow rate of the inspection liquid TS in the second wire section 4b is determined from the first image acquired in the pre-dropping image acquisition step (step S101) and the second image acquired in the post-dropping image acquisition step (step S103) (step S104).

[0042] Next, based on the outflow rate obtained in step S104, the quality of the crimping of the crimping part 3 is determined (step S105). If the outflow rate is below the threshold (step S105: Yes), the crimping of the crimping part 3 is determined to be "good" (step S106). On the other hand, if the outflow rate exceeds the threshold (step S105: No), the crimping of the crimping part 3 is determined to be "poor" (step S107). Steps S104 to S107 correspond to the determination process.

[0043] The threshold for the outflow rate can be determined, for example, from at least one of the outflow rates of good products and defective products manufactured in the past.

[0044] Figure 7 is a flowchart showing another example of the crimping determination method according to the embodiment. As shown in Figure 7, in this example, in the judgment process, the void ratio of the crimped portion 3 is determined by AI analysis based on the outflow rate, and the quality of the crimped state of the crimped portion 3 is determined based on the void ratio.

[0045] More specifically, a first image is acquired (pre-dropping image acquisition step; step S201), the inspection liquid TS is dropped onto the first wire section 4a (dropping step; step S202), a second image is acquired (post-dropping image acquisition step; step S203), and the outflow rate of the inspection liquid TS is determined (step S204). Steps S201 to S204 can be performed in the same manner as steps S101 to S104 described above.

[0046] Next, based on the outflow rate obtained in step S204, the void ratio of the crimped portion is determined by AI analysis (step S205).

[0047] Next, based on the void ratio obtained in step S205, the quality of the crimping of the crimped portion 3 is determined (step S206). If the void ratio is below the threshold (step S206: Yes), the crimping of the crimped portion 3 is determined to be "good" (step S207). On the other hand, if the void ratio exceeds the threshold (step S206: No), the crimping of the crimped portion 3 is determined to be "poor" (step S208). Steps S204 to S208 correspond to the determination process.

[0048] The threshold for porosity can be determined, for example, from at least one of the porosity values ​​of good products and defective products manufactured in the past.

[0049] In the examples shown in Figures 6 and 7, the inspection liquid TS is dropped onto the first wire section 4a during the dropping process, and images of the second wire section 4b are acquired during the pre-dropping image acquisition process and the post-dropping image acquisition process. However, as described above, the inspection liquid TS may also be dropped onto the second wire section 4b during the dropping process, and images of the first wire section 4a may be acquired during the pre-dropping image acquisition process and the post-dropping image acquisition process.

[0050] (Crimping judgment program) Furthermore, in the embodiment, the above-described pressure determination method may be provided as a program. In other words, in the embodiment, a pressure determination program can be provided that comprises the above-described dropping step, post-dropping image acquisition step, and determination step. This pressure determination program may further include the above-described pre-dropping image acquisition step.

[0051] (Recording medium) Furthermore, in the embodiment, a recording medium on which the crimping determination program described above is recorded can be provided. The recording medium is at least readable by a computer. The recording medium may be read-only or may be read-and-write enabled.

[0052] The crimping determination device and crimping determination method according to the embodiment will be described in more detail below with reference to Experimental Examples 1 to 4. Figures 8(a) to 8(c) are images showing the data from Experimental Example 1. Figures 9(a) to 9(c) are images showing the data from Experimental Example 2. Figures 10(a) to 10(c) are images showing the data from Experimental Example 3. Figures 11(a) to 11(c) are images showing the data from Experimental Example 4. Figures 12(a) and 12(b) are tables and graphs showing the data for Experimental Examples 1-4.

[0053] In experimental examples 1 to 4, a first image was obtained before dropping the inspection liquid TS onto the first wire section 4a, and a second image was obtained after dropping the inspection liquid TS onto the first wire section 4a. Figures 8(a), 9(a), 10(a), and 11(a) are the first images from Experimental Examples 1-4, respectively. Figures 8(b), 9(b), 10(b), and 11(b) are the second images from Experimental Examples 1-4, respectively. Figures 8(c), 9(c), 10(c), and 11(c) are difference images showing the change from the first image to the second image in Experimental Examples 1-4, respectively. The difference image is obtained by subtracting the first image from the second image and then binarizing it. In Figures 8(a) to 8(c), 9(a) to 9(c), 10(a) to 10(c), and 11(a) to 11(c), the first wire section 4a and the second wire section 4b are shown by dashed lines.

[0054] In Experimental Examples 1-4, the number of pixels in the first wire section 4a and the number of pixels in the second wire section 4b were determined from the difference image. The results are shown in the table in Figure 12(a). In addition, in Experimental Examples 1-4, the outflow rate was determined from the number of pixels in the first wire section 4a and the number of pixels in the second wire section 4b. The results are shown in the table in Figure 12(a).

[0055] Furthermore, in Experimental Examples 1-4, the average porosity was calculated from cross-sectional images of 20 samples from the same lot used in Experimental Examples 1-4. Alternatively, the average porosity of the crimped portion 3 may be determined by imaging the crimped portion 3 using X-ray CT. The results are shown in the table in Figure 12(a). Also, in Experimental Examples 1-4, the outflow rate and average porosity are plotted on a graph in Figure 12(b).

[0056] As shown in Figures 12(a) and 12(b), Experimental Examples 1 to 4 suggested a correlation between the outflow rate and the average porosity. More specifically, in Experimental Example 1, where the average porosity was approximately 0.4% and the compression condition was good, the outflow rate was approximately 0.5%. In contrast, in Experimental Example 2, where the average porosity was approximately 3.5% and the compression condition was poor, the outflow rate was approximately 2.4%. Similarly, in Experimental Example 3, where the average porosity was approximately 8.5% and the compression condition was poor, the outflow rate was approximately 4.6%. Similarly, in Experimental Example 4, where the average porosity was approximately 15.5% and the compression condition was poor, the outflow rate was approximately 6.2%.

[0057] This suggests that a low outflow rate indicates a good crimping condition, while a high outflow rate indicates a poor crimping condition. More specifically, it suggests that a good crimping condition can be determined if the outflow rate is 2% or less, preferably 1% or less, and more preferably 0.5% or less. The threshold for the outflow rate used to determine whether the crimping is good or bad can be appropriately set according to, for example, the performance required of the wire harness 10.

[0058] Furthermore, the correlation between the outflow rate and the average porosity suggests that the porosity can be estimated based on the outflow rate. More specifically, for example, based on the measurement results of the outflow rate and average porosity of multiple samples, a graph can be created with the outflow rate on the x-axis and the average porosity on the y-axis, and the porosity corresponding to the calculated outflow rate can be estimated from the resulting calibration curve.

[0059] The following describes the operation and effects of the crimping determination device, crimping determination method, crimping determination program, and recording medium according to the embodiment.

[0060] When manufacturing wire harnesses, it is necessary to prevent defective wire harnesses from being shipped. More specifically, for example, it is necessary to sort out defective wire harnesses by determining the quality of the crimping.

[0061] In contrast, according to this embodiment, the quality of the crimping can be easily determined by dropping the inspection liquid TS onto one wire section (for example, the first wire section 4a) and making a determination based on the image of the other wire section (for example, the second wire section 4b) after the drop. Furthermore, according to this embodiment, unlike when the determination is made by observing the cross-sectional shape of the crimped section 3, the determination can be made without destroying the wire harness 10. Therefore, for example, the wire harness 10 can be used as is after the determination. In addition, since the determination can be made non-destructively, it can be applied to, for example, 100% inspection in the manufacturing process, and the presence or absence of inspection and the basis for the determination result can be confirmed on the product by looking at the product's appearance.

[0062] Furthermore, by dropping the inspection liquid TS onto the first wire section 4a and acquiring an image of the second wire section 4b, it is possible to suppress the flow of the inspection liquid TS to the part closer to the base end than the second wire section 4b (for example, the part covered by the covering member 5). This further reduces the influence of the inspection liquid TS on the wire harness 10 after the determination.

[0063] Furthermore, by determining the outflow rate of the inspection fluid TS from the first and second images and making a judgment based on the outflow rate, the quality of the crimping can be determined more accurately.

[0064] Furthermore, by determining the porosity from the outflow rate of the inspection fluid TS and making a judgment based on the porosity, the quality of the crimping can be determined more accurately.

[0065] Furthermore, by dropping the test solution TS containing a coloring agent, it becomes easier to determine the quality of the crimping compared to using a test solution TS without a coloring agent.

[0066] Furthermore, by dropping the test solution TS containing an organic solvent, the test solution TS can be easily removed after the determination by methods such as evaporation. This further reduces the influence of the test solution TS on the wire harness 10 after the determination.

[0067] As described above, the embodiment provides a crimping determination device, a crimping determination method, a crimping determination program, and a recording medium that can reduce the market release of wire harnesses with crimping defects.

[0068] (Wire harness processing machine) Figure 13 is a block diagram showing a wire harness processing apparatus according to an embodiment. As shown in Figure 13, the wire harness processing apparatus 200 according to the embodiment includes a holding unit 120, a dripping unit 130, a control unit 150, and a heating unit 170. The wire harness processing apparatus 200 processes the area around the crimping portion 3 of the wire harness 10.

[0069] The holding part 120 holds the wire harness 10. In this example, the holding part 120 holds multiple wire harnesses 10. The number of wire harnesses 10 held by the holding part 120 may be one or two or more. The holding part 120 is, for example, a jig. The holding part 120 can be provided as needed and is optional.

[0070] The dropping section 130 drops the processing liquid PL onto either the first wire section 4a or the second wire section 4b. The dropping section 130 includes, for example, a pump. The processing liquid PL contains a low-viscosity thermosetting resin. The thermosetting resin includes, for example, an epoxy resin. Preferably, the processing liquid PL contains, for example, a colorant. The colorant includes, for example, at least one of a pigment, a dye, and a fluorescent colorant. The colorant is, for example, a color ink.

[0071] The dropping section 130 is electrically connected to the control unit 150. The dropping section 130 dispenses the processing fluid PL by driving a pump in response to a command signal from the control unit 150, for example. In other words, the control unit 150 controls the operation of the dropping section 130, for example.

[0072] The heating section 170 hardens the processing liquid PL dropped from the dropping section 130 by heating it. The heating section 170 is provided around the first wire section 4a and the second wire section 4b. The heating section 170 is, for example, a sheathed heater, hot plate, or panel heater suitable for localized heating.

[0073] The heating unit 170 is electrically connected to the control unit 150. The heating unit 170 heats the area around the first wire section 4a and the second wire section 4b in response to a command signal from the control unit 150, for example. In other words, the control unit 150 controls the operation of the heating unit 170, for example.

[0074] The control unit 150 is electrically connected to the dripping section 130 and the heating section 170. The control unit 150 controls the operation of the dripping section 130 by, for example, outputting a command signal to the dripping section 130. The control unit 150 also controls the operation of the heating section 170 by, for example, outputting a command signal to the heating section 170.

[0075] Figures 14(a) and 14(b) are explanatory diagrams showing an example of a wire harness processing apparatus according to an embodiment. As shown in Figures 14(a) and 14(b), in the wire harness processing apparatus 200, for example, the processing liquid PL is dripped onto the first wire section 4a at the tip using the dripping part 130.

[0076] Figure 14(a) is a schematic diagram showing the case when the crimping state of the crimping section 3 is good. Figure 14(b) is a schematic diagram showing the case when the crimping state of the crimping section 3 is poor. As shown in Figure 14(b), when the crimping state of the crimping section 3 is poor, when the processing liquid PL is dropped onto the first wire section 4a, the processing liquid PL passes through the crimping section 3 due to capillary action and flows out to the second wire section 4b. Then, the processing liquid PL is heated by the heating section 170, causing the processing liquid PL to harden in the first wire section 4a, the second wire section 4b, and the crimping section 3.

[0077] In contrast, as shown in Figure 14(a), when the crimping state of the crimping section 3 is good, even if the processing liquid PL is dripped onto the first wire section 4a, the processing liquid PL does not pass through the crimping section 3 and does not flow out to the second wire section 4b. Then, the processing liquid PL is heated by the heating section 170, causing the processing liquid PL to harden in the first wire section 4a.

[0078] Figures 15(a) and 15(b) are explanatory diagrams showing another example of a wire harness processing apparatus according to the embodiment. As shown in Figures 15(a) and 15(b), in the wire harness processing apparatus 200, for example, the processing liquid PL may be dripped onto the second wire portion 4b on the base end side by the dripping part 130.

[0079] Figure 15(a) is a schematic diagram showing the case where the crimping of the crimping section 3 is good. Figure 15(b) is a schematic diagram showing the case where the crimping of the crimping section 3 is poor. In this example as well, as in Figures 14(a) and 14(b), if the crimping of the crimping section 3 is poor, the processing liquid PL is dropped onto the second wire section 4b and then heated by the heating section 170, causing the processing liquid PL to harden in the first wire section 4a, the second wire section 4b, and the crimping section 3 (Figure 15(b)). In contrast, if the crimping of the crimping section 3 is good, the processing liquid PL is dropped onto the second wire section 4b and then heated by the heating section 170, causing the processing liquid PL to harden in the second wire section 4b (Figure 15(a)).

[0080] (Wire harness processing method) Figure 16 is a flowchart illustrating an example of a wire harness processing method according to the present invention. As shown in Figure 16, in the crimping determination method according to the embodiment, first, the processing liquid PL is dropped onto the first wire portion 4a using the dropping portion 130 (dropping step; step S301). In the dropping step, the processing liquid PL containing a thermosetting resin is dropped. In the dropping step, it is preferable to drop the processing liquid PL containing a coloring agent.

[0081] Next, the heating unit 170 heats the processing liquid PL that was dropped in the dropping step to harden it (heating step; step S302).

[0082] The following describes the operation and effects of the wire harness processing apparatus and wire harness processing method according to the present invention.

[0083] When manufacturing wire harnesses, it is necessary to prevent defective wire harnesses from being shipped. More specifically, for example, it is necessary to process defective wire harnesses to improve the crimping condition.

[0084] In contrast, according to this embodiment, if the crimping state of the crimping section 3 is poor, the processing liquid PL can be hardened in the first wire section 4a, the second wire section 4b, and the crimping section 3 to fill the gap. This improves the crimping state of the crimping section 3 if it is poor.

[0085] Furthermore, by dripping the processing liquid PL onto the first wire section 4a, it is possible to suppress the flow of the processing liquid PL to the part closer to the base end than the second wire section 4b (for example, the part covered by the covering member 5). This further reduces the unintended effects of the processing liquid PL on the wire harness 10 after processing.

[0086] Furthermore, by dropping a processing liquid PL containing a coloring agent, the processed wire harness 10 can be more easily identified. Also, for example, it is possible to determine whether the processed wire harness 10 originally had a good crimping condition or whether the crimping condition was improved by the processing. For example, if the processing liquid PL is dropped onto the first wire section 4a, and the cured processing liquid PL is present only on the first wire section 4a, it can be determined that the crimping condition was originally good. On the other hand, for example, if the processing liquid PL is dropped onto the first wire section 4a, and the cured processing liquid PL is present on both the first wire section 4a and the second wire section 4b, it can be determined that the crimping condition was improved by the processing. This makes quality control easier.

[0087] As described above, according to the embodiment, a wire harness processing apparatus and a wire harness processing method are provided that can reduce the market release of wire harnesses with crimping defects.

[0088] Furthermore, the crimping determination device according to the embodiment may also serve as the wire harness processing device according to the embodiment. For example, by using a thermosetting resin as the inspection liquid TS, it is possible to determine whether the crimping state is good or bad, and if the crimping state is poor, it is possible to improve the crimping state. In other words, it is possible to determine whether the crimping state is good or bad and to improve the crimping state simultaneously.

[0089] Although several embodiments of the present invention have been illustrated above, these embodiments are presented as examples only and are not intended to limit the scope of the invention. These novel embodiments can be implemented in various other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These embodiments and their variations are included in the scope and spirit of the invention, as well as in the claims of the invention and its equivalents. Furthermore, the embodiments described above can be implemented in combination with each other. [Explanation of symbols]

[0090] 1 electric wire, 2 crimp terminals, 2a, 2b First and second mounting parts, 3. Crimping section, 4a, 4b 1st wire section, 2nd wire section, 5 Covering member, 10 wire harnesses, 20 holding part, 30 dripping unit, 40 Image acquisition unit, 50 Control unit, 60 Display section, 100 Crimping detection device, 120 holding part, 130 dripping section, 150 Control unit, 170 heating section, 200 wire harness processing machine, PL processing fluid, TS test solution

Claims

1. A device for determining the quality of the crimping of a wire harness in which crimp terminals are crimped to electric wires, The wire harness has a crimped portion where the electric wire is crimped by the crimp terminal, a first wire portion where the electric wire is exposed on the tip side of the crimped portion, and a second wire portion where the electric wire is exposed on the base end side of the crimped portion, wherein the wire harness has a dripping portion for dripping an inspection liquid onto either the first wire portion or the second wire portion, An image acquisition unit that acquires an image including the other of the first wire section and the second wire section, A control unit that determines the quality of the crimping state of the crimped portion based on the aforementioned image, Equipped with, The image acquisition unit acquires a first image before the inspection liquid is dropped and a second image after the inspection liquid is dropped. The control unit determines the outflow rate of the inspection fluid in the other of the first wire section and the second wire section from the first image and the second image, and determines whether the crimping state of the crimped section is good or bad based on the outflow rate, as a crimping determination device.

2. The aforementioned dropping part drops the inspection liquid onto the first wire portion. The crimping determination device according to claim 1, wherein the image acquisition unit acquires an image including the second wire portion.

3. The crimping determination device according to claim 1, wherein the control unit determines the average void ratio of the cross-section of the crimped portion by AI analysis based on the outflow rate, and determines whether the crimping state of the crimped portion is good or bad based on the void ratio.

4. The crimping determination device according to claim 1 or 2, wherein the control unit determines the average void ratio of the cross-section of the crimped portion by AI analysis based on the image, and determines whether the crimping state of the crimped portion is good or bad based on the void ratio.

5. The pressure determination device according to any one of claims 1 to 4, wherein the dropping part drops the inspection liquid containing the coloring agent.

6. The pressure determination device according to any one of claims 1 to 5, wherein the dropping part drops the inspection solution containing an organic solvent.

7. A method for determining the quality of the crimping of a wire harness in which crimp terminals are crimped to electric wires, The wire harness has a crimped portion where the electric wire is crimped by the crimp terminal, a first wire portion where the electric wire is exposed on the tip side of the crimped portion, and a second wire portion where the electric wire is exposed on the base end side of the crimped portion, wherein the step is to drop a test liquid onto either the first wire portion or the second wire portion. Following the dropping step, a post-dropping image acquisition step is performed to acquire an image including the other of the first wire section and the second wire section. After the step of acquiring an image after dropping, a determination step is performed to determine whether the crimping state of the crimped portion is good or bad based on the image. Equipped with, The process further includes a pre-dropping image acquisition step, in which an image including the other of the first wire section and the second wire section is acquired before the aforementioned dropping step. In the pre-dropping image acquisition step, a first image is acquired before the inspection solution is dropped. In the step of acquiring an image after dropping, a second image is acquired after dropping the inspection solution. A crimping determination method comprising: determining the outflow rate of the inspection liquid in the other of the first wire section and the second wire section from the first image and the second image in the determination step, and determining whether the crimping state of the crimped section is good or bad based on the outflow rate.

8. In the aforementioned dropping step, the inspection liquid is dropped onto the first wire portion. The crimping determination method according to claim 7, wherein in the step of acquiring an image after dripping, an image including the second wire portion is acquired.

9. The crimping determination method according to claim 7, wherein in the determination step, the average void ratio of the cross-section of the crimped portion is determined by AI analysis based on the outflow rate, and the quality of the crimping state of the crimped portion is determined based on the void ratio.

10. The crimping determination method according to claim 7 or 8, wherein in the determination step, the average void ratio of the cross-section of the crimped portion is determined by AI analysis based on the image, and the quality of the crimping state of the crimped portion is determined based on the void ratio.

11. The pressure determination method according to any one of claims 7 to 10, wherein in the dropping step, the inspection liquid containing the coloring agent is dropped.

12. The pressure determination method according to any one of claims 7 to 11, wherein the inspection solution containing an organic solvent is dropped in the dropping step.

13. A program that causes a computer to determine whether the crimping of wires in a wire harness, in which crimp terminals are crimped to electric wires, is good or bad. To the aforementioned computer, The wire harness has a crimped portion where the electric wire is crimped by the crimp terminal, a first wire portion where the electric wire is exposed on the tip side of the crimped portion, and a second wire portion where the electric wire is exposed on the base end side of the crimped portion, wherein the step is to drop a test liquid onto either the first wire portion or the second wire portion. Following the dropping step, a post-dropping image acquisition step is performed to acquire an image including the other of the first wire section and the second wire section. After the step of acquiring an image after dropping, a determination step is performed to determine whether the crimping state of the crimped portion is good or bad based on the image. Make it run, Prior to the aforementioned dripping step, a pre-drip image acquisition step is further performed to acquire an image including the other of the first wire section and the second wire section. In the pre-dropping image acquisition step, a first image is acquired before the inspection solution is dropped. In the step of acquiring an image after dropping, a second image is acquired after dropping the inspection solution. A crimping determination program that, in the determination step, determines the outflow rate of the inspection liquid in the other of the first wire section and the second wire section from the first image and the second image, and determines whether the crimping state of the crimped section is good or bad based on the outflow rate.

Images