crimping machine with terminal pre-check

Abstract

The crimping machine (100) includes an anvil (120) having a lower die (122) with a lower forming surface (124), the anvil configured to support a crimp barrel (184) of a terminal (102) that receives a wire (104). The crimping machine includes a press (130) having an upper die (132) with an upper forming surface (134). The press is movable relative to the anvil during the crimping process to connect the crimp barrel to the wire. A crimp area (106) is defined between the upper forming surface and the lower forming surface. The crimping machine includes a vision system (200) positioned to view the crimp area. The vision system includes an imaging device (202) configured to image the crimp barrel of the terminal and the wire. The vision system operates the imaging device to take images prior to the crimping process for performing a verification pre-check prior to the crimping process.

Description

[[Technical Field]]

[0001] The subject matter of the present specification generally relates to crimping machines. [[Background Art]]

[0002] Electrical terminals may be crimped to wires by a crimping machine, such as a benchtop machine or a lead making machine, to form lead wires or wire harnesses. In a typical crimping operation, a terminal is placed in the crimping area of the crimping machine, and a wire is inserted into the ferrule or barrel of the terminal. The ram of the crimping machine then travels along the crimping stroke toward the wire and the terminal. The ram pinches or crimps the terminal around the wire, thereby mechanically and electrically connecting the wire to the terminal and forming a lead wire.

[0003] The position and orientation of the wire relative to the terminal in the crimping area, and the position of the terminal relative to the tooling in the crimping area, are important to the overall production capacity and production efficiency of the crimping machine. For example, production lead wires must meet very stringent crimp specifications. Wires that are not properly positioned relative to the terminal, either laterally or longitudinally, may fail to meet crimp specifications. In addition, terminals incorrectly positioned in the tooling may fail to meet crimp specifications. Some known crimping machines use various post-termination checks to ensure crimp quality. For example, some known crimping machines use crimp force analysis and / or position analysis for crimp quality testing. Other systems use tensile testing or cross-sectional cutting of finished termination ends for crimp quality analysis. Some known crimp quality tests are destructive to the termination end, which wastes time and materials. In addition, crimp quality testing is performed after crimping is completed. Termination ends that do not meet crimp specifications are discarded, which wastes time and materials. Post-termination checks are particularly problematic in applications using high-cost cable assemblies or wire harnesses such as those used in the automotive industry, which have multiple termination ends. In this case, if any of the termination ends does not meet crimp specifications, the entire wire harness may be discarded. [[Summary of the Invention]]

[0004] Here, the present invention will be described as an example with reference to the attached drawings. [Brief explanation of the drawing]

[0005] [Figure 1] This figure shows a crimping machine according to an exemplary embodiment. [Figure 2] This figure shows a portion of a lead wire or wire harness according to an exemplary embodiment. [Figure 3] This is a front view of a portion of a crimping machine, captured by a visual system according to an exemplary embodiment. [Figure 4] This is a left-hand image of a portion of a crimping machine, captured by a visual system according to an exemplary embodiment. [Figure 5] This is a right-hand image of a portion of a crimping machine, captured by a visual system according to an exemplary embodiment. [Figure 6] This is a top view image of a portion of a crimping machine, taken by a visual system according to an exemplary embodiment. [Figure 7] This is a top view image of a portion of a crimping machine, taken by a visual system according to an exemplary embodiment. [Figure 8] This is a top view image of a portion of a crimping machine, taken by a visual system according to an exemplary embodiment. [Modes for carrying out the invention]

[0006] Figure 1 shows a crimping machine 100 according to an exemplary embodiment. The crimping machine 100 is used to crimp a terminal 102 to the end of a wire 104 in the crimping area 106 of the crimping machine 100. The wire 104 may be part of a wire harness containing multiple wires 104. In various embodiments, the terminal 102 may be a high-voltage power terminal such as a blade terminal or a socket terminal. In alternative embodiments, other types of terminals may be provided. In various embodiments, the terminal 102 on the wire 104 may be used in automotive applications, for example, as part of a battery system in an electric vehicle.

[0007] In an exemplary embodiment, the crimping machine 100 includes a visual system 200 which includes one or more imaging devices 202 configured to image terminals 102 and / or wires 104 and / or other components of the crimping machine 100. The imaging devices 202 may be a camera, scanner, optical reader, or other type of imaging device. The visual system 200 is used for monitoring crimp quality to identify defects such as damage to terminals or wires, incorrect placement of terminals or wires, etc., and to verify that the terminals, wires, and crimp dies are appropriate, etc. In an exemplary embodiment, the visual system 200 performs a verification pre-check before the crimping process. For example, the visual system 200 operates the camera 202 to take images before the crimping process in order to perform a verification pre-check. The verification pre-check process checks and verifies specific termination criteria before the crimping process is performed. This improves crimp quality, reduces scrap and waste, and increases product throughput.

[0008] The crimping machine 100 includes a cabinet 110 that holds various components of the crimping machine 100. The cabinet 110 is defined by one or more walls 112 surrounding a cavity 114. The crimping machine 100 includes a termination component that is received within the cavity 114. For example, the termination component includes an anvil 120 and a press 130 that is movable relative to the anvil 120. The crimping area 106 is defined between the anvil 120 and the press 130. The terminal 102 is crimped to the end of the wire 104 between the anvil 120 and the press 130. In an exemplary embodiment, the anvil 120 is fixed or stationary. Alternatively, the anvil 120 may be movable within the cabinet 110 during the crimping process.

[0009] The anvil 120 includes a lower die 122 having a lower forming surface 124. The lower forming surface 124 has a forming profile used to shape the terminal 102 during the crimping process. In various embodiments, the lower forming surface 124 may be planar. In other various embodiments, the lower forming surface 124 may be non-planar, including, for example, a curved or angled profile. The anvil 120 is located at the bottom of the crimping area 106 and is used to support the crimping barrel and / or wire 104 of the terminal 102 during the crimping process. For example, the bottom of the terminal 102 may be supported by the lower forming surface 124. In exemplary embodiments, the lower die 122 is removable and replaceable. For example, a set of lower dies 122 having lower forming surfaces 124 of different sizes and / or shapes may be provided to form different terminals 102. For example, different lower dies 122 may be used to crimp terminals 102 of different sizes or to form different types of crimps on each terminal 102.

[0010] The press 130 includes an upper die 132 having an upper forming surface 134. The upper forming surface 134 has a forming profile used to shape the terminal 102 during the crimping process. In various embodiments, the upper forming surface 134 may have an M-shape. For example, the upper forming surface 134 may have a centrally located wedge for forming the crimping barrel of the terminal 102. In various embodiments, the upper forming surface 134 may be used to form an F-crimp. The press 130 is positioned at the top of the crimping area 106. The press 130 is driven toward the anvil 120 during the crimping process to crimp the terminal 102 to the wire 104. In an exemplary embodiment, the press 130 includes a ram 136 driven up and down by an actuator 138. In various embodiments, the actuator 138 may be an electric motor used to drive the ram 136 during the crimping process. In alternative embodiments, other types of actuators, such as hydraulic or pneumatic actuators, may be used. In exemplary embodiments, the upper die 132 is removable and replaceable. For example, a set of upper dies 132 having upper forming surfaces 134 of different sizes and / or shapes may be provided for forming different terminals 102. For example, different upper dies 132 may be used to crimp terminals 102 of different sizes or to form different types of crimps for each terminal 102.

[0011] In an exemplary embodiment, the crimping machine 100 includes a controller 150 operably coupled to a press 130. The controller 150 may include a computer and / or processor for controlling the operation of the crimping machine 100. In an exemplary embodiment, the crimping machine 100 includes a user interface 152 associated with the controller 150. The user interface 152 includes a display 154 and one or more user inputs 156. The user inputs 156 may include buttons, dials, knobs, keyboards, keypads, mice or pointer devices, or other types of user inputs. In an exemplary embodiment, the display 154 is configured to display one or more images from a visual system 200. For example, the display 154 may display an image of the crimping area 106. The display 154 may display terminals 102 and / or wires 104. The display 154 may display the lower die 122 and / or upper die 132.

[0012] The controller 150 controls the operation of the press 130 during the crimping process. The controller 150 moves the press 130 during the crimping process. For example, the controller 150 may be operably coupled to the actuator 138 to turn the actuator 138 on and off during the crimping process. The controller 150 is communicatively coupled to the visual system 200. The components of the controller 150 and the visual system 200 may be housed together in the cabinet 110. The controller 150 receives input from the visual system 200 to control the crimping process. For example, the controller 150 may receive a first signal if the system passes a verification precheck and a second signal if the system fails the verification precheck. If the system passes the verification precheck, the controller 150 may allow the crimping process to proceed. If the system fails the verification precheck, the controller 150 may restrict or not allow the crimping process to proceed. Therefore, the crimping machine 100 produces high-quality crimps by limiting the crimping process unless the system passes certain verification criteria.

[0013] In an exemplary embodiment, the visual system 200 includes an image analysis module 204 that performs image analysis for verification prechecks. The image analysis module 204 may include one or more processors and one or more memories for performing image analysis. The processors and / or memories may be provided on one or more circuit boards. The controller 150 may be coupled to a circuit board to communicate with the image analysis module 204. The image analysis module 204 compares images from the camera 202 to verification criteria to determine whether the verification precheck passes or fails. In an exemplary embodiment, the image analysis module 204 processes the images using a shape recognition tool to determine the verification results for terminals 102 and / or wires 104 and / or crimp dies 122, 132. In various embodiments, the images are processed by extracting boundary and surface features detected in the images and comparing the boundaries and surfaces with an image analysis model 204. The image analysis module 204 may compare the locations of the extracted boundaries and surfaces with acceptable limits or ranges defined within the image analysis module 204. Images may be taken before and / or after termination. For example, a check may be performed after termination, and the visual system 100 may be able to determine any deviation from a confirmed pre-check in order to infer whether the termination is appropriate.

[0014] In an exemplary embodiment, the visual system 200 includes an artificial intelligence (AI) learning module 206. The AI ​​learning module 206 uses artificial intelligence to train the image analysis module 204 and improve the inspection accuracy of the image analysis module 204. For example, the visual system 200 may use a camera 202 to capture multiple images of the crimping area, such as images without terminals, images with terminals, and images with terminals and wires. The images are used to train the AI ​​learning module 206, such as comparing various situations and configurations of terminals and wires within the crimping area. Some of the images may correspond to good crimps and some may correspond to poor crimps to aid in the training of the AI ​​learning module 206. The AI ​​learning module 206 uses artificial intelligence to infer crimp quality based on the images. The AI ​​learning module 206 customizes and configures the image analysis module 204 based on the images received from the camera 202. In addition to being pre-trained during the calibration process, the image analysis module 204 may be updated and trained in real time during the operation of the crimping machine 100. The AI ​​learning module 206 may be capable of operating in learning mode to train the image analysis module 204 and further develop the image analysis model. The image analysis model 204 changes over time based on input from the AI ​​learning module 206 (for example, based on images of terminals 102 and wires 104 captured by the camera 202). The AI ​​learning module 206 includes a model and executable code that can be pre-trained by a separate entity or trained in the field by a user.

[0015] Figure 2 shows a portion of a lead wire or wire harness according to an exemplary embodiment. Figure 2 shows a terminal 102 and wire 104 according to an exemplary embodiment before termination. The wire 104 includes a conductor 170 and an insulator 172 surrounding the conductor 170.

[0016] In various embodiments, the wire 104 may be a shielded wire having a coaxial outer shield (not shown) with a conductor 170 and an insulator 172 sandwiched between the outer shield and the conductor 170. An outer jacket (not shown) surrounds the outer shield. In other embodiments, for example in the exemplary embodiment, the insulator 172 forms the outer jacket. In the exemplary embodiment, different wires 104 may have insulators 172 of different colors that may correspond to the wire gauge of the wire 104. In the exemplary embodiment, the color of the insulator may be determined by a visual system 200 for pre-check verification. In various other embodiments, the diameter of the insulator 172 may be determined by a visual system 200 for pre-check verification.

[0017] The conductor 170 may be a stranded wire. Alternatively, the conductor 170 may be a solid core conductor. The conductor 170 has a diameter corresponding to the wire gauge of the wire 104. In an exemplary embodiment, the diameter of the conductor 170 may be determined by a visual system 200 for pre-check verification.

[0018] Wire 104 is prepared by removing a portion of the insulator 172 at the end of wire 104 to expose the conductor 170. The length of the exposed conductor 170 is referred to as the strip length. For example, the strip length is equal to the length of the insulator 172 removed. In an exemplary embodiment, the strip length may be determined by a visual system 200 for pre-check verification. The exposed portion of the conductor 170 is positioned at terminal 102 for mechanical and electrical connections between terminal 102 and wire 104. In an exemplary embodiment, the position of the conductor 170 relative to terminal 102 may be determined by a visual system 200 for pre-check verification. For example, the visual system 200 may determine the length of the conductor 170 that will be received in the crimp barrel portion of terminal 102, and / or the amount of the conductor 170 that will protrude beyond the crimp barrel portion of terminal 102. The visual system 200 may determine the length of the insulator 172 that will be received in the crimp barrel portion of terminal 102, if present.

[0019] Terminal 102 is manufactured from a metallic material and is conductive. Terminal 102 is configured to mechanically and electrically couple to wire 104 during the crimping process. In an exemplary embodiment, terminal 102 extends between mating end 180 and finished end 182. Finished end 182 is configured to crimp to the end of wire 104. For example, finished end 182 may be crimped to an insulator 172 and / or conductor 170. Finished end 182 includes a crimping barrel 184 configured to receive wire 104. The crimping barrel 184 includes a cup 186 with crimping tabs 188 positioned on its sides. The crimping tabs 188 are configured to fold over during the crimping process to mechanically and electrically couple to the conductor 170 of wire 104. In an exemplary embodiment, the size and shape of the crimping barrel 184 may be determined by a visual system 200 for pre-check verification. For example, the length and / or width and / or height of the crimp tab 188 may be determined by the visual system 200. The size of the cup 186 may be determined by the visual system 200. The relative positions of the wire 104 and the crimp barrel 184 may be determined by the visual system 200.

[0020] In various embodiments, the mating end 180 forms a socket configured to receive a blade terminal. For example, the socket may have a rectangular shape. In various other embodiments, the socket may have a cylindrical shape. In alternative embodiments, the mating end 180 may be a blade (e.g., a substantially planar rectangular structure) configured to be inserted into a mating terminal. In various other embodiments, the mating end 180 may be a pin such as a cylindrical pin. In alternative embodiments, the mating end 180 may have other shapes and features. For example, the mating end 180 may include a post such as a threaded post. Alternatively, the mating end 180 may include an opening such as a threaded opening configured to receive a bolt. In alternative embodiments, other types of mating ends may be used. In an exemplary embodiment, the size and / or shape of the mating end 180 may be determined by the vision system 200 for pre-verification check.

[0021] FIG. 3 is a front image of a portion of the crimping machine 100 captured by the vision system 200 according to an exemplary embodiment. FIG. 4 is a left side image of a portion of the crimping machine 100 captured by the vision system 200 according to an exemplary embodiment. FIG. 5 is a right side image of a portion of the crimping machine 100 captured by the vision system 200 according to an exemplary embodiment. FIGS. 3 to 5 show the terminal 102 and the wire 104 in the crimping region 106. FIG. 3 shows the lower die 122 and the upper die 132. FIGS. 4 and 5 show the lower die 122, while the upper die 132 is blocked from view or located outside the drawings.

[0022] In an exemplary embodiment, the anvil 120 includes a lower die graphic identifier 210, and the press 130 includes an upper die graphic identifier 212. The lower die graphic identifier 210 is located on the lower die 122, and the upper die graphic identifier 212 is located on the upper die 132. In the exemplary embodiment, the lower die graphic identifier 210 is located on the upper surface of the lower die 122. In an alternative embodiment, other locations are possible. In the exemplary embodiment, the upper die graphic identifier 212 is located on the front surface of the upper die 132. In an alternative embodiment, other locations are possible. Optionally, a plurality of lower graphic identifiers 210 and / or a plurality of upper graphic identifiers 212 may be provided. The plurality of lower graphic identifiers 210 may be different from each other. The plurality of upper graphic identifiers 212 may be different from each other. In an exemplary embodiment, the graphic identifiers 210, 212 are computer-readable labels. For example, graphic identifiers 210 and 212 are scannable by the visual system 200. In exemplary embodiments, graphic identifiers 210 and 212 are machine-readable optical labels. For example, graphic identifiers 210 and 212 may be QR codes®, barcodes, data matrix codes, or other types of optical labels. In alternative embodiments, other types of identifiers may be used, such as the surface of the lower die 122 or upper die 132, a pattern on the lower die 122 or upper die 132, or other features identifiable by the visual system 200. In exemplary embodiments, graphic identifiers 210 and 212 may be analyzed by the visual system 200 for verification pre-check. For example, the visual system 200 may determine in the machine that the correct lower die 122 and the correct upper die 132 are being used to perform the crimping operation before performing the crimping operation.

[0023] In use, the terminal 102 and the wire 104 are loaded into the crimping area 106 of the crimping machine 100. For example, the terminal 102 is disposed on the anvil 120. The anvil 120 includes an arrangement mechanism for arranging the terminal 102 relative to the lower die 122. For example, the arrangement mechanism may be a wall or a surface that engages with the terminal 102 and positions the terminal 102. In an exemplary embodiment, the terminal 102 is arranged such that the crimping barrel 184 rests on the lower forming surface 124 of the lower die 122. The wire 104 is loaded onto the crimping barrel 184. For example, the stripped end of the wire 104 is arranged such that the conductor 170 is received in the crimping barrel 184. Optionally, a part of the insulator 172 may be arranged in the crimping barrel 184. Alternatively, no part of the insulator 172 is arranged in the crimping barrel 184.

[0024] After the terminals 102 and wires 104 are positioned in the crimping area 106, the visual system 200 is operated to perform a verification precheck. For example, camera 202 is operated to image the crimping area 106. In an exemplary embodiment, the terminals 102 and wires 104 are visible in the image. In an exemplary embodiment, the lower die 122 and upper die 132 are visible in the image. Optionally, multiple cameras 202 are positioned at different locations relative to the crimping area 106. The multiple cameras 202 image the crimping area 106 from different angles. Images from the multiple cameras 202 are analyzed to perform a verification precheck before the crimping operation is performed. In various embodiments, the visual system 200 is operated manually. For example, a user may initiate a verification precheck at the user interface 152 (shown in Figure 1). In an alternative embodiment, the visual system 200 may be operated automatically, for example, periodically or continuously. When the visual system 200 is activated, the camera 202 takes an image of the crimping area 106. The image taken by the camera 202 may be in the visible spectrum, or it may be in another spectrum, such as an infrared image or an X-ray image. The visual system 200 analyzes the image to determine if one or more verification criteria are met. If the verification criteria are met, the verification precheck becomes a passed verification precheck, and the crimping process is permitted to proceed. For example, the controller 150 (shown in Figure 1) may signal the actuator 138 (shown in Figure 1) to move the press 130 across the crimping stroke. If one or more verification criteria are not met, the verification precheck becomes a failed verification precheck, and the crimping process is restricted. For example, the press 130 cannot move across the crimping stroke to perform the crimping operation.

[0025] In various embodiments, the verification criteria for verification precheck include checking that a suitable lower die 122 is provided within the anvil 120. For example, different lower dies 122 may be used for terminating different terminals. The verification precheck ensures that a suitable lower die 122 is provided for a particular terminal during terminating. In various embodiments, the verification criteria for verification precheck include checking that a suitable upper die 132 is provided within the press 130. For example, different upper dies 132 may be used for terminating different terminals. The verification precheck ensures that a suitable upper die 132 is provided for a particular terminal during terminating. Optionally, the lower die 122 and upper die 132 may be part of a matched set. The verification precheck may determine that the lower die 122 and upper die 132 are part of a matched set. In an exemplary embodiment, the visual system 200 checks the lower die 122 and the upper die 132 by scanning and analyzing the lower digraphic identifier 210 and the upper digraphic identifier 212.

[0026] In various embodiments, the verification criteria for verification precheck include checking the proper orientation of the lower die 122 within the anvil 120. For example, the verification precheck is used to determine that the lower die 122 is facing forward, for example, towards the wire. In various embodiments, the verification criteria for verification precheck include checking the proper orientation of the upper die 132 within the press 130. For example, the verification precheck is used to determine that the upper die 132 is facing forward, for example, towards the wire. In an exemplary embodiment, the visual system 200 checks the lower die 122 and the upper die 132 by scanning and analyzing the lower die graphic identifier 210 and the upper die graphic identifier 212.

[0027] In various embodiments, the verification criteria for verification precheck include checking the proper placement of the terminal 102 within the crimping area 106. For example, verification precheck may be used to determine that the terminal 102 is properly positioned relative to the lower die 122. Verification precheck may also be used to determine that the terminal 102 is properly positioned relative to the upper die 132. In various embodiments, verification precheck verifies the front-to-back placement of the terminal 102 within the crimping area 106. In various embodiments, verification precheck verifies the lateral placement of the terminal 102 within the crimping area 106. In various embodiments, verification precheck verifies the vertical placement of the terminal 102 within the crimping area 106. For example, verification precheck may verify that the crimping barrel 184 of the terminal 102 rests on the lower forming surface 124 of the lower die 122. In an exemplary embodiment, the visual system 200 performs a verification precheck by analyzing the image and performing pattern recognition or boundary recognition to identify features of the terminal 102. For example, the visual system 200 may determine the position of the crimp barrel 184 by determining the front or edge of the terminal 102 and / or the outer surface of the crimp barrel 184 and / or the position of the crimp tab 188.

[0028] In various embodiments, the verification criteria for the verification precheck include checking the proper placement of the wire 104 within the crimping area 106. For example, the verification precheck is used to determine that the wire 104 is properly positioned relative to the terminal 102. In various embodiments, the verification precheck verifies the front-to-back placement of the wire 104 relative to the terminal 102. In various embodiments, the verification precheck verifies the lateral placement of the wire 104 relative to the terminal 102. In various embodiments, the verification precheck verifies the vertical placement of the wire 104 relative to the terminal 102. In various embodiments, the verification precheck verifies the angular position of the wire 104, for example, with respect to one or more axes and / or relative to the terminal 102. For example, the verification precheck may determine that the angular deviation from one or more axes is within an acceptable range. In an exemplary embodiment, the visual system 200 performs the verification precheck by analyzing an image and performing pattern recognition or boundary recognition to identify features of the wire 104. For example, the visual system 200 may determine the positions of the end 174 of the conductor 170 and / or the end 176 of the insulator 172. The visual system 200 may determine the positions of the sides of the conductor 170 and / or the sides of the insulator 172. The visual system 200 may determine the positions of other features of the wire 104, such as the outer shield and / or outer jacket. In various embodiments, the visual system 200 may determine the proper placement of the wire 104 relative to the terminal 102 by comparing the wire centerline with the crimp barrel centerline. For example, if the offset of the wire centerline relative to the crimp barrel centerline exceeds a threshold distance, the wire 104 cannot be properly positioned relative to the terminal 102, leading to a failure of the verification precheck.

[0029] In various embodiments, a verification precheck is used to determine that the correct terminal 102 and the correct wire 104 are positioned within the crimping area 106. The visual system 200 may determine the size and / or type of terminal 102 based on the image. For example, the visual system 200 may determine the height and / or width and / or length of terminal 102, or features of terminal 102 such as the crimping barrel 184, in order to determine that the correct terminal 102 is positioned within the crimping area 106. The visual system 200 may determine the size and / or type of wire 104 based on the image. For example, the visual system 200 may determine the color of the insulator 172 to determine the type of wire 104. The visual system 200 may determine the diameter of the conductor 170 and / or the diameter of the insulator 172 to determine the type of wire 104.

[0030] In various embodiments, a verification precheck is used to determine the proper preparation of the wire 104 before crimping. For example, the visual system 200 may determine the strip length of the insulator 172 to determine that a sufficient length of conductor 170 is exposed beyond the insulator 172 for terminating the terminal 102. The strip length may be determined by identifying the end 174 of the conductor 170 and the end 176 of the insulator 172.

[0031] In various embodiments, the verification precheck determines the proper placement of the wire 104 relative to the terminal 102 by determining the length of the insulator 172 placed within the crimp barrel 184. In various embodiments, any length of insulator 172 within the crimp barrel 184 results in a failure of the verification precheck. In alternative embodiments, a specific length of insulator 172 is designed to be placed within the crimp barrel 184. Any length of insulator 172 exceeding a predetermined allowable length results in a failure of the verification precheck.

[0032] In various embodiments, the verification precheck determines the proper placement of the wire 104 to the terminal 102 by determining the length of the conductor 170 that extends beyond the crimp barrel 184. For example, the visual system 200 determines the amount of cable protruding behind the crimp barrel 184. In various embodiments, any length of conductor 170 protruding beyond the crimp barrel 184 corresponds to a failure of the verification precheck. In alternative embodiments, a specific length of conductor 170 is designed to protrude beyond the crimp barrel 184. Any length of conductor 170 exceeding a predetermined allowable length corresponds to a failure of the verification precheck. The visual system 200 may determine the amount of cable extending forward of the crimp barrel 184 to determine whether the verification precheck passes or fails.

[0033] In exemplary embodiments, the system may be configured to use only some of the verification prechecks, or to use all of them. For example, the system may be configured in the user interface 152 to enable or disable any permutation of the verification prechecks.

[0034] Figure 6 is a top view image of a portion of the crimping machine 100 captured by the visual system 200 according to an exemplary embodiment. Figure 6 shows the terminal 102 and wire 104 in the crimping area 106. Figure 6 shows the image displayed on the display 154 (shown in Figure 1) in the user interface 152. In the exemplary embodiment, the visual system 200 is configured to overlay a verification graphic 220 on the image displayed on the display 154 for user verification. The verification graphic 220 relates to verification criteria used by the visual system 200 for verification prechecks. For example, the verification graphic 220 corresponds to verification criteria used by the image analysis module 204 that set acceptable limits or ranges. The verification graphic 220 may be superimposed limit lines included in the user interface 152 that are configurable or adjustable by the user to impose minimum and maximum tolerances that should be applied to the verification precheck. Thus, the end user can calibrate or adjust the verification criteria to suit their requirements. Limit lines may be adjusted during or before execution time to adjust or update the validation criteria. The criteria used for validation prechecks are based on both images and overlaid validation graphics. Validation graphics 220 may be used during training of a neural network operated by the visual system 200, for example, during factory calibration or setup. For example, the visual system 200 may overlay validation graphics 220 on images to train acceptable limits for validation prechecks. Validation graphics 220 may be generated by a computer during training of a neural network operated by the visual system 200. In an exemplary embodiment, the visual system 200 uses validation precheck criteria to perform validation prechecks. Validation precheck criteria may be generated by a training process using the crimping machine 100 or another machine, for example, in a manufacturing facility where the crimping machine is pre-trained and calibrated, and then uploaded to the crimping machine 100.

[0035] The verification graphic 220 provides a visual representation of the verification criteria used by the visual system 200 for verification pre-checks. Various types of verification graphics 220 may be used by the visual system 200. For example, the verification graphic 220 may include lines (solid or dashed), boxes, dots, arrows, circles, triangles, other shapes, or other graphics. The verification graphic 220 may include letters and / or numbers overlaid on the image. In exemplary embodiments, the verification criteria may be customizable by the user. For example, the user may adjust, customize, or define the verification criteria available to the visual system 200 for verification pre-checks. In various embodiments, the verification criteria are customized by the user by manually adjusting the position of the verification graphic 220 in the image to change the range or limits of the verification criteria. The strictness of the verification criteria may be increased or decreased by the user to make it easier to fail or pass the pre-check. The verification criteria may be customizable during the calibration mode of the operation of the visual system 200. Additionally or alternatively, the verification criteria may be customizable during the normal operation of the visual system 200.

[0036] In various embodiments, the verification criterion includes an insulating strip range 230 related to the strip length of the insulator 172, corresponding to the exposed length of the conductor 170. The strip range 230 is identified by a forward line 232 and a backward line 234. In an alternative embodiment, the insulating strip range 230 may be defined by a box. The strip range 230 may be resizable by moving the forward line 232 and / or the backward line 234. Optionally, the strip range 230 may be indicated by a first color (e.g., green) if the strip length meets the verification criterion, and by a second color (e.g., red) if the strip length fails to meet the verification criterion.

[0037] In various embodiments, the verification criteria include an angle limit line 240 related to the angle of the wire 104 relative to the terminal 102. For example, the wire 104 may be curved, twisted, bent, or otherwise positioned within the crimping barrel 184 such that the wire centerline is angled with respect to the terminal centerline. The angle limit line 240 identifies the acceptable angle limit of the wire 104 relative to the terminal 102. The angle limit line 240 may be customizable, for example, by rotating the angle limit line 240 with respect to the terminal centerline. Optionally, the angle limit line 240 may be indicated in a first color when the angle of the wire 104 meets the verification criteria, and in a second color when the angle of the wire 104 fails to meet the verification criteria.

[0038] In various embodiments, the verification criterion includes a wire gauge line 250 used to represent the wire gauge of the wire 104. The wire gauge line 250 may form a box. The wire gauge line 250 is used to determine that the appropriate wire 104 is present in the crimping area 106. The wire gauge line 250 may be customizable. Optionally, the wire gauge line 250 may be indicated by a first color if the wire gauge of the wire 104 meets the verification criterion, and by a second color if the wire gauge of the wire 104 fails the verification criterion.

[0039] In various embodiments, the verification criterion includes a wire protrusion line 260 used to represent the amount of protrusion of the conductor 170 from the crimp barrel 184 and / or the amount of protrusion of the insulator 172 to the crimp barrel 184. The wire protrusion line 260 identifies an acceptable range for the conductor protrusion and / or the insulator protrusion. In various embodiments, the wire protrusion line 260 includes a front wire protrusion line 262 at the front of the crimp barrel 184 and a rear wire protrusion line 264 at the rear of the crimp barrel 184. The front wire protrusion line 262 correlates to the position of the end 176 of the insulator 172 relative to the crimp barrel 184. The rear wire protrusion line 264 correlates to the position of the end 174 of the conductor 170 relative to the crimp barrel 184. The wire protrusion line 260 may be customizable, for example, by shifting the wire protrusion line 260 forward or backward. Optionally, the wire protrusion 260 may be indicated in a first color if the amount of protrusion of the conductor 170 and / or insulator 172 meets the verification criteria, and may be indicated in a second color if the amount of protrusion of the conductor 170 and / or insulator 172 fails to meet the verification criteria.

[0040] Figure 7 is a top view image of a portion of the crimping machine 100 taken by the visual system 200 according to an exemplary embodiment. Figure 8 is a top view image of a portion of the crimping machine 100 taken by the visual system 200 according to an exemplary embodiment. Figures 7 and 8 show verification graphics 220 overlaid on the images. In the exemplary embodiment, the verification graphics 220 include wire protrusion lines 260. Comparing the images shown in Figures 7 and 8, the wire protrusion line 260 is customized in Figure 8 compared to Figure 7. For example, the wire protrusion line 260 is shifted to narrow the acceptable range for the position of the end 174 of the conductor 170. In Figure 7, the end 174 of the conductor 170 is within the range of the wire protrusion line 260, and is therefore classified as a passing verification precheck. On the other hand, in Figure 8, the end 174 of the conductor 170 is outside the range of the wire protrusion line 260, and is therefore classified as a failing verification precheck.

[0041] It should be understood that the above description is intended to be illustrative, not restrictive. For example, the embodiments (and / or their aspects) described above may be used in combination with one another. In addition, numerous modifications may be made to adapt the teachings of the present invention to specific situations or materials, without departing from the scope of the invention. The dimensions of various components, the types of materials, the orientations, and the number and location of various components described herein are intended to define the parameters of a particular embodiment and are not restrictive, but merely illustrative embodiments. By considering the above description, numerous other embodiments and modifications within the spirit and scope of the claims will become apparent to those skilled in the art. Thus, the scope of the invention should be determined, together with the appended claims, with respect to the entire range of equivalents to which such claims apply. In the appended claims, the terms “including” and “in which” are used as plain English equivalents of the corresponding terms “comprising” and “wherein.” Furthermore, in the following claims, terms such as “first,” “second,” and “third” are used merely as designations and are not intended to impose numerical requirements on their subjects. Furthermore, the following limitations of claims are not written in means-plus-function form unless such limitations explicitly use the phrase “means for” followed by a functional description lacking further structure, and are not intended to be interpreted under 112(f) of the U.S. Patent Act.

Claims

1. Crimping machine (100), - An anvil (120) having a lower die (122) having a lower forming surface (124) The anvil is configured to support the crimping barrel (184) of the terminal (102) that receives the wire (104), and includes an anvil (120), - A press (130) having an upper die (132) having an upper forming surface (134) The press is movable relative to the anvil during the crimping process to connect the crimping barrel to the wire, and the crimping area (106) is defined between the upper forming surface and the lower forming surface, and the press (130) - A visual system (200) arranged to visually inspect the crimping area, The visual system includes an imaging device (202) configured to image the crimp barrel and wire of the terminal, and the visual system includes a visual system (200) which causes the imaging device to take an image before the crimping process in order to perform a verification precheck before the crimping process, A crimping machine (100) equipped with the following: The visual system (200) performs the verification precheck of the position of the wire in the direction of extension of the wire with respect to the crimping barrel that receives the wire. The imaging device (202) is incorporated into the crimping machine (100), The anvil (120) includes a lower digraphic identifier (210), which is machine or computer readable and is located on the lower die (122). The press (130) includes an upper diagraphic identifier (212), which is readable by machine or computer and is located on the upper die (132). The imaging device (202) is configured to capture the lower digraphic identifier and the upper digraphic identifier, The visual system (200) is configured to read the lower digraphic identifier and the upper digraphic identifier in the image in order to perform the verification precheck. Crimping machine (100).

2. The visual system (200) processes the image to determine whether the verification precheck is a passing verification precheck or a failing verification precheck. The crimping machine (100) according to claim 1.

3. The controller (150) is further operably coupled to the press (130), The controller is configured to move the press during the crimping process, The controller operates the press based on the verification precheck. The crimping machine (100) according to claim 1.

4. The controller (150) operates the press (130) if the verification precheck is a passing verification precheck. The controller restricts the operation of the press if the verification precheck is a failed verification precheck. The crimping machine (100) according to claim 3.

5. With additional cabinets, The anvil (120) and the press (130) are received in the cabinet. The aforementioned visual system (200) includes a bracket, The imaging device (202) is attached to the bracket, The bracket is connected to the cabinet. The crimping machine (100) according to claim 1.

6. The upper digraphic identifier (212) and the lower digraphic identifier (210) are labels, The visual system (200) of the crimping machine (100) is configured to scan the label. The crimping machine (100) according to claim 1.

7. The lower digraphic identifier (210) is a scannable barcode. The upper digraphic identifier (212) is a scannable barcode. The crimping machine (100) according to claim 1.

8. The system further comprises a user interface that is communicatively connected to the aforementioned visual system (200), The user interface includes a display, The aforementioned image is displayed on the screen for user confirmation. The crimping machine (100) according to claim 1.

9. The display overlays a verification graphic (220) onto the image for user verification. The verification graphic relates to the verification criteria used by the visual system (200) for the verification precheck. The crimping machine (100) according to claim 8.

10. The overlaid verification graphic (220) is customizable by the user to adjust the verification criteria used by the visual system (200) during the verification precheck. The crimping machine (100) according to claim 9.

Images