AI Vision Cable Crimping for Conductor Core Position Accuracy
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Solution Overview
Problem
Existing twisted pair cable crimping technologies face challenges in accurately positioning conductor cores due to positional deviations and potential damage to fine conductive wires, leading to unstable crimping quality and difficulty in identifying the actual number of conductive wires, which affects product quality.
Innovation Solution
A twisted pair cable crimping system utilizing an artificial intelligence vision device to recognize geometric centers and wire counts, combined with a position calibration and adjustment mechanism to ensure precise crimping, and a crimping device with fixed and movable molds to secure the conductor cores at the correct position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a guiding structure is used to guide the conductor core to the correct crimping position, then the crimping process can be automated, but the guiding structure cannot reliably guide the conductor core to the correct crimping position due to positional deviations, leading to unstable crimping quality
Solution Approach 1:
The system performs preliminary detection of the conductor core's actual position using a vision device before the crimping operation. Based on the detected position deviation, the system pre-calculates and sets the appropriate compensation value and crimping mode, ensuring the conductor core will be accurately positioned during crimping despite initial deviations.
Solution Approach 2:
The system uses a vision detection device to detect the actual position of the conductor core, compares it with the ideal position, and feeds back the position deviation information. This feedback is used to dynamically adjust the crimping position through compensation values, forming a closed-loop control system that ensures accurate crimping.
2Productivity
If the conductor core is processed without position calibration, then the processing speed is faster, but the conductor core cannot be accurately positioned at the predetermined crimping position due to positional deviations
Solution Approach 1:
The system performs preliminary detection of the conductor core's actual position using a vision device before the crimping operation. Based on the detected position deviation, the system pre-calculates and sets the appropriate compensation value and crimping mode, ensuring the conductor core will be accurately positioned during crimping despite initial deviations.
Solution Approach 2:
The system replaces complex mechanical guiding structures with a vision-based detection and control system. The vision device detects position deviations, and the control system calculates compensation values to adjust the crimping position, eliminating the need for elaborate mechanical guidance while maintaining high positioning accuracy.
3Productivity
If the actual number of fine conductive wires cannot be identified, then the processing is simpler and faster, but the quality of twisted pair cable products cannot be ensured
Solution Approach 1:
The system replaces manual inspection or complex mechanical counting mechanisms with an AI-based vision recognition system. The vision device captures images of the conductor core and uses AI algorithms to automatically identify and count the fine conductive wires, providing rapid and accurate quality assessment without adding significant processing time.
Solution Approach 2:
The system introduces an AI vision recognition system as an intermediary between the conductor core processing and quality assessment. This intermediary automatically identifies the number of fine conductive wires and provides quality judgment, eliminating the need for manual inspection while ensuring accurate quality control.
Data Source
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AI summary
The present invention discloses a twisted pair cable crimping system and a twisted pair cable crimping method. The twisted pair cable crimping system comprises: a cable fixture (5), used for clamping and fixing a twisted pair cable (10); a moving device (6) for moving the cable fixture (5) and the twisted pair cable (10) in a horizontal direction (X) perpendicular to an axial direction (Y) of the twisted pair cable (10); an artificial intelligence vision device (3) which is installed at a detection station and can mimic the human eye to recognize actual positions (P1', P2') of geometric centers of two exposed conductor cores (12) of the twisted pair cable (10) moved to the detection station, and an actual distance between the geometric centers of the two conductor cores (12) in the horizontal direction (X); a position calibration device which is suitable for calibrating the crimping position of the twisted pair cable (10) based on a position deviation between the actual position (P1', P2') and a predetermined ideal position (P1, P2) in a condition where the actual distance is not less than a predetermined safe distance, in order to eliminate the position deviation; and a crimping device (4) which is installed at a crimping station for crimping the conductor core (12) onto a terminal (2) fixed at a predetermined crimping position. When the conductor core (12) is moved to the predetermined crimping position, the geometric center of the conductor core (12) is located on the centerline of the terminal (2) fixed at the predetermined crimping position. The present invention can calibrate the crimping position of the conductor core of the twisted pair cable based on the recognized positional deviation, improving the crimping accuracy and quality of the twisted pair cable.