AI Vision Crimping for Twisted Pair Cable Core Alignment
Find Innovative SolutionsGenerate Solutions
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 wires, which affects product quality.
Innovation Solution
A twisted pair cable crimping system utilizing an artificial intelligence vision device to recognize the actual positions and number of conductive wires, coupled with a position calibration and crimping device to ensure precise alignment and quality control, including a removal mechanism for unqualified cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a guiding structure is used to guide the conductor core to the correct crimping position, then the positioning accuracy is improved, but the guiding structure cannot reliably guide the conductor core due to positional deviations, leading to unstable crimping quality
Solution Approach 1:
The patent replaces the traditional mechanical guiding structure with an artificial intelligence vision system that uses image recognition and algorithms to detect the actual position of conductor cores and calculate compensation values. This substitution allows the system to adapt to positional deviations dynamically rather than relying on fixed mechanical guides, thereby improving both positioning accuracy and crimping quality stability.
Solution Approach 2:
The patent implements a feedback mechanism where the AI vision device captures images of the conductor core positions, the system calculates the deviation from the ideal position, and then applies compensation by adjusting the crimping position accordingly. This closed-loop feedback ensures that positional deviations are continuously corrected, maintaining stable crimping quality despite variations in cable positioning.
2Ease of manufacture
If the fine conductive wires are processed during cable assembly, then the cable is prepared for crimping, but the small diameter wires are at risk of being cut or broken, reducing the actual number of conductive wires
Solution Approach 1:
The patent replaces manual or conventional mechanical inspection methods with an AI vision system that can detect and count the fine conductive wires through image analysis. This non-contact optical inspection method eliminates the need for physical handling that could cause wire breakage, while still enabling quality verification of the wire count and integrity.
3Productivity
If the actual number of fine conductive wires cannot be identified, then the processing continues, but the product quality cannot be ensured due to potential wire deficiencies
Solution Approach 1:
The patent employs an artificial intelligence vision device with image recognition algorithms to automatically detect, count, and verify the number of fine conductive wires in each conductor core. This automated optical inspection system maintains high processing throughput while ensuring accurate quality control by identifying any deficiencies in wire count before the crimping process proceeds.
Data Source
Figure 1
Figure 2
Figure 3
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), wherein each conductor core (12) of the twisted pair cable (10) comprises multiple fine conductive wires (13) twisted together; 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); and an artificial intelligence vision device (3) which is installed at a detection station and can mimic the human eye to recognize an actual number of fine conductive wires (13) in each conductor core (12) of the twisted pair cable (10). When the actual number of fine conductive wires (13) of the conductor core (12) recognized by the artificial intelligence vision device (3) is not equal to a predetermined number, the artificial intelligence vision device (3) determines that the quality of the twisted pair cable (10) is unqualified. In the present invention, the artificial intelligence vision device can mimic the human eye to recognize the actual number of fine conductive wires in the conductor core of twisted pair cable. Therefore, the present invention can pre judge the quality of twisted pair cable based on the identified actual number of fine conductive wires in the conductor core, thereby improving the quality of twisted pair cable products.