Cable Wire Insertion Verification Using Vibration Signals
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Solution Overview
Problem
Manual inspection of cable wire insertion into connector housings is tedious and error-prone, leading to incomplete electrical connections and potential downstream faults due to inconsistent or insufficient insertion.
Innovation Solution
A vibration analysis and machine learning-based system that uses a vibration sensor to detect correct cable wire insertion into a connector housing, analyzing the vibration signals with an insertion verification model trained on labeled data to provide automated feedback on insertion quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection of cable wire insertion is used, then human judgment can assess insertion quality, but the process is tedious and error-prone leading to inconsistent verification
Solution Approach 1:
The patent replaces the manual mechanical inspection process with an automated vibration analysis system. A vibration sensor captures signals during cable wire insertion, and a machine learning model automatically analyzes these signals to determine insertion quality, eliminating the need for tedious manual inspection while improving accuracy and consistency.
Solution Approach 2:
The system enables self-verification by having the insertion process itself generate the verification data. The vibration sensor captures signals during insertion, and the machine learning model automatically evaluates whether the insertion is correct, allowing the system to verify its own operation without external manual intervention.
2Reliability
If manual inspection is used to verify cable wire insertion, then flexibility in handling various insertion scenarios is maintained, but human error leads to incomplete connections and downstream faults
Solution Approach 1:
The patent replaces error-prone manual inspection with an automated sensor-based system. The vibration sensor and machine learning model provide reliable, consistent verification of cable wire insertion, eliminating human error while maintaining the ability to handle various insertion scenarios through trained recognition of different vibration patterns.
Solution Approach 2:
The system provides immediate feedback on insertion quality by analyzing vibration signals in real-time. The machine learning model evaluates the captured signals and determines whether the insertion is correct, providing reliable verification that prevents incomplete connections and downstream faults.
3Productivity
If automated vibration analysis is implemented, then inspection speed and consistency are improved, but the system complexity and initial setup requirements increase
Solution Approach 1:
The patent replaces manual inspection with an automated vibration analysis system that uses a sensor and machine learning model. This substitution dramatically increases inspection throughput and consistency while the system handles the complexity of signal analysis automatically through the trained model.
Solution Approach 2:
The machine learning model performs self-learning and automatic evaluation of vibration signals. Once trained, the system independently analyzes insertion quality without requiring complex manual setup or intervention, achieving high productivity while managing system complexity through automated processing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Provides precise and automated verification of correct cable wire insertion, reducing the risk of connection failures and human effort, ensuring consistent and stable electrical connections.
Implementation Method 1
receiving a vibration signal from a vibration sensor, the vibration signal representing a vibration caused by insertion of a cable wire into a cable cavity of a cable connector housing
Data Source
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AI summary
A method for cable wire insertion verification includes, at an insertion verification system, receiving a vibration signal from a vibration sensor. The vibration signal represents vibration caused by insertion of a cable wire into a cable cavity of a cable connector housing. The vibration signal is input to an insertion verification model trained to evaluate whether input vibration signals are consistent with correct cable wire insertion. The insertion verification model outputs an indication that the vibration signal is consistent with correct insertion of the cable wire into the cable cavity.