Automatic Wire Arranging Device Using CCD Visual Identification
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Solution Overview
Problem
Conventional manual methods for arranging core wires in cable spot soldering are prone to errors due to worker fatigue, leading to increased defect rates and costs, requiring multiple workers and extended working hours.
Innovation Solution
An automatic wire arranging device comprising a controller, driving devices, a wire clamping jig, a charge-coupled device camera, and a puncher pin, which automatically distinguishes and positions core wires based on their characteristics, such as color, using transverse, up-down, and rotational movements to accurately place them into clamping slots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual methods are used to arrange core wires by worker eyes and hands, then flexibility and adaptability are maintained, but error rates increase due to fatigue and distinguishability issues
Solution Approach 1:
The patent replaces the manual mechanical system of workers visually identifying and manually placing wires with an automated system using CCD cameras for visual identification and robotic mechanisms for wire placement. The controller processes camera images to identify wire colors and controls the robotic arm to automatically place wires in correct positions, eliminating human fatigue and error-prone manual operations.
Solution Approach 2:
The system enables self-service by allowing the automated device to independently identify wire characteristics through CCD cameras, determine correct positioning based on pre-set information, and execute wire placement without continuous human intervention. The controller autonomously processes visual data and controls the robotic mechanism to complete the arrangement task.
2Productivity
If multiple workers are deployed to arrange core wires manually, then arrangement capacity increases, but labor costs and working hours increase
Solution Approach 1:
The patent replaces multiple human workers with a single automated robotic system that can continuously identify and arrange wires at high speed. The robotic arm, controlled by a computer system processing CCD camera input, performs wire placement operations faster and more consistently than manual workers, significantly improving productivity while reducing labor requirements.
Solution Approach 2:
The automated system enables continuous operation without the breaks, fatigue, and coordination requirements of manual labor. The robotic mechanism can maintain constant wire arrangement operations, processing wires in sequence without interruption, thereby increasing overall productivity and reducing total working hours required.
3Reliability
If manual wire arrangement is performed, then device complexity is low, but defect rates increase and repair costs rise
Solution Approach 1:
The patent introduces an automated system with CCD cameras, image processing controllers, and robotic mechanisms to replace manual wire arrangement. This increased device complexity enables precise visual identification of wire colors and characteristics, accurate positioning control, and consistent placement execution, thereby significantly reducing soldering defects and associated repair costs.
Solution Approach 2:
The system incorporates feedback through CCD cameras that continuously capture wire position and characteristic information, which the controller processes to verify correct identification and placement. This closed-loop feedback mechanism ensures high accuracy in wire arrangement, minimizing errors and defects despite the increased system complexity.
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
The automatic system reduces manpower needs, decreases working hours, lowers defect rates, and enhances the speed of wire arrangement, thereby reducing the overall cost of spot soldering by minimizing errors and increasing efficiency.
Implementation Method 1
at least one charge-coupled device camera facing towards the wire clamping jig, and connected with the controller. The at least one charge-coupled device camera is capable of distinguishing different characteristics of each of the plurality of the core wires
Data Source
AI summary
An automatic wire arranging device includes a controller, at least one driving device electrically connected with the controller, a wire clamping jig, a wire arranging rotor, at least one charge-coupled device camera and a puncher pin. The wire clamping jig is connected with the at least one driving device. The wire arranging rotor has a spindle, and a cylinder-shaped base portion fastened to a tail end of the spindle. An outer side surface of the base portion is equipped with a plurality of clamping portions. The plurality of the clamping portions are used for clamping a plurality of different characteristic core wires. The wire arranging rotor is connected with the at least one driving device. The at least one charge-coupled device camera faces towards the wire clamping jig and is connected with the controller. The puncher pin is movably disposed above the wire clamping jig.