Closed-Barrel Crimp Terminal Inspection via External Marking
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Solution Overview
Problem
The challenge lies in manufacturing a connection structural body with stable conductivity using a closed-barrel-type crimp terminal, where the insertion depth and state of the insulated wire into the pressure-bonding section cannot be visually confirmed, making it difficult to ensure reliable conductivity during the manufacturing process.
Innovation Solution
A method involving a cover stripping step, wire insertion step, and pressure-bonding step, followed by inspection steps to ensure accurate insertion and bonding of the wire tip into the closed-barrel-type pressure-bonding section, utilizing markings and inspection means to verify the insertion state and pressure-bonded state, allowing for efficient inspection and production of connection structural bodies with stable conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a closed-barrel-type pressure-bonding section is used to prevent corrosion, then reliability of conductivity is improved, but the ability to visually confirm insertion depth and state deteriorates
Solution Approach 1:
A marker is introduced as an intermediary element that can be visually detected from the exterior of the closed-barrel-type pressure-bonding section. This marker indicates the insertion depth and state of the conductor without requiring direct visual access to the interior bonding interface, thus resolving the contradiction between corrosion protection and inspection capability
Solution Approach 2:
The insertion state information is copied from the interior bonding interface to the exterior surface through the marker. Instead of directly observing the insertion depth inside the closed barrel, a corresponding visual indicator is created on the outside that replicates the state information, enabling non-intrusive inspection
2Weight of moving object
If miniaturization of crimp terminal is implemented for weight reduction and space saving, then weight and volume are reduced, but the ability to confirm pressure-bonded state deteriorates
Solution Approach 1:
The marker serves as an intermediary that translates the pressure-bonding state information into a visible form on the exterior of the miniaturized crimp terminal. This allows inspection of bonding quality without increasing the size of the terminal itself, maintaining weight and space benefits while improving detectability
3Difficulty of detecting and measuring
If conventional open-barrel-type crimp terminal is used, then ease of visual inspection is maintained, but corrosion resistance deteriorates
Solution Approach 1:
The marker acts as an intermediary that provides visual inspection capability equivalent to the open-barrel design, while the closed-barrel structure maintains corrosion resistance. The marker transfers the bonding state information to the exterior without requiring the barrel to be open
Data Source
AI summary
A cover stripping step of peeling off an insulating cover on a distal end side of an insulated wire to form a wire tip; a marking step of forming a marking on the insulating cover at a predetermined position; a first marking inspection step of inspecting a stripping state and the marking; a wire insertion step of inserting the wire tip into a closed-barrel-type pressure-bonding section; a pressure-bonding step of pressure-bonding the pressure-bonding section to be connected to the wire tip; and a second marking inspection step of inspecting a pressure-bonded state of the pressure-bonding section to the wire tip using the marking are performed in this order, and the first marking inspection step and the second marking inspection step are performed using the same inspection step part.