Conductive Micrometer Prevents Manual Measurement Bypass
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Solution Overview
Problem
Workers often intentionally bypass actual measurements when using micrometers to ensure proper crimping force for wire terminals, leading to unstable connections and quality control issues, as the system relies on registered standard measurements without verifying actual compliance.
Innovation Solution
A micrometer with a conductive frame, anvil, and spindle that automatically transmits the measured gap value to an external device only when the anvil and frame are electrically short-circuited, preventing intentional non-compliance by ensuring accurate measurement and quality control through automatic data transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If workers manually measure sample terminals using a micrometer and transmit measurements to a POP terminal, then quality control of crimping connections can be maintained, but workers may intentionally bypass actual measurements leading to unreliable quality control
Solution Approach 1:
The patent replaces the manual mechanical measurement process with an automated measurement system. The micrometer automatically measures the crimped terminal dimensions and transmits data to the POP terminal, eliminating the need for workers to manually operate the micrometer and reducing opportunities for intentional bypass of measurement procedures.
Solution Approach 2:
The system implements automatic feedback by measuring the actual crimped terminal, comparing it against standard ranges stored in the POP terminal, and providing immediate feedback on whether the crimping quality meets specifications. This closed-loop feedback system ensures reliable quality control without relying on worker compliance.
2Manufacturing precision
If workers repeatedly perform sample measurements for many types of wires, then proper crimping force can be determined, but the measuring work becomes troublesome and time-consuming
Solution Approach 1:
The system enables self-service by allowing the micrometer to automatically perform measurements and transmit data without requiring worker intervention for each measurement. The POP terminal automatically compares measurements against stored standards and provides pass/fail indications, reducing the burden on workers while maintaining measurement precision.
Solution Approach 2:
The system performs preliminary actions by pre-storing standard measurement ranges for different wire and terminal types in the POP terminal. This allows the system to immediately evaluate measurements against appropriate standards without requiring workers to manually lookup or determine the correct standards for each measurement type.
3Productivity
If workers manipulate micrometer readings without actual samples to match standard ranges, then measurements can be made quickly, but actual compliance cannot be verified leading to connection failures
Solution Approach 1:
The patent replaces manual manipulation of micrometer readings with an automated measurement and data transmission system. The micrometer automatically captures actual measurement values and transmits them to the POP terminal, eliminating the ability for workers to manually manipulate readings while maintaining fast measurement capabilities.
Solution Approach 2:
The system introduces an intermediary automated data transmission mechanism between the micrometer and the POP terminal. This intermediary process ensures that actual measurement values are automatically recorded and compared against standards, preventing manual manipulation while maintaining measurement speed through automation.
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
This solution enhances quality control by ensuring accurate measurement and data transmission, reducing the likelihood of workers bypassing actual measurements, thereby improving the reliability of wire-terminal connections and productivity by streamlining the measurement process.
Implementation Method 1
an anvil (15) of conductive material that is fixedly coupled to one end of the frame (10) in an electrically insulated manner from the frame (10)
Data Source
AI summary
A micrometer according to the present invention comprises: a frame of conductive material; an anvil of conductive material that is fixedly coupled to one end of the frame in an electrically insulated manner from the frame; a spindle of conductive material coupled to other end of the frame in such a way as to be moved back and forth along direction of the anvil in synchronization with rotation of a thimble while making electrical contact with the frame; and a controller configured to transmit a value for current gap between the anvil and the spindle to an external device as a measurement in case the anvil and the frame are electrically short-circuited. This configuration of the micrometer allows a measurement to be sent to the external device only in the case that a conductive object is necessarily mounted between the anvil and the spindle and electrically short-circuits them.