Automated Optical Inspection of Miniaturized Connector Fitting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The miniaturization of connectors has made it difficult to ensure inspection accuracy of fitted states due to smaller allowance dimensions and dimension tolerances, leading to potential assembly defects and quality deterioration in mass-production processes.
Innovation Solution
A method and device that utilize a camera and image processing to measure the deformation of elastically deformable engagement detents, comparing the measured data to reference data to determine proper fitting, with adjustable lighting and camera positioning for accurate imaging and measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If connectors are miniaturized to reduce size, then the compactness and portability are improved, but the allowance dimension and dimension tolerance become smaller making inspection accuracy difficult to ensure
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical inspection system using a camera and image processing. The system captures images of the connector fitting state and automatically determines proper or improper fitting based on image analysis, eliminating the need for manual measurement and inspection while maintaining high accuracy even with miniaturized connectors.
Solution Approach 2:
The patent creates an optical copy (image) of the connector fitting state using a camera. Instead of directly measuring the physical connector dimensions, the system captures an image of the fitting state and analyzes it to determine proper or improper fitting, allowing inspection without direct physical contact or complex measurement tools.
2Adaptability or versatility
If manual fitting operation is performed by human workers, then flexibility and adaptability are maintained, but mistakes and assembly defects occur inevitably
Solution Approach 1:
The patent implements an automated inspection system that performs self-inspection of the connector fitting state. The camera and image processing system automatically capture images and determine fitting quality without human intervention, allowing the system to self-verify assembly quality and eliminate human errors while maintaining operational flexibility.
Solution Approach 2:
The patent introduces a feedback mechanism where the inspection results are automatically determined and can trigger appropriate actions. The system provides immediate feedback on fitting quality by analyzing images and determining proper or improper fitting states, enabling real-time quality control and preventing defective products from proceeding to the next stage.
3Extent of automation
If a mark-based inspection method is used with optical sensors, then automated inspection capability is achieved, but the complexity of setting mark position increases due to involvement of multiple dimensions including allowance dimension
Solution Approach 1:
The patent extracts the inspection target from complex dimensional measurements to a simpler visual feature. Instead of setting mark positions based on multiple dimensions including allowance dimensions and tolerances, the system inspects the fitting state directly through image capture, eliminating the need for complex mark positioning and reducing setup complexity.
Solution Approach 2:
The patent transitions from one-dimensional dimensional measurement to two-dimensional image-based inspection. By capturing the fitting state in an image plane, the system converts complex multi-dimensional measurement problems into simpler image analysis, allowing automated inspection without the complexity of precise mark positioning in multiple dimensions.
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
Ensures reliable inspection accuracy of connector fitting states even with small allowance dimensions, preventing defective products and maintaining quality by automatically determining proper or improper fits based on measured deformation data.
Implementation Method 1
a camera 11 for imaging the fitting state of the connectors
Implementation Method 2
Engagement detents i.e. locking arms that are deformable elastically are provided on the female connector. The engagement detents are deformed elastically and go over the engagement portions so as to engage with the engagement portions.
Data Source
AI summary
According to one embodiment, one of two connectors, and a circuit board on which the other of the connectors is mounted are prepared. The one of the connectors has an engagement portion. The other of the connectors has an elastically deformable engagement detent. The engagement detent can go over the engagement portion and be engaged with the engagement portion. One of the connectors is fitted to the other of the connectors. A portion of the electric equipment is imaged by a camera. A piece of data which changes is measured from an obtained picture image. A deformation of the engagement detent occurs with going-up of the engagement detent onto the engagement portion. Whether or not the connectors are properly fitted is determined. Fitting of the connectors is performed again when it is determined that the connectors are not properly fitted.