Connector Wire Contact Insertion Verification by Image Feedback
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manual insertion of wire contacts into connectors is time-consuming and error-prone, leading to increased costs and potential improper connections.
Innovation Solution
A system comprising at least one image acquisition device and processing circuitry to visually identify and confirm the full insertion of a wire contact into a connector, providing feedback on correct insertion depth and hole location.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated wire insertion techniques are used, then productivity and consistency are improved, but the system may improperly insert wire contacts into incorrect holes, requiring complex verification mechanisms
Solution Approach 1:
The patent implements a feedback mechanism where images are captured before and after insertion, processed to determine insertion status, and used to verify correct placement. This closed-loop verification ensures automated insertion maintains high reliability by detecting and correcting errors.
Solution Approach 2:
The patent replaces manual visual inspection with an automated image processing system. Cameras and image processing algorithms substitute for human operators to verify insertion accuracy, enabling consistent high-speed automated operation without sacrificing reliability.
2Adaptability or versatility
If manual wire contact insertion is performed, then flexibility and adaptability are maintained, but time consumption and error rates increase
Solution Approach 1:
The system performs self-verification by automatically capturing images, processing them to determine insertion status, and identifying errors without human intervention. This maintains the flexibility of automated operation while eliminating time-consuming manual inspection.
Solution Approach 2:
Manual inspection and verification tasks are replaced with automated image processing algorithms that quickly analyze insertion status, dramatically reducing assembly time while maintaining adaptability to different wire contact configurations.
3Measurement precision
If multiple image acquisition devices are used to verify insertion depth, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent uses multiple cameras positioned at different angles to capture images of the wire contact insertion hole. By analyzing the same feature from different dimensional perspectives, the system achieves precise depth measurement without requiring complex specialized sensors.
Solution Approach 2:
The system creates multiple optical copies (images) of the insertion hole from different angles using standard cameras. These image copies are then processed to extract precise depth information, avoiding the need for complex physical measurement devices.
Data Source
AI summary
A method, system and computer program product are provided for determining wire contact insertion based on image analysis. Methods include: acquiring at least one image of a connector having a plurality of wire contact insertion holes; identifying a wire contact within a wire contact insertion hole of the plurality of wire contact insertion holes; determining that the wire contact insertion hole is a correct wire contact insertion hole; determining that the wire contact has been fully inserted into the correct wire contact insertion hole; and providing feedback indicating that the wire contact is fully inserted into the correct wire contact insertion hole. The feedback includes in some cases a first indicator indicating that the wire contact is in the correct wire contact insertion hole and a second indicator indicating that the wire contact is fully inserted into the correct wire contact insertion hole.