Connector Housing Vision Inspection for Cable Insertion Depth

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Solution Overview

Problem

Cable wire insertion into connector housings is prone to inconsistencies and errors, leading to inefficient and time-consuming manual inspection, which may result in insufficient insertion causing connectivity issues.

Innovation Solution

A machine vision system is employed to capture inspection images of connector housings, using stereo triangulation and machine learning algorithms to estimate the insertion depth of cable wires, providing real-time feedback on insertion accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual inspection is used to check cable wire insertion, then flexibility and simplicity are maintained, but inspection precision and reliability deteriorate due to human error and inconsistencies

Engineering Contradiction:

Improveinsertion depth measurement precisionVSAvoidinspection system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces manual mechanical inspection with an automated machine vision system that uses imaging cameras and computer algorithms to detect and measure cable wire insertion depth. This substitution eliminates human error while maintaining inspection effectiveness through automated image processing and depth calculation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system creates visual copies (images) of the cable wire insertion state using cameras, then analyzes these copies to determine insertion depth. This copying approach allows non-contact measurement and enables precise detection without physically interacting with the inserted components.

Inventive Principle:

Principle #26Copying

2Productivity

If manual inspection methods are used, then device complexity remains low, but productivity and inspection speed deteriorate due to time-consuming processes

Engineering Contradiction:

Improveinspection speedVSAvoidinspection system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent replaces slow manual inspection with automated machine vision technology that can capture and analyze multiple images simultaneously. This enables parallel processing of insertion depth measurements across multiple cable wires, dramatically increasing inspection speed while reducing the need for human labor.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables continuous inspection by automatically capturing images and processing depth measurements without interruption. The automated workflow allows for uninterrupted monitoring of cable wire insertion, eliminating the discontinuous nature of manual inspection and improving overall productivity.

Inventive Principle:

Principle #20Continuity of useful action

3Reliability

If automated machine vision system is implemented, then measurement precision and productivity improve, but device complexity increases

Engineering Contradiction:

Improveinsertion detection reliabilityVSAvoidinspection system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces unreliable manual detection with automated machine vision systems that provide consistent and repeatable measurements. The automated system eliminates variability introduced by human operators, ensuring high reliability in detecting insertion depth and identifying improper insertions.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system implements feedback mechanisms by analyzing captured images, calculating insertion depths, and providing immediate detection results. This closed-loop feedback enables real-time identification of insertion errors and allows for corrective actions, thereby improving overall process reliability and quality control.

Inventive Principle:

Principle #23Feedback

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 system enhances the precision and efficiency of cable wire insertion by detecting and correcting insertion errors, ensuring proper cable wire placement and reducing manual inspection time.

Implementation Method 1

receiving, from a camera system, an inspection image of a connector housing

Methodology Applied

Scientific EffectPhotography: Photography

Implementation Method 2

using stereo triangulation and machine learning algorithms to estimate the insertion depth

Methodology Applied

Scientific EffectTriangulation:

Data Source

PatentUS20250329004A1Cable wire insertion depth monitoring

Publication Date: 2025.10.23 THE BOEING CO

AI summary

A method for cable wire insertion monitoring includes receiving, from a camera system, an inspection image of a connector housing held in a housing retainer of a housing inspection system. Insertion of a cable wire into a corresponding cable cavity of the connector housing is detected via an insertion monitoring machine vision system. Based at least in part on the inspection image, an insertion depth of the cable wire into the corresponding cable cavity is estimated. An indication of the insertion depth of the cable wire is output.