Connector Housing Vision Verification for Cable Wire Insertion
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Solution Overview
Problem
Manual inspection of cable wire insertion into connector housings is tedious and prone to errors, leading to inconsistent and time-consuming construction processes.
Innovation Solution
A method utilizing a camera system and machine vision system to classify the connector housing type and verify correct cable wire insertion into corresponding cavities, employing machine learning models for recognition and verification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual inspection of cable wire insertion is performed, then human workers can detect insertion errors, but the process becomes tedious and time-consuming with inconsistent results
Solution Approach 1:
The patent replaces the manual mechanical inspection process with an automated machine vision system using cameras and image processing algorithms. The system captures images of the connector housing and cable wires, then automatically analyzes them to verify correct insertion, eliminating the need for tedious manual inspection while maintaining high detection accuracy.
Solution Approach 2:
The inspection system performs self-verification by automatically comparing the captured images against expected insertion patterns and connector specifications. The system independently detects insertion errors without requiring human intervention, enabling the process to self-correct and verify its own accuracy.
2Productivity
If automated machine vision system is implemented, then inspection speed and accuracy improve, but device complexity increases
Solution Approach 1:
The machine vision system is designed to handle multiple connector types and cable wire configurations through a single unified platform. The system can classify different connector housing types and adapt its verification criteria accordingly, reducing the need for multiple specialized inspection devices while maintaining high productivity.
Solution Approach 2:
The patent introduces an image processing intermediary layer that translates physical insertion states into digital analysis. By capturing images and processing them through algorithms, the system creates an intermediate digital representation that simplifies the verification process and reduces the complexity of direct physical measurement and inspection.
3Adaptability or versatility
If connector housing types vary in size and shape with different cable cavity distributions, then customization is achieved, but automatic verification becomes more difficult
Solution Approach 1:
The verification system dynamically adapts its inspection criteria based on the detected connector type. The system first classifies the connector housing type by analyzing the image features, then automatically adjusts the verification parameters and expected patterns according to the specific connector configuration, enabling it to handle various sizes, shapes, and cable cavity distributions without manual reconfiguration.
Solution Approach 2:
The system performs preliminary classification of the connector housing type before conducting the actual insertion verification. By first identifying the connector type and its specific characteristics from the image, the system prepares the appropriate verification criteria in advance, simplifying the subsequent verification process and reducing overall complexity.
Data Source
AI summary
A method for cable wire insertion verification includes receiving, from a camera system, an inspection image of a connector housing held in a housing retainer of a housing inspection system. Via a connector recognition machine vision system, the connector housing is classified as a recognized connector housing type based, at least in part, on a comparison between the inspection image of the connector housing and a template image corresponding to the recognized connector housing type. For one or more cable cavities of the connector housing, the method includes automatically verifying whether a correct cable wire is inserted into the cable cavity according to the recognized connector housing type.