Crimp Machine Vision Pre-Check for Terminal Position Validation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing crimp machines face inefficiencies due to the need for post-termination quality checks, which are often destructive and wasteful, especially in high-cost applications like the auto industry, where improper wire or terminal positioning can result in entire wire harnesses being discarded if crimp specifications are not met.
Innovation Solution
A crimp machine equipped with a vision system that performs a validation pre-check by imaging the crimp zone before the crimping process, using computer-readable graphic identifiers and image analysis to ensure proper positioning and die alignment, thereby preventing wasteful crimping operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If post-termination quality checks are performed, then crimp quality is ensured, but time and materials are wasted due to destructive testing and discarding non-conforming terminations
Solution Approach 1:
The patent applies preliminary action by performing validation checks before the crimping operation. The vision system captures images of the wire and terminal positioning prior to crimping, allowing the system to verify correct positioning and prevent defective crimps before they occur, thereby eliminating the need for subsequent destructive testing and material waste.
Solution Approach 2:
The patent replaces mechanical destructive testing methods (pull tests, cross-sectioning) with an optical vision system. The imaging device captures visual data of the termination components, and image analysis algorithms automatically assess positioning quality, substituting physical destruction with non-contact optical inspection.
2Reliability
If post-termination quality checks are performed, then crimp quality is ensured, but material waste increases due to discarding non-conforming terminations
Solution Approach 1:
The vision system performs preliminary validation of wire and terminal positioning before the crimping operation occurs. By detecting positioning errors in advance, the system prevents defective terminations from being created, thereby eliminating material waste from discarded non-conforming parts while maintaining high crimp quality through pre-crimp verification.
3Loss of substance
If vision system performs pre-check validation, then material waste is reduced, but device complexity increases
Solution Approach 1:
The patent introduces a vision system as an intermediary between the positioning stage and crimping operation. This intermediary component captures images and performs automated image analysis to validate positioning, serving as a non-intrusive mediator that prevents defective crimps without requiring complex manual inspection procedures or extensive system redesign.
4Reliability
If imaging device captures image prior to crimping, then pre-check validation is enabled, but processing time may increase
Solution Approach 1:
The vision system is integrated into the crimping machine workflow to perform image capture and analysis continuously during the production process. By embedding the imaging and validation functions within the existing crimping cycle, the system maintains continuous operation without significant interruptions, ensuring validation accuracy while minimizing added processing time through seamless integration.
Data Source
AI summary
A crimp machine is provided and includes an anvil having a lower die having a lower forming surface. The anvil is configured to support a crimp barrel of a terminal that receives a wire. The crimp machine includes a press having an upper die having an upper forming surface. The press is movable relative to the anvil during a crimping process to connect the crimp barrel to the wire. A crimp zone is defined between the upper forming surface and the lower forming surface. The crimp machine includes a vision system positioned to view the crimp zone. The vision system includes an imaging device configured to image the crimp barrel of the terminal and the wire. The vision system operates the imaging device to capture an image prior to the crimping process for performing a validation pre-check prior to the crimping process.