Crimp Terminal Inspection Using Gradation Illumination

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Solution Overview

Problem

Existing appearance inspection devices for crimp terminals face difficulties in detecting deformation due to uniform illumination, which leads to halation issues, making it hard to assess deformed portions effectively.

Innovation Solution

The device employs a planar gradation light source with varying brightness applied through a light diffusion plate, allowing the illumination to change directionally, which is reflected on the crimp terminal's surface, enabling cameras to capture images that differentiate between deformed and non-deformed states by altering brightness patterns.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If uniform illumination light is applied onto the crimp terminal, then the illumination is even and complete, but it causes halation and makes it difficult to detect deformed portions

Engineering Contradiction:

Improveillumination uniformityVSAvoiddeformation detection accuracy

Core Design Contradiction:

Illumination intensityVSMeasurement precision

Solution Approach 1:

The illumination device uses a light diffusion plate with a gradation pattern where different regions have different light transmission characteristics. The plate includes a first region with higher light transmission and a second region with lower light transmission, creating non-uniform illumination that adapts to different areas of the crimp terminal to enhance deformation detection while preventing halation in critical areas.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The light diffusion plate modifies the illumination parameters by creating a gradation pattern with varying light transmission rates across different regions. This parameter change transforms uniform illumination into directional, non-uniform illumination that improves the contrast and visibility of deformed portions on the crimp terminal surface.

Inventive Principle:

Principle #35Parameter changes

2Illumination intensity

If bright illumination is applied to the entire crimp terminal, then the overall visibility is improved, but halation occurs on deformed portions making them harder to check

Engineering Contradiction:

Improveoverall brightnessVSAvoidhalation

Core Design Contradiction:

Illumination intensityVSObject-affected harmful factors

Solution Approach 1:

The light diffusion plate creates localized illumination zones with different intensities. The first region provides brighter illumination for areas requiring higher visibility, while the second region provides softer illumination to prevent halation on deformed portions, thus addressing both overall visibility and halation prevention through spatially differentiated light transmission.

Inventive Principle:

Principle #3Local quality

3Device complexity

If uniform light is used for illumination, then the inspection process is simple, but gentle unevenness and deformation are difficult to detect

Engineering Contradiction:

Improveillumination system simplicityVSAvoiddeformation detection capability

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The light diffusion plate serves as an intermediary component between the light source and the crimp terminal. It transforms simple uniform light into complex directional illumination with gradation patterns, enhancing deformation detection capability while maintaining a relatively simple overall device structure. The plate acts as a passive optical element that modifies light distribution without requiring complex control systems.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

This approach allows for accurate detection of terminal deformation by varying brightness, distinguishing between fair-quality and defective products without human intervention, while reducing halation and improving determination accuracy, especially for bent stabilizers.

Implementation Method 1

a light diffusion plate 15...transmits light from the flat light source 12 while diffusing the light

Methodology Applied

Scientific EffectLight diffusion: Diffusion

Implementation Method 2

the camera C1, C3 is disposed at a position at which the gradation light source 15 appears, as a reflected image on a surface of the crimp terminal (T)

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentUS11236994B2Appearance inspection device of crimp terminal

Publication Date: 2022.02.01 YAZAKI CORP

AI summary

The appearance inspection device inspects an appearance of a crimp terminal by capturing an image of the crimp terminal with a camera while applying illumination light onto the crimp terminal. The device includes an illumination unit for applying illumination light onto a crimp terminal and cameras that capture an image of the crimp terminal. A planar gradation light source having brightness that gradually changes in a predetermined direction from one side on an illumination surface toward another side is provided as the illumination unit. The cameras are disposed such that the gradation light source is reflected on an image obtained by the camera capturing the image of the crimp terminal, as a reflected image on a surface of the crimp terminal.