Hairpin Scan Sorting for Insulation Damage Detection
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Solution Overview
Problem
The existing methods for sorting hairpins with damaged insulating films are inefficient and costly, often requiring manual labor, which increases process time and costs.
Innovation Solution
An inspection apparatus that includes a scan module with a scan brush to detect electrical connections and a grasping/feeding module to move hairpins through a scan area, allowing for rapid identification and sorting of defective hairpins with damaged insulating films.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual labor is used to sort hairpins with damaged insulating films, then sorting can be performed, but the process time and costs increase
Solution Approach 1:
The patent replaces manual mechanical inspection with an automated optical inspection system that uses a camera to capture images of the hairpin's shaped portion and automatically detects insulating film damage, thereby eliminating manual labor and reducing process time
Solution Approach 2:
The inspection system enables the hairpin inspection process to perform self-detection and self-sorting of defective products through automated image processing and classification, without requiring external manual intervention
2Reliability
If manual inspection is used to identify defective hairpins, then defective products can be sorted, but the cost for sorting increases
Solution Approach 1:
The patent replaces costly manual inspection with an automated optical inspection system using a camera and image processing algorithms, which provides consistent and reliable detection of insulating film damage while reducing labor costs
Solution Approach 2:
The system creates a visual copy (image) of the hairpin's shaped portion and performs inspection on the copied image data, allowing for accurate defect detection without direct physical contact or manual handling
3Reliability
If additional inspection is performed before shaping, then insulating film damage can be detected, but the process period increases
Solution Approach 1:
The patent performs the inspection action at the most appropriate moment in the manufacturing process - immediately after shaping when the shaped portion is created and the insulating film is most vulnerable to damage, allowing for timely detection without adding extra process time
Solution Approach 2:
The inspection process is merged with the existing manufacturing flow by positioning the camera to inspect the shaped portion as it is being formed or immediately after shaping, combining the shaping and inspection operations into a seamless integrated process
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 apparatus enables rapid and efficient sorting of hairpins, reducing process time and costs by integrating inspection into the manufacturing process, enhancing efficiency and allowing real-time sorting of defective products.
Implementation Method 1
a scan module configured to perform an electrical connection test on a hairpin based on the hairpin passing through a scan area
Data Source
AI summary
A hairpin inspection apparatus includes a base plate, a scan module configured to perform an electrical connection test on an object based on the object passing through a scan area, the scan module including a scanner disposed above the base plate. The apparatus also includes a grasping/feeding module including a grasping unit configured to hold the object. The grasping/feeding module is configured to move the grasping unit along a predetermined closed loop so that the grasped object passes through the scan A controller is configured to determine whether the object passing through the scan area is defective. If the object is determined to be defective, a sorting/collection box receives it from the grasping unit. If the object is determined to be acceptable, a take-out module receives the object from the grasping unit.