Optical Crimp Monitoring for Pre-Crimp Sleeve Alignment Checks
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Solution Overview
Problem
Existing crimping quality assurance methods, such as force/displacement monitoring, are inadequate for identifying the cause of undesirable crimp quality and do not effectively prevent reject crimps or reduce unnecessary time expenditure.
Innovation Solution
A method utilizing optical sensors and evaluation electronics to acquire and compare image data of contact sleeves and cables with reference data, allowing for pre-crimping checks to ensure proper alignment and dimensions, and post-crimping monitoring of crimp quality through force/displacement curve analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If force/displacement monitoring is used during crimping, then crimping process parameters can be measured, but the cause of undesirable crimp quality cannot be identified
Solution Approach 1:
The patent applies preliminary action by capturing images of the contact sleeve and cable before crimping occurs. This allows the system to record the initial state of components, enabling later comparison to determine whether defects existed before crimping or were caused by the crimping process itself, thereby identifying the root cause of quality issues
Solution Approach 2:
The patent uses optical imaging to create visual copies of the contact sleeve and cable at different stages (before and after crimping). These image copies serve as records that can be analyzed and compared to identify defects and their causes, providing information that force/displacement measurements alone cannot provide
2Productivity
If conventional quality assurance methods are used, then crimping process can continue without interruption, but reject crimps cannot be prevented and unnecessary time is spent on faulty crimps
Solution Approach 1:
The patent implements feedback by continuously monitoring crimping images and comparing them against reference data or previously captured images. When defects are detected, the system can immediately signal for process adjustment or rejection of faulty crimps, preventing waste of time on rework while maintaining high throughput through automated real-time quality control
Solution Approach 2:
By capturing images before crimping and comparing pre-crimp and post-crimp images, the system can identify defects before they result in reject crimps. This preliminary detection allows for immediate correction or rejection, preventing unnecessary time expenditure on faulty crimps while maintaining production flow
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
Significantly reduces inadequate crimp quality by preventing faulty crimps and identifying material or operational issues, thereby enhancing crimping efficiency and reducing waste, making the process more reliable and economical.
Implementation Method 1
a first optical sensor for acquiring and/or recording first image data of the contact sleeve
Data Source
AI summary
A method is provided for ensuring and/or checking the quality of a crimping using a crimping machine for crimping a cable with a contact sleeve and using a first optical sensor for detecting and/or recording first image data of the contact sleeve and using an evaluation electronics system. The method includes detecting the first image data of the contact sleeve by the first optical sensor; carrying out, via the evaluation electronics system, a first comparison of the first image data of the first optical sensor with first reference data of a predetermined contact sleeve; checking the first comparison for the presence of a predetermined first criterion; and, if the predetermined first criterion is satisfied, outputting a first signal. The detection of the first image data and the first comparison and the checking for the first criterion and the output of the first signal are carried out before the cable is crimped with the contact sleeve. A crimping machine suitable for carrying out the above method is also provided.