Wire Harness Fitting Sound Detection with Optical State Sensing
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Solution Overview
Problem
Existing methods for detecting fitting sounds during the assembly of wire harness components are inaccurate and inefficient, leading to potential manufacturing defects due to improper electrical connections.
Innovation Solution
A fitting sound detection device equipped with a learning model that adapts to different types and locations of fitting members, utilizing an optical sensor and microphone to accurately detect fitting sounds, and a user interface to provide real-time feedback, reducing power consumption through state management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sound data is collected by a wristwatch device worn by a worker, then the fitting sound can be detected, but the detection accuracy is insufficient due to background noise and distance from the fitting location
Solution Approach 1:
The patent introduces a detection device that serves as an intermediary between the fitting operation and the detection system. This device includes a microphone positioned near the fitting location and an optical sensor that detects the fitting state, acting as a mediator to capture accurate fitting sound data while filtering out background noise interference that would affect wristwatch-based detection
Solution Approach 2:
The patent replaces the mechanical wristwatch-based sound detection with an integrated detection system combining acoustic sensing (microphone) and optical sensing. The optical sensor detects the fitting state by measuring light reflection or transmission changes, substituting the purely acoustic wristwatch method with a multi-sensory approach that eliminates background noise interference
2Measurement precision
If a detection device with multiple sensors is used to improve detection accuracy, then fitting sound detection precision increases, but device complexity and power consumption increase
Solution Approach 1:
The patent combines the microphone and optical sensor into a single integrated detection device that performs both acoustic and optical detection functions. This merging of sensing modalities into one unified device improves detection accuracy while avoiding the complexity of managing separate detection systems, as the device processes both signal types through a single controller
Solution Approach 2:
The detection device is designed with multi-functionality, serving both as an acoustic detector (microphone for fitting sound) and an optical detector (optical sensor for fitting state verification). This universal device performs multiple detection functions simultaneously, reducing the need for separate specialized devices and simplifying the overall system architecture
3Reliability
If continuous monitoring is performed to ensure accurate detection, then fitting operation quality improves, but power consumption increases
Solution Approach 1:
The controller performs detection processing periodically or event-driven rather than continuously. The optical sensor monitors the fitting state by detecting light changes that occur only during actual fitting operations, allowing the system to enter low-power states between events while maintaining reliable detection when needed
Solution Approach 2:
The optical sensor enables the system to self-verify the fitting state by detecting physical changes (light reflection/transmission) that occur during fitting. This self-service capability allows the device to confirm successful fitting without continuous active monitoring, reducing power consumption while maintaining quality assurance
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
Enhances the accuracy and efficiency of fitting operations by providing precise detection of fitting sounds, improving workability and reducing manufacturing defects.
Implementation Method 1
an optical sensor that detects light reflected from or transmitted through the wire harness
Implementation Method 2
a microphone that collects sounds
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A fitting sound detection device includes: a microphone (21); a holding member (1) arranged to hold a fitting member provided on an end of a wire harness; a sensor (25) arranged to detect the wire harness in which the fitting member is held by the holding member (1); and control means (26) configured to control execution of a determination process to determine whether or not sound collected by the microphone (21) includes a fitting sound by the fitting member on a basis of sound data based on the sound collected by the microphone (21), wherein the control means (26) is further configured to execute the determination process while the sensor (25) detects the wire harness, and not execute the determination process while the sensor (25) does not detect the wire harness.