Plated Wire Rod Defect Detection via Skin-Passing and Camera Inspection
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Solution Overview
Problem
The manufacturing of plated wire rods often results in defects such as scratches and peeling of metal plating, leading to increased contact resistance in metal terminals, which complicates the assembly and connection of electrical components, especially as the number of circuits increases in electrical appliances.
Innovation Solution
A manufacturing method and apparatus that utilize a camera inspection device with a light source and imaging mechanism to accurately detect defects on the surface and interface of plated wire rods, allowing for the removal of defects like peeling and scratches, thereby ensuring a high-quality plated wire rod with reduced contact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal plating is applied to conductive metal wire rod, then contact resistance is reduced, but defects such as scratches and peeling occur on the plating surface
Solution Approach 1:
The patent applies skin-passing (a light rolling process) to the plated wire rod before final drawing to prevent defects such as scratches and peeling during subsequent processing. This preliminary action stabilizes the plating layer and prevents harmful defects from occurring during manufacturing.
2Adaptability or versatility
If the number of terminals is increased to accommodate more circuits, then connection capability is improved, but insertion force and assembly workload increase
Solution Approach 1:
The patent changes the surface parameters of the metal terminal by applying metal plating and controlling the alloy layer exposure, which reduces the coefficient of friction. This allows for smoother insertion and reduced assembly force, making it easier to handle even when multiple terminals are present.
3Manufacturing precision
If die-drawing is performed after heat treatment on plated wire rod, then shape precision is improved, but metal plating is scratched or peeled off
Solution Approach 1:
The patent performs skin-passing before die-drawing to preliminarily stabilize the plating layer and prevent scratches and peeling during subsequent die-drawing operations. This preliminary action protects the plating integrity while still allowing shape precision to be achieved.
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 method effectively detects and removes defects, resulting in a plated wire rod with improved contact reliability and reduced contact resistance, enhancing the assembly and connection efficiency of electrical components.
Implementation Method 1
a camera inspection device with a light source and imaging mechanism to accurately detect defects on the surface and interface of plated wire rods
Data Source
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AI summary
A manufacturing method of a plated wire rod, the method including: preparing a plated wire rod precursor including a base material that is wire-drawn and that has a linear shape and a plating film that is provided on a surface of the base material, where the base material is made of first metal and the plating film is made of second metal of a different composition from the first metal; obtaining a plated wire rod-intermediate body by performing skin-passing on the plated wire rod precursor using a die; inspecting, after the skin-passing, for presence/absence of a defect in the plated wire rod-intermediate body using an eddy current testing device and a camera inspection device; and obtaining a plated wire rod by removing the defect in the plated wire rod-intermediate body that is detected in the inspecting.