Pyramid Mirror Wire Inspection System
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Solution Overview
Problem
Current wire inspection techniques are labor-intensive and time-consuming, particularly when dealing with multiple wire types, as they often require manual visual inspection and are limited to single inspection operations, leading to inefficiencies and potential errors in strip and crimp quality.
Innovation Solution
An automated wire inspection system using a simple optical design with a pyramid structure of mirrors and a single or multiple cameras to capture comprehensive side views of wire segments, eliminating self-reflection issues and enabling fast, accurate inspection of multiple wire types without the need for visual character recognition or barcode reading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual visual inspection is used to ensure proper wire processing, then inspection accuracy is maintained, but labor time and costs increase significantly
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical inspection system that uses a camera to capture images of wire segments and processes them through image analysis algorithms. This substitution eliminates the need for human inspectors while maintaining inspection accuracy through automated defect detection capabilities.
Solution Approach 2:
The system creates a visual copy (image) of the wire segment using a camera, then analyzes this copy through image processing to detect defects. This allows inspection without physically handling or moving the wire segment, significantly reducing inspection time while maintaining accuracy.
2Device complexity
If a single camera is used to reduce system complexity, then device complexity is reduced, but the ability to capture comprehensive side views of wire segments is limited
Solution Approach 1:
The patent uses mirror assemblies to reflect light and create multiple viewing angles from a single camera position. The mirrors effectively add spatial dimensions to the viewing capability, allowing the camera to capture side views of wire segments that would otherwise require multiple cameras positioned at different locations.
Solution Approach 2:
The mirror assembly acts as an intermediary between the single camera and the wire segment, redirecting light paths to provide comprehensive side views. This intermediary component enables one camera to perform the function of multiple cameras without increasing system complexity.
3Adaptability or versatility
If traditional inspection systems are used for multiple wire types, then versatility is reduced, but system complexity is also reduced
Solution Approach 1:
The patent designs the inspection system with universal capabilities to inspect multiple wire types including stripped wires, crimped wires, and connectors. The image processing algorithms are configured to recognize and inspect different wire configurations, enabling a single system to perform multiple inspection functions without requiring separate specialized systems for each wire type.
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 system significantly reduces labor costs, increases inspection speed and accuracy, and can be integrated with existing machines to quickly detect defects, improving overall efficiency and reliability in wire processing.
Implementation Method 1
a mirror assembly that includes a pyramid of mirrors arranged to reflect light from the wire segment to the camera
Implementation Method 2
The wire segment is illuminated using a light source, and a plurality of images are acquired
Data Source
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AI summary
A wire inspection system (600) is provided. The wire inspection system includes a mirror assembly (602) including an odd number of sides (606) arranged to form a pyramid structure configured to surround a wire segment (304, 402, 404, 406, 502, 504, 506), wherein a plurality of the sides include a mirror (604), a light source (612) configured to illuminate the wire segment, and at least one camera (610) configured to acquire a plurality of images of the wire segment that are reflected by the plurality of mirrors, wherein each image of the plurality of images shows a different side of the wire segment.