Terminal Insertion Quality Monitoring via Acceleration Sensor

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Solution Overview

Problem

Existing methods for monitoring terminal insertion quality into connectors fail to comprehensively assess the entire insertion process, leading to misjudgments and suboptimal manufacturing quality.

Innovation Solution

A terminal insertion quality monitoring system that employs an acceleration sensor on a gripper to detect dynamic acceleration, a control parameter acquisition device to gather equipment data, and an artificial intelligence system to classify insertion modes based on these data, providing real-time quality assessment and optimization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If force sensor detection or camera imaging is used to monitor insertion quality, then measurement capability is improved, but measurement precision is insufficient due to inability to comprehensively reflect the whole insertion process

Engineering Contradiction:

Improveinsertion quality monitoring accuracyVSAvoidinsertion process information

Core Design Contradiction:

Measurement precisionVSLoss of information

Solution Approach 1:

The patent replaces traditional mechanical detection methods (force sensors, camera imaging) with acceleration sensor-based dynamic detection. The acceleration sensor captures dynamic acceleration signals during the terminal insertion process, which are then analyzed to extract insertion quality information. This substitution enables comprehensive monitoring of the entire insertion process rather than only endpoint detection, resolving the information loss problem while maintaining measurement precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If traditional detection methods are used, then device complexity is reduced, but manufacturing precision deteriorates due to misjudgment of insertion quality

Engineering Contradiction:

Improveterminal insertion qualityVSAvoidmonitoring system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent introduces an intermediary analysis system that processes acceleration sensor signals to determine insertion quality. The system includes signal processing modules that analyze dynamic acceleration characteristics and compare them against reference data to classify insertion quality levels. This intermediary layer translates complex acceleration signals into actionable quality assessments, improving manufacturing precision while keeping the overall device architecture manageable through modular design.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If comprehensive insertion process monitoring is implemented, then manufacturing precision is improved, but loss of time increases due to additional detection and analysis steps

Engineering Contradiction:

Improveinsertion quality assessment accuracyVSAvoidquality monitoring time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent implements continuous monitoring of the terminal insertion process using acceleration sensors that capture dynamic acceleration signals throughout the entire insertion sequence. The system continuously analyzes these signals in real-time, enabling ongoing quality assessment rather than discrete endpoint checks. This continuous action approach ensures comprehensive quality monitoring without significant time penalties, as the detection occurs naturally during the insertion process itself.

Inventive Principle:

Principle #20Continuity of useful action

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

This system enables comprehensive monitoring and improvement of terminal insertion quality by accurately classifying insertion modes and optimizing control parameters, enhancing manufacturing quality and reducing errors.

Implementation Method 1

an acceleration sensor disposed on a gripper of a terminal insertion equipment and configured to detect a dynamic acceleration of the gripper

Methodology Applied

Scientific EffectAcceleration detection: Accelerometer

Data Source

PatentUS11204603B2Terminal insertion quality monitoring system

Publication Date: 2021.12.21 TYCO ELECTRONICS (SHANGHAI) CO LTD

AI summary

A terminal insertion quality monitoring system includes an acceleration sensor disposed on a gripper of a terminal insertion equipment and configured to detect a dynamic acceleration of the gripper while using the gripper to insert a terminal into a housing, a control parameter acquisition device configured to acquire a plurality of control parameters of the terminal insertion equipment while inserting the terminal into the housing, and an artificial intelligence system adapted to classify the detected dynamic acceleration and the acquired control parameters into a plurality of different insertion modes by analyzing and calculating the detected dynamic acceleration and the acquired control parameters. The different insertion modes have a plurality of different grades of terminal insertion quality. The artificial intelligence system is configured to monitor a terminal insertion quality of the terminal according to the insertion mode to which the detected dynamic acceleration and the acquired control parameters correspond.