Twisted Pair Cable Crimping with AI Vision Position Calibration
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Solution Overview
Problem
Existing crimping technologies face challenges in accurately positioning the conductor core of twisted pair cables due to positional deviations and potential damage to fine conductive wires, leading to unstable crimping quality and difficulty in identifying the actual number of conductive wires.
Innovation Solution
A crimping system utilizing an artificial intelligence vision device to recognize geometric centers and distances of conductor cores, a position calibration device to correct positional deviations, and a crimping device with fixed and movable molds to ensure precise crimping, along with a removal device for unqualified cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a guiding structure is used to guide the conductor core to the correct crimping position, then the crimping process can be performed, but the guiding structure cannot reliably guide the conductor core to the correct crimping position, leading to unstable crimping quality
Solution Approach 1:
The patent replaces the traditional mechanical guiding structure with an artificial intelligence vision system that uses image recognition and calculation to determine the actual positions of conductor cores. The vision device captures images of the conductor cores, calculates their geometric centers and distances, and provides data for position calibration, eliminating the unreliable mechanical guidance while achieving precise positioning through optical measurement and computational analysis.
2Loss of information
If traditional detection methods are used, then the crimping process can proceed, but it is impossible to identify and determine the actual number of fine conductive wires in the conductor core
Solution Approach 1:
The patent employs an artificial intelligence vision device with image recognition algorithms to detect and count the fine conductive wires in the conductor core. The vision device captures high-resolution images, processes them through AI algorithms to identify individual wires, and determines the actual wire count, replacing traditional mechanical or manual detection methods that could not provide this information.
3Productivity
If the conductor core is crimped without accurate position calibration, then the crimping process can be performed quickly, but the conductor core may not be accurately positioned at the predetermined crimping position
Solution Approach 1:
The patent implements position calibration as a preliminary step before crimping. The artificial intelligence vision device first detects the actual positions of the conductor cores, calculates their geometric centers and distances, and determines position deviations from the ideal positions. This calibration information is then used to adjust the crimping process, ensuring accurate positioning before the actual crimping action occurs.
Solution Approach 2:
The system uses feedback from the artificial intelligence vision device to monitor and adjust the conductor core positioning. The vision device continuously detects the actual positions, compares them with the ideal positions, and provides feedback for position calibration. This closed-loop feedback mechanism ensures that the conductor cores are accurately positioned at the predetermined crimping positions while maintaining efficient production节奏.
Data Source
AI summary
A twisted pair cable crimping system includes a cable fixture clamping and fixing a twisted pair cable, a moving device moving the cable fixture, and an artificial intelligence vision device installed at a detection station to recognize an actual position of a pair of geometric centers of a pair of conductor cores of the twisted pair cable and an actual distance between the geometric centers. The crimping system includes a position calibration device calibrating a crimping position of the twisted pair cable based on a position deviation between an actual position and a predetermined ideal position where the actual distance is not less than a predetermined safe distance. A crimping device installed at a crimping station crimps a conductor core onto a terminal fixed at a predetermined crimping position. The geometric center of the conductor core is located on a centerline of the terminal fixed at the predetermined crimping position.