Vision System for Shield Trim Inspection on Cables
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Solution Overview
Problem
The manual process of trimming and inspecting shielded cables is labor-intensive, prone to errors, and lacks automation, leading to inefficiencies and quality control challenges, especially in ensuring the shield's trim length and integrity meet specifications.
Innovation Solution
A semi-automated and fully automated system utilizing a vision system with multiple cameras and planar reflective surfaces to provide a 360-degree view, performing color and dimensional analysis to evaluate shield trim quality, ensuring compliance with quality control specifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual inspection of shield trim is performed, then quality control can be conducted, but the process is labor-intensive and slow
Solution Approach 1:
The patent replaces manual mechanical inspection with an automated vision system using digital cameras and image processing algorithms. The system captures images of the shield trim and automatically analyzes them to detect defects, broken strands, and measure trim length, eliminating the need for manual visual inspection while maintaining quality control standards.
Solution Approach 2:
The vision system creates a digital copy (image) of the physical shield trim for inspection. By capturing and analyzing images rather than directly examining the physical object, the system enables automated quality assessment without physical contact, improving both speed and consistency of inspection.
2Productivity
If automated processing system is implemented, then productivity increases, but there is no current solution for visually inspecting trimmed shields
Solution Approach 1:
The patent introduces a vision system that uses digital cameras and computer vision algorithms to perform automated inspection of trimmed shields. This optical measurement system replaces the need for manual inspection methods, enabling automated processing systems to detect defects, measure trim lengths, and assess shield quality without human intervention.
Solution Approach 2:
The system changes the inspection parameters by using image processing to analyze various characteristics of the shield trim including color, brightness, trim length, and presence of defects. By transforming physical properties into measurable image parameters, the system enables automated detection and measurement capabilities.
3Area of stationary object
If multiple cameras and mirrors are used to achieve 360-degree view, then inspection coverage is improved, but device complexity increases
Solution Approach 1:
The patent uses mirrors to reflect light and create virtual images of the shield trim from multiple angles, effectively adding spatial dimensions to the inspection field of view. This allows a single camera to capture 360-degree coverage by viewing the object from multiple reflected perspectives simultaneously, avoiding the need for multiple physical cameras.
Solution Approach 2:
The mirrors serve as intermediary elements that mediate between the camera and the shield trim. By placing mirrors at strategic positions, the system enables the camera to indirectly view portions of the shield that would otherwise be inaccessible, achieving comprehensive coverage through optical intermediaries rather than direct line-of-sight from multiple cameras.
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 cycle time, increases quality consistency, and eliminates ergonomic issues, enabling repeatable and consistent quality across end products by automating shield trimming and inspection processes.
Implementation Method 1
The system uses a multiplicity of cameras and a corresponding multiplicity of planar reflective surfaces (hereinafter 'mirrors') in order to achieve a 360-degree view of the area on the cable to be inspected
Implementation Method 2
The system includes a digital camera system and a processing system that receives information from the camera system
Data Source
AI summary
Semi-automated (with manual feeding) and fully automated (with automated feeding) solutions for using a vision system to evaluate shield trim quality on shielded cables. The vision system uses a multiplicity of cameras and a corresponding multiplicity of mirrors in order to achieve a 360-degree view of the cable segment to be inspected. Cables to be inspected are positioned in a repeatable location based on the strip length of the cable (where the edge of the cable jacket is located relative to the end of the cable). The processing system receives a live image feed from the camera system and then uses color and dimensional analysis of the acquired images to determine whether the shield trim meets quality control specifications or not.