Wire Conductor Evaluation Using Conductive Brush Current Measurement
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Solution Overview
Problem
There is a need for an efficient method to evaluate the integrity and electrical conductivity of insulated wire segments used in electronic devices, as existing methods do not effectively differentiate between acceptable and unacceptable wire segments based on their conductivity levels.
Innovation Solution
A system and method involving passing the insulated portion of the wire segment through an electrically conductive brush with an established potential, determining the conducted current, comparing it to a predetermined value, and directing accepted or rejected segments to separate areas using a conveyor and controller, with the option of automated processing and DC power source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional wire evaluation methods are used, then the evaluation process is simple, but the ability to differentiate between acceptable and unacceptable wire segments based on conductivity levels is insufficient
Solution Approach 1:
The patent replaces traditional mechanical or visual inspection methods with an electrical field-based measurement system. A conductive brush establishes an electrical potential across the wire segment, and current flow is measured to evaluate conductivity. This substitution enables precise differentiation of conductivity levels while maintaining operational simplicity through automated measurement and sorting mechanisms.
2Productivity
If manual wire segment sorting is used, then the equipment complexity is low, but the productivity and sorting accuracy are insufficient
Solution Approach 1:
The system enables wire segments to be automatically evaluated and sorted based on their inherent electrical conductivity properties. The conductive brush automatically establishes electrical contact, measures current flow, and the controller automatically directs segments to appropriate bins based on measured values. This self-service approach eliminates manual inspection and sorting, significantly improving productivity while the automation handles the complexity of differentiation.
3Measurement precision
If high electrical potential is applied to the brush, then the conductivity measurement sensitivity is improved, but the energy consumption and potential damage to wire segments increases
Solution Approach 1:
The system utilizes changes in electrical potential and current measurement parameters to optimize conductivity detection. By adjusting the electrical potential applied through the conductive brush and measuring the resulting current flow, the system achieves sensitive conductivity differentiation. The controller processes these electrical parameter changes to determine acceptance or rejection of wire segments, enabling precise measurement while managing energy consumption through controlled potential application.
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 method allows for the accurate evaluation and sorting of wire segments based on their conductivity, ensuring only acceptable segments are used in electronic devices, thereby improving the reliability and efficiency of internal connections.
Implementation Method 1
an electrical potential is established on the brush by a power source. The method also includes determining a value of electrical current that is conducted through the wire segment by the brush when the potential is established on the brush
Data Source
AI summary
A method of evaluating an electrically conductive wire segment having an insulated intermediate portion and non-insulated ends includes passing the insulated portion of the wire segment through an electrically conductive brush. According to the method, an electrical potential is established on the brush by a power source. The method also includes determining a value of electrical current that is conducted through the wire segment by the brush when the potential is established on the brush. The method additionally includes comparing the value of electrical current conducted through the wire segment with a predetermined current value to thereby evaluate the wire segment. A system for evaluating an electrically conductive wire segment is also disclosed.