Wire Contact Insertion Verification Using Image Feedback

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Solution Overview

Problem

Manual and automated wire contact insertion processes in wire bundle assemblies are time-consuming and prone to errors, leading to increased costs and quality defects, while existing automated techniques may improperly insert wire contacts, halting the process and requiring correction.

Innovation Solution

A computer-implemented method and system using image acquisition devices and computing devices to visually identify and confirm that a wire contact is fully inserted and seated within the correct wire contact insertion hole, providing feedback through adaptive thresholding and triangulation to ensure proper insertion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If automated wire insertion techniques are used, then productivity is improved, but manufacturing precision deteriorates due to improper insertion

Engineering Contradiction:

Improveassembly speedVSAvoidinsertion accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system captures images of the wire contact insertion hole before and after insertion, processes these images to detect the wire contact's presence and depth, and provides feedback to determine whether the wire contact is fully inserted. This closed-loop feedback mechanism enables automated insertion while maintaining high precision through visual verification.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces manual visual inspection and mechanical measurement methods with an automated image processing system. The system uses image capture devices and computational algorithms to detect wire contact insertion status, substituting mechanical measurement tools and human operators with an automated optical detection system.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If manual wire insertion is used, then manufacturing precision is maintained, but productivity deteriorates due to time consumption

Engineering Contradiction:

Improveinsertion accuracyVSAvoidassembly speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The system performs self-verification by automatically capturing images, processing them through algorithms, and determining insertion status without requiring external inspection. The wire contact insertion process includes built-in visual verification that autonomously confirms proper insertion, eliminating the need for separate manual inspection steps.

Inventive Principle:

Principle #25Self-service

3Productivity

If automated wire insertion is used, then productivity is improved, but reliability deteriorates due to improper insertion and process halts

Engineering Contradiction:

Improveassembly speedVSAvoidinsertion reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system captures an image of the wire contact insertion hole before the wire contact is inserted, establishing a reference state. This preliminary image capture allows the system to compare the post-insertion state against the pre-insertion state, enabling reliable detection of proper insertion and preventing process continuation if insertion is improper.

Inventive Principle:

Principle #10Preliminary action

4Manufacturing precision

If visual verification is implemented, then manufacturing precision is improved, but device complexity increases

Engineering Contradiction:

Improveinsertion verification accuracyVSAvoidsystem complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent extracts only the critical visual information needed for insertion verification from the complex image data. By focusing specifically on detecting the wire contact's presence and depth within the insertion hole, the system achieves high verification accuracy while avoiding the complexity of comprehensive image analysis of the entire assembly.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentEP4266138B1Method and system for machine determining wire contact insertion

Publication Date: 2025.12.31 THE BOEING CO

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AI summary

A method, system and computer program product are provided for determining wire contact insertion based on image analysis. Methods include: acquiring at least one image of a connector having a plurality of wire contact insertion holes; identifying a wire contact within a wire contact insertion hole of the plurality of wire contact insertion holes; determining that the wire contact insertion hole is a correct wire contact insertion hole; determining that the wire contact has been fully inserted into the correct wire contact insertion hole; and providing feedback indicating that the wire contact is fully inserted into the correct wire contact insertion hole. The feedback includes in some cases a first indicator indicating that the wire contact is in the correct wire contact insertion hole and a second indicator indicating that the wire contact is fully inserted into the correct wire contact insertion hole.