Wire Crimp Quality Detection Using Thermal Sensor Profiles
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Solution Overview
Problem
Existing wire termination monitoring systems primarily rely on force and dimension measurements, which are insufficient for ensuring the quality of crimps, as they do not effectively assess the thermal characteristics of the termination process.
Innovation Solution
A crimping apparatus equipped with thermal sensors that monitor the thermal properties of the crimping zone to determine the quality of the crimp by comparing the collected thermal data to stored profiles, allowing for the identification of defective terminations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If force and dimension measurements are used to monitor wire termination, then the monitoring system is simple to implement, but the quality assessment is insufficient and cannot effectively evaluate thermal characteristics
Solution Approach 1:
The patent replaces mechanical measurement systems (force and dimension sensors) with a thermal measurement system using infrared sensors or thermal cameras. This substitution enables the detection of thermal characteristics during crimping, providing more accurate quality assessment of wire terminations without requiring complex mechanical measurement apparatus.
Solution Approach 2:
The patent monitors temperature as a critical parameter during the crimping process. By tracking thermal characteristics (temperature changes, thermal patterns) instead of relying solely on force and dimension parameters, the system achieves more accurate quality assessment. The thermal parameters provide insight into the actual bonding quality and material behavior during crimping.
2Reliability
If thermal sensors are added to monitor thermal properties, then the quality determination becomes more accurate, but the device complexity increases
Solution Approach 1:
The patent employs non-contact thermal sensing methods (infrared sensors, thermal imaging) that eliminate the need for physical contact with the crimping zone. This approach provides reliable thermal data for quality determination without adding complex mechanical structures or interfering with the crimping process, thus maintaining operational simplicity while improving reliability.
Solution Approach 2:
The patent uses thermal radiation as an intermediary to transfer information about the crimping quality. Instead of directly measuring mechanical properties, the system detects thermal energy emitted from the crimped joint, which serves as a mediator indicating the quality of the termination. This indirect measurement approach simplifies the apparatus structure while enhancing determination reliability.
3Measurement precision
If traditional monitoring methods are used, then the system is easier to operate, but defective terminations cannot be reliably identified
Solution Approach 1:
The patent implements a feedback system where thermal sensor data is continuously monitored and compared against predetermined acceptance criteria. The system automatically provides feedback on whether the termination meets quality standards, enabling reliable defective termination identification. This automated feedback mechanism maintains ease of operation by eliminating the need for manual interpretation of complex thermal data.
Solution Approach 2:
The patent establishes specific thermal parameter thresholds (temperature ranges, thermal patterns) that indicate acceptable versus defective terminations. By monitoring these defined parameters and comparing them against preset criteria, the system achieves reliable defect detection while maintaining operational simplicity through automated decision-making based on clear parameter boundaries.
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 provides a reliable method for assessing crimp quality through thermal analysis, enabling the detection of defective terminations and ensuring proper electrical and mechanical connections without destructive testing, with applications beyond crimping in various termination processes.
Implementation Method 1
The thermal sensor monitors the thermal properties of the crimp made by the applicator
Implementation Method 2
an ultrasonic module transmits acoustic signals through a crimped terminal and a wire onto which it has been crimped
Data Source
Figure 1
Figure 2
AI summary
A crimping apparatus (10) and method which allows for determining the quality of a crimp.The method includes terminating the wire (26), monitoring the thermal properties of the termination with one or more thermal sensors (28) and comparing the monitored thermal properties to stored thermal properties to determine if the termination is defective. If the termination is defective, the termination is discarded. The apparatus (10) includes an applicator (12) which has an anvil (22) and a crimp tool (20) which is movable relative to the anvil (22). The anvil (22) and a crimp tool (20) define a crimping zone (18) of the apparatus (10). A thermal sensor (28) is mounted on the crimping apparatus (10)proximate the applicator (12). The thermal sensor (28) monitors the thermal properties of the crimp made by the applicator (12) to determine if the crimp is defective.