Wire Fitting Measurement Using Contactless Distance Sensors
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Solution Overview
Problem
Existing mechanical devices for measuring the height of wire fittings, such as crimp contacts, face challenges with small crimp contacts due to space constraints and high manufacturing costs for precise mechanisms, and are unable to accurately measure small crimp contacts below 2 mm.
Innovation Solution
A contactless scanning method and device using distance sensors and triangulation to create a surface model of the wire fitting, eliminating the need for mechanical centering and allowing for the measurement of both small and large wire fittings without wear, suitable for manual, semi-automatic, and fully automatic machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mechanical measuring devices are used to measure the height of wire fittings, then measurement capability is provided, but the devices cannot accurately measure small crimp contacts below 2 mm due to space constraints and require very fine and precise mechanisms that increase manufacturing costs
Solution Approach 1:
The patent replaces the mechanical measuring device with an optical measuring device that uses a laser beam to scan the wire fitting. This substitution eliminates the need for fine mechanical mechanisms and centering devices, thereby reducing manufacturing costs while maintaining or improving measurement accuracy for small crimp contacts
Solution Approach 2:
The optical measuring device creates a light profile (optical copy) of the wire fitting cross-section by scanning it with a laser beam. This copying approach allows measurement of the entire wire fitting including small features without requiring physical contact or complex mechanical structures
2Measurement precision
If mechanical measuring devices are used, then height measurement is possible, but the mechanical side and height centering occupy space that prevents measurement of small crimp contacts with conductor crimp lengths below 2 mm
Solution Approach 1:
The patent replaces mechanical centering devices and contact points with an optical scanning system. The laser beam can measure the wire fitting without physical contact, eliminating the space required for mechanical centering structures and enabling measurement of very small crimp contacts
3Reliability
If mechanical measuring devices are used, then measurement can be performed, but wear of the tools processing wire fittings cannot be promptly detected and measurement errors due to incorrect centering occur
Solution Approach 1:
The optical measuring device eliminates mechanical centering mechanisms entirely. The laser scanning system can accurately measure the wire fitting position and dimensions without requiring precise mechanical alignment, thereby improving measurement reliability and enabling detection of tool wear through consistent measurements
Solution Approach 2:
The optical measuring device automatically scans and measures the wire fitting without requiring manual centering or adjustment. The system self-adjusts to measure the actual position of the wire fitting, eliminating errors due to incorrect centering and providing reliable measurements for quality control
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
Enables accurate, wear-free measurement of wire fittings over large areas, eliminating measurement errors and allowing for the detection of tool wear, while reducing manufacturing costs and improving measurement efficiency.
Implementation Method 1
contactless distance measurements...taken in accordance with a scanning pattern...create a surface model
Data Source
AI summary
A method for contactless scanning of a wire fitting wherein the wire fitting is scanned by a first distance sensor and by a second distance sensor. The first distance sensor contactlessly scans the wire fitting, in this case a conductor crimp of a crimp contact, multiple times from below. The second distance sensor contactlessly scans the conductor crimp of the crimp contact from above. From the measurement values with the associated “x”, “y” coordinates, geometrical data of the wire fitting are determined.