Wire Fitting Position Measurement Using Integrated Optical Sensor
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Solution Overview
Problem
Existing devices for fitting electric wire sleeves lack the ability to automatically determine the correct positioning of wire fittings on wires, leading to potential errors in fitting and subsequent processing steps.
Innovation Solution
A device with a movable fitting head that uses a combination of a transmitter and receiver to measure the position and form of the wire fitting during the fitting process, allowing for real-time determination of correct placement without affecting productivity or measurement accuracy, and accommodating wires of varying dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a measurement system is added to determine wire fitting position, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The measurement system (transmitter and receiver) is integrated into the fitting head structure, combining the fitting function and measurement function into a single integrated unit. This reduces overall device complexity while maintaining measurement precision.
Solution Approach 2:
The fitting head is designed to perform multiple functions: both the mechanical fitting operation and the optical measurement of wire fitting position. This multi-functionality eliminates the need for separate measurement devices, reducing system complexity.
2Measurement precision
If quality inspection is performed during backward movement, then measurement accuracy is improved, but productivity decreases
Solution Approach 1:
The measurement process occurs continuously during the necessary backward movement of the fitting head, converting what would be idle time into productive measurement time. This maintains productivity while achieving accurate quality inspection.
Solution Approach 2:
The wire fitting is positioned and secured during the forward movement before the backward measurement movement begins, ensuring the measurement is performed on a properly positioned fitting rather than during the positioning process itself.
3Measurement precision
If the wire end is held stationary during measurement, then measurement precision is improved, but the complexity of wire handling increases
Solution Approach 1:
Instead of moving the wire during measurement, the fitting head is moved backward while the wire remains stationary. This inverts the traditional approach and simplifies the wire handling requirement while maintaining measurement precision.
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 quality inspection of wire fittings without reducing productivity, allowing for immediate detection of fitting errors and release of the wire for further processing, regardless of wire length or dimension.
Implementation Method 1
by means of a combination of a transmitter (101) and receiver (102) the position and form of the wire fitting (17) is measured
Data Source
AI summary
A fitting head has a sleeve receptacle and a widener, the fitting head being displaceable forward/backward in the direction of the longitudinal axis of a wire. Also arranged on the fitting head are a transmitter and a receiver. The transmitter generates a curtain-like beam that is positioned between the sleeve receptacle and the widener and can be measured by the receiver. Like the sleeve receptacle and the widener, transmitter and receiver are displaceable forward/backward in the longitudinal axis of the wire, during the forward movement the wire fitting or sleeve being fitted onto the wire and during the backward movement the sleeve being positionally measured. The movement of the fitting head is measured by a stationary measuring head and a scale that moves together with the fitting head. During evaluation of the measurement results, fitting faults are detected.