Wire Harness Crimp Inspection Using Test Solution Flow Imaging
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Solution Overview
Problem
In electronic device wiring, insufficient crimping of terminals to electric wires can lead to oxidation, detachment, increased resistance, and heat generation, making it challenging to determine the quality of the crimped state and prevent crimping failures in wire harnesses.
Innovation Solution
A crimping determination device that includes a dropping unit to apply a test solution and an image acquisition unit to assess the crimped state by analyzing the outflow of the solution, using AI analysis to determine the porosity and quality of the crimped connection without damaging the wire harness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional inspection methods are used to determine crimping quality, then the inspection process becomes complex and time-consuming, but the determination accuracy remains insufficient
Solution Approach 1:
The patent applies color change principle by using test solutions that exhibit different colors or fluorescent properties when contacting wire harnesses with different crimping qualities. The image acquisition unit captures these color differences, and the control unit determines crimping quality based on the color analysis, enabling accurate non-contact inspection without complex mechanical processes
Solution Approach 2:
The patent replaces complex mechanical inspection methods with an optical-based system. Instead of using mechanical probes or contact-based measurement devices, the invention uses image acquisition units to capture optical characteristics (color, fluorescence) of the wire harness, and the control unit processes these images to determine crimping quality, significantly simplifying the inspection process
2Measurement precision
If destructive testing methods are used to assess crimped state, then accurate quality determination can be achieved, but the wire harness is damaged and cannot be used
Solution Approach 1:
The patent replaces destructive mechanical testing with non-contact optical inspection. The image acquisition unit captures images of the wire harness without physical contact or damage, and the control unit analyzes these images to accurately determine crimping quality, preserving the wire harness for continued use
Solution Approach 2:
The patent uses color changes as an indicator of crimping quality without damaging the product. Test solutions are applied that change color or exhibit fluorescence based on the crimping state, allowing visual assessment through image capture while keeping the wire harness intact and usable
3Productivity
If manual inspection methods are used to screen wire harnesses, then flexibility in processing can be maintained, but productivity is reduced and time consumption increases
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical inspection system. The image acquisition unit rapidly captures images of wire harnesses, and the control unit automatically processes these images to determine crimping quality, dramatically increasing inspection speed and productivity while eliminating manual labor time
Solution Approach 2:
The patent creates optical copies (images) of the wire harnesses for inspection purposes. The image acquisition unit captures visual information without touching the original product, allowing rapid digital analysis and determination of crimping quality, which is much faster than manual inspection methods
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, non-destructive determination of the crimped state, allowing for effective screening and potential improvement of crimped connections, reducing the risk of shipping wire harnesses with crimping failures and enhancing quality control in manufacturing.
Implementation Method 1
The dropping unit drops a test solution to either one of the first electric wire portion and the second electric wire portion. The image acquisition unit acquires an image including the other one of the first electric wire portion and the second electric wire portion.
Data Source
Figure 1
Figure 2A~2C
Figure 3
AI summary
A crimping determination device (100) according to an embodiment includes a dropping unit (30), an image acquisition unit (40), and a control unit (50). The dropping unit (30) drops a test solution (TS) to a wire harness (10). The wire harness (10) includes a crimped portion (3) in which an electric wire (1) is crimped by a crimping terminal (2), a first electric wire portion (4a) in which the electric wire (1) is exposed on a distal end side, and a second electric wire portion (4b) in which the electric wire (1) is exposed on a proximal end side. The dropping unit (30) drops the test solution (TS) to either one of the first electric wire portion (4a) and the second electric wire portion (4b). The image acquisition unit (40) acquires an image including the other one of the first electric wire portion (4a) and the second electric wire portion (4b). The control unit (50) determines a quality of a crimped state of the crimped portion (3) based on the image.