JP2017009469A - Device for detection of terminal crimping failure - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enable a highly accurate decision to be performed in a short processing time using narrow range image data as an image for deciding a terminal crimping failure.SOLUTION: Image data of a range R from an end part of a terminal tip end side of an insulation barrel 21 of an electric wire with a terminal to the end part of the insulation barrel of a wire barrel 22 is obtained by a camera, and a crimping failure of the terminal which appears inside and outside of the range is detected on the basis of the image data. Whether or not the top end of a core wire 11 of the insulation electric wire is at an appropriate position is decided on the basis of the result in which whether or not the top end of the insulation coating 12 is located at a predetermined position and the result in which whether or not a removal of an insulation coating of the electric wire is appropriate by setting an inspection frame Rso as to surround an end edge of the insulation coating on the basis of brightness of each pixel inside the inspection frame Rin the image data.SELECTED DRAWING: Figure 7

Description

  The present invention relates to a terminal crimping failure detection device for inspecting the attachment state of a terminal of a terminal-attached electric wire with a terminal attached to an end of an insulated wire.

  FIG. 8 is a diagram illustrating a terminal mounting portion of a terminal-attached electric wire. In FIG. 8, 1 is an insulated wire, 11 is its core wire, 12 is an insulation coating, 2 is a terminal, 21 is an insulation barrel, 22 is a wire barrel, and 23 is a terminal tip.

  Such an electric wire with a terminal is manufactured by a terminal crimping apparatus. At that time, the insulated wire 1 is cut to a predetermined length, and the insulating coating 12 at the end is peeled off by a certain length, and then sent to a terminal crimping device together with the terminal 2 having a predetermined shape, and the terminal 2 is connected to the end of the insulated wire 1. Is mounted and is pressed from above to compress and attach the portions of the insulating barrel 21 and the wire barrel 22 of the terminal 2 to a predetermined shape. Such an operation is continuously repeated to automatically manufacture a large amount of electric wires with terminals.

  In such a terminal crimping apparatus, when the terminal is crimped, the position of the terminal 2 with respect to the insulated wire 1 may be shifted and attached, and depending on the direction of the shift, it can be divided into deep hitting and shallow hitting. As shown in FIG. 9 (A), the end of the core wire 11 protrudes excessively from the wire barrel 22 as shown in FIG. On the other hand, as shown in FIG. 9B, the shallow hitting is a state where the tip of the core wire 11 is hidden in the wire barrel 22.

  Moreover, due to the relationship between the core wire 11 and the wire barrel 22, there is also a crimp failure called core wire overlap and core wire spillage. Among them, the core wire overlap means a state in which a part of the core wire 11 is overlapped on the wire barrel 22 as shown in FIG. Further, the core wire spillage refers to a state in which a part of the core wire 11 has protruded from the wire barrel 22 as shown in FIG. Further, as shown in FIG. 10C, as a result of the core wire overlap and core wire spill, a part of the core wire 11 protrudes from the wire barrel 22 and turns to the back side of the wire barrel 22. Sometimes.

  If such a crimp failure occurs, it must be detected and eliminated. Therefore, for example, as disclosed in Patent Document 1, a technique has been developed in which a terminal crimping state is identified by processing an image obtained by photographing the terminal crimping state with a camera to detect a crimping failure.

  FIG. 11 is a diagram illustrating a method of detecting a crimp failure in a conventional terminal crimp failure detection apparatus. While the terminal-attached electric wire with the terminal crimped by the terminal crimping device is conveyed by the conveying device, the terminal portion is photographed by the camera to obtain the image P. Then, based on the shape of the terminal in the image P, X and Y reference coordinate axes are set, and detection frames a, b, c, d,... As shown in FIG.

  The detection frames a, b, c, and d are for detecting an abnormal position of the terminal. The detection frames are scanned in the vertical direction in the figure to detect the degree of luminance change, and based on this, the deep and shallow strike states of the terminals are detected.

  The detection frames e, f, and g are for detecting core line spillage from the wire barrel 22, and the core line spillage is determined depending on whether or not there is any pixel having a certain luminance or higher in the detection frame. Detect the presence or absence.

Next, a method for detecting an abnormality in each part will be described.
(1) Deep hammering Deep hammering means that the position where the insulating barrel 21 grips the insulating coating 12 of the insulated wire 1 is too deep, as shown in FIG. 9A, which is detected by the detection frames b and d. To do. In a normal state, since the core wire 11 in which a large number of thin wires are bundled is present in the detection frame b, the number of luminance changes increases in the direction across the electric wire. Further, since the flat plate portion of the terminal 2 is located in the detection frame d, the luminance change is reduced in the direction crossing the electric wire.

  On the other hand, in the deep hit state, the insulating coating 12 is exposed to the other end of the insulating barrel 21 and the tip of the core wire 11 is also exposed to the other end of the wire barrel 22. Therefore, in the detection frame b, the change in luminance is reduced in the direction crossing the electric wire because of the insulating coating 12. Further, since the core wire 11 is in the detection frame d, the luminance change increases in the direction crossing the electric wire.

  Therefore, the detection frames b and d are scanned in the direction crossing the electric wire to obtain the luminance at each position, and the rise of the luminance from the valley portion exceeds the predetermined width, and the luminance from the peak portion decreases beyond the predetermined width. When the count number is less than the predetermined number in the detection frame b, it is determined that the insulation coating 12 is present, and the determination of “defective” is performed. Further, in the detection frame d, when the count number exceeds a predetermined number, it is determined that the core wire 11 is present there, and “defect” is determined. Also in this case, since the determination is made based on the number of changes in luminance, even if there is a slight twist in the electric wire with terminal and the interval between the peaks and valleys of the luminance change fluctuates, it can be detected without any problem.

(2) Shallow hammering As shown in FIG. 9B, shallow hammering refers to a state where the insulating barrel 21 is too shallow to grip the insulating coating 12 of the insulated wire 1 and is detected by the detection frames a and c. In a normal state, since the insulating coating 12 is present in the detection frame a, the number of luminance changes in the detection frame a is reduced in the direction across the electric wire. In addition, since there is a core wire 11 in which a plurality of fine wires are twisted in the detection frame c, the luminance changes every time the thin wires are crossed, and the number of luminance changes increases.

  On the other hand, the insulation coating 12 is not exposed to the other end of the insulating barrel 21 and the tip end portion of the core wire 11 is not exposed to the other end of the wire barrel 22 in the shallow hit state. Therefore, since the core wire 11 exists in the detection frame a, the luminance change increases in the direction across the electric wire. Further, since the core wire 11 is not present in the detection frame c, the luminance change is reduced in the direction across the electric wire.

  Therefore, the detection frames a and c are scanned in the direction crossing the electric wire to obtain the luminance at each position, and the rise from the valley of the luminance exceeds the predetermined width and the reduction from the peak of the luminance beyond the predetermined width. The number of occurrences is counted, and pass / fail is determined based on whether or not the count exceeds a predetermined number. When the count number exceeds a predetermined number in the detection frame a, it is determined that the core wire 11 is present there, and “defect” is determined. Further, in the detection frame c, when the count number is less than the predetermined number, it is determined that the core wire 11 does not come out there, and “defect” is determined. As described above, since the determination is made based on the number of changes in luminance, even if there is a slight twist in the electric wire with terminal and the interval between the peaks and valleys of the luminance change fluctuates, it can be detected without any problem.

(3) Core wire spillage As shown in Fig. 10 (B), core wire spillage is a state in which a part of the core wire 11 protrudes from an originally empty part, and is detected by the detection frames e, f, and g. To do. In the detection frames e, f, and g, there is nothing originally and should be a single background color, but when a part of the core wire 11 protrudes, an image appears there. Therefore, if any one of the detection frames e, f, and g has a certain luminance or higher, a “defective” determination is made.

  If it does in this way, the crimping | compression-bonding defect of the terminal of an electric wire with a terminal can be detected automatically.

JP 2011-174719 A

  However, since the conventional terminal crimping failure detection device needs to set the detection frames a, b, c, d,... In a wide range, the image P for determination is included so that all of them are included. As a result, there is a problem that a wide range of images is required, and therefore, a defective portion in the image is imaged small, which causes a decrease in determination accuracy. On the other hand, if the resolution of the image is increased, the accuracy of the determination can be improved. However, if an attempt is made to increase the resolution of the image using a high-pixel camera, the number of pixels to be processed becomes enormous, and the captured image Since data processing takes time, there is a limit to increasing the resolution.

  In addition, of the core wire spillage, the core wire may turn to the back side of the wire barrel so that it traces the surface of the terminal. To detect such defects, the spilled core wire passes through the detection frame for detecting core wire spillage. There is a risk of being undetectable. Therefore, in order to detect a defect in which the core wire has turned to the back side of the wire barrel, there is a problem that another camera is required for photographing the back side of the wire barrel.

  Moreover, although there is no description in particular in patent document 1 about the detection of a core line overlap, it will usually determine with it being defective when a core line is detected on the image of a wire barrel part. However, depending on the position of the core wire on the wire barrel, it is difficult to detect the core wire. In particular, the joints of the left and right wire barrels are often shaded on the image, and the core wire is detected at that portion. There is a problem that it is almost impossible to do. In particular, when the surface of the wire barrel and the core wire are the same color, the core wire and the wire barrel cannot be distinguished from each other by color, which makes it more difficult to detect the core wire overlap.

  In view of such problems, the present invention makes it possible to perform highly accurate determination in a short processing time using image data in a narrow range as an image for determination, and the core wire goes around the back side of the wire barrel. The purpose is to make it possible to detect a failure that has occurred with a single camera and to easily detect the overlap of core wires.

  In order to solve the above-mentioned problem, the invention according to claim 1 of the present application removes the insulating coating on the end of the insulated wire, crimps the insulating barrel of the terminal to the end of the insulating coating, and removes the insulating coating. A terminal crimping failure detection apparatus for a terminal-attached electric wire in which a wire barrel of the terminal is crimped to an exposed core wire portion, and the wire barrel from an end portion of the terminal end side of the insulating barrel of the electric wire with terminal by an imaging unit The image data in a range up to the end of the insulating barrel is acquired, and the crimping failure of the terminal appearing inside and outside the range is detected based on the image data.

  The invention according to claim 2 of the present application is the invention according to claim 1, wherein in the image data, an inspection frame is set so as to surround an end of the wire barrel on the electric wire side, and each of the inspection frames in the inspection frame is set. Based on the luminance of the pixel, it is determined whether or not the edge line is continuous, and the presence or absence of core line overlap is determined.

Further, the invention according to claim 3 of the present application is the invention according to claim 1, wherein in the image data, an inspection frame is set so as to surround an edge of a terminal side portion between the insulating barrel and the wire barrel, Based on the luminance of each pixel in the inspection frame, it is determined whether or not the edge side line of the terminal side portion is continuous, and the presence or absence of core spillage is determined.

  Further, the invention according to claim 4 of the present application is the invention according to claim 1, wherein before the crimping of the terminal, it is determined whether or not the removal of the insulation coating of the wire was appropriate by the wire terminal inspection device, and In the image data, an inspection frame is set so as to surround the edge of the insulating coating, and whether or not the edge of the insulating coating is at a predetermined position based on the luminance of each pixel in the inspection frame. It discriminate | determines and it is determined whether the front-end | tip of the core wire of the said insulated wire exists in the appropriate position of a terminal based on the discrimination | determination result and the discrimination | determination result of the said electric wire terminal inspection apparatus.

The present invention has the following effects.
That is, in the invention according to claim 1, image data in a range from the end portion on the terminal end side of the insulating barrel to the end portion on the insulating barrel side of the wire barrel is acquired by the imaging unit. Then, on the basis of the image data, the crimping failure of the terminal appearing inside and outside the range is detected. As a result, an image for determination appears outside the above-mentioned range using image data in a narrow range from the end on the terminal end side of the insulating barrel to the end on the insulating barrel side of the wire barrel of the electric wire with terminal. High accuracy determination can be performed in a short processing time including defective crimping of terminals.

  According to a second aspect of the present invention, in the terminal crimping defect detecting device according to the first aspect, in the image data, an inspection frame is set so as to surround an end of the wire barrel on the electric wire side. Based on the luminance of each pixel, it is determined whether or not the edge lines are continuous, and the presence or absence of core line overlap is determined. As a result, it is easy to detect the overlap of the core wires.

  According to a third aspect of the present invention, in the terminal crimping defect detecting device according to the first aspect, in the image data, an inspection frame is provided so as to surround an edge of a terminal side portion between the insulating barrel and the wire barrel. Based on the brightness of each pixel in the inspection frame, it is determined whether or not the line at the edge of the terminal side is continuous, and the presence or absence of core spillage is determined. As a result, not only is it easy to detect core wire spillage, but it is also possible to detect defects in which the core wire has turned to the back side of the wire barrel with a single camera.

  Further, in the invention according to claim 4, in the terminal crimping defect detecting device according to claim 1, it is determined whether or not the removal of the insulation coating of the wire was appropriate by the wire terminal inspection device before crimping the terminal. In the image data, an inspection frame is set so as to surround the edge of the insulation coating, and the edge of the insulation coating is in a predetermined position based on the luminance of each pixel in the inspection frame. It is determined whether or not the tip of the core wire of the insulated wire is at an appropriate position of the terminal based on the determination result and the determination result of the wire terminal inspection device. As a result, it is possible to determine the tip position of the core wire of an insulated wire based on a narrow range of image data from the end of the insulated barrel terminal to the end of the insulated barrel side of the wire barrel. Therefore, it is possible to detect deep and shallow strikes accurately and easily.

It is a figure which shows the terminal crimping process of the electric wire with a terminal. It is a figure which shows the imaging range in this invention. It is a figure which shows an electric wire terminal inspection apparatus. It is a figure which shows the determination method of a core line overlap. It is a figure which shows the luminance change at the time of performing the scan of FIG. It is a figure which shows the determination method of a core wire spill. It is a figure which shows the determination method of the core wire position with respect to a terminal. It is a figure which shows the terminal attachment part of an electric wire with a terminal. It is a figure which shows the state of deep strike and shallow strike. It is a figure which shows the state of a core wire overlap and a core wire spill. It is a figure which shows the detection frame in the conventional terminal crimping defect detection apparatus.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

  FIG. 1 is a diagram illustrating a terminal crimping process of a terminal-attached electric wire. In the strip process A, the insulating coating 12 at the end of the insulated wire 1 cut to a predetermined length is peeled off by a certain length. In the subsequent strip miss detection step B, image data of the end portion of the insulated wire 1 from which the insulation coating has been peeled off in the strip step A is acquired, and the length of the exposed portion of the core wire is within a predetermined range based on the image data. It is determined whether or not there is.

  For example, the image data of the edge part of the insulated wire 1 is acquired through an electric wire terminal inspection apparatus as shown in FIG. This electric wire terminal inspection apparatus 3 is provided with a laser light source 4 at the tip lower portion 3a, and is provided with a light detector 5 at the tip upper portion 3b across the space 3c so as to face the laser light source 4. The photodetector 5 is composed of a line CCD 6 in which a large number of pixels are arranged in a straight line. The laser light source 4 irradiates a laser beam L toward the light detector 5.

  In such an electric wire terminal inspection device 3, the electric wire end portion to be inspected is moved in the horizontal direction in the space portion 3 c in a state parallel to the pixel arrangement direction of the line CCD 6. At that time, the control unit 7 repeatedly scans each pixel of the line CCD 6 at a high speed, and at each line scan, receives data indicating whether or not the laser beam has been sensed from each pixel. A two-dimensional image is acquired, and the end of the wire is inspected based on the two-dimensional image.

  In addition, although the thing of the system shown in FIG. 3 was demonstrated as an example as an electric wire terminal inspection apparatus, the length of the exposed part of the core wire of the insulated electric wire 1 which peeled insulation coating is in a predetermined range. For example, the image data of the end portion of the insulated wire 1 with the insulation coating peeled off is acquired using a camera, and the length of the exposed portion of the core wire is obtained based on the image data. It is also possible to discriminate them.

  In this way, the insulated wire 1 in which the length of the portion where the core wire is exposed is determined to be within a predetermined range in the strip miss detection step B is sent to the terminal crimping step C to attach the terminal. In the terminal crimping step C, the insulated wire 1 is fed into a terminal crimping device together with the terminal 2 having a predetermined shape, the terminal 2 is mounted on the end of the insulated wire 1 and placed, and pressed from above, thereby insulating the barrel 21 of the terminal 2. The wire barrel 22 is compressed and attached to a predetermined shape.

  Thus, the insulated wire 1 having the terminal attached to the end in the terminal crimping step C is sent to the defect detection step D to inspect the terminal attachment state.

  As shown in FIG. 2, the terminal crimping failure detection device used in the failure detection step D uses a camera to connect the end of the wire barrel 22 to the end of the wire barrel 22 from the end of the wire barrel 22 to the end of the wire barrel 22. The image data of the narrow range R up to is acquired, and the crimping failure of the terminal mainly appearing in the portion other than the range R such as core line overlap, core line spill, deep hit, shallow hit is detected based on the image data. In this way, high-precision determination can be performed in a short processing time using image data with a small data amount.

Hereinafter, detection of terminal crimp failure by the terminal crimp failure detection apparatus of the present invention will be described. Detection is performed by setting X and Y reference coordinate axes based on the shape of the terminal in the image data in the range R, setting an inspection frame based on the reference coordinate axes X and Y, and scanning the inspection frame. To do.

(1) Detection of Core Line Overlap FIG. 4 is a diagram showing a method for determining core line overlap. The reference numerals correspond to those in FIG. The image data of the range R, to set the inspection frame R ₁ into a position surrounding the wire-side edge of the wire barrel 22. Then, in order to the inspection frame R ₁ toward the bottom from the top, by scanning in the lateral direction, measuring the difference in brightness between adjacent pixels.

FIG. 5 is a diagram showing a change in luminance when the scan of FIG. 4 is performed. If there is a luminance change that exceeds the threshold as shown in FIG. 5A, it is determined that there is an edge, and if there is no luminance change that exceeds the threshold as shown in FIG. Judge that there is no edge. Therefore, the inside of the inspection frame R ₁ of FIG. 4 from the uppermost in the order toward the bottom, when scanning in the horizontal direction, in a portion where the core wire 11 is wrapped in a wire barrel 22, the edges of the wire barrel 22 Incidentally, as shown in FIG. 5A, a luminance change exceeding the threshold appears, and it is determined that there is an edge there. On the other hand, at the place where the core wire 11 overlaps the wire barrel 22, the edge is not detected as shown in FIG.

Therefore, in order to the inspection frame R ₁ toward the bottom from the top, by scanning in the lateral direction, first to the edge is detected at the end from the detection, an edge is detected continuously in the same position If there is no portion where the core wire 11 overlaps the wire barrel 22, it can be determined that “the core wires do not overlap”. On the other hand, if a line where no edge is detected appears between the first edge detection and the last detection, the core wire 11 overlaps the wire barrel 22 at that point. It can be determined that there is a core line overlap.

(2) Detection of core wire spillage FIG. 6 is a diagram showing a method of determining core wire spillage. The reference numerals correspond to those in FIG. The image data of the range R, to set the inspection frame R ₂ so as to surround the edge of the terminal side between the insulation barrel 21 and the wire barrel 22. Then, in order to the inspection frame R ₂ from insulation barrel 21 side to the wire barrel 22 side, by scanning in a direction crossing the terminal edge, measuring the difference in brightness between adjacent pixels.

The test frame R ₂ of FIG. 6, is scanned sequentially from the insulating barrel 21 side to the wire barrel 22 side, in the absence of core 11 spilled location, at the edge of the terminal side, FIG. 5 (A) Thus, a luminance change exceeding the threshold appears, and it is determined that there is an edge there. On the other hand, at a portion where the spilled core wire 11 is present, an edge is not detected as shown in FIG.

Thus, the inside of the inspection frame R _2, in order from the insulating barrel 21 side to the wire barrel 22 side, by scanning in a direction crossing the terminal edge, until the first edge is detected at the end from the detection of the same If the edge is detected continuously at the position, there is no spillage of the core wire 11, so it can be determined that there is no spillage of the core wire. On the other hand, if a line in which no edge is detected appears, there is a spillage of the core wire 11 at that point, so it can be determined that “the spilling of the core wire is present”.

Further, among the core wire spills, the core wire 11 may turn to the back side of the wire barrel 22 so as to trace the surface of the terminal. Since 11 does not pass through the detection frame for detecting core spillage, there is a possibility that it cannot be detected. On the other hand, in the present invention, determination is made based on whether or not the core wire 11 crosses the edge of the terminal. In order for the core wire 11 to turn to the back side of the wire barrel 22, the core wire 11 is always connected to the terminal edge. In accordance with the present invention, another one for shooting the back side of the wire barrel 22 is used.
Even if a camera is not provided, it is possible to detect a defect in which the core wire 11 has turned to the back side of the wire barrel 22.

(3) Detection of deep hitting and shallow hitting FIG. 7 is a diagram showing a method of determining the core wire position with respect to the terminal. The reference numerals correspond to those in FIG. In the image data in the range R, the inspection frame R ₃ is set so as to surround the edge of the insulating coating 12. Then, in order to the inspection frame R ₃ towards the bottom from the top, by scanning in the lateral direction, measuring the difference in brightness between adjacent pixels.

The inside inspection frame R ₃ in FIG. 7 in order toward the bottom from the top, is scanned in the lateral direction, at the edge of the insulating coating 12 of the insulated wire 1, as shown in FIG. 5 (A), the threshold A luminance change exceeding 1 appears, and it is determined that there is an edge there. By performing repeated such scan the inspection frame R ₃ from top to bottom, is seen the position of the edge of the insulating coating 12 of the insulated wire 1.

  On the other hand, in this insulated wire 1, it has been confirmed that the length of the portion where the core wire is exposed is within a predetermined range in the strip miss detection step B. Therefore, it can be determined whether or not the end of the core wire 11 is at an appropriate position of the terminal depending on whether or not the end edge of the insulating coating 12 of the insulated wire 1 is at a predetermined position.

  It is determined whether or not the edge of the insulation coating is in a predetermined position, and based on the determination result and the determination result of the wire terminal inspection device, the tip of the core wire of the insulated wire is at the appropriate position of the terminal. Determine if there is

1 Insulated wire 11 Core wire 12 Insulation coating 2 Terminal 21 Insulating barrel 22 Wire barrel 23 Terminal tip

Claims (4)

The insulation coating of the end of the insulated wire is removed, the terminal insulation barrel is crimped to the end of the insulation coating, and the terminal wire barrel is crimped to the exposed core portion by removing the insulation coating. A terminal crimping failure detection device,
The imaging means obtains image data in a range from the terminal end side end of the insulating barrel to the end of the wire barrel on the insulating barrel side of the electric wire with terminal, and based on the image data, the range A terminal crimping defect detecting device that detects a crimping defect of a terminal that appears inside and outside the terminal.   In the image data, an inspection frame is set so as to surround an end of the wire barrel on the electric wire side, and based on the luminance of each pixel in the inspection frame, whether the edge line is continuous or not is determined. The terminal crimping failure detection device according to claim 1, wherein the terminal crimping failure detection device determines and determines whether or not core wires overlap.   In the image data, an inspection frame is set so as to surround an edge of the terminal side portion between the insulating barrel and the wire barrel, and the edge of the terminal side portion is set based on the luminance of each pixel in the inspection frame. 2. The terminal crimping defect detection device according to claim 1, wherein it is determined whether or not the line is continuous and whether or not the core wire is spilled is determined.   Before crimping the terminal, determine whether or not the insulation coating of the wire has been properly removed by a wire terminal inspection device, and set an inspection frame to surround the edge of the insulation coating in the image data. Based on the luminance of each pixel in the inspection frame, it is determined whether the edge of the insulating coating is at a predetermined position, and based on the determination result and the determination result of the wire terminal inspection device The terminal crimping defect detection device according to claim 1, wherein it is determined whether or not a tip of the core wire of the insulated wire is at an appropriate position of the terminal.

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