FORM 2
THE PATENT ACT 1970
&
The Patents Rules, 2003
COMPLETE SPECIFICATION
10 (See section 10 and rule 13)
1. TITLE OF THE INVENTION:
“A System for Determining the Details of A Physical Parameter of Crimps”.
APPLICANT(s):
Name Nationality Address
AGAIN DIGITECH PVT.
LTD.
Indian
Company
FT-G 202, Sudarshan Appt.,
Karve Nagar, Pune - 411052,
Maharashtra, India.
2. PREAMBLE TO THE DESCRIPTION:
PROVISIONAL
The following specification describes the
invention.
COMPLETE
The following specification
particularly describes the invention
and the manner in which it is to be
performed
2
Field 5 of the invention
[0001] The present invention relates to crimps. More specifically,
the present invention relates to a system for determining the details of a physical
parameter of crimps.
10
Background of the invention:
[0002] A crimp is a solderless electrical connection formed by
combining multiple wire strands and is typically used to terminate a stranded
15 wire. The process of formation of crimp is called as “crimping”. Multiple small
wires are grouped in electrical application to form a wire segment. Crimping is
normally performed by first inserting the wire segment end into a crimp tool, and
the crimping tool is manually pressed. Further, the crimps are connected to
external connectors based on the application. The most common application of
20 crimps is in wire harnesses, where multiple wires are crimped and connected to a
connector end, and such multiple connector ends are collectively connected to a
connector end.
[0003] The crimping process provides a common terminal for two
25 or more wires, and all the wires, which are crimped together may act as a single
electrical conductor. The crimping process alters the physical parameters or
geometry of metal wire, such as thickness, length etc., due to compression. As the
electrical parameters such as potential difference, current, resistance, and the like
depend on the metal wire's geometry, the crimping causes a significant amount of
30 resistance to the flow of electric current through the metal wire.
[0004] Due to the problems mentioned above, there is a drop in
electrical parameters such as voltage, resistance, inductance etc., across the crimp.
Also, the connector end attached to the crimp has some air gap therebetween (no
3
perfect physical contact). Hence, there is a need to measure 5 the efficiency of the
crimp to determine the suitability of the crimp for a specific application.
[0005] Presently, various testing systems and methods are
available for testing crimps in the wire harnesses. The system and methods
10 include physical inspection techniques such as manual inspection, measuring the
strength of the crimp by applying an external force (as mentioned in the patent
application CN1025393C), capturing the images of the crimp and image
processing etc. (as mentioned in patent application US6442498B1). Also, the
presently used systems include a complex setup for inspecting the crimp by a
15 physical measurement and are difficult to operate. Further, some of the present
methods utilize destructive testing for measuring the physical parameters such as
air gap, width, thickness etc. of the crimps, which results in wastage of material.
Also, for measuring the crimp's physical parameters, there is a need to perform a
separate measurement cycle for each wire segment, which makes the process time
20 consuming.
[0006] Therefore, there is a need for a system for determining the
details of the physical parameters of crimps, which overcomes the prior art
problems.
25
Objects of the invention
[0007] An object of the present invention is to provide a system
for determining the details of a physical parameter of crimps.
30
[0008] Another object of the present invention is a system for
determining the details of a physical parameter of crimps, which eliminates the
need for destructive testing of crimps to measure physical parameters.
4
[0009] Yet another object of the present 5 invention is a system for
determining the details of a physical parameter of crimps, which reduces the time
consumed in testing multiple crimps for each physical parameter.
[0010] Yet another object of the present invention is to provide a
10 system for determining the details of a physical parameter of crimps in wire
harnesses, wherein the system eliminates the cost required for arranging the setup
for manual physical testing of the crimps and is easy to operate.
15 Summary of the invention
[0011] The present invention relates to a system for determining
the details of a physical parameter of crimps. More specifically, the present
system relates to the measurement of crimps in wire harnesses. The system may
20 include an electrical parameter supply unit adapted to supply one or more
electrical parameters therefrom to a first wire segment and a second wire
segment, when the first wire segment and the second wire segment connected
thereto, and the electrical parameter supply unit operated accordingly. The second
wire segment can be substantially identical to the first wire segment. The first
25 wire segment can have a first crimp formed between a first connector end and the
first wire segment. The second wire segment can have a second crimp formed
between a second connector end and the second wire segment.
[0012] Further, the system may include a measuring unit having a
30 first measuring pin and a second measuring pin. In a first measurement cycle, the
first measuring pin can be adapted to have a first physical contact with the first
wire segment at a first position. The first position can be between the first crimp
and a first distal end of the first connector end with a predefined first distance
therebetween. The second measuring pin can be adapted to have a second
35 physical contact with the first wire segment at a second position. The second
5
position may be in between the first crimp and a first wire 5 segment distal end with
a predefined second distance therebetween.
[0013] When a first predefined quantity of electrical parameter is
supplied to the first wire segment, the measuring unit can measure the quantity of
10 electrical parameter between the first and second positions. Subsequently, in a
second measurement cycle, the first measuring pin can be adapted to have a third
physical contact with the second wire segment at a third position. The third
position can be between the second crimp and a second distal end of the second
connector end with a predefined third distance therebetween. The magnitude of
15 the predefined first distance and the predefined third distance can be the same.
Further, the second measuring pin can be adapted to have a fourth physical
contact with the second wire segment at a fourth position. The fourth position can
be between the second crimp and a second wire segment distal end with a
predefined fourth distance therebetween. The magnitude of the predefined second
20 distance and the predefined fourth distance can be the same.
[0014] When a second predefined quantity of electrical parameter
is supplied to the second wire segment, the measuring unit can measure the
quantity of electrical parameters between the third and fourth positions. The
25 quantity of the first predefined quantity of electrical parameters and the second
predefined quantity of electrical parameters can be the same.
[0015] Further, a workstation can be connected to the measuring
unit. The measuring unit can send information about measured electrical
30 parameters from the first measurement cycle and the second measurement cycle
to the workstation. The first crimp can be a pre-accepted efficient crimp, wherein
the details of a first physical parameter of the first crimp can be prestored within
the workstation and the measured electrical parameter in the first measurement
cycle can be a standard quantity of electrical parameter. The workstation can be
35 adapted to compare the received measured electrical parameters of the first
6
measurement cycle and the second measurement cycle to determine 5 the details of
a second physical parameter of the second crimp. Further, a display unit can be
connected to the workstation. The display unit can be adapted to display the
details of the second physical parameter of the second crimp.
10 [0016] Further, the present invention also provides a method for
determining the details of a physical parameter of crimps. The method comprises
steps of supplying one or more electrical parameters to a first wire segment and to
a second wire segment by an electric parameter supply unit by connecting the first
wire segment and the second wire segment thereto and operating the electrical
15 parameter supply unit accordingly, making a first physical contact between a first
measuring pin of a measuring unit and a first position, making a second physical
contact between a second measuring pin of the measuring unit and a second
position, measuring the quantity of electrical parameters between the first position
and the second position by the measuring unit upon supplying a first predefined
20 quantity of electrical parameters to the first wire segment.
[0017] Further, making a third physical contact between the first
measuring pin and a third position over the second wire segment, making a fourth
physical contact between the second measuring pin and a fourth position over the
25 second wire segment, measuring the quantity of electrical parameters between the
third position and the fourth position by the measuring unit upon supplying a
second predefined quantity of electrical parameters to the second wire segment.
30 [0018] Further, sending information about measured electrical
parameters of the first wire segment and the second wire segment to a workstation
connected to the measuring unit, comparing the received information about
measured electrical parameters of the first wire segment and the second wire
segment by the workstation, comparing the received information about measured
35 electrical parameters of the first wire segment and the second wire segment and
7
determining the details of a second physical parameter 5 of the second crimp by a
workstation, and displaying the details of the second physical parameter of the
second crimp by a display unit connected to the workstation.
[0019] Further, the present invention also discloses an embodiment
10 of a system for determining the details of a physical parameter of crimps. The
system may include an electrical parameter supply unit adapted to supply one or
more electrical parameters therefrom to a first wire segment and to a second wire
segment when the first wire segment and the second wire segment connected
thereto, and the electrical parameter supply unit operated accordingly. The second
15 wire segment can be substantially identical to the first wire segment. The first
wire segment can have a first crimp formed between a first connector end and the
first wire segment. The second wire segment can have a second crimp formed
between a second connector end and a second wire segment.
20 [0020] Further, the system may include a first measuring unit
having a first measuring pin and a second measuring pin. The first measuring pin
may be adapted to have a first physical contact with the first wire segment at a
first position. The first position can be between the first crimp and a first distal
end of the first connector end with a predefined first distance therebetween. The
25 second measuring pin can be adapted to have a second physical contact with the
first wire segment at a second position. The second position can be between the
first crimp and a first wire segment distal end with a predefined second distance
therebetween. When a first predefined quantity of electrical parameters is
supplied to the first wire segment, the first measuring unit can measure the
30 quantity of electrical parameters between the first and second positions.
[0021] Further, the system may include a second measuring unit
having a third measuring pin and a fourth measuring pin. The third measuring pin
can be adapted to have a third physical contact with the second wire segment at a
35 third position. The third position can be between the second crimp and a second
8
distal end of the second connector end with a predefined 5 third distance
therebetween. The magnitude of the predefined first distance and the predefined
third distance can be the same. The fourth measuring pin can be adapted to have a
fourth physical contact with the second wire segment at a fourth position. The
fourth position can be between the second crimp and a second wire segment distal
10 end with a predefined fourth distance therebetween. The magnitude of the
predefined second distance and the predefined fourth distance can be the same.
[0022] When a second predefined quantity of electrical parameters
is supplied to the second wire segment, the second measuring unit can measure
15 the quantity of electrical parameters between the third and fourth positions. The
quantity of the first predefined quantity of electrical parameters and the second
predefined quantity of electrical parameters can be the same. A workstation can
be connected to the first measuring unit and the second measuring unit. The first
measuring unit and the second measuring unit can send information about
20 measured electrical parameters of the first wire segment and the second wire
segment to the workstation. The first crimp can be a pre-accepted efficient crimp,
wherein the details of a first physical parameter of the first crimp can be prestored
within the workstation and the measured electrical parameter of the first wire
segment can be a standard quantity of electrical parameter.
25
[0023] The workstation can be adapted to compare the received
measured electrical parameters of the first wire segment and the second wire
segment to determine the details of a second physical parameter of the second
crimp. Further, a display unit can be connected to the workstation. The display
30 unit can be adapted to display the details of the second physical parameter of the
second crimp.
[0024] Further, the present invention also provides an embodiment
of a method for determining the details of a physical parameter of crimps. The
35 method comprises steps of supplying one or more electrical parameters to a first
9
wire segment and to a second wire segment by an electrical 5 parameter supply unit
when the first wire segment and the second wire segment connected thereto and
the electrical parameter supply unit operated accordingly, making a first physical
contact between a first measuring pin of a first measuring unit and a first position
over the first wire segment,
10
[0025] Further, making a second physical contact between a
second measuring pin of the first measuring unit and a second position over the
first wire segment, measuring the quantity of electrical parameters between the
first position and the second position by the first measuring unit upon supplying a
15 first predefined quantity of electrical parameters to the first wire segment by the
electrical parameter supply unit, making a third physical contact between a third
measuring pin of the second measuring unit and a third position over the second
wire segment.
20 [0026] Further, making a fourth physical contact between a fourth
measuring pin of the second measuring unit and a fourth position over the second
wire segment, measuring the quantity of electrical parameters between the third
position and the fourth position by the second measuring unit upon supplying a
second predefined quantity of electrical parameters to the second wire segment by
25 the electric parameter supply unit, sending information about measured electrical
parameters of the first wire segment and the second wire segment to a workstation
by the first measuring unit and the second measuring unit respectively, comparing
the received measured electrical parameters of the first wire segment and the
second wire segment to determine the details of a second physical parameter of
30 the second crimp by the workstation and displaying the details of the second
physical parameter of the second crimp by a display unit connected to the
workstation.
35
10
Brief description 5 of drawings:
[0027] The advantages and features of the present invention will
be understood better with reference to the following detailed description and
claims taken in conjunction with the accompanying drawings, wherein like
10 elements are identified with like symbols, and in which:
[0028] Figure 1a shows a sectional view of a first crimp in
accordance with the present invention;
15 [0029] Figure 1b shows a sectional view of a second crimp in
accordance with the present invention;
[0030] Figure 2 shows a schematic block diagram of an
embodiment of a system for determining the details of a physical parameter of
20 crimps in accordance with the present invention;
[0031] Figure 3 shows a schematic block diagram of an
embodiment of a system for determining the details of a physical parameter of
crimps in accordance with the present invention;
25
[0032] Figure 4 shows a flow chart of an embodiment of a method
for determining the details of a physical parameter of crimps in accordance with
the present invention;
30 [0033] Figure 5 shows a schematic block diagram of an
embodiment of a system for determining the details of a physical parameter of
crimps in accordance with the present invention; and
11
[0034] Figure 6 shows a flow chart 5 of a method for determining
the details of a physical parameter of crimps in accordance with the present
invention.
10 Detailed description of the invention
[0035] An embodiment of this invention, illustrating its features,
will now be described in detail. The words "comprising," "having," "containing,"
and "including," and other forms thereof, are intended to be equivalent in
15 meaning and be open-ended in that an item or items following any one of these
words is not meant to be an exhaustive listing of such item or items or meant to
be limited to only the listed item or items.
[0036] The terms “first,” “second,” and the like, herein do not
20 denote any order, quantity, or importance, but rather are used to distinguish one
element from another, and the terms “a” and “an” herein do not denote a
limitation of quantity, but rather denote the presence of at least one of the
referenced items.
25 [0037] The disclosed embodiments are merely exemplary of the
invention, which may be embodied in various forms.
[0038] The present invention relates to a system for determining
the details of a physical parameter of crimps. In the present embodiment, the
30 invention relates to a system for determining details of a physical parameter of
crimps in wire harnesses. The present system applies to any electrical crimp used
in multiple electrical circuits or applications. The system provides a clear
interpretation of the details of the physical parameter of the crimp than the
manual physical inspection methods. The system eliminates the need for
12
destructive testing of crimps to measure physical parameters. 5 Also, the system
reduces the time consumed in testing multiple crimps for each physical
parameter. Also, the system involves a reduction in setup cost due to compact size
and simple construction.
10 [0039] Referring to figure 2, a system (100a) for determining the
details of a physical parameter of crimps is illustrated in accordance with the
present invention. The system (100a) includes an electrical parameter supply unit
(10), a first wire segment (20c), a second wire segment (30c), a measuring unit
(40), a workstation (210) and a display unit (13). In the preferred embodiment,
15 the first wire segment (20c) is substantially identical to the second wire segment
(30c) i.e. one of the physical parameters of the wire segments such as length,
width is (are) unequal and other physical parameters are identical in both the first
wire segment (20c) and second wire segment (30c).
20 [0040] The first wire segment (20c) has a first crimp (20a) formed
between a first connector end (20b) and the first wire segment (20c), as shown in
figure 2. Also, the second wire segment (30c) has a second crimp (30a) formed
between a second connector end (30b) and the second wire segment (30c) as
shown in figure 3. The first connector end (20b) and the second connector end
25 (30b) are hollow metallic ends having crimped metal wires fixed therein to
establish a connection with an external connector housing.
[0041] The electrical parameter supply unit (10) is adapted to
supply one or more electrical parameters therefrom to the first wire segment (20c)
30 and the second wire segment (30c) connected thereto when the electrical
parameter supply unit (10) is operated accordingly. In the preferred embodiment,
the electrical parameter supply unit (10) is a voltage source or a current source or
a frequency supply unit. The electric parameter supply unit (10) has an interface
for controlling the operation of the electric parameter supply unit (10) such as
35 making the electrical parameter supply unit (10) ON-OFF, changing the type of
13
supply parameter between voltage, current, frequency etc. 5 The interface for
controlling the operation of the electric parameter supply unit (10) is a manually
operated or electronically operated control module.
[0042] The electrical parameters supplied to the first wire segment
10 (20c) and the second wire segment (30c) are voltage or current or frequency in
the preferred embodiment. The measurement operation of the physical parameters
of the crimps is performed in two measuring cycles, a first measurement cycle
(220) as shown in figure 2 and a second measurement cycle (230) as shown in
figure 3. The second measurement cycle (230) is performed after the first
15 measurement cycle (220).
[0043] In the preferred embodiment, the measuring unit (40) is a
voltmeter or an ammeter or an LCR meter or a multimeter or an oscilloscope. The
measuring unit (40) has a first measuring pin (40a) and a second measuring pin
20 (40b). A distance (40f) between the first measuring pin (40a) and the second
measuring pin (40b) is adjustable. During the first measurement cycle (220), the
first measuring pin (40a) is adapted to have a first physical contact (140) with the
first wire segment (20c) at a first position (50), as shown in figure 2.
25 [0044] The first position (50) is over a metal surface (51) of the
first wire segment (20c). The first position (50) is between the first crimp (20a)
and a first distal end (20d) of the first connector end (20b) as shown in figure 2.
In the preferred embodiment, there is a predefined first distance (80) between the
first crimp (20a) and the first position (50).
30
[0045] Further, the second measuring pin (40b) is adapted to have
a second physical contact (150) with the first wire segment (20c) at a second
position (60), as shown in figure 2. The second position (60) is between the first
crimp (20a) and a first wire segment distal end (20e). The first wire segment
35 distal end (20e) is an end part of the insulation covering over the first wire
14
segment (20c), as shown in figure 2. There is a predefined 5 second distance (90)
between the first crimp (20a) and the second position (60).
[0046] During the operation of the first measurement cycle (220),
the electric power supply unit (10) supplies a first predefined quantity of
10 electrical parameter to the first wire segment (20c). In the preferred embodiment,
the first predefined quantity of electrical parameter supplied to the first wire
segment (20c) is an electromotive force or a frequency of an electric current or a
combination of these.
15 [0047] The measuring unit (40) measures the quantity of electrical
parameters between the first position (50) and the second position (60). The
electric parameter measured between the first position (50) and the second
position (60) is a potential difference or an electric current, resistance, inductance,
or impendence.
20
[0048] Further, the operation of the second measurement cycle
(230) occurs subsequent to the first measurement cycle (220). The second
measurement cycle (230) is shown in figure 3. The first measuring pin (40a) of
the measuring unit (40) is adapted to have a third physical contact (160) with the
25 second wire segment (30c) at a third position (70).
[0049] The third position (70) is between the second crimp (30a)
and a second distal end (30d) of the second connector end (30b) as shown in
figure 3. There is a predefined third distance (110) between the second crimp
30 (30a) and the third position (70). In the preferred embodiment, the magnitude of
the predefined first distance (80) and the predefined third distance (110) is the
same as shown in figure 3.
[0050] Further, the second measuring pin (40b) is adapted to have
35 a fourth physical contact (170) with the second wire segment (30c) at a fourth
15
position (180). The fourth position (180) is between the 5 second crimp (30a) and a
second wire segment distal end (30e) as shown in figure 3. The fourth position
(180) is over a metal surface (52) of the second wire segment (30). The second
wire segment distal end (30e) is at the edge of the insulation over the second wire
segment (30c) as shown in figure 3. The magnitude of the predefined second
10 distance (90) and the predefined fourth distance (190) is the same in the preferred
embodiment.
[0051] Further, the electric parameter supply unit (10) supplies a
second predefined quantity of electrical parameter to the second wire segment
15 (30c). The second predefined quantity of electrical parameter supplied to the
second wire segment (30c) is an electromotive force or a frequency of an electric
current or a combination of these. The measuring unit (40) measures the quantity
of electrical parameters between the third position (70) and the fourth position
(180). The quantity of electrical parameters between the third position (70) and
20 the fourth position (180) is a potential difference or an electric current or a
resistance or an inductance or an impendence In the preferred embodiment, the
quantity of the first predefined quantity of electrical parameters supplied to the
first wire segment (20c) and the second predefined quantity of electrical
parameters supplied to the second wire segment (30c) is the same.
25
[0052] Further, the workstation (210) receives the measured
electrical parameters of the first measurement cycle (220) and the second
measurement cycle (230). In the preferred embodiment, the first crimp (20a) is a
pre-accepted efficient crimp and the measured electrical parameter in the first
30 measurement cycle (220) is a standard quantity of electrical parameter. The
details of a first physical parameter of the first crimp (20a) are prestored in the
workstation (210). Generally, according to industry standards, the standard first
crimp (20a) may be symmetric, may have compact strands and the height (14) to
width (15) ratio may be within range of 55% to 70%.
35
16
[0053] The details of the first physical parameter 5 of the first crimp
(20a) are the quantitative and qualitative parameters of the first crimp (20a). The
quantitative parameters of the first crimp (20a) are magnitudes of height, width,
air gap, no. of wire strands crimped together, tensile strength etc. and the
qualitative parameters of the first crimp (20a) are the percentage efficiency of the
10 first crimp (20a), indication regarding whether the first crimp (20a) is defective or
acceptable etc. In the preferred embodiment, the quantitative parameters of the
first crimp (20a) are height (14), width (15) and air gap (16) as shown in figure
1a.
15 [0054] The workstation (210) includes a processing unit (11) and a
memory unit (12) for storing the measured electrical parameters received from the
first measurement cycle (220) and the second measurement cycle (230). In the
preferred embodiment, the workstation (210) has a user interface such as
keyboard or mouse or buttons to control the operation of the system (100a) such
20 as switching the system (100a) between ON-OFF, calibration, switching the unit
of measurement (i.e. ampere, microampere, volt, millivolt) etc.
[0055] The processing unit (11) is a microcontroller or a
microprocessor or a controller or a processor or a logic controller and the memory
25 unit (12) is a cloud server or a hard drive or an IOT device. In the preferred
embodiment, the workstation (210) is connected to an authentication system (not
shown in the figure). The authentication system is a biometric system such as a
fingerprint sensor or a face recognition system or a password-protected system.
The authentication system is adapted to provide access of the system (100a) to an
30 authenticated user only when the authentication system is operated accordingly.
[0056] The workstation (210) is adapted to compare the received
measured electrical parameters of the first measurement cycle (220) and the
second measurement cycle (230) to determine the details of a second physical
35 parameter of the second crimp (30a). In the preferred embodiment, the details of
17
the second physical parameter of the second crimp (30a) 5 are the quantitative and
qualitative parameters of the second crimp (30a) as shown in figure 1b. The
quantitative parameters of the second crimp (30a) are height, width, air gap
(volume), no. of wire strands crimped together, tensile strength etc. and the
qualitative parameters of the second crimp (30a) are the percentage efficiency of
10 the second crimp (30a), indication regarding whether the second crimp (30a) is
defective or acceptable etc.
[0057] In the preferred embodiment, the quantitative parameters of
the second crimp (30a) are height (17), width (18) and air gap (19) as shown in
15 figure 1b. The workstation (210) performs a comparison between the physical
parameter of the first crimp (20a) with the electrical parameters of the first crimp
(20a) that are measured by the measuring unit (40). The prestored details of the
first physical parameter of the first crimp (20a) are determined by standard
measuring methods such as manual or photographic inspection and manually
20 stored in the workstation (210) as a reference value.
[0058] The magnitude of the air gap is measured by any standard
measuring method. For example – let us take the air gap of magnitude 0.5mm3 be
the first physical parameter of the first crimp (20a). The measuring unit (40)
25 measures the voltage drop across the first crimp (20a) as 5V. Hence, the
workstation (210) stores the value of 0.5 mm3 air gap for 5V voltage drop across
the first crimp (20a).
[0059] The details of comparison of the first measurement cycle
30 (220) and the second measurement cycle (230) are updated in the cloud server of
the memory unit (12) in real-time. The real-time measurement of the electrical
parameters means the actual time or instantaneous measurement when the system
(100a) is operating.
18
[0060] Further, a display unit (13) is 5 connected to the workstation
(210). In the preferred embodiment, the display unit (13) is a screen or a monitor.
The display unit (13) is adapted to display the details of the second physical
parameter of the second crimp (30a). The second physical parameter of the
second crimp (30a) is displayed as a numerical value of the height or width or air
10 gap or no. of wire strands within the second crimp (30a), tensile strength etc. or a
percentage value of the efficiency of the second crimp (30a) with respect to the
first crimp (20a).
[0061] For example, the electrical parameter supply unit (10)
15 supplies a current of 5 microamperes to the first wire segment (20c) and the
second wire segment (30c). In the first cycle of the measurement (220), the first
measuring pin (40a) of the measuring unit (40) is made in contact with the first
position (50) over the first wire segment (20c) at a distance (80) of 5mm from the
first crimp (20a) and the second measuring pin (40b) is made in contact with the
20 second position (60) at distance (90) of 3 mm from the first crimp (20a). The
measuring unit (40) measures the potential difference across the first position (50)
and the second position (60) as 5V.
[0062] The value measured by the measuring unit (40) is sent to
25 the workstation (210) and stored in the memory unit (12). The values of the first
physical parameters of the first crimp (20a) such as length of 100 cm, a width of
5mm, a height of 4 mm, an air gap of 0.5mm, a tensile strength of 20Mpa etc. are
prestored in the workstation. The workstation (210) stores the value 5V as a
standard value of the electrical parameter for the first crimp (20a) for a specific
30 set of measured values of the first physical parameters of the first crimp (20a).
[0063] Subsequently, in the second measurement cycle (230), the
measuring unit (40) measures the potential difference between the third position
(70) and the fourth position (180) of the second wire segment (30c) and send the
35 measured value to the workstation (210). The measured value of the potential
19
difference between the third position (70) and the 5 fourth position (180) is
measured as 3.5 V. Here, the first crimp (20a) is the standard crimp. The
workstation (210) compares the value 3.5 V with the voltage value 5V measured
for the first crimp (20a) and calculates the value of the second physical parameter,
for example, air gap within the second crimp (30a) to be 1mm and displays the
10 calculated results on the display unit (13).
[0064] Also, the display unit (13) calculates the efficiency of the
second crimp (30a) as (3.5/5) * 100 = 70%. Further, based on the efficiency value
of the second crimp (30a), a signal indicating whether the second crimp (30a) is
15 defective or acceptable is also displayed on the display unit (13). The signal may
include an “ERROR” message on displayed on the display unit (13) or a light
indicator which shows light of red colour in case of defective second crimp (30a).
[0065] Referring now to the figure 4, a method (200a) for
20 determining the details of a physical parameter of crimps in accordance with the
present invention is illustrated. For the sake of brevity, the method (200a) is
described in conjunction with the system (100a).
[0066] The method (200a) starts at step 210.
25
[0067] At step 211, the electric parameter supply unit (10) supplies
one or more electrical parameters to the first wire segment (20c) and the second
wire segment (30c) by connecting the first wire segment (20c) and the second
wire segment (30c) thereto and operating the electrical parameter supply unit (10)
30 accordingly. The second wire segment (30c) is substantially identical to the first
wire segment (20c). The first wire segment (20c) is having the first crimp (20a)
formed between the first connector end (20b) and the first wire segment (20c), the
second wire segment (30) is having the second crimp (30a) formed between the
second connector end (30b) and the second wire segment (30c).
35
20
[0068] At step 212, the first physical 5 contact (140) is made
between the first measuring pin (40a) of the measuring unit (40) and the first
position (50). The first position (50) is between the first crimp (20a) and a first
distal end (20d) of the first connector end (20b) with a predefined first distance
(80) therebetween.
10
[0069] At step 213, the second physical contact is made between
the second measuring pin (40b) and the second position (60). The second position
(60) is between the first crimp (20a) and a first wire segment distal end (20e) with
a predefined second distance (90) therebetween.
15
[0070] At step 214, the quantity of electrical parameters between
the first position (50) and the second position (60) is measured by the measuring
unit (40) upon supplying a first predefined quantity of electrical parameters to the
first wire segment (20c).
20
[0071] At step 215, the third physical contact (160) is made
between the first measuring pin (40a) and the third position (70). The third
position (70) is between the second crimp (30a) and the second distal end (30d) of
the second connector end (30b) with a predefined third distance (110)
25 therebetween and the magnitude of the predefined first distance (80) and the
predefined third distance (110) is same.
[0072] At step 216, the fourth physical contact (170) is made
between the second measuring pin (40b) and the fourth position (180). The fourth
30 position (180) is between the second crimp (30a) and the second wire segment
distal end (30e) with a predefined fourth distance (190) therebetween and the
magnitude of the predefined second distance (90) and the predefined fourth
distance (190) is same.
21
[0073] At step 217, the measuring unit 5 (40) measures the quantity
of electrical parameters between the third position (70) and the fourth position
(180) upon supplying a second predefined quantity of electrical parameters to the
second wire segment (30c). The quantity of the first predefined quantity of
electrical parameters supplied to the first wire segment (20c) and the second
10 predefined quantity of electrical parameters supplied to the second wire segment
(30c) is the same.
[0074] At step 218, the measuring unit (40) sends the information
about measured electrical parameters of the first wire segment (20c) and the
15 second wire segment (30c) to the workstation (210) connected to the measuring
unit (40). The first crimp (20a) is a pre-accepted efficient crimp, wherein the
details of a first physical parameter of the first crimp (20a) are prestored in the
workstation (210) and the measured electrical parameter for the first wire segment
(20c) is a standard quantity of electrical parameter.
20
[0075] At step 219, the workstation (210) compares the received
information about measured electrical parameters of the first wire segment (20c)
and the second wire segment (30c) and determines the details of the second
physical parameter of the second crimp (30a) with respect to the first crimp (20a).
25
[0076] At step 220, the display unit (13) displays the details of the
second physical parameter of the second crimp (30a).
[0077] The method (200a) ends at step 221.
30
[0078] In another embodiment, the system (100b) includes two
separate measuring units. The system (100b) is less time consuming as compared
to the system (100a), because the system (100a) measures the physical parameters
of the second crimp (30a) in two separate measuring cycles, whereas the system
35 (100b) measures the physical parameters in only one cycle of measurement.
22
[0079] Referring to figure 5, a system 5 (100b) for determining the
details of a physical parameter of crimps in accordance with the present invention
is illustrated. The system (100b) includes an electrical parameter supply unit (10),
a first wire segment (20c), a second wire segment (30c), a first measuring unit
(40ab), a second measuring unit (40be), a workstation (210) and a display unit
10 (13). In the preferred embodiment, the first wire segment (20c) is identical to the
second wire segment (30c). i.e. one of the physical parameters of the wire
segments such as length, width, is (are) unequal and other physical parameters are
identical in both the first wire segment (20c) and second wire segment (30c).
15 [0080] The first wire segment (20c) has a first crimp (20a) formed
between a first connector end (20b) and the first wire segment (20c) as shown in
figure 5. Also, the second wire segment (30c) has a second crimp (30a) formed
between a second connector end (30b) and the second wire segment (30c). The
first connector ends (20b) and the second connector ends (30b) are hollow
20 metallic ends having crimped metal wires fixed therein to establish connection
with an external connector housing.
[0081] The electrical parameter supply unit (10) is adapted to
supply one or more electrical parameters therefrom to the first wire segment (20c)
25 and the second wire segment (30c) connected thereto when the electrical
parameter supply unit (10) is operated accordingly. In the preferred embodiment,
the electrical parameter supply unit (10) is a voltage source or a current source or
a frequency supply unit. The electric parameter supply unit (10) has an interface
for controlling the operation of the electric parameter supply unit (10). The
30 interface for controlling the operation of the electric parameter supply unit (10) is
a manually operated control module. In the preferred embodiment, the electrical
parameters supplied to the first wire segment (20c) and the second wire segment
(30c) are voltage or current or frequency.
23
[0082] The first measuring unit (40ab) has 5 a first measuring pin
(40ac) and a second measuring pin (40bc). In the preferred embodiment, the first
measuring unit (40ab) is a voltmeter or an ammeter or an LCR meter or a
multimeter or an oscilloscope. A distance (40g) between the first measuring pin
(40ac) and the second measuring pin (40bc) is adjustable.
10
[0083] The first measuring pin (40ac) is adapted to have a first
physical contact (140) with the first wire segment (20c) at a first position (50) as
shown in figure 5. The first position (50) is over a metal surface (53) of the first
wire segment (20c). The first position (50) is between the first crimp (20a) and a
15 first distal end (20d) of the first connector end (20b) as shown in figure 5. In the
preferred embodiment, there is a predefined first distance (80) between the first
crimp (20a) and the first position (50).
[0084] Further, the second measuring pin (40bc) is adapted to have
20 a second physical contact (150) with the first wire segment (20c) at a second
position (60) as shown in figure 5. The second position (60) is between the first
crimp (20a) and a first wire segment distal end (20e). The first wire segment
distal end (20e) is an end part of the insulation covering over the first wire
segment (20c), as shown in figure 5. There is a predefined second distance (90)
25 between the second crimp (30a) and the second position (60).
[0085] During the operation of the system (100b), the electric
power supply unit (10) supplies a first predefined quantity of electrical parameter
to the first wire segment (20c). In the preferred embodiment, the first predefined
30 quantity of electrical parameter supplied to the first wire segment (20c) is an
electromotive force or a frequency of an electric current or a combination of
these.
[0086] The first measuring unit (40ab) measures the quantity of
35 electrical parameters between the first position (50) and the second position (60).
24
The electric parameter measured between the first 5 position (50) and the second
position (60) is a potential difference or an electric current, resistance, inductance,
or impendence.
[0087] Further, the second measuring unit (40be) has a third
10 measuring pin (40ae) and a fourth measuring pin (40bh). The second measuring
unit (40be) is a voltmeter, an ammeter, a LCR meter, a multimeter, or an
oscilloscope. The third measuring pin (40ae) of the second measuring unit (40be)
is adapted to have a third physical contact (160) with the second wire segment
(30c) at a third position (70).
15
[0088] The third position (70) is between the second crimp (30a)
and a second distal end (30d) of the second connector end (30b) as shown in
figure 5. There is a predefined third distance (110) between the second crimp
(30a) and the third position (70). In the preferred embodiment, the magnitude of
20 the predefined first distance (80) and the predefined third distance (110) is the
same as shown in figure 5.
[0089] Further, the fourth measuring pin (40bh) is adapted to have
a fourth physical contact (170) with the second wire segment (30c) at a fourth
25 position (180). The fourth position (180) is between the second crimp (30a) and a
second wire segment distal end (30e) as shown in figure 5. The fourth position
(180) is over a metal surface (54) of the second wire segment (30).
[0090] The second wire segment distal end (30e) is at the edge of
30 the insulation over the second wire segment (30c) as shown in figure 5. In the
preferred embodiment, the magnitude of the predefined second distance (90) and
the predefined fourth distance (190) is the same.
[0091] Further, the electric parameter supply unit (10) supplies a
35 second predefined quantity of electrical parameter to the second wire segment
25
(30c). The second predefined quantity of electrical parameter 5 supplied to the
second wire segment (30c) is an electromotive force or a frequency of an electric
current or a combination of these.
[0092] The second measuring unit (40be) measures the quantity of
10 electrical parameters between the third position (70) and the fourth position (180).
The quantity of electrical parameters between the third position (70) and the
fourth position (180) is a potential difference or an electric current or a resistance
or an inductance or an impendence. In the preferred embodiment, the quantity of
the first predefined quantity of electrical parameters supplied to the first wire
15 segment (20c) and the second predefined quantity of electrical parameters
supplied to the second wire segment (30c) is the same.
[0093] Further, the workstation (210) is connected to the first
measuring unit (40ab) and the second measuring unit (40be). The workstation
20 (210) receives the measured electrical parameters of the first wire segment (20c)
and the second wire segment (30c). In the preferred embodiment, the workstation
(210) has a user interface such as keyboard or mouse or buttons to control the
operation of the system (100b) such as switching the system (100b) between ONOFF,
calibration, switching the unit of measurement (i.e. ampere, microampere,
25 volt, millivolt) etc. In the preferred embodiment, the first crimp (20a) is a preaccepted
efficient crimp and the measured electrical parameter in the first
measurement cycle (220) is a standard quantity of electrical parameter.
[0094] The details of a first physical parameter of the first crimp
30 (20a) are prestored in the workstation (210). The details of the first physical
parameter of the first crimp (20a) are the quantitative and qualitative parameters
of the first crimp (20a) as shown in figure 1a. The quantitative parameters of the
first crimp (20a) are height, width, air gap, no. of wire strands crimped together,
tensile strength etc. and the qualitative parameters of the first crimp (20a) are the
26
percentage efficiency of the first crimp (20a), indication 5 regarding whether the
first crimp (20a) is defective or acceptable etc.
[0095] Further, in the system (100b), the workstation (210)
includes a processing unit (11) and a memory unit (12) for storing the measured
10 electrical parameters received from the first wire segment (20c) and the second
wire segment (30c). The processing unit (11) is a microcontroller or a
microprocessor or a controller or a processor or a logic controller and the memory
unit (12) is a cloud server or a hard drive or an IOT device.
15 [0096] In the preferred embodiment, the workstation (210) is
connected to an authentication system (not shown in figure). The authentication
system is a biometric system such as a fingerprint sensor or a face recognition
system, or a password-protected system. The authentication system is adapted to
provide access of the system (100b) to an authenticated user only when the
20 authentication system is operated accordingly.
[0097] The workstation (210) is adapted to compare the received
measured electrical parameters of the first wire segment (20c) and the second
wire segment (30c) to determine the details of a second physical parameter of the
25 second crimp (30a). In the preferred embodiment, the details of the second
physical parameter of the second crimp (30a) are the quantitative and qualitative
parameters of the second crimp (30a) as shown in figure 1b. The quantitative
parameters of the second crimp (30a) are height, width, air gap, no. of wire
strands crimped together, tensile strength etc. and the qualitative parameters of
30 the second crimp (30a) are the percentage efficiency of the second crimp (30a),
indication regarding whether the second crimp (30a) is defective or acceptable
etc.
[0098] The workstation (210) performs a comparison between the
35 physical parameter of the first crimp (20a) with the electrical parameters of the
27
first crimp (20a) that are measured by the measuring 5 unit (40). The prestored
details of the first physical parameter of the first crimp (20a) are determined by
standard measuring methods such as manual or photographic inspection and
manually stored in the workstation (210) as a reference value.
10 [0099] The magnitude of the air gap is measured by any standard
measuring method. For example – let us take the air gap of magnitude 0.5mm3 be
the first physical parameter of the first crimp (20a). The measuring unit (40)
measures the voltage drop across the first crimp (20a) as 5V. Hence, the
workstation (210) stores the value of 0.5 mm3 air gap for 5V voltage drop across
15 the first crimp (20a).
[00100] The details of comparison of the first crimp (20a) and the
second crimp (30a) are updated in the cloud server of the memory unit (12) in
real-time. The real-time measurement of the electrical parameters means the
20 actual time or instantaneous measurement when the system (100b) is operating.
[00101] Further, a display unit (13) is connected to the workstation
(210). In the preferred embodiment, the display unit (13) is a screen or a monitor.
The display unit (13) is adapted to display the details of the second physical
25 parameter of the second crimp (30a) with respect the first crimp (20a). The
second physical parameter of the second crimp (30a) is displayed as numerical
value of the height or width or air gap or no. of wire strands within the second
crimp (30a), tensile strength etc. or a percentage value of the efficiency of the
second crimp (30a) with respect to the first crimp (20a).
30
[00102] For example, let the first wire segment (20c) and second
wire segment (30c) supplied with a current of 10 microamperes by the electrical
parameter supply unit (10). The first measuring pin (40ac) of the first measuring
unit (40ab) is made in contact with the first position (50) over the first wire
35 segment (20c) at a distance (80) of 5mm from the first crimp (20a) and the second
28
measuring pin (40bc) of the first measuring unit (40ac) 5 is made in contact with
the second position (60) at distance (90) of 3 mm from the first crimp (20a). The
first measuring unit (40ab) measures the potential difference across the first
position (50) and the second position (60) as 10V.
10 [00103] The value measured by the first measuring unit (40ab) is
sent to the workstation (210) and stored in the memory unit (12). The values of
the first physical parameters of the first crimp (20a) such as length of 100cm, a
width of 5mm, a height of 4mm, an air gap of 0.5mm, a tensile strength of 20Mpa
etc. are prestored in the workstation. The workstation (210) stores the value 6V as
15 a standard value of the electrical parameter for the first crimp (20a) for a specific
set of measured values of the first physical parameters of the first crimp (20a).
[00104] Further, the third measuring pin (40ae) of the second
measuring unit (40be) is made in contact with the third position (70) of the
20 second wire segment (30c) and the fourth measuring pin (40bh) is made in
contact with the fourth position (180) of the second wire segment (30c).
[00105] The first measuring unit (40ab) measures the potential
difference between the first position (50) and the second position (60) of the first
25 wire segment (20c) and the second measuring unit (40be) measures the potential
difference between the third position (70) and the second fourth position (180) of
the second wire segment (30c). The first measuring unit (40ab) and the second
measuring unit (40be) send the measured value of potential difference across the
first crimp (20a) and the second crimp (30a) respectively to the workstation (210).
30 The measured value of the potential difference between the third position (70)
and the fourth position (180) is measured as 6V. Here, the first crimp (20a) is the
standard crimp.
[00106] The workstation (210) compares the value 5V with the
35 voltage value 5V measured for the first crimp (20a) and calculates the value of
29
the second physical parameter, for example, air gap within 5 the second crimp (30a)
to be 1mm and displays the calculated results on the display unit (13). Also, the
display unit (13) calculates the efficiency of the second crimp (30a) as: (5/6) *
100 = 83%. Further, based on the efficiency value of the second crimp (30a), a
signal indicating whether the second crimp (30a) is defective or acceptable is also
10 displayed on the display unit (13). The signal may include an “ERROR” message
on displayed on the display unit (13) or a light indicator which shows light of red
colour in case of defective second crimp (30a).
[00107] Referring now to figure 6, a method (200b) for determining
15 the details of a physical parameter of crimps in accordance with the present
invention is illustrated. For the sake of brevity, the method (200b) is described in
conjunction with the system (100b).
[00108] The method (200b) starts at step 310.
20
[00109] At step 311, the electrical parameter supply unit (10)
supplies one or more electrical parameters to the first wire segment (20c) and to
the second wire segment (30c) when the first wire segment (20c) and the second
wire segment (30c) connected thereto and the electrical parameter supply unit
25 (10) operated accordingly. The second wire segment (30c) is substantially
identical to the first wire segment (20c). The first wire segment (20c) is having
the first crimp (20a) formed between the first connector end (20b) and the first
wire segment (20c), the second wire segment (30) is having the second crimp
(30a) formed between the second connector end (30b) and the second wire
30 segment (30c).
[00110] At step 312, the first physical contact (140) is made
between the first measuring pin (40ac) of the first measuring unit (40ab) and the
first position (50). The first position (50) is between the first crimp (20a) and the
30
first distal end (20d) of the first connector end (20b), with 5 a predefined first
distance (80) therebetween.
[00111] At step 313, the second physical contact (150) is made
between the second measuring pin (40bc) of the first measuring unit (40ab) and
10 the second position (60). The second position (60) is between the first crimp (20a)
and the first wire segment distal end (20e) with a predefined second distance (90)
therebetween.
[00112] At step 314, the first measuring unit (40ab) measures the
15 quantity of electrical parameters between the first position (50) and the second
position (60) upon supplying the first predefined quantity of electrical parameters
to the first wire segment (20c) by the electrical parameter supply unit (10).
[00113] At step 315, the third physical contact (160) is made
20 between the third measuring pin (40ae) of the second measuring unit (40be) and
the third position (70) over the second wire segment (30c). The third position (70)
is between the second crimp (30a) and the second distal end (30d) of the second
connector end (30b) with a predefined third distance (110) therebetween, and the
magnitude of the predefined first distance (80) and the predefined third distance
25 (110) is same.
[00114] At step 316, the fourth physical contact (170) is made
between the fourth measuring pin (40bh) of the second measuring unit (40be) and
the fourth position (180) over the second wire segment (30c). The fourth position
30 (180) is between the second crimp (30a) and the second wire segment distal end
(30e) with a predefined fourth distance (190) therebetween and the magnitude of
the predefined second distance (90) and the predefined fourth distance (190) is
same.
31
[00115] At step 317, the second measuring unit 5 (40be) measures the
quantity of electrical parameters between the third position (70) and the fourth
position (180) upon supplying the second predefined quantity of electrical
parameters to the second wire segment (30c) by the electric parameter supply unit
(10). The quantity of the first predefined quantity of electrical parameters
10 supplied to the first wire segment (20c) and the second predefined quantity of
electrical parameters supplied to the second wire segment (30c) is the same.
[00116] At step 318, the first measuring unit (40ab) and the second
measuring unit (40be) send information about measured electrical parameters of
15 the first wire segment (20c) and the second wire segment (30c) respectively to a
workstation (210). The first crimp (20a) on the first wire segment (20c) is a preaccepted
efficient crimp wherein the details of a first physical parameter of the
first crimp (20a) are prestored in the workstation (210) and the measured
electrical parameter of the first wire segment (20c) is a standard quantity of
20 electrical parameter.
[00117] At step 319, the workstation (210) compares the received
measured electrical parameters of the first wire segment (20c) and the second
wire segment (30c) and determines the details of a second physical parameter of
25 the second crimp (30a).
[00118] At step 320, the display unit (13) displays the details of a
second physical parameter of the second crimp (30a) with respect to the first
crimp (20a).
30
[00119] The method (200b) ends at step 321.
[00120] Similarly, as per the requirement of a user (testing
operator), the efficient first crimps can be defined, and crimps of another wire
35 harness can be compared, and comparison details are displayed by the system
32
(100a or 100b). The user can measure the physical parameters 5 of multiple wire
harness crimps against a standard crimp. Here, the user can be a quality assurance
engineer, a lab operator, or research professional responsible for testing the wire
harness activities.
10 [00121] Thus, the present invention has advantage providing the
system (100a and 100b) which determines the details of physical parameters of
crimps in wire harnesses by measuring the electrical parameters across the crimps
and provides a reliable and efficient alternative to the wire harness selection as
compared to manual physical inspection methods. The system (100a and 100b)
15 also eliminates the need for multiple measurements on each wire harness to
measure physical parameters, thereby reducing the operating time during quality
check.
[00122] Also, the system (100a and 100b) requires a simple and
20 cost-effective measurement setup to inspect multiple wire harnesses at a time
without affecting the accuracy of measurement. Further, the system (100a and
100b) avoids use of destructive testing methods such as cutting of wire segment
for measuring the cross-sectional parameters such as height, width, air gap,
applying longitudinal force on the wire segment to determine the tensile strength
25 thereof etc., thereby eliminates the wastage of the material of the wire harness
during testing.
[00123] The foregoing descriptions of specific embodiments of the
present invention have been presented for purposes of illustration and description.
30 They are not intended to be exhaustive or to limit the present invention to the
precise forms disclosed, and obviously, many modifications and variations are
possible in light of the above teaching. The embodiments were chosen and
described in order to explain the principles of the present invention best and its
practical application, to thereby enable others skilled in the art to best utilise the
35 present invention and various embodiments with various modifications as are
33
suited to the particular use contemplated. It is understood 5 that various omission
and substitutions of equivalents are contemplated as circumstance may suggest or
render expedient, but such are intended to cover the application or
implementation without departing from the spirit or scope of the claims of the
present invention.
10
34
5 We Claim:
1. A system (100a) for determining the details of a physical parameter of crimps,
the system (100a) includes an electrical parameter supply unit (10) adapted to
supply one or more electrical parameters therefrom to a first wire segment (20c)
and to a second wire segment (30c) when the first wire segment (20c) and the
10 second wire segment (30c) connected thereto and the electrical parameter supply
unit (10) operated accordingly, the second wire segment (30c) is substantially
identical to the first wire segment (20c), the first wire segment (20c) is having a
first crimp (20a) formed between a first connector end (20b) and the first wire
segment (20c), the second wire segment (30c) is having a second crimp (30a)
15 formed between a second connector end (30b) and the second wire segment
(30c), the system (100a) characterized in that:
a measuring unit (40) having a first measuring pin (40a)
and a second measuring pin (40b), wherein in a first measurement cycle (220), the
first measuring pin (40a) is adapted to have a first physical contact (140) with the
20 first wire segment (20c) at a first position (50), the first position (50) is between
the first crimp (20a) and a first distal end (20d) of the first connector end (20b),
with a predefined first distance (80) therebetween, the second measuring pin
(40b) is adapted to have a second physical contact (150) with the first wire
segment (20c) at a second position (60), the second position (60) is between the
25 first crimp (20a) and a first wire segment distal end (20e) with a predefined
second distance (90) therebetween, wherein upon supplying a first predefined
quantity of electrical parameter to the first wire segment (20c), the measuring unit
(40) measures the quantity of electrical parameter between the first position (50)
and the second position (60);
30 wherein subsequently, in a second measurement cycle
(230), the first measuring pin (40a) is adapted to have a third physical contact
(160) with the second wire segment (30c) at a third position (70), the third
position (70) is between the second crimp (30a) and a second distal end (30d) of
the second connector end (30b) with a predefined third distance (110)
35
therebetween, the magnitude of the predefined first 5 distance (80) and the
predefined third distance (110) is same, the second measuring pin (40b) is
adapted to have a fourth physical contact (170) with the second wire segment
(30c) at a fourth position (180), the fourth position (180) is between the second
crimp (30a) and a second wire segment distal end (30e) with a predefined fourth
10 distance (190) therebetween, the magnitude of the predefined second distance
(90) and the predefined fourth distance (190) is same;
wherein upon supplying a second predefined quantity of
electrical parameter to the second wire segment (30c), the measuring unit (40)
measures the quantity of electrical parameters between the third position (70) and
15 the fourth position (180), the quantity of the first predefined quantity of electrical
parameters and the second predefined quantity of electrical parameters is same;
a workstation (210) connected to the measuring unit (40),
the measuring unit (40) sends information about measured electrical parameters
to the workstation (210);
20 wherein the first crimp (20a) is a pre-accepted efficient
crimp with the details of a first physical parameter of the first crimp (20a) are
prestored in the workstation (210) and the measured electrical parameter in the
first measurement cycle (220) is a standard quantity of electrical parameter;
wherein the workstation (210) is adapted to compare the
25 received measured electrical parameters of the first measurement cycle (220) and
the second measurement cycle (230) to determine the details of a second physical
parameter of the second crimp (30a); and
a display unit (13) connected to the workstation (210), the
display unit is adapted to display the details of the second physical parameter of
30 the second crimp (30a).
2. A system (100b) for determining the details of a physical parameter of crimps in
wire harnesses, the system (100b) includes an electrical parameter supply unit
(10) adapted to supply one or more electrical parameters therefrom to a first
35 wire segment (20c) and to a second wire segment (30c) when the first wire
36
segment (20c) and the second wire segment (30c) 5 connected thereto and the
electrical parameter supply unit (10) operated accordingly, the second wire
segment (30c) is substantially identical to the first wire segment (20c), the first
wire segment (20c) is having a first crimp (20a) formed between a first
connector end (20b) and the first wire segment (20c), the second wire segment
10 (30c) is having a second crimp (30a) formed between a second connector end
(30b) and a second wire segment (30c), the system (100) characterized in
that:
a first measuring unit (40ab) having a first measuring pin
(40ac) and a second measuring pin (40bc), the first measuring pin (40ac) is
15 adapted to have a first physical contact (140) with the first wire segment (20c) at
a first position (50), the first position (50) is between the first crimp (20a) and a
first distal end (20d) of the first connector end (20b), with a predefined first
distance (80) therebetween, the second measuring pin (40bc) is adapted to have a
second physical contact (150) with the first wire segment (20c) at a second
20 position (60), the second position (60) is between the first crimp (20a) and a first
wire segment distal end (20e) with a predefined second distance (90)
therebetween, wherein upon supplying a first predefined quantity of electrical
parameters to the first wire segment (20c), the first measuring unit (40ab)
measures the quantity of electrical parameters between the first position (50) and
25 the second position (60);
a second measuring unit (40be) having a third measuring
pin (40ae) and a fourth measuring pin (40bh), the third measuring pin (40ae) is
adapted to have a third physical contact (160) with the second wire segment (30c)
at a third position (70), the third position (70) is between the second crimp (30a)
30 and a second distal end (30d) of the second connector end (30b) with a predefined
third distance (110) therebetween, the magnitude of the predefined first distance
(80) and the predefined third distance (110) is same, the fourth measuring pin
(40bh) is adapted to have a fourth physical contact (170) with the second wire
segment (30c) at a fourth position (180), the fourth position (180) is between the
35 second crimp (30a) and a second wire segment distal end (30e) with a predefined
37
fourth distance (190) therebetween, the magnitude 5 of the predefined second
distance (90) and the predefined fourth distance (190) is same;
wherein upon supplying a second predefined quantity of
electrical parameters to the second wire segment (30c), the second measuring unit
(40be) measures the quantity of electrical parameters between the third position
10 (70) and the fourth position (180), the quantity of the first predefined quantity of
electrical parameters and the second predefined quantity of electrical parameters
is same;
a workstation (210) connected to the first measuring unit
(40ab) and the second measuring unit (40be), the first measuring unit (40ab) and
15 the second measuring unit (40be) send information about measured electrical
parameters of the first wire segment (20c) and the second wire segment (30c) to
the workstation (210);
wherein the first crimp (20a) is a pre-accepted efficient
crimp with the details of a first physical parameter of the first crimp (20a) are
20 prestored in the workstation (210) and the measured electrical parameter of the
first wire segment (20c) is a standard quantity of electrical parameter;
wherein the workstation (210) is adapted to compare the
received measured electrical parameters of the first wire segment (20c) and the
second wire segment (30c) to determine the details of a second physical
25 parameter of the second crimp (30a); and
a display unit (13) connected to the workstation (210) , the
display unit is adapted to display the details of the second physical parameter of
the second crimp (30a).
30 3. A method (200a) for determining the details of a physical parameter of crimps,
the method (200) includes steps of supplying one or more electrical parameters
to a first wire segment (20c) and to a second wire segment (30c) by an electric
parameter supply unit (10) by connecting the first wire segment (20c) and the
second wire segment (30c) thereto and operating the electrical parameter supply
35 unit (10) accordingly, wherein the second wire segment (30c) is substantially
38
identical to the first wire segment (20c), the first wire 5 segment (20c) is having a
first crimp (20a) formed between a first connector end (20b) and the first wire
segment (20c), the second wire segment (30) is having a second crimp (30a)
formed between a second connector end (30b) and the second wire segment
(30c), the method (200a) characterized in that:
10 making a first physical contact (140) between a first
measuring pin (40a) of a measuring unit (40) and a first position (50), wherein the
first position (50) is between the first crimp (20a) and a first distal end (20d) of
the first connector end (20b) with a predefined first distance (80) therebetween;
making a second physical contact (150) between a second
15 measuring pin (40b) of the measuring unit (40) and a second position (60), the
second position (60) is between the first crimp (20a) and a first wire segment
distal end (20e) with a predefined second distance (90) therebetween;
measuring the quantity of electrical parameters between
the first position (50) and the second position (60) by the measuring unit (40)
20 upon supplying a first predefined quantity of electrical parameters to the first wire
segment (20c);
making a third physical contact (160) between the first
measuring pin (40a) and a third position (70) wherein the third position (70) is
between the second crimp (30a) and a second distal end (30d) of the second
25 connector end (30b) with a predefined third distance (110) therebetween and the
magnitude of the predefined first distance (80) and the predefined third distance
(110) is same;
making a fourth physical contact (170) between the
second measuring pin (40b) and a fourth position (180), wherein the fourth
30 position (180) is between the second crimp (30a) and a second wire segment
distal end (30e) with a predefined fourth distance (190) therebetween and the
magnitude of the predefined second distance (90) and the predefined fourth
distance (190) is same;
measuring the quantity of electrical parameters between
35 the third position (70) and the fourth position (180) by the measuring unit (40)
39
upon supplying a second predefined quantity of electrical 5 parameters to the
second wire segment (30c), wherein the quantity of the first predefined quantity
of electrical parameters and the second predefined quantity of electrical
parameters is same;
sending information about measured electrical parameters
10 of the first wire segment (20c) and the second wire segment (30c) to a
workstation (210) connected to the measuring unit (40), wherein the first crimp
(20a) is a pre-accepted efficient crimp with the details of a first physical
parameter of the first crimp (20a) are prestored in the workstation (210) and the
measured electrical parameter for the first wire segment (20c) is a standard
15 quantity of electrical parameter;
comparing the received information about measured
electrical parameters of the first wire segment (20c) and the second wire segment
(30c) to determine the details of a second physical parameter of the second crimp
(30a) by the workstation (210); and
20 displaying the details of the second physical parameter of
the second crimp (30a) by a display unit (13) connected to the workstation (210).
4. A method (200b) for determining the details of a physical parameter of crimps,
the method (200b) includes steps of supplying one or more electrical parameters
25 to a first wire segment (20c) and to a second wire segment (30c) by an electrical
parameter supply unit (10) when the first wire segment (20c) and the second wire
segment (30c) connected thereto and the electrical parameter supply unit (10)
operated accordingly, wherein the second wire segment (30c) is substantially
identical to the first wire segment (20c), the first wire segment (20c) is having a
30 first crimp (20a) formed between a first connector end (20b) and a first wire
segment (20c), the second wire segment (30) is having a second crimp (30a)
formed between a second connector end (30b) and the second wire segment (30c),
the method (200b) characterized in that:
making a first physical contact (140) between a first
35 measuring pin (40ac) of a first measuring unit (40ab) and a first position (50)
40
wherein the first position (50) is between the first crimp (5 20a) and a first distal
end (20d) of the first connector end (20b), with a predefined first distance (80)
therebetween;
making a second physical contact (150) between a second
measuring pin (40bc) of the first measuring unit (40ab) and a second position
10 (60), wherein the second position (60) is between the first crimp (20a) and a first
wire segment distal end (20e) with a predefined second distance (90)
therebetween;
measuring the quantity of electrical parameters between
the first position (50) and the second position (60) by the first measuring unit
15 (40ab) upon supplying a first predefined quantity of electrical parameters to the
first wire segment (20c) by the electrical parameter supply unit (10);
making a third physical contact (160) between a third
measuring pin (40ae) of the second measuring unit (40be) and a third position
(70) over the second wire segment (30c), wherein the third position (70) is a
20 position between the second crimp (30a) and a second distal end (30d) of the
second connector end (30b) with a predefined third distance (110) therebetween,
the magnitude of the predefined first distance (80) and the predefined third
distance (110) is same;
making a fourth physical contact (170) between a fourth
25 measuring pin (40bh) of the second measuring unit (40be) and a fourth position
(180) over the second wire segment (30c), wherein the fourth position (180) is
between the second crimp (30a) and a second wire segment distal end (30e) with
a predefined fourth distance (190) therebetween and the magnitude of the
predefined second distance (90) and the predefined fourth distance (190) is same;
30 measuring the quantity of electrical parameters between
the third position (70) and the fourth position (180) by the second measuring unit
(40be) upon supplying a second predefined quantity of electrical parameters to
the second wire segment (30c) by the electric parameter supply unit (10), wherein
the quantity of the first predefined quantity of electrical parameters and the
35 second predefined quantity of electrical parameters is same;
41
sending information about measured electrical 5 parameters
of the first wire segment (20c) and the second wire segment (30c) to a
workstation (210) by the first measuring unit (40ab) and the second measuring
unit (40be) respectively, wherein the first crimp (20a) is a pre-accepted efficient
crimp with the details of a first physical parameter of the first crimp (20a) are
10 prestored in the workstation (210) and the measured electrical parameter of the
first wire segment (20c) is a standard quantity of electrical parameter;
comparing the received measured electrical parameters of
the first wire segment (20c) and the second wire segment (30c) to determine the
details of a second physical parameter of the second crimp (30a) by the
15 workstation (210); and
displaying the details of the second physical parameter of
the second crimp (30a) by a display unit (13) connected to the workstation (210).
5. The system (100a) as claimed in claim 1, wherein the details of the first physical
20 parameter of the first crimp (20a) include quantitative parameters and qualitative
parameters of the first crimp (20a).
6. The system (100b) as claimed in claim 2, wherein the details of the first physical
parameter of the first crimp (20a) include quantitative parameters and qualitative
25 parameters of the first crimp (20a).
7. The system (100a) as claimed in claim 1, wherein the details of the second
physical parameter of the second crimp (30a) include quantitative parameters and
qualitative parameters of the second crimp (30a).
30
8. The system (100b) as claimed in claim 2, wherein the details of the second
physical parameter of the second crimp (30a) include quantitative parameters and
qualitative parameters of the second crimp (30a).
42
9. The system (100a) as claimed in claim 1, the electrical parameter 5 supply unit (10)
is a voltage source or a current source or a frequency supply unit.
10. The system (100b) as claimed in claim 2, the electrical parameter supply
unit (10) is a voltage source or a current source or a frequency supply unit.
10
11. The system (100a) as claimed in claim 1, the measuring unit (40) is a
voltmeter or an ammeter or an LCR meter or a multimeter or an oscilloscope.
12. The system (100b) as claimed in claim 2, the first measuring unit (40ab) is
15 a voltmeter or an ammeter or an LCR meter or a multimeter or an oscilloscope
and the second measuring unit (40be) is a voltmeter or an ammeter or an LCR
meter or a multimeter or an oscilloscope.
13. The system (100a) as claimed in claim 1, wherein the first predefined
20 quantity of electric parameter supplied to the first wire segment (20c) and the
second predefined quantity of electric parameter supplied to the second wire
segment (30c) is an electromotive force or a frequency of an electric current or a
combination of these.
25 14. The system (100b) as claimed in claim 2, wherein the first predefined quantity
of electric parameter supplied to the first wire segment (20c) and the second
predefined quantity of electric parameter supplied to the second wire segment
(30c) is an electromotive force or a frequency of an electric current or
combination of these.
30
15. The system (100a) as claimed in claim 1, the electrical parameters measured
between the first position (50) and the second position (60) is a potential
difference or an electric current or a resistance or an inductance or an
impendence and the electrical parameters measured between the third position
43
(70) and the fourth position (180) is a potential difference or an 5 electric current
or a resistance or an inductance or an impendence.
16. The system (100b) as claimed in claim 2, the electrical parameters measured
between the first position (50) and the second position (60) is a potential
10 difference or an electric current or a resistance or an inductance or an
impendence and the electrical parameters measured between the third position
(70) and the fourth position (180) is a potential difference or an electric current
or a resistance or an inductance or an impendence.
15 17. The system (100a) as claimed in claim 1, wherein a distance (40f) between the
first measuring pin (40a) and the second measuring pin (40b) of the measuring
unit (40) is adjustable.
18. The system (100b) as claimed in claim 2, wherein a distance (40g) between the
20 first measuring pin (40ac) and the second measuring pin (40bc) of the first
measuring unit (40ab) and a distance (40g) between the third measuring pin
(40ae) and the fourth measuring pin (40bh) of the second measuring unit (40be)
is adjustable.
25 19. The system (100a) as claimed in claim 1, wherein the workstation (210)
includes a processing unit (11) and a memory unit (12) for storing the measured
electrical parameters received from the first measurement cycle (220) and the
second measurement cycle (230).
30 20. The system (100b) as claimed in claim 2, wherein the workstation (210)
includes a processing unit (11), a memory unit (12) for storing the measured
electrical parameters received from the first wire segment (20c) and the second
wire segment (30c).
44
21. The system (100a) as claimed in claim 20, wherein the processing 5 unit (11) is a
microcontroller or microprocessor or controller or processor or logic controller,
the display unit (13) is a screen, or a monitor and the memory unit (12) is a
cloud server or a hard drive or an IOT device.
10 22. The system (100b) as claimed in claim 21, wherein the processing unit (11) is a
microcontroller or microprocessor or controller or processor or logic controller,
the display unit (13) is a screen, or a monitor and the memory unit (12) is a
cloud server or a hard drive or an IOT device.
15 23. The system (100a) as claimed in claim 1, wherein the electric parameter supply
unit (10) has an interface for controlling the operation of the electric parameter
supply unit (10).
24. The system (100b) as claimed in claim 2, wherein the electric parameter supply
20 unit (10) has an interface for controlling the operation of the electric parameter
supply unit (10).
25. The system (100a) as claimed in claim 1, wherein the workstation (210) is
connected to an authentication system, the authentication system is adapted to
25 provide access of the system (100) to an authenticated user only when the
authentication system is operated accordingly.
26. The system (100b) as claimed in claim 2, wherein the workstation (210) is
connected to an authentication system, the authentication system is adapted to
30 provide access of the system (100) to an authenticated user only when the
authentication system is operated accordingly.
27. The system (100a) as claimed in claim 21, the details of comparison of the first
measurement cycle (220) and the second measurement cycle (230) are updated
35 in the cloud server of the memory unit (12) in real-time.
45
28. The system (100b) as claimed in claim 22, the details of 5 comparison of the first
wire segment (20c) and the second wire segment (30c) are updated in the cloud
server of the memory unit (12) on real-time.