Lead insertion system and method

A system for determining whether a lead is securely inserted into a connector includes an actuator for moving the lead to a plurality of positions, a position sensor for measuring a position of the lead relative to the connector, and a force sensor for measuring an actual force exerted on the lead at each of the plurality of positions to define an actual force signature. A processor compares the actual force signature to a predetermined force signature to determine whether the lead is disposed within the opening of the connector. The method includes the steps of moving the lead to a plurality of positions, establishing an actual force signature, and establishing a predetermined force signature. If the actual force signature is within the predetermined force signature, then the lead is securely inserted into the opening.

FIELD

The present embodiments generally relate to a system and method for determining whether a lead is securely inserted into a connector.

BACKGROUND

There are numerous methods for providing electrical connectivity to a device or between two devices. In most industrial applications, an electrical connection to a device or between two devices is accomplished using a connector wherein a terminal end of a wire or other conductor (i.e., lead) is inserted into the connector to provide electrical connectivity. To maintain conductivity, particularly in applications where the connector is subject to continuous vibration, the lead must be securely inserted into the connector.

There are a number of methods for determining whether the lead is securely inserted into the connector. One such system includes a holding device that supports the lead, an actuator coupled to the holding device for moving the lead into the connector, and a force sensor operatively connected to the actuator for measuring a peak force exerted by the actuator. The system further includes a processor that compares the peak force exerted to a predetermined peak force. If the peak force exerted exceeds the predetermined peak force, the system concludes that the lead was placed in the opening of the connector properly.

Although generally successful, known systems and methods for inserting a lead into a connector fail to account for various processing errors that can occur when inserting the lead into the opening of the connector. For instance, if the lead is in the wrong position when the actuator exerts the peak force (i.e., too far away from the connector or misaligned relative to an opening in the connector), even if the actuator exerts a peak force that exceeds the predetermined peak force, the lead will not be securely inserted into the connector. The system, however, will incorrectly conclude that lead was securely inserted. Similarly, should the actuator exert the peak force at the wrong time, the system will conclude that the lead was inserted properly simply because the peak force exerted by the actuator exceeds the predetermined peak force. Therefore, an operator must still verify that each lead was securely inserted even though the system may have concluded that the lead was properly inserted. Often times, ensuring that the lead was properly inserted is very subjective and requires the operator to pull back on the lead to determine whether the lead will easily come out of the opening in the connector. However, as technology advances, the leads and connectors are becoming smaller and smaller making this subjective determination even more difficult.

Therefore, a system and method for inserting a lead into a connector is needed that verifies that the lead was securely inserted into the connector without requiring the operator to pull back on the lead or otherwise make a subjective determination about the secure insertion of the lead into the connector.

SUMMARY

An apparatus for determining whether a lead is securely inserted into an opening defined by a connector is provided. The apparatus includes an actuator, and a position sensor operatively connected to the actuator. A force sensor is operatively connected to the actuator for measuring an actual force exerted by the actuator at each of a plurality of positions to define an actual force signature.

Furthermore, a method of determining whether a lead is securely inserted into an opening defined by a connector is provided. The method includes the step of moving the lead to a plurality of positions. The method also includes the step of establishing the actual force signature based on the movement of the lead. In addition, the method includes the step of establishing a predetermined force signature based on a predetermined range of acceptable forces at each of the plurality of positions.

DETAILED DESCRIPTION

A lead insertion system and method that determines whether a lead is securely inserted into an opening of a connector is provided. The lead insertion system measures an actual force at which the lead is inserted into the opening of the connector and an actual position of the lead at the time the actual force is applied. In other words, the actual force is sampled as the lead moves to various positions along an insertion route. Knowing the actual force and the position at which the force was applied, it can be determined whether the actual force applied securely inserted the lead into the opening of the connector, thus no longer requiring an operator to pull back on the lead.

Referring to the figures, where like numerals indicate like or corresponding parts throughout the several views,FIG. 1illustrates an exemplary lead insertion system10having a lead12that is formed from a terminal14crimped onto a wire16. It is to be appreciated that the terminal14may be manually crimped onto the wire16with a hand crimper, or alternatively, the terminal14may be crimped onto the wire16automatically with, for example, an automatic crimping device. Furthermore, it is to be understood that the lead12may be any other type of lead known in the art. For instance, the lead12may be a wire extending from an electrical component.

A connector18is spaced from and aligned with the lead12. The connector18defines a plurality of openings20, and at least one of the openings20is aligned with the lead12. During operation, the lead insertion system10inserts the lead12into the opening20of the connector18. It is to be understood that the connector18may be any connector18known in the art that defines an opening20for receiving the lead12. For instance, the lead insertion system10may be used with a circuit board defining a plurality of openings20for receiving at least one lead12from various electrical components. In that instance, the circuit board acts as the connector18.

The lead insertion system10further includes a holding device22for supporting the lead12while the lead12is being inserted into the opening20of the connector18. As shown inFIG. 1, the holding device22defines a channel24aligned with the opening20of the connector18, and the lead12is placed in the channel24. The opening20of the connector18defines an insertion axis A along which the channel24is coaxially aligned. The lead12rests in the channel24coaxially aligned with the opening20to allow the lead12to be inserted into the opening20by traveling along the insertion axis A. It is to be understood that the holding device22may include additional or alternative features for supporting the lead12while the lead12is being inserted into the opening20of the connector18. In one embodiment, as shown inFIG. 1, in addition to the channel24, the holding device22includes fingers26for pushing the lead12into the opening20during insertion. In another embodiment, as shown inFIG. 2, the holding device22includes a gripper27. The gripper27grips the wire16while the lead12is being inserted into the opening20.

Referring back toFIG. 1, the lead insertion system10includes an actuator28coupled to the holding device22for moving the holding device22and the lead12along the insertion axis A. During operation, the actuator28moves the holding device22and the lead12through a plurality of positions located along the insertion axis A. The actuator28ofFIG. 1is shown as an actuator28having a shaft30that moves along the insertion axis A. For instance, the actuator28may include a servo drive mechanism, such as a servo motor coupled to a screw shaft, which moves along the insertion axis A. Therefore, it is to be understood that the actuator28may be any type of actuator28known in the art. It is also to be appreciated that the actuator28may be electrically or pneumatically operated.

To determine a position of the lead12relative to the opening20of the connector18along the insertion axis A, the lead insertion system10includes a position sensor32operatively connected to at least one of the actuator28and the holding device22. For instance, the position sensor32may be directly connected to the lead12to measure the position. Alternatively, the position sensor32may be directly connected to either the actuator28or the holding device22to measure the position of the actuator28or the holding device22, respectively, and determine the actual position of the lead12based on the position of the actuator28or the holding device22. Since the holding device22moves with the actuator28and the lead12is secured to the holding device22, any movement along the insertion axis A of the actuator28will result in similar movement of the holding device22and the lead12. Therefore, movement of the holding device22and the actuator28is directly related to the movement of the lead12along the insertion axis A. Because of this, the position sensor32need not measure the actual position of the lead12directly. Rather, the actual position of the lead12can be determined by measuring the actual position of the actuator28or the holding device22with position sensor32. It is to be understood that the position sensor32may be any sensor known in the art that can directly or indirectly determine the position of the lead12. For instance, the position sensor32may include an encoder.

The lead insertion system10ofFIG. 1further includes a force sensor34operatively connected to the actuator28. The force sensor34may be any sensor known in the art capable of measuring the force exerted by the actuator28. For instance, the force sensor34may include a load cell. To move the holding device22and the lead12, the actuator28exerts an actual force. The force sensor34measures the actual force exerted by the actuator28at each of the plurality of positions to define an actual force signature36. In other words, the actual force signature36is a sampling of the actual force exerted by the actuator28at each of the plurality of positions. The force sensor34measures the actual force exerted by the actuator28while the position sensor32is used to determine the position of the lead12when the actual force is applied. Therefore, the actual force signature36indicates the different actual forces that are exerted by the actuator28as the lead12moves through the plurality of positions until the lead12is inserted into the opening20of the connector18.

As shown inFIGS. 3 and 4, the lead insertion system10includes a processor38electrically connected to the force sensor34and the position sensor32. The processor38receives the actual force exerted by the actuator28from the force sensor34and the actual position of the lead12from the position sensor32to generate the actual force signature36. The processor38then compares the actual force signature36to a predetermined force signature40defined by a predetermined range of acceptable forces at each of the plurality of positions. Preferably, the predetermined force signature40is stored in a database42that is in communication with the processor38. The database42may be any database42known in the art capable of transmitting information to the processor38. Once the predetermined range of acceptable forces at each of the plurality of positions has been established to define the predetermined force signature40, the predetermined force signature40is uploaded to the database42. When needed, the database42transmits the predetermined force signature40to the processor38, and the processor38is able to compare the predetermined force signature40to the actual force signature36to determine whether the lead12is securely inserted into the opening20of the connector18. The predetermined force signature40may be changed as needed since different forces may be needed to insert the lead12into different types of connectors, and a different predetermined force signature40may be required for each different type of connector18.

The processor38may output the actual force signature36and the predetermined force signature40to a display44to indicate whether the lead12was securely inserted into the opening20of the connector18. As shown inFIGS. 3 and 4, the display44may show a graph of the actual force signature36with the actual position of the lead12along the x-axis and the actual force exerted on the y-axis. Similarly, the display44may show a graph of the predetermined force signature40with the plurality of positions on the x-axis and the predetermined range of acceptable forces on the y-axis. It is to be understood that the display44may show the graph of the actual force signature36and the graph of the predetermined force signature40simultaneously. It is also to be understood that the actual force signature36and the predetermined force signature40may be shown on the display44in other ways. For instance, the actual force, the actual position and the predetermined range of acceptable forces at each of the plurality of positions may be listed on the display44instead of graphed. Regardless of how the actual force signature36and the predetermined force signature40are presented, the display44will show an operator whether the actual force was applied by the actuator28when the lead12was at the correct position.

Referring now toFIG. 3, the display44shows the actual force signature36completely within the predetermined force signature40. In other words, each actual force measured by the force sensor34at each of the plurality of positions is within the predetermined range of acceptable forces. The actual force signature36exerted by the actuator28being within the predetermined force signature40is indicative of the lead12being securely inserted into the opening20of the connector18. Therefore, as shown inFIG. 3, the actual force was applied correctly at each of the plurality of positions, and the operator may conclude that the lead12is securely disposed within the opening20of the connector18.

Referring now toFIG. 4, the actual force signature36is partially outside the predetermined force signature40. In other words, at least one of the actual forces measured by the force sensor34exceeded or fell below the predetermined range of acceptable forces. The actual force signature36having at least one actual force outside the predetermined force signature40is indicative of the lead12not being securely inserted into the opening20of the connector18. Therefore, as shown inFIG. 4; the actual force was not applied correctly at each of the plurality of positions, and the operator may conclude that the lead12is not securely disposed within the opening20of the connector18.

Referring again toFIG. 1, the lead insertion system10may further include a nest46spaced from the holding device22. The nest46holds the connector18in place while the lead12is being inserted. In order to securely insert the lead12into the opening20of the connector18, the lead12may need to be aligned with the opening20. Once aligned, any movement of the connector18could misalign the lead12from the opening20, which may prevent the lead12from being securely inserted. To prevent movement of the connector18, the nest is at least partially disposed about the connector18.

Referring now toFIG. 5, a method100of inserting the lead12into the opening20defined by the connector18is provided. The method100includes the step102of moving the lead12to a plurality of positions. As previously discussed, the plurality of positions may be along the insertion axis A. The method100further includes the step104of establishing an actual force signature36based on the movement of the lead12. As shown inFIG. 6, the step of establishing the actual force signature36based on the movement of the lead12(step104) includes the step106of determining the position of the lead12and the step108of measuring the actual force exerted by the actuator28on the lead12at each of the plurality of positions. As discussed above, the position is measured by the position sensor32and the actual force is measured by the force sensor34.

Referring toFIG. 5, the method100further includes the step110of establishing the predetermined force signature40. As previously discussed, the predetermined force signature40is defined by the predetermined range of acceptable forces at each of the plurality of positions. Once the predetermined force signature40has been established, the method100includes the step112of comparing the actual force signature36to the predetermined force signature40to determine whether the lead12has been inserted into the opening20defined by the connector18.

Referring now toFIG. 7, the method100may further include the step110aof storing the predetermined force signature40in the database42. Accordingly, the method100includes the step110bof accessing the database42to ascertain the predetermined force signature40. The database42transmits the predetermined force signature40to the processor38so the processor38may compare the actual force signature36to the predetermined force signature40, as shown in step112.

Referring now toFIG. 8, the lead12may be formed from the terminal14crimped onto the wire16. Therefore, the method100may further include the step118of crimping the terminal14onto the wire16to form the lead12. It is to be understood that the step118of crimping may be performed manually by an operator, or alternatively, the step118may be performed automatically by a crimping machine. Once the lead12is formed, the method100may further include the step120of securing the lead12to the holding device22. If the holding device22includes a channel24as shown inFIG. 1, the step120of securing the lead12to the holding device22may further include disposing the lead12in the channel24defined by the holding device22. Disposing the lead12into the channel24may be further defined as manually or automatically placing the lead12in the channel24. Once secured to the holding device22, the method100may further include a step122of aligning the lead12with the opening20in the connector18. Aligning the lead12with the opening20may be performed manually by an operator or automatically with a lead alignment device.

The present embodiments have been particularly shown and described with reference to the foregoing examples, which are merely illustrative of the best modes for carrying out the invention. It should be understood by those skilled in the art that various alternatives to the examples of the invention described herein may be employed in practicing the invention without departing from the spirit and scope of the invention as defined in the following claims. The examples should be understood to include all novel and non-obvious combinations of elements described herein, and claims may be presented in this or a later application to any novel and non-obvious combination of these elements. Moreover, the foregoing embodiments are illustrative, and no single feature or element is essential to all possible combinations that may be claimed in this or a later application.

The present embodiments have been particularly shown and described, which are merely illustrative of the best modes. It should be understood by those skilled in the art that various alternatives to the embodiments described herein may be employed in practicing the claims without departing from the spirit and scope as defined in the following claims. It is intended that the following claims define the scope of the invention and that the method and apparatus within the scope of these claims and their equivalents be covered thereby. This description should be understood to include all novel and non-obvious combinations of elements described herein, and claims may be presented in this or a later application to any novel and non-obvious combination of these elements. Moreover, the foregoing embodiments are illustrative, and no single feature or element is essential to all possible combinations that may be claimed in this or a later application.