Patent Publication Number: US-2015082889-A1

Title: Post-crimp inspection device using ultrasonic transducer

Description:
BACKGROUND OF THE INVENTION 
     The subject matter herein relates generally to post-crimp inspection devices using ultrasonic transducers. 
     Terminals are typically crimped onto wires by means of a conventional crimping press having an anvil for supporting the electrical terminal and a ram that is movable toward and away from the anvil for crimping the terminal. In operation, a terminal is placed on the anvil, an end of a wire is inserted into the ferrule or barrel of the terminal, and the ram is caused to move toward the anvil to the limit of the stroke of the press, thereby crimping the terminal onto the wire. The ram is then retracted to its starting point. 
     New technologies in ultrasonic monitoring have been proposed for use in crimp quality monitoring. For example, U.S. Pat. No. 7,181,942 to Yost describes an ultrasonic device and method for measuring crimp connections by comparing signals with signals from a previous crimp that was determined to be desirable through destructive testing. Yost describes a method of using the ultrasonic device to recertify the desirability of the crimp connection after its formation by aligning the crimp connector with the same punch and anvil and retransmitting acoustic signals through the crimp connection and comparing the received signal with the signal received when the crimp connection was originally made. Such ultrasonic recertification is problematic because the method requires the use of the same tool using the same punch and anvil to line up with the crimp connector. Because the same tool is used, such tool must be taken off-line and is therefore not being used to create more product. Additionally, such tool typically does not have any way to limit the closing action which may cause further compression or distortion of the crimp connection, leading to inaccurate measurements. 
     A need remains for a crimp quality monitoring system having improved post-crimp inspection devices and methods. 
     BRIEF DESCRIPTION OF THE INVENTION 
     In an embodiment, a post-crimp inspection device is provided that includes first and second arms with an inspection zone being defined between the first and second arms and configured to receive a crimped terminal. At least one of the first and second arms is movable toward the crimped terminal during a testing phase. An ultrasonic transducer is coupled to the first arm. The ultrasonic transducer transmits acoustic signals toward the crimped terminal. A compliant member is positioned between the ultrasonic transducer and the crimped terminal. The ultrasonic transducer is ultrasonically coupled to the crimped terminal via the compliant member. The compliant member may conform to a contour of the terminal. The compliant member may receive, and be ultrasonically coupled to, crimped terminals that are crimped using different crimp tooling. 
     Optionally, the compliant member may be applied directly to the ultrasonic transducer. Optionally, the post-crimp inspection device may include a mounting block having a first side and a second side. The ultrasonic transducer may be coupled to the first side and the compliant member may be coupled to the second side. The second side may define an emitting face with the acoustic signals being emitted from the emitting face. The emitting face may have a contour that does not match a contour of the crimped terminal. The compliant member may be applied directly to the emitting face. The compliant member may be elastically deformed against the crimped terminal to match at least a portion of the contour of the crimped terminal. The second side may be concave to focus the acoustic signals inward toward the contact terminal. 
     Optionally, the ultrasonic transducer may define a first ultrasonic transducer and the compliant member may define a first compliant member. The post-crimp inspection device may include a second ultrasonic transducer coupled to the second arm that receives the acoustic signals and a second compliant member positioned between the second ultrasonic transducer and the crimped terminal. The crimped terminal may be ultrasonically coupled to the second ultrasonic transducer via the second compliant member. Optionally, the first and second compliant members do not touch one another. The crimped terminal may include a top, a bottom, a first side and a second side. The first compliant member may engage the top and the first and second sides. The second compliant member may engage the bottom and the first and second sides. 
     In another embodiment, a post-crimp inspection device is provided that includes first and second arms with an inspection zone being defined between the first and second arms configured to receive a crimped terminal. At least one of the first and second arms is movable toward the crimped terminal during a testing phase. An ultrasonic transducer assembly is coupled to the first arm. The ultrasonic transducer assembly has a transmitting transducer transmitting acoustic signals toward the crimped terminal. The ultrasonic transducer assembly has an emitting face through which the acoustic signals are emitted. The emitting face has a contour that does not match a contour of the crimped terminal. A compliant member is applied directly to the emitting face. The compliant member is elastically deformed against the crimped terminal to match at least a portion of the contour of the crimped terminal. The acoustic signals pass from the emitting face through the compliant member into the crimped terminal during the testing phase. 
     In a further embodiment, a post-crimp inspection device is provided that includes first and second arms with an inspection zone being defined between the first and second arms configured to receive a crimped terminal. At least one of the first and second arms is movable toward the crimped terminal during a testing phase. A first ultrasonic transducer assembly is coupled to the first arm. The first ultrasonic transducer assembly has a transmitting transducer transmitting acoustic signals toward the crimped terminal. The first ultrasonic transducer assembly has an emitting face through which the acoustic signals are emitted. The first ultrasonic transducer assembly has a first compliant member applied directly to the emitting face. The first compliant member is elastically deformed against the crimped terminal. The acoustic signals pass from the emitting face through the first compliant member into the crimped terminal during the testing phase. A second ultrasonic transducer assembly is coupled to the second arm. The second ultrasonic transducer assembly has a receiving transducer receiving the acoustic signals. The second ultrasonic transducer assembly has a receiving face through which the acoustic signals are received. The second ultrasonic transducer assembly has a second compliant member applied directly to the receiving face that is elastically deformed against the crimped terminal. The acoustic signals pass from the crimped terminal through the second compliant member into the receiving transducer during the testing phase. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a terminal crimping device according to an exemplary embodiment. 
         FIG. 2  illustrates a portion of the terminal crimping device showing an anvil and ram used to form a crimped terminal during a crimping operation. 
         FIG. 3  illustrates a portion of a post-crimp inspection device formed in accordance with an exemplary embodiment. 
         FIG. 4  illustrates a portion of the post-crimp inspection device in a closed state. 
         FIG. 5  illustrates a portion of the post-crimp inspection device in accordance with an exemplary embodiment. 
         FIG. 6  illustrates a portion of a post-crimp inspection device formed in accordance with an exemplary embodiment. 
         FIG. 7  illustrates a portion of the post-crimp inspection device formed in accordance with an exemplary embodiment. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Embodiments described herein provide a post-crimp inspection device that uses ultrasonic transducers to monitor crimp quality. The post-crimp inspection device tests a crimped terminal, after the terminal has been crimped to the wire, for certain crimp characteristics, such as crimp height, crimp geometry, crimp symmetry, roll, twist, flash, wire uniformity throughout the crimped terminal, missing strands, and the like. The post-crimp inspection device uses compliant member(s) to create an acoustic interface with the crimped terminal. The compliant member(s) allow the acoustic signals to be transmitted between ultrasonic transducer(s) and the crimped terminal. The compliant member(s) allow the same post-crimp inspection device to test and inspect different kinds of crimped terminals, such as crimped terminals from different terminal crimping devices, different sized crimped terminals, different types of crimped terminals, and the like because the compliant members conform to the contour of the crimped terminal. The Figures illustrate exemplary embodiments of a terminal crimping device that is used to form a crimped terminal as well as exemplary embodiments of a post-crimp inspection device used to inspect crimped terminals. 
       FIG. 1  is a perspective view of a terminal crimping device  100  formed in accordance with an exemplary embodiment. The terminal crimping device  100  is used for crimping terminals to wires. In the illustrated embodiment, the terminal crimping device  100  is a bench machine having an applicator  102 . Alternatively, the terminal crimping device  100  may be another type of crimping machine, such as a lead maker or a hand tool. In an exemplary embodiment, as described in further detail below, the post-crimp inspection device may be configured to inspect different kinds of crimped terminals, such as crimped terminals that are crimped using an applicator a lead-maker and a hand-tool. 
     The terminal crimping device  100  includes crimp tooling  104  that is used to form the terminal during the pressing or crimping operation. The terminal crimping device  100  has a terminating zone or crimp zone  106  defined between the crimp tooling  104 . Electrical connectors or terminals  110  and an end of a wire  112  are presented in the crimp zone  106  between the crimp tooling  104 . In an exemplary embodiment, the crimp tooling  104  used for crimping includes an anvil  114  and a ram  116 . The anvil  114  and/or the ram  116  may have removable dies that define the shape or profile of the terminal  110  during the crimping process. Changing of the dies may change the shape of the crimped terminal. The dies may be changed to accommodate a larger wire and larger terminal. In an exemplary embodiment, as described in further detail below, the post-crimp inspection device may be configured to inspect different kinds of crimped terminals, such as crimped terminals that are crimped with different dies that are swapped into the anvil  114  and/or ram  116 . In the illustrated embodiment, the anvil  114  is a stationary component of the applicator  102 , and the ram  116  represents a movable component. Alternatively, both the ram  116  and the anvil  114  may be movable. For example, with hand tools, typically both halves of the crimp tooling  104  are closed toward each other during the crimping operation. 
     The terminal crimping device  100  includes a feeder device  118  that is positioned to feed the terminals  110  to the crimp zone  106 . The feeder device  118  may be positioned adjacent to the mechanical crimp tooling  104  in order to deliver the terminals  110  to the crimp zone  106 . The terminals  110  may be guided to the crimp zone  106  by a feed mechanism to ensure proper placement and/orientation of the terminal  110  in the crimp zone  106 . The wire  112  is delivered to the crimp zone  106  by a wire feeder (not shown). 
     During a crimping operation, the ram  116  of the applicator  102  is driven through a crimp stroke by a driving mechanism  120  of the terminal crimping device  100  initially towards the stationary anvil  114  and finally away from the anvil  114 . Thus, the crimp stroke has both a downward component and an upward component. The crimping of the terminal  110  to the wire  112  occurs during the downward component of the crimp stroke. During the crimping operation, a terminal  110  is loaded onto the anvil  114  in the crimp zone  106 , and an end of the wire  112  is fed within a crimp barrel of the terminal  110 . The ram  116  is then driven downward along the crimp stroke towards the anvil  114 . The ram  116  engages the crimp barrel of the terminal  110  and deforms (e.g. folds or rolls) the ends of the crimp barrel inward around the wire  112 . The crimp tooling  104  crimps the terminal  110  onto the wire  112  by compressing or pinching the terminal  110  between the ram  116  and the anvil  114 . The ram  116  then returns to an upward position. As the ram  116  moves upward, the ram  116  releases or separates from the terminal  110 . In an exemplary embodiment, the resilient nature of the terminal  110  and/or wires  112  causes the terminal  110  to rebound slightly from the bottom dead center of the downward portion of the crimp stroke. The elastic yield or spring back of the terminal  110  will follow the ram  116  for a portion of the return or upward part of the stroke of the ram  116  until the terminal  110  reaches a final or stable size. At such point, the terminal  110  has a particular crimp height measured between the bottom and top most points of the terminal  110 . 
     The operation of the terminal crimping device  100  is controlled by a control module  130 . For example, the control module  130  may control the operation of the driving mechanism  120 . The control module  130  may control the operation of the feeder device  118  and synchronizes the timing of the crimp stroke with the timing of a feed stroke of the feeder device  118 . In an exemplary embodiment, the control module  130  includes a crimp quality module  132  that determines a crimp quality of the particular crimp. The terminal  110  may be discarded if the crimp quality does not meet certain specifications. In an exemplary embodiment, the crimp quality module  132  determines a crimp height of the terminal as a measure of crimp quality. The crimp quality module  132  may determine crimp quality based on other characteristics in addition to, or in the alternative to, the crimp height, such as a force measurement or force profile of the terminal during the crimp. The post-crimp inspection device may be used to calibrate and/or validate the analysis of the crimp quality module  132 . 
     In an exemplary embodiment, the control module  130  includes an ultrasound module  140  for transmitting and receiving ultrasonic acoustic signals. The ultrasound module  140  may cause acoustic signals to be transmitted through the terminal  110  and the wire  112  during the crimping operation. The crimp quality module  132  may determine crimp quality based on the acoustic signals transmitted through the terminal  110  and the wire  112 . The crimp quality module  132  may determine a crimp height of the terminal  110  based on the acoustic signals transmitted through the terminal  110  and the wire  112 . The crimp quality module  132  may determine a shape of the crimped terminal based on the acoustic signals transmitted through the terminal  110  and the wire  112 . The ultrasound module  140  may cause acoustic signals to be transmitted through the ram  116  and/or the anvil  114  in addition to the terminal  110  and the wire  112  during the crimping operation. For example, in some embodiments, the acoustic signals may be generated at a transducer in the ram  116 , transmitted through the ram  116 , through the terminal  110 , through the wire  112  and through the anvil  114  and then received at a transducer in the anvil  114 . In some embodiments, the acoustic signals may be generated at a transducer in the anvil  114 , transmitted through the anvil  114 , through the terminal  110 , through the wire  112  and through the ram  116  and then received at a transducer in the ram  116 . In some embodiments, the acoustic signals may be generated at a transducer in the ram  116 , transmitted through the ram  116 , through the terminal  110 , through the wire  112  and then back through the ram  116  and then received at a transducer in the ram  116 , which may be the same transducer that generated the acoustic signal. In some embodiments, the acoustic signals may be generated at a transducer in the anvil  114 , transmitted through the anvil  114 , through the terminal  110 , through the wire  112  and then back through the anvil  114  and then received at a transducer in the anvil  114 , which may be the same transducer that generated the acoustic signal. 
       FIG. 2  illustrates a portion of the terminal crimping device  100  showing the anvil  114  and the ram  116  used to form the crimp during the crimping operation. The crimp tooling  104  forms an F-crimp in the illustrated embodiment; however other shape crimp tooling or dies may form crimps having other shapes in alternative embodiments. 
     The anvil  114  has a support surface  150  used to support the terminal  110 . In the illustrated embodiment, the support surface  150  is flat and horizontal; however the support surface  150  may have other shapes and/orientations in alternative embodiments. The terminal  110  rests on the support surface  150  as the ram  116  is moved through the crimp stroke. 
     The ram  116  has a forming surface  152  that engages the terminal  110  during the crimping process. The forming surface  152  presses the sidewalls of the terminal barrel inward during the crimping process. The forming surface  152  compresses the sidewalls against the wire  112  during the crimping process. When the ram  116  is in contact with the terminal  110 , acoustic signals  158  may be transmitted across the forming surface  152  into the terminal  110  and wire  112 . The acoustic signals  158  may be transmitted across the support surface  150  into the anvil  114 . The acoustic signals  158  may be reflected at the interfaces defined at the forming surface  152  and support surface  150 . 
     In an exemplary embodiment, the ultrasound module  140  (shown in  FIG. 1 ) includes one or more ultrasonic transducers  160  that transmit and/or receive acoustic signals  158  in the ultrasonic frequency range. In the illustrated embodiment, the ultrasound module  140  includes an ultrasonic transmitting transducer  162  and an ultrasonic receiving transducer  164 . The ultrasonic transmitting transducer  162  is coupled to the ram  116 , while the ultrasonic receiving transducer  164  is coupled to the anvil  114 . In other embodiments, the ultrasonic receiving transducer  164  may be coupled to the ram  116  and/or the ultrasonic transmitting transducer  162  may be coupled to the anvil  114 . In other embodiments, rather than having dedicated transmitting and receiving transducers, either or both of the transducers  162 ,  164  may be capable of transmitting and receiving the acoustic signals  158 . In other embodiments, only one transducer  162  or  164  is needed that is capable of transmitting and receiving the acoustic signals  158 . The ultrasonic transducers  160  may be coupled to an outer surface of the crimp tooling  104 . Alternatively, the ultrasonic transducers  160  may be embedded within the crimp tooling  104 . The ultrasonic transducers  160  are ultrasonically coupled to the crimp tooling  104 , wherein the acoustic signals  158  may be transmitted to or from the ultrasonic transducers  160  to or from the crimp tooling  104 . The ultrasonic transducers  160  are ultrasonically coupled to the terminal  110  and wire  112  via the crimp tooling  104 . 
     In an exemplary embodiment, the ultrasonic transducers  160  are piezoelectric transducers that convert electrical energy into sound. The piezoelectric transducers change size when a voltage is applied thereto. The ultrasound module  140  includes electric circuitry coupled to the ultrasonic transmitting transducer  162  to supply an alternating current across the ultrasonic transducer  162  to cause oscillation at very high frequencies to produce very high frequency sound waves. The ultrasonic receiving transducer  164  generates a voltage when force is applied thereto from the acoustic signals  158  and the electric signal generated at the ultrasonic receiving transducer  164  is transmitted by electric circuitry coupled thereto to the ultrasound module  140  and/or the crimp quality module  132  (shown in  FIG. 1 ). Other types of ultrasonic transducers  160  other than piezoelectric transducers may be used in alternative embodiments, such as magnetostrictive transducers. 
     In an exemplary embodiment, the ultrasound module  140  and/or crimp quality module  132  is/are used to analyze certain crimp characteristics, such as crimp height, crimp geometry, crimp symmetry, roll, twist, flash, wire uniformity throughout the crimped terminal, missing strands, and the like. For example, the ultrasound module  140  generates the ultrasonic acoustic signal  158  at the transmitting transducer  162 . The acoustic signal  158  travels through the crimp tooling  104  and crimped terminal  110  and wire  112  in the form of a longitudinal sound wave, however the wave may be propagated in any direction. The ultrasonic receiving transducer  164  receives the acoustic signal  158  and converts such signal to an electrical signal for processing, such as by the crimp quality module  132 . Such process may be repeated approximately 500 or more times per crimp cycle. In an exemplary embodiment, the post-crimp inspection device may be used to calibrate and/or validate the analysis of the crimp quality module  132 . 
       FIG. 3  illustrates a portion of a post-crimp inspection device  200  formed in accordance with an exemplary embodiment and in an open state.  FIG. 4  illustrates a portion of the post-crimp inspection device  200  in a closed state and inspecting a crimped terminal  202 . The post-crimp inspection device  200  is used to inspect the crimped terminal  202  after the terminal  110  has been crimped to the wire  112  for certain crimp characteristics, such as crimp height, crimp geometry, crimp symmetry, roll, twist, flash, wire uniformity throughout the crimped terminal  202 , missing strands, and the like. In an exemplary embodiment, the post-crimp inspection device  200  is used to test and inspect different kinds of crimped terminals  202 , such as crimped terminals from different terminal crimping devices, different sized crimped terminals, different types of crimped terminals, and the like. 
     The post-crimp inspection device  200  includes a first arm  204  holding a first ultrasonic transducer assembly  206  and a second arm  208  holding a second ultrasonic transducer assembly  210 . An inspection zone  212  is defined between the first and second arms  204 ,  208  and between the first and second ultrasonic transducer assemblies  206 ,  210 . The crimped terminal  202  is received in the inspection zone  212 . 
     During a testing phase, at least one of the first and second arms  204 ,  208  are movable toward the crimped terminal  202  from the open state (shown in  FIG. 3 ) to the closed state (shown in  FIG. 4 ). As the first arm  204  and/or the second arm  208  are moved, the transducer assemblies  206  and/or  210  are likewise moved into position relative to the crimped terminal  202  for inspection thereof. Optionally, the first arm  204  and/or second arm  208  may have a limited amount of movement that restricts the relative positions of the first and second arms  204 ,  208  in the closed state to ensure that the crimped terminal  202  is not compressed during the testing phase. Optionally, the post-crimp inspection device  200  may be part of a machine having a actuator that moves the first and/or second arms  204 ,  208 , such as in a similar way as the applicator  102  (shown in  FIG. 1 ) moves the ram  116  (shown in  FIG. 1 ) during the crimping process. In an alternative embodiment, rather than being an electrically actuated machine, the post-crimp inspection device  200  may be a manual device, such as a hand tool or a machine having a hand operated lever that allows an operator to move the first arm  204  and/or the second arm  208  during the testing phase. 
     The first ultrasonic transducer assembly  206  includes a first ultrasonic transducer  220 . The first ultrasonic transducer assembly  206  includes a mounting block  222  and a first compliant member  224  mounted to the mounting block  222 . The mounting block  222  and compliant member  224  are ultrasonically coupled to the ultrasonic transducer  220 . Ultrasonic acoustic signals are configured to pass through the mounting block  222  and the complaint member  224  to and/or from the ultrasonic transducer  220 . The ultrasonic transducer  220 , mounting block  222  and the compliant member  224  are all supported by, and movable with, the first arm  204 . Optionally, the ultrasonic transducer  220  is coupled to the first arm  204 , the mounting block  222  is coupled to the ultrasonic transducer  220  and the compliant member  224  is coupled to the mounting block  222 . Alternatively, the mounting block  222  may be coupled to the first arm  204  and the ultrasonic transducer  220  and compliant member  224  may then be coupled to the mounting block  222 . 
     In an exemplary embodiment, the first ultrasonic transducer  220  is a transmitting transducer configured to transmit acoustic signals toward the crimped terminal  202 . The first ultrasonic transducer  220  may be referred to hereinafter as a transmitting transducer  220 . The first ultrasonic transducer  220  may be configured to receive acoustic signals in addition to, or in the alternative to, transmitting the acoustic signals. 
     The mounting block  222  has a first side  226  and a second side  228 . The transmitting transducer  220  is coupled to the first side  226 . The first compliant member  224  is coupled to the second side  228 . In an exemplary embodiment, the second side  228  defines an emitting face  230  and acoustic signals may be emitted from the emitting face  230  into the first compliant member  224 . The acoustic signals are emitted through the first compliant member  224  into the crimped terminal  202 . In alternative embodiments, the first ultrasonic transducer assembly  206  may be provided without the mounting block  222 , but rather the first compliant member  224  may be applied directly to the transducer  220 . 
     The mounting block  222  is manufactured from a material having good acoustic properties such that the acoustic signals may be efficiently transmitted through the mounting block  222  from the transmitting transducer  220  to the compliant member  224 . For example, the mounting block  222  may be manufactured from a metal material. In an exemplary embodiment, the mounting block  222  is a rigid body used to support the compliant member  224 . While the mounting block  222  is shown as being generally rectangular in cross section, it is realized that the mounting block  222  may have other shapes in alternative embodiments. For example, the first and/or second sides  226 ,  228  may be non-planar and/or non-parallel to one another. 
     The compliant member  224  is positioned between the transmitting transducer  220  and the crimped terminal  202 . In the illustrated embodiment, the compliant member  224  is applied directly to the second side  228  or emitting face  230  of the mounting block  222 . The compliant member  224  is elastically deformable. Optionally, the compliant member  224  may be an elastomer coupler. 
     The compliant member  224  is configured to engage the crimped terminal  202  and conform to a contour of the crimped terminal  202 . During use, the compliant member  224  is pressed against the crimped terminal  202  to ensure that the first ultrasonic transducer assembly  206  is adequately acoustically coupled to the crimped terminal  202  such that the acoustic signals may be transmitted between the transmitting transducer  220  and the crimped terminal  202 . 
     The compliant member  224  may have any shape to conform to the second side  228 . Optionally, the compliant member  224  may have a uniform thickness, however the compliant member  224  may have a non-uniform thickness in alternative embodiments. For example, the compliant member  224  maybe thicker at the outer sides thereof and/or at a central location thereof. 
     The compliant member  224  has a conforming surface  232  generally opposite the mounting block  222 . The conforming surface  232  is configured to engage the crimped terminal  202  and conform to the contour of the crimped terminal  202 , such as shown in  FIG. 4 . The conforming surface  232  does not necessarily need to match the contour of the crimped terminal  202  in a normal or un-deformed state (shown in  FIG. 3 ). The elastic nature of the compliant member  224  allows the conforming surface  232  to conform to the contour of the crimped terminal  202  when the first ultrasonic transducer assembly  206  is pressed against the crimped terminal  202 . In an exemplary embodiment, the first ultrasonic transducer assembly  206  is pressed against the crimped terminal  202  with sufficient force to deform the compliant member  224  to conform to the contour of the crimped terminal  202 , but not with great enough pressure to deform or change the shape of the crimped terminal  202 . 
     In an exemplary embodiment, the second side  228  of the mounting block  222  does not need to have a contour that matches the contour of the crimped terminal  202  as the compliant member  224  is used to conform to the contour of the crimped terminal  202 . The compliant member  224  allows the post-crimp inspection device  200  to test and inspect different kinds of crimped terminals, such as crimped terminals from different terminal crimping devices, different sized crimped terminals, different types of crimped terminals, and the like because of the compliant member  224  conforms to the contour of the crimped terminal  202 . The compliant member  224  is configured to receive and be ultrasonically coupled to crimped terminals  202  that are crimped using different crimp tooling, including crimped terminals  202  that have slight variations or drastic variations in the profile thereof. The post-crimp inspection device  200  is able to inspect different types of terminals without deforming or changing the shape of the crimped terminals during the testing phase (e.g. the crimp height does not change during the testing phase so that the post-crimp inspection device  200  is able to accurately measure the crimp height of the crimped terminal  202 ). 
     The second ultrasonic transducer assembly  210  includes a second ultrasonic transducer  240 . The second ultrasonic transducer assembly  210  includes a mounting block  242  and a second compliant member  244  mounted to the mounting block  242 . The mounting block  242  and compliant member  244  are ultrasonically coupled to the ultrasonic transducer  240 . Ultrasonic acoustic signals are configured to pass through the mounting block  242  and the complaint member  244  to and/or from the ultrasonic transducer  240 . The ultrasonic transducer  240 , mounting block  242  and the compliant member  244  are all supported by, and movable with, the second arm  204 . Optionally, the ultrasonic transducer  240  is coupled to the second arm  204 , the mounting block  242  is coupled to the ultrasonic transducer  240  and the compliant member  244  is coupled to the mounting block  242 . Alternatively, the mounting block  242  may be coupled to the second arm  204  and the ultrasonic transducer  240  and compliant member  244  may then be coupled to the mounting block  242 . 
     In an exemplary embodiment, the second ultrasonic transducer  240  is a receiving transducer configured to receive acoustic signals that have passed through the crimped terminal  202 . The second ultrasonic transducer  240  may be referred to hereinafter as a receiving transducer  240 . The acoustic signals received at the receiving transducer  240  are converted to electrical signals and analyzed, such as by a crimp quality module. The electrical signals may be compared to the electrical signals received by the ultrasonic receiving transducer  164  (shown in  FIG. 2 ) for calibration and/or validation of the crimp quality module  132  (shown in  FIG. 1 ). The second ultrasonic transducer  240  may be configured to transmit acoustic signals in addition to, or in the alternative to, receiving the acoustic signals. 
     The mounting block  242  has a first side  246  and a second side  248 . The transmitting transducer  240  is coupled to the first side  246 . The second compliant member  244  is coupled to the second side  248 . In an exemplary embodiment, the second side  248  defines a receiving face  250  and acoustic signals may be received through the receiving face  250  into the mounting block  242 . The acoustic signals are received after passing through the second compliant member  244  and the crimped terminal  202 . In alternative embodiments, the second ultrasonic transducer assembly  210  may be provided without the mounting block  242 , but rather the second compliant member  244  may be applied directly to the transducer  240 . 
     The mounting block  242  is manufactured from a material having good acoustic properties such that the acoustic signals may be efficiently transmitted through the mounting block  242  from the compliant member  244  to the receiving transducer  240 . For example, the mounting block  242  may be manufactured from a metal material. In an exemplary embodiment, the mounting block  242  is a rigid body used to support the compliant member  244 . While the mounting block  242  is shown as being generally rectangular in cross section, it is realized that the mounting block  242  may have other shapes in alternative embodiments. For example, the first and/or second sides  246 ,  248  may be non-planar and/or non-parallel to one another. The mounting block  242  may be shaped differently than the mounting block  222 . 
     The compliant member  244  is positioned between the transmitting transducer  240  and the crimped terminal  202 . In the illustrated embodiment, the compliant member  244  is applied directly to the second side  248  or receiving face  250  of the mounting block  242 . The compliant member  244  is elastically deformable. Optionally, the compliant member  244  may be an elastomer coupler. 
     The compliant member  244  is configured to engage the crimped terminal  202  and conform to a contour of the crimped terminal  202 . During use, the compliant member  244  is pressed against the crimped terminal  202  to ensure that the second ultrasonic transducer assembly  210  is adequately acoustically coupled to the crimped terminal  202  such that the acoustic signals may be transmitted between the transmitting transducer  240  and the crimped terminal  202 . 
     The compliant member  244  may have any shape to conform to the second side  248 . Optionally, the compliant member  244  may have a uniform thickness, however the compliant member  244  may have a non-uniform thickness in alternative embodiments. For example, the compliant member  244  maybe thicker at the outer sides thereof and/or at a central location thereof. The compliant member  244  may be shaped differently than the compliant member  224 . 
     The compliant member  244  has a conforming surface  252  generally opposite the mounting block  242 . The conforming surface  252  is configured to engage the crimped terminal  202  and conform to the contour of the crimped terminal  202 . The conforming surface  252  does not necessarily need to match the contour of the crimped terminal  202  in a normal or un-deformed state. The elastic nature of the compliant member  244  allows the conforming surface  252  to conform to the contour of the crimped terminal  202  when the second ultrasonic transducer assembly  210  is pressed against the crimped terminal  202 . In an exemplary embodiment, the second ultrasonic transducers assembly  210  is pressed against the crimped terminal  202  with sufficient force to deform the compliant member  244  to conform to the contour of the crimped terminal  202 , but not with great enough pressure to deform or change the shape of the crimped terminal  202 . 
     In an exemplary embodiment, the second side  248  of the mounting block  242  does not need to have a contour that matches the contour of the crimped terminal  202  as the compliant member  244  is used to conform to the contour of the crimped terminal  202 . The compliant member  244  allows the post-crimp inspection device  200  to test and inspect different kinds of crimped terminals, such as crimped terminals from different terminal crimping devices, different sized crimped terminals, different types of crimped terminals, and the like because of the compliant member  244  conforms to the contour of the crimped terminal  202 . The compliant member  244  is configured to receive and be ultrasonically coupled to crimped terminals  202  that are crimped using different crimp tooling, including crimped terminals  202  that have slight variations or drastic variations in the profile thereof. The post-crimp inspection device  200  is able to inspect different types of terminals without deforming or changing the shape of the crimped terminals during the testing phase (e.g. the crimp height does not change during the testing phase so that the post-crimp inspection device  200  is able to accurately measure the crimp height of the crimped terminal  202 ). 
     The crimped terminal  202  may have any shape or profile depending on the particular terminal  110  and gauge of the wire  112 . In the illustrated embodiment, the crimped terminal  202  has a top  260 , a bottom  262 , a first side  264  and a second side  266 . The bottom  262  may be flat, or alternatively may be curved. The sides  264 ,  266  may be curved or may be generally planar. The sides  264 ,  266  may be angled inward toward the top  260 . The top  260  may be flat or may be curved. The top  260  may be folded inward into the wire  112  at a center of the top  260 . 
     In an exemplary embodiment, the first compliant member  224  engages the top  260  and the first and second sides  264 ,  266 , while the second compliant member  244  engages the bottom  262  and the first and second sides  264 ,  266 . The compliant members  224 ,  244  may engage different parts of the crimped terminal  202  in other embodiments. Optionally, post-crimp inspection device  200  may receive the crimped terminal  202  in any orientation (e.g. any rotational orientation) and does not require the crimped terminal  202  to be precisely positioned within the inspection zone  212 . In an exemplary embodiment, the first and second compliant members  224 ,  244  do not engage one another. A direct ultrasonic path is not created between the compliant members  224 ,  244 , but rather the ultrasonic path is created only through the crimped terminal  202 . 
       FIG. 5  illustrates a portion of the post-crimp inspection device  200  showing the emitting face  230  and receiving face  250  of the mounting blocks  222 ,  242 , respectively, having curved surfaces. The emitting face  230  has a concave surface to direct or focus the acoustic signals toward the crimped terminal  202 . The receiving face  250  has a convex surface to direct or focus the acoustic signals toward the receiving transducer  240 . The post-crimp inspection device  200  may have other features that filter and/or direct the acoustic signals to reduce the signal-to-noise ratio of the received signals. 
       FIG. 6  illustrates a portion of a post-crimp inspection device  300  formed in accordance with an exemplary embodiment. The post-crimp inspection device  300  is similar to the post-crimp inspection device  200 , however the post-crimp inspection device  300  includes a single ultrasonic transducer  302  that is able to both transmit and receive ultrasonic acoustic signals. 
     The post-crimp inspection device  300  includes a first arm  304  that supports the ultrasonic transducer  302 . The post-crimp inspection device  300  includes a mounting block  306  and a compliant member  308 . A crimped terminal  310  is supported by a second arm  312 . The first arm  304  and/or the second arm  312  are moved relative to one another to press the compliant member  308  into the crimped terminal  310 . The transducer  302  transmits acoustic signals through the mounting block  306  and through the compliant member  308  into the crimped terminal. The acoustic signals are reflected back toward the transducer  302 , such as from the second arm  312 . Optionally, an acoustic reflector  314  may be provided along the second arm  312  that reflects the acoustic signals back toward the transducer  302 . An air interface may be used to reflect the acoustic signals. The acoustic signals received at the transducer  302  are converted to electrical signals and analyzed. 
       FIG. 7  illustrates a portion of the post-crimp inspection device  400  formed in accordance with an exemplary embodiment. The post-crimp inspection device  400  is similar to the post-crimp inspection devices  200 ,  300 , however the post-crimp inspection device  400  does not use a mounting block to support a transducer and/or compliant member. 
     The post-crimp inspection device  400  includes a first arm  402  that supports an ultrasonic transducer  404 . A compliant member  408  is applied directly to the transducer  404 . The transducer  404  transmits acoustic signals through the compliant member  408  into a crimped terminal  410 . The transducer  404  defines an emitting face  412  through which the acoustic signals are emitted. The compliant member  408  is applied directly to the emitting face  412 . 
     In an exemplary embodiment, the compliant member  408  includes multiple compliant member segments  408   a ,  408   b  selectively positioned to interface with select portions of the crimped terminal  410 . For example, the compliant members  408  are positioned along the peaks of the top of the crimped terminal  410  and do not extend entirely into the valley defined at the top of the crimped terminal  410 . The acoustic signals are thus forced to be transmitted into certain area(s) of the crimped terminal  410 , such as the tallest portion of the crimped terminal  410  or the area of the crimped terminal  410  that creates less reflections, echoes and/or noise. Any number of compliant members may be provided in alternative embodiments. 
     It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments, and are by no means limiting and are merely exemplary embodiments. Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means—plus-function format and are not intended to be interpreted based on 35 U.S.C. §112, sixth paragraph, unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.