Multisensor measurement of multi-pole connectors
Initial sample inspection of complex connector assemblies in automated measuring cycles
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Automotive electronics, consumer electronics, telecommunications, data technology, industrial electronics: in a large number of electrical and electronic systems, connectors in different designs and with a large variety of technologies ensure signal transmission and power supply.
Technological trends such as modularisation, miniaturisation and function extension open up opportunities for further growth for connectors in all areas of application. At the same time, however, these trends also increase requirements for the measurement and inspection technology, which is used to assure quality and process control of increasingly complex connector assemblies.
Flexible inspection capabilities and high measurement throughput
Dimensional accuracy of the contact elements
The perfect connection of a connector is guaranteed by the dimensional accuracy of its electrical contact elements (connector pins). For verification, the height of the pins (seating depth) related to a defined datum plane is measured. The typical length tolerance is in the range of ± 0.1 mm. It is the perfect interplay of the non-contact sensors on OPTIV M that forms the solution here; the camera sensor quickly locates the lateral position of the individual pin tips. For this purpose, the metrology software PC-DMIS provides a special image processing algorithm that allows for irregularly shaped pins to be reliably detected on the basis of a centre-of-gravity calculation. In the same measurement cycle, the vertical position of the pins is measured regardless of their shiny surface with the chromatic-confocal white light sensor. Due to the axial beam path of this non-contact distance sensor, there are no shading effects, so that even narrow and deep in the connector housing lying pin grids are reliably detected.In addition, the permissible positional deviation of each pin tip from its ideal zero position in the X and Y directions is measured. The corresponding datum is made using a constructed intersection that is derived from measured reference edges on the connector housing.
Measurement of the permissible positional deviation of the pin tips
Functional inspection of the connector housing
For some connectors - especially in the automotive industry and the eMobility sector - resistance to environmental influences, dirt and humidity are important mechanical requirements. The flatness of contact and sealing surfaces must therefore be measured.Measurement of the flatness of contact and sealing surfaces on the connector housing
The socket side of connectors also poses metrological challenges. In injection moulding or overmoulding processes, smallest cavities can be produced in very dense clusters.
Multisensor measurement of the spatial orientation of the connector sockets