Connector Pin Inspection with Ingenuity: 3D Line Scan

12 May, 2020.

Especially in the automotive industries, the quality of every single electrical connector is of utmost importance to ensure the safety and reliability of modern vehicles. To allow for high volume and cost-effective production on the other hand, a fully automated test must be applied to every single connector. In the report we propose a suitable concept based on optical methods, employing a Chromasens 3DPIXA high speed stereo line scan camera in combination with a sophisticated image data processing pipeline. The main task is to measure the relative position of pin tips to each other and also absolute with respect to the connector housing. Therefore the applied image processing algorithm must detect various numbers of plugs in the image and create corresponding regions if interest. The pin tips of a plug have to be in a predefined grid with cylindrical areas. The algorithm must define this reference grid and align this grid to the pin tips. The aim of the measurement is to detect individual pins that are not in this area. These pins could cause contact problems, the plugs must be sorted out.