JP4265027B2 - Inspection method and manufacturing method and apparatus for tape electric wire - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method and an inspection apparatus for inspecting a defect of each conductor wire immediately before a step of coating a tape wire with a laminated tape.
[0002]
[Prior art]
There are various types of tape electric wires, such as wiring in a housing of home appliances, automobile harnesses, and underfloor wiring connected to electronic office equipment in an office. The common point of the product is that the front and back surfaces of a large number of thin flat conductor wires are covered with insulating tape. In FIG. 6, the top view of the tape electric wire 100 is shown. Reference numeral 101 denotes a conductor wire, which is usually an extremely fine flat plate wire, and the front and back surfaces thereof are covered with a laminate tape 102 which is an insulator made of resin. The tape electric wire 100 is a long product made by a separately prepared production line, cut to a predetermined length, and then delivered to the user in a fixed size with the terminals of each conductor wire 101 exposed at both ends. Or, it is shipped in a long form and processed at the delivery destination.
[0003]
In recent years, in order to reduce the size of electronic devices and simplify wiring work, conductor wires have become thinner, and the pitch between conductor wires tends to become increasingly narrower. Specifically, there are products having a conductor wire thickness of 0.03 to 0.05 mm, a width of 0.3 mm, an adjacent interval of 0.2 mm, and a conductor wire number of 30 to 50. Therefore, it is important to inspect in advance for defects such as disconnection, short circuit, cross-connection, etc. of each conductor wire, and an appropriate inspection means is required.
[0004]
A conventional technique of the inspection means is proposed in Japanese Patent Laid-Open No. 8-148045. This inspection device is installed in a predetermined position with tape wires that are cut into a predetermined size and sent in a fixed size with each conductor wire exposed at both ends, and the pitch between the conductor wires of the tape wire is previously set. The electrodes consisting of a plurality of electrical contacts arranged at the same pitch as the contact are brought into contact with the exposed conductor strands at both ends of the tape wire, and a voltage is applied from the contacts to the conductor strands, thereby breaking the tape wire. After inspecting the mixed line and the like, the tape electric wire that has been inspected is discharged from a predetermined position.
[0005]
FIG. 7 shows an overall view of the inspection apparatus 200 showing the arrangement of the inspection units. The inspection apparatus 200 has an electric wire storage part 220 formed on a gantry 210 for stacking and storing tape electric wires cut into a predetermined size, and one end side thereof is installed below the electric wire storage part 220, and , A transport mechanism 230 installed on an extension line of the electric wire storage unit 220, and a tape electric wire provided adjacent to the transport mechanism 230 and drawn from the bottom of the electric wire storage unit 220 by the transport mechanism 230 at a predetermined position. An electric wire storage mechanism 240 for storing the electric wire, an electrode mechanism 250 which is located above the electric wire storage mechanism 240 and makes electrodes contact the exposed conductor wires at both ends of the tape electric wire, and the conductor of the tape electric wire via the electrode mechanism 250 An inspection mechanism 260 for inspecting disconnection or crossing by applying a voltage to the strand, and a tape electric wire that has been inspected are taken out from the electric wire storage mechanism 240 and discharged. And the ejection mechanism 270, and a inspected product stock 280 Metropolitan for receiving the transported tape cable.
[0006]
And if this inspection apparatus 200 is used, the dimension with respect to the flow direction of a product can be made small compared with the normal apparatus which is likely to be constructed in the tandem style on the extension line starting from the electric wire storage part 220, It is possible to work in a confined space. Further, it is described that the contact of the contact with each conductor wire at both ends of the tape electric wire is mechanically performed, and a voltage is applied thereto, so that an accurate electrical inspection is performed.
[0007]
[Problems to be solved by the invention]
However, this inspection apparatus 200 cannot detect the twist of each conductor wire or the abnormal approach of adjacent conductor wires. If these defects are accepted, it is likely to cause a disconnection or a short-circuit accident due to bending or twisting of the tape electric wire itself during wiring to electronic equipment or on-site wiring work. Furthermore, with this prior art, the quality after processing a long tape electric wire locally cannot be guaranteed.
[0008]
The present invention is an inspection method in which twisting, short-circuiting, and disconnection of each conductor wire are continuously non-contact inspected immediately before the tape tape laminating tape coating step, and quality assurance of a fixed or long tape electric wire can be reliably performed. And a manufacturing method and an apparatus thereof.
[0010]
[Means for Solving the Problems]
The inspection apparatus includes a camera for imaging the arrangement state of each conductor strand for each predetermined passage time between a first guide roller and a second guide roller having grooves for transferring a plurality of conductor strands. binarizing the image data, and, of the conductor element wire, twisted, overlapping, serpentine and an arithmetic unit for performing acceptability determination of disconnection, the surface discernible to indicia of defective sections of tape cable after lamination tape coated And the arithmetic unit measures a distance until the defect occurrence section reaches directly below the marking device . Then, the tape electric wire that has been inspected is shipped as a product in a predetermined fixed size or long shape after removing the identified defective occurrence section.
[0011]
In the manufacturing method, a plurality of conductor strands are passed between a first guide roller and a second guide roller, and image data obtained by imaging the conductor strands with a camera is binarized between two guide rollers. Is compared with a reference value to determine whether it is acceptable or not, and the distance until the defect occurrence section reaches just below the marking device is measured, and a plurality of laminate tapes and the conductor strands are coated with the first conductor strand to cover the conductor strands. Inserting and joining between the joining roller and the second joining roller, and then marking the surface of the failure occurrence section of the tape electric wire when the failure occurrence section comes directly below the marking device. To do.
[0012]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, an embodiment of an inspection apparatus embodying the present invention will be described in detail with reference to the drawings. FIG. 1 is an overall view showing the arrangement of each constituent unit of the inspection apparatus of the present invention. Each of the conductor wires 101a to e is guided by a guide roller 1 and a groove 1f of the guide roller 1 shown in the enlarged sectional view of FIG. It is illuminated from below the conductor wire 101 passing between the roller 1 and the second guide roller 2 by the line illumination 3 that crosses the conductor wire 101. A camera 4 as an imaging device such as a CCD camera is disposed above the opposite side. The conductor wire 101 that has passed through the second guide roller 2 is covered with a first joining roller 5 and a second joining roller 6 that press-contact the laminate tape 102 from the front and back sides, and an arrow is applied to a product drum (not shown) as a tape electric wire 100. Winded in the direction of A.
[0013]
Assuming that the transfer speed of the conductor wire 101 is about 1 m / min, the camera 4 captures an image at a timing of 1/1000 to 1/2000 seconds, inputs the image data to the arithmetic unit 7, and sets a preset threshold value. By binarizing the dark part and the bright part, it is determined whether the conductor wire 101 is twisted, short-circuited, meandered or disconnected. If there is a defect, the defect occurrence indicator lamp 8 is turned on. The recognition of the occurrence of a defect may not be visible, but may be audible such as an alarm buzzer. Next, the moving distance of the conductor wire 101 is measured by the arithmetic unit 7 from the rotation speed of the encoder 9 connected to the first bonding roller 5 or the second bonding roller 6, and the marking device 10 installed at the distance L. To mark the surface of the tape electric wire 100 in an identifiable manner.
[0014]
If there is no defect in the subsequent conductor wire 101, the defect occurrence indicator lamp 8 is turned off. The marking means may be a paint injection or a stamp. The marked defective portion is removed when shipping as a final product of the tape electric wire 100.
[0015]
The disconnection of the conductor wire 101 is reliably captured by the camera 4. As another means, a tension roller is provided between the bobbin of each conductor wire 101 and the first guide roller 1, and if the tension becomes lower than a preset tension, it can be replaced by a method in which the device is judged to be disconnected and stopped. it can.
[0016]
Next, an inspection method for detecting twisting, overlapping, meandering, disconnection, and the like of the conductor wire 101 from image data captured by the camera 4 will be described.
[0017]
The image data captured by the camera 4 after receiving the transmitted illumination below each conductor wire 101 for each set time of a separately provided timer is input to the arithmetic unit 7 and, as shown in FIG. Binarization is performed by dividing into a dark portion and a bright portion with a preset threshold value, and the pattern of the total width of the conductor wires of the tape electric wire 100 is recognized on the horizontal axis. Here, it is assumed that the dark part is a conductor element part and the bright part is a conductor element interval part. Then, if the width of the single conductor wire 101 is B, the width of the dark portion is B ′, and B ′ ≦ 0.8B, the arithmetic unit 7 determines that the conductor wire 101 is twisted, and the defect occurrence indicator lamp 8 Lights up. Thus, the production line supervisor determines whether or not the production line can be operated.
[0018]
If a torsional defect is accepted, even if a current-carrying function is temporarily present, bending or twisting of the tape electric wire itself during wiring to an electronic device or on-site wiring work, mechanical disconnection due to twisting, and joining rollers 5 and 6 4 is not preferable because residual stress is generated at the reversal point of the arrow D shown in FIG. 4 and the expansion and contraction due to the change in the ambient temperature is repeated, which eventually leads to disconnection.
[0019]
The arithmetic unit 7 that has determined that the torsion is defective identifies the defective part by the marking device 10 installed above when the broken part reaches the position of the distance L from the line illumination 3 from the rotation speed signal of the encoder 9. Command to mark on the surface of the tape electric wire 100.
[0020]
Similarly, if B ′ is B ′ ≧ 1.2B as the width of the dark portion, it is determined that the conductor wires 101 are overlapped, that is, short-circuited. If the width of the bright portion is C ′, the width of the adjacent conductor wire 101 is C, and if it exceeds the range of 0.9C ≦ C ′ ≦ 1.1C, it is determined that the conductor wire 101 is meandering. When the width of the dark part is less than the preset number B ′, it is determined that the conductor wire 101 is disconnected. The order of the above inspection items is not limited to the above description, and can be selected as appropriate. Further, the inspection result is not limited to the marking of the defective part, but the content and frequency of the defect for each inspection lot can be stored in the arithmetic unit 7 and output in an arbitrary format to be used as quality improvement management data.
[0021]
A series of these inspections will be described with reference to the flowcharts of FIGS. Along the outer periphery of the guide rollers 1 and 2 provided at a separated position, a line illumination 3 wider than the lower side of the conductor strands 101 aligned at a predetermined pitch is applied, and the camera 4 positioned at the upper side is opposed. (1) The conductor strand 101 is imaged every time set by the timer. (2) The image data is input to the arithmetic unit 7. (3) The image data is binarized and patterned into a dark part and a bright part with an arbitrary threshold value. (4) Pass / fail judgment is made in comparison with a judgment criterion inputted in advance to the arithmetic unit 7. (5) Perform each inspection of twist, overlap, meander, and disconnection.
[0022]
(6) If there is a defect, the defect occurrence indicator lamp 8 is turned on. (7) The signal of the encoder 9 is input to the arithmetic unit 7. (8) The calculation device 7 measures the distance until the defective part reaches directly below the marking device 10. (9) When a defective part comes directly under the marking device 10, a defect identification mark is attached to the surface of the tape electric wire 100. (10) Continue to check for defects. (11) After a predetermined time has elapsed, if the presence of a defect is not recognized, the failure occurrence indicator lamp 8 is turned off. (12) The tape electric wire 100 for which the pass / fail judgment has been completed is wound around the product drum regardless of the presence or absence of defects.
[0023]
【The invention's effect】
Twist, overlap and meander of each conductor wire to be inspected between two guide rollers that align each conductor wire in the manufacturing process of the tape electric wire before coating the laminate tape on the front and back of the conductor wire , And a camera that detects the disconnection in a non-contact manner, and the captured image data is input to the arithmetic unit to perform continuous pass / fail judgment. Even if it is, it is easy to check the quality.
[0024]
The image data captured by the camera is binarized to detect any twisting failure of each conductor wire that cannot be detected by an electrical sensor. By repeating the expansion and contraction, it is possible to prevent problems that eventually lead to disconnection.
[Brief description of the drawings]
FIG. 1 is an overall view of an inspection apparatus according to the present invention.
FIG. 2 is an enlarged sectional view of a guide roller of the present invention.
FIG. 3 is a pattern recognition diagram of binarized image data according to the present invention.
FIG. 4 is an enlarged view of a torsionally defective portion of the conductor wire of the present invention.
FIG. 5 is a flowchart for automatically executing the inspection of the present invention.
FIG. 6 is a plan view of a fixed-size tape electric wire.
FIG. 7 is an overall view of a conventional tape wire inspection apparatus.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1; 1st guide roller 2; 2nd guide roller 3; Line illumination 4; Camera 5; 1st joining roller 6; 2nd joining roller 7; Arithmetic device 8; Tape electric wire 101; Conductor element wire 102; Laminate tape

Claims (2)

A camera is provided between the first guide roller and the second guide roller with grooves for transferring a plurality of conductor strands, and images the arrangement state of the conductor strands for each predetermined passage time. binarized, and, of the conductor element wire, twisted, overlapping, an arithmetic unit for performing acceptability determination serpentine and disconnection attaching identification indicia to the surface of the defective section of the tape cable after lamination tape coated An inspection apparatus for a tape electric wire , comprising: a marking device , wherein the arithmetic device measures a distance until the defect occurrence section reaches directly below the marking device. A plurality of conductor strands are passed between the first guide roller and the second guide roller, and image data obtained by imaging the conductor strands with a camera is binarized between the two guide rollers, and this is used as a reference value. In comparison, the pass / fail judgment is made and the distance until the defect occurrence section reaches just below the marking device is measured, and a plurality of laminate tapes and the conductor strands are covered with the first joining roller and the first joining roller to cover the conductor strands. The tape wire is characterized in that it is inserted and joined between two joining rollers, and then the surface of the failure occurrence section of the tape wire is marked when the failure occurrence section comes directly below the marking device . Production method.

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