Automotive connector pin height measurement

Overview

Automotive connector pin height measurement

A Comparison of contact-based, 2D Camera, and Sizector^® 3D Camera solutions 

Due to the irreplaceable advantages of 3D vision technology over contact-based methods and 2D cameras, it is increasingly being adopted in a wide range of application scenarios. Today, we will examine the different solutions available for automotive connector pin height measurement.

Contact-based measurement scheme

Contact-based Method: Multiple mechanical probes make the system bulky and difficult to reconfigure for different connector types.

Alt-text: Diagram of contact-based measurement using mechanical probes to touch connector pins.

As shown in the diagram, obtaining height information for the pins (light gray icons) using contact-based measurement requires multiple mechanical probes. This results in a bulky solution with high costs in hardware and valuable production floor space.

Furthermore, switching between different test objects requires physical rearrangement of the probes, which is time-consuming and labor-intensive. Consequently, this method fails to meet the flexible demands of modern large-scale manufacturing.

2D vision scheme

Height measurement by 2D cameras typically relies on side-view imaging. However, automotive connectors often have complex geometries where a significant number of pins are surrounded or shielded by the connector housing. As a result, 2D cameras cannot capture the pins from a side angle, and it is impossible to provide height measurement results.

2D Camera Limitations: Side-view setup fails because the connector housing (blue) blocks the line of sight to the pins (gray).

Alt-text: Diagram showing 2D camera side view blocked by the automotive connector housing.

3D vision approach

Sizector® 3D Camera captures fine geometric details from a top-down, shadow-free view. 

Crisp 3D point clouds of automotive connector pins

Alt-text: Crisp 3D point clouds of automotive connector pins using Sizector 3D camera. 

The Sizector® 3D Camera overcomes the limitations of the previous two methods. Taking pictures from a top-down view prevents pin height information from shadow and occlusion (as shown in the point clouds above) and provides comprehensive height data. Beyond its compact and integrated design, Sizector offers distinct advantages in this industrial scenario:

Simplified integration

Unlike contact probes that require complex mechanisms, the camera requires only a simple static mount or a collaborative arm if needed. This makes the related mechanical design for installation much simpler.

High flexibility

Product changeover only requires a simple setting adjustment in our SDK or your own software, without mechanical retooling.

Cost-efficiency

It helps improve measurement efficiency while reducing long-term operation and maintenance costs.