Fuse Detection System
Wire Tech LTD is a wire harness manufacturing in Rome, GA. The main way of producing a harness here is through form boards. These boards contain visual cues that guide the operator though the process as well as a tester to ensure continuity of the harness.
Some of these harnesses contain a fusebox. With no way of checking the placement of fuses, this causes the largest number of rejected harnesses from costumers.
The solution was to create a system that can integrate with Dynalab testers to check the placed fuses. This is done with a control port module, raspberry pi, and 3D designed custom housing that contains a camera to image process the fuse.
The first thing to do was design a housing that can be mounted onto our form boards. There were 4 iterations of the housing with each one having elements of process improvement. The final housing having a closed environment for clean image processing. The fusebox can be slid into the housing to activate a switch which starts the python code.
The Image processing is done by creating region of interest over each fuse. It then runs an Optical Character Recognition test over each one. This allows us to compare whatever the read value is of each fuse and compare it to our target value. We also save each image taken with a time stamp as a quality assurance measure.
Example of UI images created to guide the operator through the process of fuse testing. This images will be displayed on a 7" touchscreen display that will be mounted on the form board along with the housing.
