WO2024260579A1 - Detection system for detecting an incorrectly installed plug connection of a plug connector, and data collection system for collecting measurement data for such a detection system - Google Patents

Abstract

In a detection system for detecting an incorrectly installed plug connection of a plug connector, the detection system comprises at least one plug-in attempt detection device for detecting a plug-in attempt, at least one measuring unit (3, 4, 6, 7, 8) for acquiring plug-in operation data and at least one verification device for verifying the plug connection using the data profile of acquired plug-in operation data.

Description

Detection system for detecting an incorrectly assembled plug connection of a connector and data collection system for collecting measurement data for such a detection system

The invention relates to a detection system for detecting an incorrectly mounted plug connection of a connector and a data collection system for collecting measurement data for such a detection system.

Detection systems for detecting an incorrectly assembled plug connection of a connector and data collection systems for collecting measurement data relating to the insertion of connectors are known in the prior art. During a plugging process, the plug part and coupling part of a connector or parts of these are locked into one another, with a sound signal or acoustic signal in the form of a clicking noise being emitted during this locking process. The assembly of such connectors is usually carried out manually. It is often not immediately apparent whether the plug connection has been made completely and correctly or not, i.e. whether a complete, safe and proper locking has taken place or not. It is therefore not necessarily possible to tell straight away when assembling connectors whether this assembly has been carried out completely and correctly, and therefore whether the plug connection is secure. The assembly force is strongly influenced by the person carrying out the assembly, and depends on the hand carrying out the assembly, the hand position, the sequence of movements and any possible jamming of the components to be assembled. As a rule, an incorrect plug connection will be discovered at the latest during the end-of-line test. However, an incorrectly installed plug connection of such a connector requires complex and therefore expensive rework to fix the problem of the incorrectly plugged connector.

From WO 2013/131632 A1, a control system and a method for controlling the assembly of a coupling device are known, comprising at least one connector, wherein an arrangement of a mobile Sensor device is provided in the immediate vicinity of the signal source of the connector. The signal is an electronic and/or acoustic or sound signal. The signal emitted during the plugging process is recorded and evaluated. If a sound signal, i.e. the characteristic sound of a plugging process, such as the characteristic sound of the locking or clicking of the retaining element of a connector, is emitted as a signal, this is recorded during the plugging process and evaluated in an evaluation unit. The recorded signal or sound can be separated from interference signals, in particular interference noise, and then checked to see whether proper locking has taken place, i.e. whether a secure plug connection has been achieved. The mobile sensor device is designed to detect a structure-borne and/or airborne sound signal. To detect structure-borne sound, the mobile sensor device is brought into vibrational contact with the coupling device and/or the at least one locking cam on it. The mobile sensor device is arranged on a carrier material or integrated into it, with the carrier material being disclosed as, for example, an assembly glove and/or an item of clothing and/or a device that can be worn on a person's body, such as a belt, a watch or a bracelet, into which the mobile sensor device can be or is integrated. The data recorded by the mobile sensor device is evaluated in a decentralized evaluation unit arranged nearby and/or in a central evaluation unit. The recorded data is transmitted via WLAN, Bluetooth, cable, one or more USB interfaces or via radio.

From WO 2016/070984 A1, a device and a method for monitoring an assembly of two components by means of a click fastening for connecting the components are known, wherein a sensor for detecting an assembly force and a sound receiver are present. During the assembly of the two components, the force applied to at least one of the two components is measured by means of a device used to connect the two components and the sound generated during the assembly of the two components. The course of the measured force is measured as a function of time and/or the course of the measured sound as a function of time is recorded. The progression of the force as a function of time and/or the progression of the sound as a function of time are evaluated and a signal is generated that indicates the quality of the assembly of the click fastening if the progression of the force as a function of time and/or the progression of the sound as a function of time corresponds to a predetermined criterion. Furthermore, during the assembly of the two components, the acceleration of a finger and/or a hand of an operator carrying out the assembly is measured. Using the assembly force as a basis as a signal is only suitable to a limited extent, since this depends on the person carrying out the assembly, whereby, for example, if the two components are misaligned during the plugging process, this has a major influence on the assembly force. Furthermore, the assembly force is difficult to detect and requires complex measuring sensors. The process is therefore prone to errors. The discriminatory power between a correct plug connection and an incorrect one is also difficult to determine with a force sensor. The acoustic sensor is susceptible to interference from distant background noise, such as the volume in an assembly hall. Assessing a proper plug connection and an improper one using an acoustic sensor and a motion sensor at the same time increases reliability and selectivity, but requires rapid processing of the recorded data, which entails a comparatively high effort in terms of high performance of the electronic components and in terms of size.

From WO 2015/053936 A1, a system for ensuring the joining of a connector is known, in which a microphone is arranged near the joining zone of electrical connectors, wherein the microphone is designed to detect an audible noise as soon as the electrical connector is joined. Furthermore, an output unit is provided which is connected to the microphone and receives the audio signals from the microphone. The output unit processes the audio signals to ensure the joining connection. The output unit filters out background noise to amplify the audio signals. Due to the use of an acoustic sensor, the system is suitable for applications in which a low to medium Separation is sufficient and/or in environments where little noise influences the measurement result. During evaluation, there is a limitation in the separation between a proper plug connection and an improper one.

WO 2017/062124 A1 also discloses a system for ensuring a joint connection of a connector. This comprises a sensor unit worn by the user, which is worn near or on the hand of the operator, wherein the sensor unit comprises an acoustic sensor which is arranged near a joint zone of electrical connectors. The acoustic sensor can detect an acoustic noise as soon as the electrical connector is joined. The system also comprises a controller worn by the user, which is connected to the acoustic sensor, wherein the controller receives the audio signals from the acoustic sensor and processes the audio signals to determine the joint status of a connector. The controller gives the operator feedback regarding the joint status of the connector. Due to the use of an acoustic sensor, this system is also suitable for applications in which a low to medium selectivity is sufficient and/or in environments in which only little noise influences the measurement result. Here, too, the evaluation results in a limitation in the ability to distinguish between a proper plug connection and an improper one.

Another system for ensuring a joint connection of a connector is known from WO 2017/062122 A1. This comprises an acoustic sensor that is arranged near a joining zone of electrical connectors, wherein the acoustic sensor is designed to detect audible noises as soon as the electrical connector is joined. Furthermore, a connector identification sensor is provided that is arranged near the electrical connectors. The connector identification sensor is designed to identify the presence of electrical connectors. The system also comprises a controller that is connected to the acoustic sensor and the connector identification sensor, wherein the controller receives the connector identification signals from the connector identification sensor. as well as the acoustic signals from the acoustic sensor. The controller processes the connector identification signals and the acoustic signals to check the safety of the joint connection. However, the connection identification sensor does not contribute to the evaluation of the plug connection, i.e. the question of whether it is correct or not, so that here too there is a limitation in the discriminatory power between a correct plug connection and an incorrect one.

Furthermore, FR 3 024 522 B1 discloses a system and a method for determining the locking of a manual connection of a lockable quick connector. In this case, a carrier is fixed to an operator, with at least one acoustic sensor being provided for measuring acoustic signals emitted by the connection. The measured acoustic signal is recorded. The recorded acoustic signals are filtered and compared with acoustic reference signals that are representative of the locking state of the connector, with a result of this comparison being obtained at the same time. A message is sent to the operator with regard to whether a locked state has been achieved or not. The method also includes detecting a movement of a first hand of the operator in order to measure movements of this first hand that are representative of the attempt to connect the connector. The detection of the movements serves to trigger the start of the measurement and recording of the acoustic signals. Furthermore, an auxiliary recording of the movements of the first hand measured during the recording of the movements is provided, and an auxiliary filtering of the recorded movements of the first hand and subsequently an auxiliary comparison of the recorded and filtered movements of the first hand with the reference movements showing an attempt at connection. As soon as a movement of the user's first hand is detected, a recording is triggered. Acoustic signals are recorded over a period of time and the filters and the comparison devices process the signals at an interval which lasts from a few tenths of a second before a trigger state to a few tenths of a second after. A two-stage test is thus carried out in sequential order, whereby the assessment of the quality of the The plug connection, i.e. whether it is correct or not, is only determined in the second step using the acoustic sensor alone. In the first step, the motion signal only triggers the recording of the acoustic signal.

From DE 10 2014 016 153 A1, a device and method are known which are suitable for monitoring an assembly of two components to be connected by means of a clip fastening, wherein a sensor for detecting an assembly force and a sound receiver are present. The sensor for detecting an assembly force and/or the sound receiver are arranged on a glove. In the method for monitoring an assembly of two components to be connected by means of a clip fastening, wherein the two components are brought together in order to carry out the assembly by means of a clip fastening, the force applied to at least one of the two components is measured during the assembly of the two components by means of a device which is used to connect the two components, and the sound which is generated during the assembly of the two components. The course of the force as a function of time and/or the course of the sound as a function of time is evaluated and a signal is generated which indicates a quality of the assembly of the clip fastening if the course of the force as a function of time and/or the course of the sound as a function of time corresponds to a predetermined criterion.

The above-mentioned devices and methods for monitoring assembly connections predominantly use acoustic detection, e.g. by detecting a clicking sound when a locking lug engages in an anchor or locking receptacle provided for this purpose. Some of the devices and methods also include pressure or acceleration sensors. The devices are usually limited to the main detection of signals from a finger or thumb of the hand of an operator who is carrying out the plugging process. The present invention is therefore based on the object of providing a detection system which serves to ensure assembly and therefore reliably detects incorrectly assembled plug connections.

The problem is solved for a detection system for detecting an incorrectly mounted plug connection of a connector, wherein the detection system comprises at least one plug-in attempt detection device for detecting a plug-in attempt, at least one measuring unit for recording plug-in process data and at least one verification device for verifying the plug connection via the data profile of recorded plug-in process data. The problem is also solved by a data collection system for collecting measurement data, wherein the data collection system comprises at least two measuring units, at least one data evaluation unit and at least one flexible carrier, wherein the at least two measuring units and the data evaluation unit are arranged on the flexible carrier and in close proximity to one another, wherein the measuring units each comprise at least one acceleration sensor and at least one of the measuring units comprises at least one microphone. Further developments of the invention are defined in the dependent claims.

This creates a detection system and a data collection system for collecting measurement data, in particular for collecting measurement data for such a detection system, in which on the one hand a plug-in attempt is detected by at least one plug-in attempt detection device, on the other hand measuring units for recording data of the respective plug-in processes and also at least one verification device are provided, by means of which an assessment of the quality of a respective plug connection is made possible after completion of the plug-in process based on the recorded plug-in process data by evaluating the recorded or recorded data profile. In contrast to the solutions of the prior art, the detection of incorrectly mounted plug connections and not just a verification of correctly mounted plug connections is provided for assembly security. For this purpose, the plug-in attempt is already detected, Subsequently, verification is carried out using the data profile of the plug-in process data.

Advantageously, at least one first measuring unit for detecting hand gestures for a plugging attempt and at least one second measuring unit for detecting the plugging process are provided, in which data on acceleration and/or force absorption as well as the released energy are recorded via the sound.

Due to the complexity of the trigger hand movements to be analyzed, which are recorded by the at least one first measuring unit and which are analyzed by the at least one plug-in attempt detection device for the presence of a plug-in attempt, rule-based data processing is usually not sufficient. The detection system therefore advantageously comprises at least one type of artificial intelligence, e.g. one or more artificial neural networks, with the help of which all measuring unit inputs can be converted or are converted as inputs to a binary output to indicate the decision of a correct plug connection or an incorrect plug connection. With the help of such an (artificial) neural network, all measuring unit or sensor inputs can be converted as inputs to a binary output, i.e. the decision plug connection OK.

(= proper plug connection is present) or NOK (= there is no proper or correct plug connection).

The measuring units can be or will be arranged on at least one of the fingers and the thumb of at least one hand of an operator who carries out the plugging process. The measuring units can be or will be arranged in particular on or at at least one carrier, in particular a flexible carrier. Such a carrier can be or will be designed, for example, in the manner of a glove, partial glove or in another manner suitable for fastening to a hand of an operator. If at least one flexible carrier is provided, this can be designed, for example, as a glove, partial glove and/or in the form of at least two straps that connect at least two measuring units and the at least one wrist unit to one another. For example, three islands can be provided, with two of these, a measuring unit is or will be arranged on each of them and the wrist unit is or will be arranged on the third, and are or will be connected to one another via straps or other connecting devices. Cables extending between the measuring units and the wrist unit can be fixed to the connecting devices. For example, two textile straps can be provided to which cables extending between the measuring units and the wrist unit are fixed. In order to be able to releasably fix straps in particular, but also individual areas of a glove or partial glove to one another in order to create a secure and good hold on an operator's hand, for example at least one Velcro fastener, at least one lacing or at least one other fastening device can be provided.

The detection system further advantageously comprises at least one wrist unit for arranging on a wrist of an operator carrying out a plugging process. The at least one wrist unit advantageously comprises at least one microphone for recording ambient noise and at least one microcontroller. In a sound data processing of the at least one microcontroller of the wrist unit, a comparison is made with the recorded data of a measuring unit that can be arranged or is arranged on a thumb of a hand of an operator, which can also be referred to as a thumb unit, in order to improve the recognition of the sound profile of the locking of the plug partners of the connector. This means that the sound profile of the locking of the plug part and coupling part as plug partners of a connector can be recorded more precisely in order to be able to better recognize this sound profile in the recorded data.

The at least one wrist unit further advantageously comprises at least one gyroscope or a gyroscopic device, wherein the gyroscope or the gyroscopic device records movement data of a hand of an operator, which are used as an identification trigger for opening a measurement window, wherein within the measurement window the presence of a data or signals characterizing the correct mating process.

The measuring units or sensors are preferably arranged on the fingers of one or both hands of an operator who is carrying out the plugging processes in such a way that they do not interfere with the operator when working with their hands, but still record all relevant measured values. Therefore, in a preferred embodiment, the measuring units can be arranged or are arranged intermedially or proximally on the fingers and/or thumb of at least one hand of an operator. In particular, when the measuring units are arranged on the thumb and index finger or between the thumb and index finger of at least one hand of an operator, the measuring units can be arranged or will be arranged in the area of the metacarpal bones of the hand. The sensors or measuring units, i.e. the sensory hardware units, are therefore not arranged in the area of the distal phalanx of the finger, rarely distally in the area of a middle phalanx of the finger, preferably intermedially, i.e. on the proximal phalanx of the finger, or proximally in the area of the metacarpal bone, with the proximal arrangement being particularly preferred.

It is also advantageous for the measuring units to be arranged in a rotational manner or rotated on or around the middle or proximal phalanx of the finger. When arranged on a thumb of an operator's hand, the at least one measuring unit can be arranged on the inside facing the index finger of the hand; when arranged on an index finger of an operator's hand, the at least one measuring unit can be arranged on the inside facing the thumb. In particular, an arrangement with a rotation in the direction of the top of the hand can be provided. When arranged on a middle finger and/or a ring finger and/or a little finger of an operator's hand, the arrangement in the direction of the top of the hand is particularly suitable.

A data collection system comprises at least two measuring units and at least one data evaluation unit, wherein the at least two measuring units and the data evaluation unit are mounted in close proximity to one another on a carrier, in particular a flexible carrier. The measuring units each contain at least one acceleration sensor and, in total, at least one microphone across all measuring units, i.e. at least one of the measuring units has at least one microphone. Redundancy can be created by providing a respective acceleration sensor or acceleration sensor on each measuring unit. With an advantageous provision of two microphones instead of just one, greater variability can also be created.

It is also advantageous for the at least one microphone of the at least one of the measuring units to be directed towards the fingertip or thumbtip of the hand of an operator carrying the measuring unit. This enables particularly good and interference-free recording of the acoustic signals that occur during the plugging process. Furthermore, at least one opening can advantageously be arranged in a housing of the measuring unit, which is covered by at least one membrane to protect against dust and water. The measuring unit or its housing is advantageously sealed from the environment. The at least one microphone is arranged in the housing of the measuring unit such that it is arranged inside the housing in the area of the opening or directly adjacent to it. In order to protect the microphone and the other components of the measuring unit, which are arranged inside its housing, from dust and water, the at least one opening is provided with the at least one membrane or covered by it. The opening is preferably directed towards the fingertip of a finger of the hand of an operator carrying the measuring unit(s). In order to be able to record and evaluate the audio signals in the best possible quality, the microphone is placed on the measuring unit, also known as the thumb unit, which is arranged on the thumb of the hand of an operator who is carrying out the plugging process, in the area of the opening for sound transmission and the opening is provided with or covered with a membrane to protect the microphone in particular. The opening covered by the at least one membrane is advantageously aligned towards the tip of the thumb in order to be able to better record audio signals from the plugging process compared to ambient noise. To record ambient noise, the at least one wrist unit includes at least one microphone. Since at least one of the at least two measuring units also includes a microphone, the microphone of the wrist unit is at least a second microphone that records ambient noise. In the sound data processing of the at least one microcontroller of the wrist unit, a comparison is made with the data recordings of the measuring unit, which is/will be arranged on the thumb of one hand of an operator carrying out the plugging process, so that the sound profile of the locking can be better recognized.

The at least one wrist unit further advantageously comprises at least one gyroscope or at least one gyroscopic device and a 3-axis acceleration sensor. This makes it particularly easy to record acceleration signals and movement data of an operator's hand, the latter, as already mentioned above, being used as an identification trigger to open a measurement window, wherein the presence of data or signals characterizing a proper plugging process is checked within the measurement window.

The data evaluation unit can be attached to the back of the hand of an operator who is carrying out a plugging process to be assessed, as movement data can be recorded better there than on the wrist. The wrist can distort movements that are carried out when assembling the connector, or movements recorded by a wrist unit on the wrist may be incorrectly evaluated.

Since operators perform delicate assembly tasks using the so-called tweezer grip when plugging a connector, the provision of at least two measuring units is particularly advantageous. The tweezer grip refers to holding the assembly piece or the parts of the connector, i.e. the plug part and the coupling part, between the index finger and thumb. Therefore, arranging the measuring units proximally on the thumb and index finger of one of the operator's hands is particularly advantageous. Depending on the type of plugging process, it varies whether the index finger or the thumb of one hand until a locking lug on the connector snaps into place.

More complex plugging tasks can be carried out with the help of additional fingers. The little finger can be particularly helpful when plugging the parts of a connector through narrow openings to push the plug part forward. This little finger is then advantageously provided with a measuring unit in order to be able to record and forward the signals from the plugging process. Depending on the application of the detection system or the data collection system, a different number of measuring units and a different arrangement of these can be provided on the fingers of at least one of the two hands of an operator carrying out the respective plugging process.

The at least one wrist unit can comprise at least one RFID unit with which a respective assembly station from which the wrist unit is used or RFID-tagged plugs can be made recognizable in the same IT system or are made recognizable as plug connections verified via the data collection system. The wrist unit thus comprises at least one RFID unit with which either the current assembly station from which the wrist unit is used can be recognized or RFID-tagged plug parts or plug connectors that can be made recognizable in the same IT system as the verified plug connections via the data collection system.

The data collection system can further advantageously be provided with or be equipped with at least one transmitting device for sending the recorded data to a data transmitter via WLAN, LTE, Bluetooth and/or radio technologies. The data transmitter can be a gateway, a server or an edge device. Furthermore, at least one local or cloud-based database for storing the collected data, a cloud for carrying out analyses of the plugging processes and at least one graphical evaluation unit for displaying evaluation results are provided. The operators who carry out the plugging processes carry the data collection system or the Detection system or its components during assembly of the connectors on at least one hand or wrist. The data collection system or in particular its wrist unit can send data, e.g. via WLAN, LTE, Bluetooth or other wireless technologies, to a data transmitter, such as a gateway, a server or an edge device. The data is stored in a local or cloud-based database. Analyses of the plugging processes can be carried out in an internal or external cloud and made available via a graphical evaluation.

In a method for checking and evaluating the quality of a plug connection of a connector that includes at least one locking stage, which method records a characteristic assembly movement pattern, a so-called "event" is first detected via the movement pattern of the hand of an operator carrying out the plugging process. In this case, such an event is understood to be a potential assembly attempt, i.e. a characteristic plugging movement that can be detected. The event activates acceleration sensors or

Accelerometer of one of the measuring units of the data collection system. If an increase is detected within a short period of time, the microphone is also switched on. It is also possible to have the acceleration sensors or acceleration sensors permanently record data (so-called streaming) and, in the case of an event, to analyze the last specifiable n milliseconds or n seconds of the recording and switch on the microphones based on this. The same applies to the microphones; these can also record acoustic signals or stream the data and discard all data until an event occurs. If the event was not a plug-in attempt, the data is discarded again. This results in the advantage of an energy-saving process in which the recording of personal audio data is significantly reduced compared to state-of-the-art solutions.

Die allgemeine Auflistung einzelner Merkmale des Datensammelsystems findet sich in der ersten Spalte der vorstehenden Tabelle, die jeweilige Umsetzung dieser Merkmale in den jeweiligen Ausführungsformen 1 bis 5 des Datensammelsystems findet sich in deren jeweiliger Spalte. Bei der ersten Ausführungsform des Datensammelsystems ist ein 1 -Achs- Beschleunigungssensor als Anzahl an Sensor- bzw. Messeinheitseingängen zum Erfassen der Gestensteuerung einer Hand einer Bedienperson, die einen Steckvorgang, der überwacht wird, durchführt, an der Handgelenkeinheit vorgesehen. Anordnungsstelle an der Handgelenkseinheit ist auf der Handgelenksoberseite. Es sind zwei Messeinheiten vorgesehen, die an einem Handschuh angeordnet sind. Die Datenverbindung zwischen Messeinheiten und Handgelenkseinheit ist durch Kabel verwirklicht. Die Positionen der Messeinheiten an den Fingern bzw. Daumen und Finger ist intermedial. Die Beschleunigungssensoren in den Messeinheiten sind in Form von 1 -Achs- Beschleunigungssensoren ausgeführt. Die Start/Stopp-Aktivierung erfolgt durch Betätigen eines Schalters am Gerät, also den Messeinheiten und/oder der Handgelenkseinheit. The table below lists five different versions 1 to 5 of the data collection system.

The general list of individual features of the data collection system can be found in the first column of the table above, the respective implementation of these features in the respective embodiments 1 to 5 of the data collection system can be found in their respective column. In the first embodiment of the data collection system, a 1-axis acceleration sensor is provided on the wrist unit as a number of sensor or measuring unit inputs for detecting the gesture control of a hand of an operator who is carrying out a plug-in process that is being monitored. The location on the wrist unit is on the top of the wrist. Two measuring units are provided, which are arranged on a glove. The data connection between the measuring units and the wrist unit is implemented by cable. The positions of the measuring units on the fingers or thumb and finger are intermedial. The acceleration sensors in the measuring units are designed in the form of 1-axis acceleration sensors. Start/stop activation takes place by pressing a switch on the device, i.e. the measuring units and/or the wrist unit.

In the second embodiment of the data collection system, a gyroscope with six channels as the number of sensor or measuring unit inputs for detecting the gesture control of a hand of an operator who is carrying out a plugging process that is being monitored is provided on the wrist unit. The location on the wrist unit is on the top of the hand. Three measuring units are provided, which are arranged on two gloves. These are therefore arranged on the two hands of an operator carrying out the plugging process, i.e. the operator wears two appropriately equipped gloves while carrying out the plugging processes when assembling the connectors. The data connection between the measuring units and the wrist unit is implemented via Bluetooth. The positions of the measuring units on the fingers or thumb and fingers are proximal. The acceleration sensors in the measuring units are designed as 3-axis acceleration sensors. Start/stop activation is carried out by geofencing. In the third embodiment of the data collection system, a gyroscope with nine channels as the number of sensor or measuring unit inputs for detecting the gesture control of a hand of an operator who is carrying out a plug-in process that is being monitored is provided on the wrist unit. Four measuring units are provided. The data connection between the measuring units and the wrist unit is implemented via WiFi (WLAN). The positions of the measuring units on the fingers or thumb and fingers can be provided distally. The acceleration sensors in the measuring units are designed in the form of a 6-axis gyroscope. Start/stop activation is carried out by reading an auto ID.

In the fourth embodiment of the data collection system, five measuring units are provided and proprietary radio is used as a data connection between the measuring units and the wrist unit. The acceleration sensors in the measuring units are designed in the form of a 9-axis gyroscope.

In the fifth embodiment of the data collection system, LTE is provided as the data connection between the measuring units and the wrist unit.

The five embodiments show examples of different embodiments that are possible with the data collection system in relation to the individual variable features thereof, which are mentioned in the first column. Further embodiments can be formed in particular by combining each variant in one row in the above table with each variant in each of the other rows. Of course, any mixed forms of the different embodiments listed can also be provided.

To explain the invention in more detail, embodiments of the invention are described in more detail below with reference to the drawings. These show: Figure 1 is a plan view of a right hand of an operator, which is provided with a partial glove with a detection system according to the invention with a data collection system according to the invention, comprising five measuring units according to the invention and a wrist unit according to the invention,

Figure 2 is a sketch of a right hand of an operator, on which a measuring unit according to the invention is arranged on the index finger and on the thumb of the hand, the measuring unit arranged on the thumb being provided with an opening with a microphone arranged behind it, Figure 3 is a sketch of a left hand of an operator for

Illustration of the different arrangement possibilities of measuring units on the hand, here on the thumb and index finger of the hand,

Figure 4 is a schematic diagram of two measuring units according to the invention, Figure 5 is a schematic diagram of a wrist unit according to the invention, Figure 6 is a schematic diagram of the communication paths of a detection system according to the invention with a data collection system according to the invention, Figure 7 is a signal-time diagram for illustrating a trigger cascade with a measurement or verification time window according to the invention, and

Figure 8 is a flow chart showing the individual steps of data acquisition according to the invention.

Figure 1 shows a first embodiment of a data collection system 1 according to the invention for collecting measurement data. The data collection system 1 comprises a flexible carrier 2 in the form of a partial glove. In the embodiment shown in Figure 1, two measuring units 3, 4 and a data evaluation unit 5 are attached to the flexible carrier 2. Figure 1 also shows further measuring units 6, 7, 8, which can also be either designed as part of the flexible carrier 2 or attached to it or arranged separately from it on a hand 10 of an operator who is carrying out a plug-in process of a connector, which cannot be seen in Figure 1, however. One of the measuring units 3, 4, 6, 7, 8 can be arranged on each of the fingers 11, 12, 13, 14 and the thumb 15 of the hand 10. As can be further seen from Figure 1, the data evaluation unit 5 is arranged on the back of the right hand 10, attached to the flexible carrier 2 in the form of the partial glove. The data evaluation unit 5 comprises a motion sensor in order to be able to record movement data from the operator's hand. Since an arrangement on the wrist can distort movements during assembly, arranging the data evaluation unit 5 on the back of the hand is particularly suitable. This is particularly possible when arranging the data evaluation unit 5 on a glove or partial glove, since the choice of positioning on the flexible carrier 2 can be very variable. The provision of the measuring unit 3 on the thumb 15 and the measuring unit 4 on the index finger 11 of the operator's hand 10 enables the operator to carry out the plugging process in a tweezer grip for delicate assembly tasks, with the respective assembly piece, i.e. the parts of a connector, being held between the index finger and thumb. In order to be able to carry out a plugging process, and in particular a successful plugging process, without hindrance and to be able to record it well, it is advisable to provide a measuring unit on the thumb and index finger of the hand 10.

In the embodiment shown in Figure 1, the two measuring units 3, 4 are each arranged intermedially on the thumb 15 and index finger 11. As can be seen from Figure 3, for example, there are various ways of arranging the measuring units on the hand, here on the left hand 16, of an operator. The respective measuring unit 4 is arranged here once distally, i.e. on the middle phalanx of the finger, the distal arrangement being identified by the reference numeral 110, once intermedially, this arrangement on the base phalanx being identified by the reference numeral 111, and once proximal, the proximal arrangement being identified by the reference numeral 112. The proximal arrangement is provided in Figure 3 in the area of a metacarpal bone of the hand 16. The arrangement does not necessarily have to be above the metacarpal bone, but can also be provided slightly offset from it. On the thumb 15 in the illustration In Figure 3, the measuring unit 3 is arranged intermedially, i.e. at the proximal phalanx of the thumb, which is indicated by the reference numeral 1 13.

Corresponding arrangements of the respective measuring unit 6, 7, 8 can be provided not only on the index finger 11, but also on the other fingers 12, 13, 14 of the hand, if this is desired. If, for example, more complex plug-in tasks are carried out, the other measuring units 6, 7, 8 can also be arranged on the other fingers 12, 13, 14 of the operator's hand 10. If, for example, during the plug-in process it is necessary for a plug part to be inserted into a narrow opening in a coupling part of a connector to be joined, the little finger 14 can also be used to help push the plug part forward. Accordingly, for such a plug-in process, arranging the measuring unit 8 on the little finger 14 of the operator's hand 10 is suitable in order to be able to easily record signals from the plug-in process and forward them to the data evaluation unit.

As can be seen from Figure 2, an arrangement of the two measuring units 3, 4 on the index finger 11 and on the thumb 15 of the right hand 10 of an operator is provided there, corresponding to Figure 1. The measuring unit 3, which is arranged on the thumb 15 of the person, comprises a microphone 30. This can also be seen from the sketched detailed view of the two measuring units 3, 4 in Figure 4. The measuring unit 3 comprises a housing 31 provided with an opening 32. The microphone 30 is arranged in the area of the opening 32 in the interior 33 of the housing 31 of the measuring unit 3. The opening 32 is sealed to the outside by a membrane 34 in order to prevent dirt and water from entering. Acoustic signals can still pass through the membrane 34. In order to be able to reliably record a possible click signal, which can characterize a correct plugging process, together with other data and signals, the opening 32 in the housing 31 of the measuring unit 3 is aligned in the direction of the thumb tip 150 of the thumb 15 of the operator's hand 10. This is shown in Figure 2 and also indicated by the arrow P1 in Figure 4. The arrow P1 points in the direction of the thumb tip 150. The measuring unit 3 further comprises a first acceleration sensor 35 and a second acceleration sensor 36 within its housing 31. The acceleration sensor(s) 35, 36 can be used to detect accelerations of the hand 10. The measuring unit 3 thus records both acoustic signals and acceleration signals. In order to be able to indicate to the operator whether the plugging process has been carried out correctly or incorrectly, in this case to be able to indicate this visually, the measuring unit 3 further comprises an optical display in the form of an LED 37 within its housing 31.

The measuring unit 4, which is also shown in Figure 4 and is arranged on the index finger 11 of the hand 10 (see Figures 1 and 2), also comprises a housing 40. An acceleration sensor 41 as well as electronics or electronic components 42 are arranged inside or in the interior 44 of the housing 40. Furthermore, the housing 40 of the measuring unit 4 also comprises an optical display device, shown here in the form of an LED 43. Of course, instead of the LEDs 37 and 43, another type of optical display and/or a haptic and/or an acoustic or other display can also be provided. The acceleration sensor 41 of the measuring unit 4 can thus detect accelerations of the index finger 11 during plugging processes.

Because the opening 32 in the housing 31 of the measuring unit 3 is aligned on the thumb 15 of the operator's hand 10 in the direction of the thumb tip 150, audio signals of the plugging process can be captured very well despite ambient noise.

In Figure 5, a wrist unit 9 is outlined, which also comprises a housing 90 provided with an opening 91. This opening 91 is also covered with a membrane 92 in order to be able to reliably prevent dirt, dust and liquid from penetrating into the interior 93 of the housing 90. Inside or in the interior 93 of the housing 90 of the wrist unit 9, a microphone 94 is also arranged in the area of the opening 91 in the housing 90 in order to be able to record ambient noise. This is recorded in the Sound data processing in a microcontroller 95, which is also arranged in the housing 90 of the wrist unit 9, is combined with the acoustic signals that are generated by the measuring unit 3, which is arranged on the thumb 15 of the operator's hand 10. This makes it easier to recognize the locking signal from the acoustic signals recorded by the measuring unit 3, which provides information about whether or not a plug-in process was carried out successfully. When the coupling part and plug part or the plug partners of a connector lock together, a characteristic sound profile occurs, which can be filtered out from the acoustic signals recorded by the microphone 30 of the measuring unit 3 by comparing it with the acoustic signals recorded by the microphone 94 of the wrist unit 9.

The wrist unit 9 also includes an acceleration sensor 96 and a gyroscope or a gyroscopic device 97 for recording general movement data, which serves as an identification carrier for opening a measurement window or verification window for verifying a correct plugging process or an incorrect plugging process. The wrist unit and its structure corresponds to the data evaluation unit 5, as shown in Figure 1 arranged on the flexible carrier.

In order to be able to send the result of the data evaluation within the microcontroller 95 to a display device and/or to a device that externally monitors the plugging processes, the wrist unit 9 includes a transmitter unit 99 in its housing 90, via which data can be sent wirelessly via WLAN and Bluetooth. The wrist unit 9 also includes an RFID antenna or a gate 98 and an optical display, here in the form of an LED 100. A visual display of the quality of the plugging process, i.e. whether an incorrect plugging process has taken place or a correct plugging process, can thus be displayed directly on the wrist unit 9, namely via the LED 100.

Via the RFID antenna or Gate 98 it is possible to set a current station from which the wrist unit or the measuring units and the Wrist unit, i.e. the data collection system 1, is used. This is indicated in Figure 6. Here, the wrist unit 9 of the data collection system 1 is recognized at a respective assembly station 200, 201, 202, at which plug connectors are mounted. The part of the data collection system 1 that is arranged on the operator 18 is thus recognized here at the individual assembly stations 200, 201, 202. Furthermore, it is possible to make RFID-tagged plug connectors recognizable in the same system as the verified plug connections via the data collection system 1 via the RFID antenna or the gate 98 of the wrist unit 9.

Figure 6 also shows that the data collection system 1 sends data, for example via WLAN, LTE, Bluetooth or other radio technologies, to a data transmitter, such as a gateway, a server or an edge device. Figure 6 shows an example of a data transmitter 210. The data transmission is indicated by three arrows 211. The data is stored in a local or external cloud-based database. Such a database 212 is also indicated in Figure 6. Analyses of the plug-in processes are carried out in an internal or external cloud 213. The results of the analyses can be made available to a wide variety of people via a graphical evaluation. A device for data processing or graphical processing in the form of a display 214 is also indicated in Figure 6.

Figure 7 shows a trigger cascade, which means that not just one trigger signal, but a cascade of triggers to trigger the check as to whether a sought-after signal, such as a characteristic acoustic signal, is present within a verification time window, is only carried out after several trigger signals have been present. In the uppermost signal-time diagram, an event is detected due to the exceedance of a threshold value Si in the movement data of the hand 10 of the operator 18, thus a potential assembly attempt, i.e. a characteristic plugging movement of the hand. When the threshold value Si in the movement data (the movement amplitude) is exceeded, an event trigger T _E is detected. This activates acceleration sensors 35, 36, 41, 96 of the measuring units 3, 4 and the Wrist unit 9. If an increase in the acceleration of the hand is detected within a short period of time, the microphone 30, 94 is switched on. The acceleration signals are shown in the second signal-time diagram in Figure 7. If the acceleration signal or the amplitude of the acceleration signal exceeds the threshold value S ₂ indicated there, an assembly attempt is detected by the amplitude peak or assembly trigger T _MV . This assembly trigger T _MV is therefore the second trigger that signals an assembly attempt. The microphone 30 of the measuring unit 3 and possibly also the microphone 94 of the wrist unit 9 are then switched on. If the acoustic signals also exceed a predetermined threshold value S3, which is shown in the third signal-time diagram in Figure 7, assembly is determined by this assembly amplitude M _A , i.e. assembly verification takes place. The acoustic signals that are recorded after the microphone is switched on to determine whether assembly verification is present are within a verification time window or measurement window M _v . The presence of assembly verification M _A acts as a trigger to open the verification time window or measurement window M _v . Accordingly, two trigger signals T _E and T _MV are present before the verification time window or measurement window M _v opens, within which the presence of assembly verification M _A is checked. This is therefore a trigger cascade.

It is also possible to have the acceleration sensors permanently record acceleration data, i.e. to operate a streaming, and only in the event of an event that is detected by the occurrence of the event trigger T _E , to analyze the last predeterminable n milliseconds or n seconds of the recording and only switch on the microphones based on this, i.e. microphone 30 of the measuring unit 3 and microphone 94 of the wrist unit 9. The same can also be done for the microphones, i.e. they permanently record acoustic signals, but they only temporarily store all the recorded data until an event occurs, i.e. the presence of the event trigger T _E and the trigger for the assembly attempt T _MV, and discard them again after checking whether the assembly amplitude M _A is present. If the event was not If the device is plugged in, all data is discarded. This means that the procedure is energy-saving and the recording of personal audio data can be reduced to the minimum necessary in accordance with the General Data Protection Regulation.

Figure 8 shows a flow chart with individual steps of data acquisition by the data collection system 1. In a first step 220, the data acquisition system 1 is switched on. In a second step 221, optical and haptic feedback is given that the data collection system 1 is ready to carry out data collection and evaluation. In a third step 222, a start button or a corresponding switch is pressed, which starts the recording of data. In a fourth step 223, movement data is first recorded. In a fifth step 224, a query is made as to whether an assembly attempt has taken place. In a sixth step 225, a query is made as to whether an event has been detected, i.e. whether an event trigger is present. In the event that no event trigger is present, in a seventh step 226 the operator 18 operates a corresponding switch, which enables the recorded data to be overwritten. In an eighth step 227, the recorded data set is saved and sent to an artificial intelligence for training. Thereafter, the recording of movement data is resumed as the next step, thus continuing the process with the fourth step 223.

If an event was detected in the sixth step 225, a measurement window M _v or verification window is opened in a ninth step 228 and the recording of acceleration and acoustic data is started. In the tenth step 229, it is determined whether a predefined trigger time window has already been exceeded. If this is the case, the assembly attempt is terminated in an eleventh step 230 and the fourth step 223 is started again, i.e. the recording of movement data. If the trigger time window has not yet been exceeded, a twelfth step 231 is used to check whether a stop has been activated, i.e. whether the data collection is to be aborted. If this is the case, the system continues with the eleventh step 230, i.e. the termination of the assembly attempt, and a Recording of movement data started in the fourth step 223. If no stop was pressed, the thirteenth step 232 checks whether suitable recording profiles have been recorded, i.e. whether a proper plugging process has been determined. If this is not the case, a corresponding NIO signal is output in the fourteenth step 233, i.e. the signal of an improper plugging process. This can be done haptically and/or visually, for example via the LED 37 of the measuring unit 3, LED 43 of the measuring unit 4 or LED 100 of the wrist unit 9 mentioned above. If a proper plugging process has been recorded, i.e. a suitable recording profile for a proper plugging process, the assembly results are saved in the next fifteenth step 234 so that they can be archived as part of quality assurance. The recording of movement data, i.e. the fourth step 223, can then be started again. The same applies if no proper plugging process (see step 233) was detected.

The extended data acquisition process, as outlined in the flow chart in Figure 8, is very efficient and information is fed back to an artificial intelligence for continuous learning of the data collection system 1 . As an alternative to manually operating switches or buttons, the opening and closing of the measurement window or verification time window as well as a signal for the next plugging process can also be triggered automatically, for example by entering and exiting a geofence, e.g. in a real-time location system, or by reading in an audio ID, a barcode, a data matrix code or an RFID tag.

In addition to the embodiments of a data collection system for collecting measurement data described above and shown in the figures, in particular for a detection system for detecting an incorrectly mounted plug connection of a connector, as well as such a detection system, numerous others can be formed, in particular any combination of the above-mentioned features of these, wherein in each case at least two measuring units, at least one Data evaluation unit and at least one flexible carrier for arranging the measuring units and the data evaluation unit, in particular in the form of a wrist unit, on a hand or wrist of an operator who carries out the plugging process. The at least two measuring units and the data evaluation unit are arranged in close proximity to one another. The measuring units each comprise at least one acceleration sensor and at least one of the measuring units at least one microphone.

list of reference symbols

1 data collection system

2 flexible straps

3 measuring units

4 measuring units

5 data evaluation unit

6 measuring units

7 measuring units

8 measuring units

9 wrist unit

10 (right) hand

11 fingers/index finger

12 fingers/middle finger

13 fingers/ring finger

14 fingers/little finger

15 thumbs

16 left hand

18 operators

30 microphones

31 housings

32 opening

33 Interior of 31

34 membrane

35 first acceleration sensor

36 second acceleration sensor

37 LED

40 housings

41 acceleration sensor

42 Electronics

43 LED

44 Interior of 40

90 housings

91 opening membrane

interior of 90

microphone

Microcontroller Accelerometer Gyroscope

RFID antenna/gate transmitter unit LED distal arrangement intermedial arrangement proximal arrangement/in the metacarpal bone area intermedial arrangement thumb tip first assembly station second assembly station third assembly station data transmitter data transmission database cloud

Data preparation/graphical processing device first step second step third step fourth step fifth step sixth step seventh step eighth step ninth step tenth step eleventh step twelfth step 232 thirteenth step

233 fourteenth step

234 fifteenth step

P1 arrow

51 threshold

T _E Event trigger

52 threshold

T MV assembly trigger/assembly attempt

5 ₃ threshold

M _A Assembly amplitude/assembly verification

M _v Verification time window/measurement window

Claims

claims 1. Detection system for detecting an incorrectly mounted plug connection of a connector, wherein the detection system comprises at least one plug-in attempt detection device for detecting a plug-in attempt, at least one measuring unit (3, 4, 6, 7, 8) for recording plug-in process data and at least one verification device for verifying the plug connection via the data profile of recorded plug-in process data. 2. Recognition system according to claim 1, characterized in that at least one first measuring unit for recognizing hand gestures for a plugging attempt and at least one second measuring unit for detecting the plugging process are provided, in which data on acceleration and/or force absorption as well as the released energy are recorded via the sound. 3. Recognition system according to claim 1 or 2, characterized in that the recognition system comprises at least one type of artificial intelligence by means of which all measuring unit inputs are or can be converted as inputs to a binary output for indicating the decision of a correct plug connection or an incorrect plug connection. 4. Recognition system according to one of the preceding claims, characterized in that the measuring units can be arranged or are arranged on at least one of the fingers (11, 12, 13, 14) and the thumb (15) of at least one hand (10, 16) of an operator (18) who carries out a plugging process, in particular by arranging the measuring units (3, 4, 6, 7, 8) on or on at least one carrier, in particular a flexible carrier (2). 5. Detection system according to one of the preceding claims, characterized in that the detection system comprises at least one wrist unit (9) for arranging on a wrist of an operator (18) carrying out a plugging process, wherein the at least one wrist unit (9) comprises at least one microphone (94) for recording ambient noise and at least one microcontroller (95), wherein in a sound data processing of the at least one microcontroller (95) of the wrist unit (9) a comparison is made with the recorded data of a measuring unit (3) that can be arranged or is arranged on a thumb (15) of a hand (10, 16) of an operator (18) in order to improve the recognition of the sound profile of the locking of the plug partners of the connector. 6. Recognition system according to claim 5, characterized in that the at least one wrist unit (9) comprises at least one gyroscope (97), wherein the gyroscope (97) records movement data of a hand (10, 16) of an operator (18), which are used as identification triggers for opening a measuring window (M _v ), wherein the presence of data or signals characterizing a proper plugging process is checked within the measuring window (M _v ). 7. Recognition system according to one of claims 4 to 6, characterized in that the measuring units (3, 4, 6, 7, 8) can be arranged or are arranged intermedially or proximally on the fingers (11, 12, 13, 14) and/or the thumb (15) of at least one hand (10, 16) of an operator (18), in particular when the measuring units (3, 4) are arranged on the thumb (15) and index finger (11) or between the thumb (15) and index finger (11) of at least one hand (10) of an operator (18), the measuring units (3, 4) can be arranged or are arranged in the region of the metacarpal bones of the hand (109). 8. Recognition system according to claim 7, characterized in that the measuring units (3, 4, 6, 7, 8) are arranged in a rotational or rotating manner on the middle or base of the finger, in particular when arranged on a thumb (15) of a hand (10) on the inside directed towards the index finger (11) of the hand (10), when arranged on an index finger (11) of a hand (10) on the inside directed towards the thumb (15), in particular with a rotation in the direction of the top of the hand (10), when arranged on a middle finger (12) and/or a ring finger (13) and/or a little finger (14) of a hand (10) are arranged in the direction of the top of the hand (10) of the operator (18). 9. Data collection system (1) for collecting measurement data, in particular for a recognition system according to one of the preceding claims, characterized in that the data collection system (1) comprises at least two measuring units (3, 4), at least one data evaluation unit (5) and at least one flexible carrier (2), wherein the at least two measuring units (3, 4) and the data evaluation unit (5) are arranged on the flexible carrier (2) and in close proximity to one another, wherein the measuring units (3, 4) each comprise at least one acceleration sensor (35, 36) and at least one of the measuring units (3, 4) comprises at least one microphone (30). 10. Data collection system (1) according to claim 9, characterized in that the at least one microphone (30) of the at least one of the measuring units (3, 4) is aligned with the fingertip or the thumbtip (150) of a thumb (15) of a hand (10) of an operator (18) carrying the measuring unit(s) (3, 4, 6, 7, 8). 11. Data collection system (1) according to claim 10, characterized in that in a housing (31) of the measuring unit (3) at least one opening (32) is arranged, which is covered by at least one membrane (34) for protection against dust and water. 12. Data collection system (1) according to one of claims 9 to 11, characterized in that at least one wrist unit (9) is provided, wherein the at least one wrist unit (9) comprises at least one gyroscope (97) and a 3-axis acceleration sensor (96). 13. Data collection system (1) according to claim 12, characterized in that the at least one wrist unit (9) comprises at least one microphone (94) for recording ambient noise. 14. Data collection system (1) according to claim 12 or 13, characterized in that the at least one wrist unit (9) comprises at least one RFID unit (98) with which a respective assembly station (200, 201, 202), from which the wrist unit (9) is used, or RFID-tagged plugs can be made or are made recognizable in the same IT system as plug connections verified via the data collection system (1). 15. Data collection system (1) according to one of claims 9 to 14, characterized in that the data collection system (1) can be provided with or is provided with at least one transmitting device (99) for sending the collected data via WLAN, LTE, Bluetooth and/or radio technologies to a data transmitter (210), in particular a gateway, a server or an edge device as a data transmitter, at least one local or cloud-based database (212) is provided for storing the collected data, a cloud (213) for carrying out analyses of the plugging processes and at least one graphical evaluation unit (214) for displaying evaluation results. 16. Data collection system (1) according to one of claims 9 to 15, characterized in that the at least one flexible carrier (2) is designed as a glove, as a partial glove and/or in the form of at least two bands that connect at least two measuring units (3, 4, 6, 7, 8) and the at least one wrist unit (9) to one another.