Precise Measurement of MTD Connector Assemblies

Background

For the inspection of MTD connector assemblies, precise measurement and reliable verification are essential in ensuring functionality. In this project, senswork was tasked with developing a system capable of measuring pin positions, capturing connector coding, and checking housing dimensions with extremely tight tolerances. The goal was to provide a fast and highly accurate inspection solution that could be seamlessly integrated into manual test stations.

Application & Solution

In this project, senswork introduced its new test equipment concept for highly integrated manual test stations for the first time. A high-resolution camera system was implemented to measure the pin positions of the MTD connector assembly, capture the connector coding, and verify the housing dimensions with a precision tolerance of 0.1 mm.

The inspection is carried out from three different sides of the connector assembly, ensuring complete and reliable coverage. To guarantee traceability, a color dot spray system marks components that have passed inspection, with the marking itself being rechecked before the component is removed. Two of the three cameras are equipped with a servo focus axis, which provides uniform sharpness across all inspection levels and eliminates the need for manual adjustment.

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The process is managed by a Siemens control system that ensures the correct inspection sequence and provides a visualization of the overall system status. The actual testing is performed using senswork VisionCommander® software, which incorporates a virtual plug gauge to confirm correct pin positions with high accuracy.

Tasks

• Inspection of connectors and connector assemblies
• Simultaneous inspection of PCB and interface side
• Measurement of pin positions
• Acquisition of connector coding
• Verification of housing dimensions

Outcome

The system achieves precise measurement of connector assemblies within 0.1 mm tolerance and completes inspections in 2–4 seconds per component. Uniform image sharpness is ensured by servo-focused cameras, while the integrated marking system provides clear traceability. The solution enables reliable, repeatable inspections and allows for quick adaptation to new component types.

For a free feasibility study to see which technology is best for your quality automation, email [email protected] for a request.