End connector wafers are then loaded by the operator into the locating fixtures. The wafer loading position is accurately maintained via a precision vacuum chucking system. Individual vacuum systems are used for each of the three nests.

Once all of the parts are secured in place the automatic test and inspection process begins by way of a conveniently located operator interface console.

Should one of the vacuum units fail to sense that the part was securely in place, the cell will alert the operator and pause until loading is corrected.

With the multiple part images produced and stored by the vision system computer, SynerSight™ inspection technique,s including dimensional gauging of critical product features, are performed along with presence inspection for fastening devices, critical electrical contacts and ground contact shields.

Once the vision tests are completed, the cell automatically performs electrical testing. This is achieved by advancing three sets of pogo pin arrays over the parts and lowering them to a designated electrical test area on the product. Once the pogo pins make contact with the part, several electrical tests are performed. These tests include a continuity test, a short circuit test, and a dielectric leakage test.

With tests and inspection complete, the part was deemed to be passed (or failed) by the system, the cell shuts down the vacuum units and indicats to the machine operator through a green light that the part is good. A red light is used to indicate a failure.

The system is set to use six cameras to view the cable assemblies. Three cameras view the product from above and three more are precisely located on the base of the machine to look at the sides of the part. (Not shown in view.)

The system uses a static lighting setup with fiber optic ring lights to illuminate the parts.

A polarizer/analyzer combination of filters is installed to the ring light and the camera in order to enhance the contrast between the black Delrin fixture and the white body of the part. This filtering technique also enhances the contrast between the metallic surfaces on which the electrical tests are conducted and the body of the part.

In order to qualify the vision system as a measurement system, it needs to demonstrate an acceptable accuracy and repeatability. The repeatability of the system is described in terms of a percentage of the smallest tolerance that the system must measure.

In this particular case, the repeatability of the system is required to be 0.0006" (0.015mm) at six sigma. This number is derived from 10% of the total tolerance of the tightest tolerance product feature. The accuracy of the system is determined by measuring the dimension of some known standard. The deviation between what the vision system's reported dimension and the known standard, is the accuracy or bias of the system. This is done by using the Adept calibration templates that are supplied with the system.

The pogo pins are interchangeable in design and serve to probe the test areas of the product.

Once the pogo pins are in their test position, continuity, short circuit, and dielectric leakage tests aare performed. All of these functions were performed by the Horizon test unit. The unit's cycle is initiated via an electronic signal from the vision system's computer.