Connectors Manufacturing
Ensure Perfect Pin Integrity and Zero-Defect Assembly
In connector manufacturing, a single bent pin or contaminated terminal can cause catastrophic failures in the field—from automotive safety systems to medical devices to aerospace electronics. The high pin density and reflective surfaces of modern connectors make traditional vision systems unreliable, leading to excessive false rejects or worse, escaped defects.
Overview.ai's AI vision platform is purpose-built for the unique challenges of connector inspection. Our systems learn the precise characteristics of your specific connector designs and can reliably detect bent pins, missing terminals, contamination, and plating defects—even on the most reflective surfaces and complex geometries.
Why Overview.ai for Connector Manufacturing?
Achieve 100% inspection coverage without sacrificing line speed. Our AI handles the reflective surfaces and tight tolerances that defeat traditional vision systems. Reduce customer returns and warranty claims while eliminating the costly false rejects that hurt your yield. Deploy new connector variants in hours, not weeks, with our intuitive training interface.
Key Applications
Bent Pin Detection
Detect even subtle pin deflections that can cause intermittent connections or complete failures. Our AI measures pin position and angle with sub-pixel accuracy, catching bent, tilted, or misaligned pins across hundreds of contacts simultaneously. Works reliably on high-density connectors where traditional vision struggles.
Terminal Presence & Position Verification
Verify every terminal is present and correctly seated. Our system detects missing terminals, incorrect insertion depth, and terminals that have backed out of their cavities. Ensure proper terminal retention force before connectors leave your facility.
Housing Defect Inspection
Identify cracks, flash, short shots, and contamination on connector housings. Our AI inspects complex molded geometries including locking features, polarization keys, and sealing surfaces that are critical to connector performance and reliability.
Plating & Surface Quality
Verify plating integrity on contact surfaces. Detect plating defects including bare spots, discoloration, pitting, and contamination that affect electrical conductivity and corrosion resistance. Critical for automotive and aerospace applications with stringent reliability requirements.
Wire-to-Board Assembly Verification
Confirm correct wire insertion and crimp quality in assembled connectors. Our system verifies wire color sequence, insertion depth, and detects wires that have pulled back from their terminals. Prevent field failures caused by incomplete wire terminations.
High-Speed Connector Inspection
Meet the stringent requirements of high-speed data connectors. Inspect USB-C, HDMI, and other high-density interfaces for the precise pin alignment and surface quality required for reliable signal integrity at multi-gigabit speeds.