FIELD OF THE INVENTION
[0001] This invention relates generally to mass termination of flat multiconductor cable
and pertains more particularly to methods for making assemblies of ribbon cable and
insulation-displacing contact connectors (IDC connectors).
BACKGROUND OF THE INVENTION
[0002] Various apparatus has been made available heretofore for purchasers or suppliers
of flat multiconductor cable and IDC connectors to make assemblies of same, for example,
in portable tool version, such as is shown in U.S. Patent No. 4,386,461, and in the
form of a bench press, as in U.S. Patent No. 4,020,540. In these devices, the IDC
connector is placed in a lower die and the flat cable is placed in confronting relationship
with the contacts. An upper die is then applied forcibly against the lower die, forcing
the cable conductors independently into electrical engagement with the contacts.
[0003] In a recent commercial product, known as the "LAT-CON
T.M. .050 Connector System" of Panduit, a reel-fed pneumatic termination press is provided
wherein individual IDC connectors releasably secured to a web are fed from a reel
into a press having a loading die to seat same. The particular IDC connectors usable
in this system include a housing supporting the contacts and a cover overlying the
contacts and supported at one end by a so-called living hinge. To insert a ribbon
conductor in the seated connector, one lifts the cover pivotally about its hinge and
advances the cable transversely into the connector, i.e., along an axis orthogonal
to the cable longitudinal axis. With the cable so positioned, a die above the connector
cover is activated to effect crimping and thus mass terminating the cable.
[0004] While the last-mentioned system adds a level of semi-automation as against the earlier
two devices discussed above, it is limited in use to the IDC connectors of type having
such pivotal cover. In that many IDC connectors manufactured and sold are of type
different than that for which the semi-automated system is adopted, substantial need
exists for accommodating in automated, or semi-automated fashion the bulk of the connectors
at hand.
SUMMARY OF THE INVENTION
[0005] This invention has as its primary object the provision of expedited manufacture of
assemblies of ribbon cable and IDC connectors.
[0006] A more particular object of the invention is the provision of methods for termination
of ribbon cable by the use of connectors of type having a cover latchingly supported
at both ends to a connector housing and translatable for mass terminating the cable.
[0007] In its method aspect, the invention accommodates stripping of connectors individually
from a reel, movement thereof to a termiantion station and movement of a ribbon cable
along its longitudinal axis to the termination station.
[0008] In its system and apparatus aspects, the invention introduces cable guide apparatus
for effectively registering the ribbon cable and seated connector, and introduces
a controller for coordination of the various steps at hand.
[0009] The invention will be further understood from the following detailed description
of preferred embodiments thereof and from the drawings wherein like reference numerals
identify like parts throughout.
DESCRIPTION OF THE DRAWINGS
[0010]
Fig. 1 is a perspective view showing an individual connector secured to a web.
Fig. 2 is a plan view illustrating a reel upon which the web of Fig. 1 is wound and
illustrating an end portion of the web in unreeled fashion.
Fig. 3 is a perspective view showing a loading die for connector seating and a portion
of a connector chute and web egress guide.
Fig. 4 is a plan view incorporating the Fig. 1 web and the Fig. 3 loading die.
Figs. 5 and 6 are respective operable and inoperable states of a released connector
pusher.
Fig. 7 is a front elevation of the Fig. 3 loading die with connector (sectioned) ,
and cable in place.
Figs. 8-11 are respective plan, front (along section plane IX-IX of Fig. 8), right
end and left end views of a cable guide and registration device.
Fig. 12 is a plan view of a web with connector orientation different from that of
Fig. 1, shown with an orientation change device.
Fig. 13 is a plan view of the orientation change device of Fig. 12.
Fig. 14 is a further plan view of the orientation change device of Figure 12 together
with the lower die of Fig. 3.
Fig. 15 is a schematic diagram of a pneumatic controller.
DESCRIPTION OF PREFERRED EMBODIMENTS AND PRACTICES
[0011] Referring to Fig. 1, web or substrate 10 includes an adhesive layer 12 and has perforations
14 extending transversely therethrough at an upper margin. Connector 16 is mounted
on web 10 and adhered thereto releasably by layer 12, the connector including base
or housing 18 and cover 20, the cover having latch legs 22a and 22b extending downwardly
in registry with cooperating latch structure on base 18. Opening 23 exists as between
base 18 and cover 20 into which upwardly extend insulation-displacing contacts engageable
with a ribbon cable (Fig. 7) entered into slot 23. As the connectors are disposed
on the elongate substrate, the contacts are substantially parallel to the substrate
longitudinal axis. In Fig. 2, web 10 is shown with a plurality of connectors 16 and
is reeled upon reel 24 which is supported for rotation about shaft 26.
[0012] Turning to Fig. 3, lower or loading die 28 defines a connection seat 30 leading to
stop wall 32, which extends slightly above the floor of seat 30. Die 28 is supported
fixedly with connector chute 34, the latter including a channel 36, which defines
a predetermined path for connector movement.
[0013] A web egress guide 38 extends laterally from chute 34.
[0014] Fig. 4 illustrates the Figure 3 apparatus together with web 10 in residence in both
channel 36 and guide 38. This stage of activity is achieved by threading web 10 into
the feed end of chute 34 and guiding an end of the web into slot 38 into registry
with web puller or advancer 40, same having projections 42 and 44 which are enterable
in perforations 14 (Fig. 1). In the stage of activity in Fig. 4, web 10 has been advanced
by puller 40 in measure releasing connector 16-1 therefrom, same being accomplished
by initial advance of the web along its longitudinal axis and in such predetermined
path defined by chute 34 and subsequent movement of the web at an angle to the predetermined
path, i.e., in the direction of guide 38. Connector 16-1 is constrained in its movement,
throughout such initial and subsequent web movements, to movement in the predetermined
path, same being effected by chute walls 34a and 34b and floor 34c. Upon release in
leading part from the web, it will be seen that connector 16-1 confronts advance wall
portion 34a-l in such constrained movement. Upstream connectors 16-2 and 16-3 will
subsequently be advanced to connector seat 30 by withdrawal of puller 40 from engagement
with web 10, movement leftwardly thereof in slot 38a, re-engagement with web 10, and
subsequent rightward movement of puller 40.
[0015] In the embodiment under discussion, released connector 16-1 is advanced from its
position illustrated in fig. 4 fully to registration with stop wall 32 through the
agency of pusher 46, illustrated in Figs. 5 and 6 and shown schematically in Fig.
4 leftwardly of its operative position. As seen in Figs. 5 and 6, pusher 46 comprises
a rod 48 pivotally supporting element 50 about pin 52. Rod 48 is supported for translatory
motion by supports 54 and 56. In Fig. 5, element 50 is distended so as to engage the
rearward surface of connector 16-1 and impel same to confront stop wall 32 on movement
of rod 48. In Fig. 6, element 50 is shown in inoperative state, having been rotated
into illustrated position to permit the next connector to be released to pass freely
therebelow.
[0016] Ribbon cable 58 (Figs. 4 and 7) is now guided into opening 23 (Fig. 1) of connector
16-1 and into registry above insulation-displacing contacts 60 and 62 of connector
16-1, as shown in Fig. 7. Upper or compression die 64 is now advanced by actuating
rod 66 to force cover 20 downwardly, thereby effecting movement of cable 58 onto contacts
60 and 62 to effect electrical connection between the conductors of cable 58 and such
contacts.
[0017] Referring to Figs. 8-11, cable guide 68 of the invention is dimensioned for translatory
movement on top surface 70 (Fig. 3) of lower die 28 within rails 72 and 74 thereof.
An upstanding manually grippable projection 76 is provided on upper surface 78 for
this purpose. Cable guide 68 includes a leftward open channel 80 for cable entry and
includes an interior spring 82 having an upper expanse 84 secured to guide top wall
86 and a depending portion 88 cantilever-supported by portion 84 and extending to
an end 90 elevated above cable guide floor 92 by slightly less than the vertical depth
D of cable 58, thereby to dress cable 58 and position same precisely adjacent registration
lug 94 of guide 68. The dimensions W and H of lug 94 are selected such that lug 94
registers against interior walls 20a and 20b (Fig. 1) of cover 20 and extends upwardly
above ceiling 18a of base 18 correspondingly to the height of contacts 60 and 62 thereabove.
With such dimensioning, it will be seen that cable 58 is guided into exacting, non-interfering,
overlying registry with contacts 60 and 62, as in Fig. 9.
[0018] Turning to Fig. 12, an alternate orientation of connectors on the web is shown wherein
web 96 has releasably secured thereto connectors 98. Here, web 96 is in vertical feed
disposition in contrast to the horizontal web feed disposition of Figs. 1-4.
[0019] Web 96 is displaced as shown in Fig. 12 (rearwardly) for connector release, whereupon
the released connector is applied to slot 106 of orientator 104, which is rotatable
with shaft 108 (Fig. 13). Upon ninety degree rotation of orientator 104, the situation
of Fig. 14 applies, i.e., slot 106 is now in alignment with connector seat 30. An
air blast is now introduced into slot 106 by nozzle 110, whereupon the released connector
in slot 106 is advanced to seat 30.
[0020] Fiq. 15 shows a control system for a pneumatic version of apparatus in accordance
with the invention. Assuming a connector to be in place for crimpinq, cable quide
68 is displaced from engagement with the connector to its leftward position in Fig.
15. Pressure from source S now flows through valve 112, the state of which changes
upon such movement of guide 68. Pressure is now furnished through valve 114 to displace
the spool of valve 116, pressurizing line 118 and activatina crimp valve 120. Upon
the completion of the crimp cycle, valve 122 is operated bv pressure chanqe in line
124 and line 126 reversely displaces the spool of valve 116. This renders line 128
pressurized, causing feed cylinder 130 to advance the web for feeding of the next
connector. Upon completion of the stroke of cylinder 130, rod 132 changes the state
of valve 134, providing communication between lines 136 and 138.
[0021] Line 140, also now pressurized, operates orientation cylinder 142. Upon completion
of ninety-decree rotation of orientation device 104, rod 144 changes the state of
valve 146. If the previously crimped connector is removed, valve 148 provides communication
between lines 150 and 162, thus pressurizing line 154 to displace the spool of valve
156 and issue a blast of pressure through valve 156 to nozzle 158, advancing the next
connector into seat 30. At this juncture slide 68 is advanced to register the cable
with such connector and, upon withdrawal, the cycle repeats.
[0022] While a mass termination station is shown in the form of fixed lower die 28 and fixed
upper die 64, same may of course be comprised of fixtures having removable insert
dies for accommodating various differently-shaped connectors. Also, mechanical structure,
such as for substrate-independent connector movement (pusher 46) and substrate advance
(puller 40) may take on various configurations. Further, while two diverse web feed
dispositions are shown, various other dispositions will now be apparent. In this connection,
orientator 104 may be provided with a family of inserts for slot 106 to accommodate
different sized connectors.
[0023] Various other changes in practice and modifications to structure may be introduced
without departing from the invention. Thus, the particularly disclosed preferred embodiments
and practices are intended in an illustrative and not in a limiting sense. The true
scope of the invention is set forth in the following claims.
1. A system for mass termination of multi-conductor flat cable by insulation-displacement
contact connectors, comprising:
(a) means for unwinding and advancing a reeled substrate having said connectors releasably
secured thereto;
(b) means for removing said connectors from said substrate;
(c) die means for individually seating such removed connectors and for forcing conductors
of said cable into electrical engagement with the contacts of such removed connectors;
and :
(d) cable guide means for receiving said cable and entering into said seated connectors
and guiding said cable into registry with said contacts thereof.
2. The system claimed in claim 1 wherein said cable guide means is supported for movement
from such entrance thereof into said seated connectors into an inoperative position.
3. The system claimed in claim 2 further including means (e) responsive to residence
of said cable guide means in said inoperative position for operating said means (c).
4. The system claimed in claim 3 further including means (f) for sensing the completion
of such operation of said means (c) and thereupon operating said means (b).
5. The system claimed in any one of Claims 1 to 4 further including means for receiving
such removed connectors, changing the orientation thereof, and delivering same to
said means (c).
6. The system claimed in claim 4 further including means (g) for receiving such removed
connectors, changing the orientation thereof, and delivering same to said means (c),
and means (h) for sensing the completion of operation of said means (g):
7. A method for mass termination of elongate flat multi- conductor cable by use of
elongate connectors havQJg87531 insulation-displacing contacts arranged in at least
one longitudinal row therein, comprising the steps of:
(a) releasably assembling individual such connectors to a substrate;
(b) defining a cable mass termination station;
(c) advancing said substrate along a preselected path to dispose an individual such
connector at said cable mass termination station;
(d) advancing said cable along the cable longitudinal axis to said cable mass termination
station and into overlying registry with said insulation-displacing contacts of said
individual connector; and
(e) moving said cable relative to said insulation-displacing contacts and effecting
electrical engagement of said cable conductors individually with said insulation-displacing
contacts.
8. The invention claimed in claim 7 wherein said step (a) is practiced by providing
an elongate such substrate and by so applying said connectors thereto as to dispose
said insulation-displacing contacts, substantially parallel to the longitudinal axis
of said substrate.
9. The invention claimed in claim 7or Claim 8 wherein said connectors include a body
supporting said insulation-displacing contacts and a cover movably supported on said
housing to effect practice of said step (d).
10. The invention claimed in claim 9 wherein said connectors define an opening between
said cover and said body rendering said insulation-displacing contact accessible,
said step (d) being practiced by providing a cable guide having a portion thereof
registrable in said opening upon advance of said cable to said cable mass termination
station.