Electrical harness fabrication method and apparatus

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

[0001] The present invention relates generally to methods and apparatus for making an electrical harness of the type including a connector having a housing with insulation displacement type contacts loaded therein, each contact connected to an insulation clad wire.

2. Brief Description of the Prior Art

[0002] Manufacturers of electronic products today are relying on electrical harnesses employing insulation displacement type contacts to provide the efficiencies and cost reductions necessary in a competitive marketplace. A typical electrical harness employed today is one which generally comprises a connector having a housing with insulation displacement type contacts loaded therein. Each contact is connected to an insulation clad wire. The wires may be an associated group of discrete conductors, or may comprise a flat ribbon cable assembly of the type having either flat or round conductors.

[0003] Because of the desirability of eliminating labour costs, automatic equipment is now being employed to produce electrical harnesses of the type described above.

[0004] US-A-4,441,251 discloses a method and apparatus for manufacturing harness assemblies comprising two connectors having wires extending between the connectors. The two connectors are positioned adjacent to each other in an insertion zone with the wire receiving portions of terminals in the connectors in alignment. The wires are located in two spaced-apart planes in alignment with the terminals and the wires are moved towards the connectors and into the wire receiving portions of the terminals. Thereafter, the one connector with the wires attached is removed and the other connector is moved through and beyond the insertion zone and wires are pulled from reels and located in the insertion zone in the spaced-apart planes. The cycle is then repeated in placing two additional connectors in the insertion zone between the two planes of wires. A specific apparatus for carrying out the method automatically is also disclosed. The connectors are two row connectors but essentially symmetric in form.

[0005] A further example of automatic equipment for producing electrical harnesses is disclosed in US-A-4,235,015.

[0006] US-A-4,235,015 discloses a method of producing an electrical cable harness, including mass terminating the first ends of a plurality of double-ended insulation-clad wires each to an insulation displacement terminal of a connector, the method including the steps of loading a connector onto a first transport assembly at a first station thereof, said first transport assembly being operable to move said connector between said first and a second station of said first transport assembly, feeding and measuring wires so that the first ends thereof are positioned adjacent said connector at said second station of said first transport assembly, terminating the first ends of said wires to said connector at said second station of said first transport assembly to form a first finished end of said harness and then returning said first transport assembly to said first station thereof thereby drawing a predetermined length of said wires past said second station of said first transport assembly, removably mounting one of a plurality of different, selectively actuable harness finishing modules for mass terminating second ends of said wires on a second transport assembly having a first station and a second station the same as the second station of the first transport assembly, and moving said module from said first station of said second transport assembly to said second station to finish the second wire ends.

[0007] The machine of US-A-4,235,015 finishes the second ends of the wires at the second station by means of a pair of cooperating assemblies which move in from opposite sides of the second station to perform the desired finishing operation, but to change the cooperating assemblies to provide a different finishing operation is awkward and time consuming.

[0008] Moreover, to change the machine of US-A-4,235,015 to accommodate different connectors or wire configurations requires significant modification to the machine. Also the wires of the trailing harness end must be cut free and then moved into position over the second connector. This is sometimes undesirable, as in the case where the connector of EP-A-0191977 published 27th August 1986 (described below) is employed.

[0009] Another harness making machine is disclosed in commonly owned EP-A-0153387 filed 4th January, 1985. Briefly, the machine includes first and second connector nests each movable from their respective connector loading station to a common termination station. Arrangements must be provided for properly aligning the connector of each harness end with the ends of the harness wires to which it is terminated. Also, consideration in aligning each connector relative to the termination head must be made to account for the oppositely facing connector orientations at each harness end. Although generally satisfactory, the machine in use today is not suitable for terminating double-ended harnesses where the connectors are not symmetric with respect to an axis of the wire array. An example of this type of connector is described below with respect to EP-A-0191977. Like the machine of United States Patent No. 4,235,015, this machine is not readily reconfigurable if the connector style or the wire array is changed.

[0010] One particular type of electrical connector in use today is described in the above-mentioned EP-A-0191977. Disclosed therein is a modular multi-row electrical connector which mates with an array of pins. The connector has an integrally formed housing with opposed top and bottom surfaces extending between opposed forward mating and rearward end walls, and with two rows of axially extending terminal receiving cavities. Each cavity is defined by spaced-apart sidewalls extending between the forward mating and rearward end walls, a bottom wall, and a top wall opening to the top housing surface, so that all of the wires can be inserted for termination from the upper housing surface. The two rows of terminal receiving cavities are stacked one on top of the other in a staggered configuration, so that the terminal receiving cavities of the lower rows are located between the terminal receiving cavities of their upper rows. The rows are joined together by selectively removable web portions to form a plurality of commonly joined separable connector modules, each module including at least one upper row cavity and at least one lower row cavity.

[0011] United States Patent No. 4,091,531 issued May 30, 1978 discloses a bench tool for terminating a dual-row connector having opposed mating and wire receiving ends. The terminals at the mating end of the connector are aligned such that the top and bottom rows are directly above and below each other. The wire receiving end of the terminals, however, are aligned in staggered rows as described above, so that wires of both rows can be inserted from a single direction. An arbor press is provided having upper and lower tooling members with the upper member being driven toward the lower member during termination. The upper member receives a connector with terminals having insulation displacing slots opening in a downward direction. The bottom tooling member has a series of stacked plates with particularly configured upper saw tooth-like edges. A flat ribbon cable is inserted between the upper and lower tooling members, and the arbor press is activated to terminate both rows simultaneously. After termination, an operator releases the press and withdraws the terminated cable harness from the machine.

[0012] The machine of United States Patent No. 4,091,531 is manually operable, requiring an operator to load the connectors and cable, to terminate one to the other, and to remove the cable harness.

[0013] It is desirable to provide a machine for making electrical harness which is fully automatic in operation, which is more readily reconfigurable for making different harnesses using a method of the present invention, and which is capable of mass terminating connectors which are not symmetric with respect to an axis of the wire array.

[0014] The present invention provides a method of producing an electrical cable harness including mass terminating the first ends of a plurality of double-ended insulation-clad wires each to an insulation displacement terminal of a connector the method including the steps of: loading a connector onto a first transport assembly at a first station thereof, said first transport assembly being operable to move said connector between said first and a second station of said first transport assembly; feeding and measuring wires so that the first ends thereof are positioned adjacent said connector at said second station of said first transport assembly; terminating the first ends of said wires to said connector at said second station of said first transport assembly to form a first finished end of said harness and then returning said first transport assembly to said first station thereof thereby drawing a predetermined length of said wires past said second station of said first transport assembly; removably mounting one of a plurality of different, selectively actuable, harness finishing modules on a frame assembly of a second transport assembly having a first station which may be a connector loading station and a second station the same as said second station of said first transport assembly; moving said second transport assembly with said frame assembly and said module from said first station of said second transport assembly to said second station; keeping said second transport assembly at said second station while actuating said module to simultaneously finish the second wire ends to form a second finished harness end thereby to form a single or a double-ended cable harness as desired depending upon the one of the harness finishing modules selected for finishing the second wire ends and then moving said second transport assembly together with said frame assembly and said module to said first station of said second transport assembly to make ready for the production of another harness.

[0015] The present invention also provides a multi-station apparatus for automatically producing an electrical cable harness including mass terminating the first ends of a plurality of double-ended insulation-clad wires each to an insulation displacement terminal of a connector, the apparatus including a first connector transport assembly for receiving and moving a connector between two stations, means for loading the connector onto said first connector transport assembly at a first station thereof, wire feeding means for feeding and measuring the wires so that the first ends thereof are associated with the connector at the second station of said first connector transport assembly, wire termination means for terminating the first ends of the wires to said connector at said second station to form a first finished end of said harness, a further transport assembly having a first station which may be a connector loading station and a second station the same as said second station of said first connector transport assembly, said further transport assembly removably supporting one of a plurality of harness finishing modules on said apparatus, said harness finishing module being movable by said further transport assembly to said second station to finish simultaneously second ends of the wires to form the second finished harness end and being movable by said further transport assembly to said first station of said further transport assembly to ready the machine to begin another harness making cycle, characterised in that the said further transport assembly has a frame assembly removably supporting said one harness finishing module, said further transport assembly is movable together with the frame assembly and the harness finishing module from said first station of the further transport assembly to the second station thereof and, while the second transport assembly is kept at said second station, the harness finishing module is actuated to finish simultaneously said second ends, thereby to form a single or double-ended cable harness as desired, and said further transport assembly is movable together with the frame assembly and said harness finishing module from said second station of the further transport assembly to said first station of the further transport assembly to ready the machine to begin another harness making cycle.

[0016] An embodiment of the apparatus of the present invention may include means for removing polarizing members extending from a connector housing. The polarizing members comprise locating pegs which project from the top and bottom surfaces of the above-described connector of EP-A-0191977 so as to extend beyond, but not overlie, the mating end wall thereof. The apparatus may comprise means for presenting at least one rotated connector to a peg removal station and means for selectively removing at least one of said pegs in said axial direction immediately adjacent one of said top and bottom surfaces.

[0017] A further embodiment of the apparatus of the present invention may also include means for processing the above-described connector of EP-A-0191977. Thus, the apparatus may include means for rotating the connector so that the forward mating end is upwardly directed, with the wires of a completed harness assembly extending in a downward direction, and a series of knife-like selectively programmable web separating members to be driven into the housing in an axial direction so as to selectively remove at least one of the webs connecting the connector rows. When completed, each connector module comprises a separate connector terminated to a predetermined number of wires, so as to form a separate harness therewith.

[0018] The apparatus according to another embodiment of the present invention may still further include an arrangement for transporting terminated harnesses from one work station to another, wherein the connectors have a plurality of aligning tabs extending from their mating end wall to form a channel extending along the mating end wall. A track is provided with a first rail complementarily shaped with the channel, and opposing second and third spaced apart rail members opposing the first rail. The connector is slid along the track, such that the first rail is received in the channel, and the second and third rails engage the rearward connector end wall adjacent the top and bottom connector surfaces.

[0019] Embodiments of the present invention also provide a harness making machine for presenting the wires to the terminals in each of the staggered rows of a connector of EP-A-0191977, in a simple fully automatic two-step operation. The wires are fed to the termination station at a first predetermined level, and a wire preparation module having upper and lower portions is positioned at the termination station, so that the wire is positioned between the portions. The lower portion includes a connector nest receiving a connector of the type wherein rows of terminal receiving cavities are staggered with all of the cavities open in an upward direction, so that all of the wires can be inserted for termination from the upper connector housing surface. The cavities of the lower rows are positioned between the cavities of their upper rows, with the cavity sidewalls of upper rows acting as wire guides to aid in the passage of wires to lower rows for termination therein.

[0020] An elevator is provided at the termination station so that, with the module placed over the elevator, the connector nest can be raised to engage the wires with the connector housing, such that the wires to be terminated in the upper row are bent with a predetermined upward angular deflection. The module also includes wire insertion blades disposed above the connector nest, in alignment with the wires. Upon lowering of the insertion blades, and subsequent termination of the wires to the terminals, the wires terminated to the lower row have an equal but downwardly directed angular deflection.

[0021] Some ways of carrying out the present invention in both its method and apparatus aspects will now be described by way of example and not by way of limitation with reference to drawings which show specific embodiments of apparatus according to the present invention.

[0022] In the drawings, wherein like elements are referenced alike,

FIG. 1 is a plan view of a machine of the present invention:

FIG. 2 is an elevation view of the machine of FIG. 1;

FIG. 3 is a schematic flow diagram illustrating a method of the present invention, wherein a connector is terminated at a first termination station;

FIG. 4 is a schematic flow diagram illustrating a method of the present invention wherein a connector is terminated at a second termination station;

FIG. 5 illustrates the automatic harness ejection;

FIG. 6 shows an optional wire stripping assembly for use at the second termination station;

FIG. 7 shows a polarizing projection removal station;

FIG. 8 shows a web removal station for splitting a connector stick into separate connector modules;

FIG. 9 shows the connector stick of FIG. 8 in greater detail; and

FIG. 10 shows the modularization of the termination stations.

DESCRIPTION OF THE SPECIFIC EMBODIMENTS

I. Introduction

[0023] FIGS. 1 to 5 show an electrical harness machine of the present invention, generally designated at 10. Machine 10 automatically produces a completed electrical harness, generally designated 12, as shown in Fig. 7a. The electrical harness 12 includes at least one connector, generally designated 14 and a plurality of insulation-clad wires 40. The connector is described in the aforementioned EP-A-0191977 filed 12th November, 1985, which is herein incorporated by reference to the extent necessary for an understanding of the present invention.

[0024] Referring to FIGS. 9a, 9b, connector 14 comprises an insulated housing 16 having a plurality of preloaded insulation displacement contacts 18. Housing 16 is integrally molded with opposed top and bottom surfaces 20, 22 extending between opposed forward mating and rearward end walls 24, 26. The connector includes an upper row 28 and a lower row 30 of axially extending terminal receiving cavities 32. Each cavity 32 is defined by spaced-apart sidewalls 34 extending between the forward mating and rearward end walls 24, 26. Each cavity further includes a bottom wall 36 and an opposed top wall 38 opening to the top housing surface 20, so that all of the wires 40 can be inserted for termination from the upper housing surface 20.

[0025] The rows 28, 30 are stacked one on top of the other in a staggered configuration, so that the terminal receiving cavities of lower row 30 are located between the terminal receiving cavities of its upper row 28, with the sidewalls 34 of the upper row acting as wire guiding channels 42 to aid in the passage of wires to be terminated in the lower row 30.

[0026] As further disclosed in EP-A-0191977 the rows 28, 30 are joined together by selectively removable web portions 44 so as to form a plurality of commonly joined separable connector modules 46, each module including at least one upper row cavity 32U, and at least one lower row cavity 32L.

[0027] The wires 40 can comprise an array of discrete insulation clad conductors, or alternatively may comprise suitably prepared flat ribbon cable, as is known in the art.

[0028] Each cavity 32 receives a metallic terminal 18 having a conventional insulation displacement slot which is adapted to slice through the insulation of insulation clad wires 40. The connector modules, generally designated at 46, may comprise any convenient number of upper row cavities which need not be the same as the number of lower row cavities. For example, a connector module may comprise only a single upper row cavity, disposed between two lower row cavities, to form a three-circuit connector. Further, multiple modules may be left attached to each other to form a larger circuit connector, if desired.

II. Brief Description of the Electrical Harness Making Machine

[0029] Looking once again at Figs. 1 and 2, the machine 10 is seen to generally include first and second transport assemblies 50, 52, which carry connectors 14 between first and second loading stations 54, 56 and a common termination station 58. The transport assemblies include frames or carriers 60, 62 on which selectively manually dismountable wire preparation modules generally indicated at 66, 68 are provided for each assembly 50, 52, respectively. As can be seen in Figs. 2-4, each wire preparation module 66, 68 includes a connector nest 70, 72 which maintains a connector 14 in a fixed predetermined orientation. Wire preparation modules 66, 68 further include wire insertion blades 74, 76 opposing connector 14 in alignment with the terminals thereof. Each wire preparation module also includes means for actuating the insertion blades, typically taking the form of an air cylinder, an electric solenoid or other selectively actuable drive means 78, 80.

[0030] Referring to Fig. 1, each transport assembly 50, 52 is mounted for travel between a respective connector loading station 54, 56 and a common termination station 58. Transport assembly 50, for example, is mounted for reciprocation along track rails 88 extending between loading station 54 and termination station 58. Similarly, transport assembly 52 is mounted for reciprocation on track rails 90 between the second loading station 56 and termination station 58.

[0031] Wires 40 extend from a wire supply 92 to termination station 58 where they are alternately terminated to connectors carried on the two transport assemblies 50, 52.

[0032] As indicated in Figs. 1 and 2, a transport elevator 94 of the toggle-lock type is the only operative device located at termination station 58, all other necessary equipment being brought to the termination station by carriers 60, 62. The transport elevator 94 alternately raises each carrier 60, 62 and the wire preparation modules 66, 68 carried thereon.

[0033] Each module 66, 68 includes spaced-apart upper and lower wire preparation module portions designated by the suffixes "U" and "L", respectively. Wire receiving gaps 96, 98 are formed between opposing upper and lower wire preparation module portions. Upon positioning at termination station 58, the carrier beds 60', 62' are raised by transport elevator 94, to bring the lower preparation module portion into engagement with wires 40 to assist in the termination. Carrier beds 60', 62' are elevated by guide rods 82, 83 which contact elevator 94. To ensure a return downward movement of the lower wire preparation module portions, each lower portion is provided with a pull-down solenoid 84, 85.

III. Method of Cable Harness Fabrication

[0034] Referring initially to Figs. 1-3, at the initial cycle of cable harness fabrication, wires 40 are extended from wire supply 92 such that their free ends are predeterminedly positioned at termination station 58 (see Figs. 1 and 2). A first transport assembly 50, after receiving a connector 14, is moved from loading station 54 to termination station 58 such that wires 40 are received in gap 96 of its associated wire preparation module 66. The connector nest 70 is initially located below wires 40, and insertion blades 74 are located above the wires, in alignment therewith (Fig. 2). Referring to Fig. 3a, transport elevator 94 raises the lower portion of wire preparation module 66, so as to advance connector nest 70 and the connector 14 carried therein, upwardly toward wires 40. At the topmost extent of its travel, connector 14 displaces every other wire 40 with an upward angular deflection, as illustrated in Fig. 3b. That is, the upwardly deflected wires 40U are engaged by the sidewalls 34 of the upper terminal receiving cavities 32. The wires 40L to be terminated in the lower row 30 are received in channels 42 formed between adjacent upper row cavities 32. Thereafter, actuator 78 is energized so as to drive insertion blades 74 in a downward direction, so as to insert and thereby mass terminate wires 40 in connector terminals 18. Transport assembly 50 then returns to loading station 54, thereby drawing a predetermined length of wire from wire supply 92, past termination station 58.

[0035] Thereafter, the second transport assembly 52 is loaded with a connector at second loading station 56, and is advanced to termination station 58, where it is elevated by transport elevator 94. For the purpose of this introduction, the second wire preparation module 68 can be assumed to be functionally identical to that of the first module 66, in that it mass terminates wires 40 to a second connector 14. As will be described hereinafter in greater detail, wire preparation module 68 differs in its wire handling and other related capabilities. For example, the second wire preparation module contains a travelling wire comb to ensure proper alignment between wires 40 and the terminals 18 of the connector carried thereon.

[0036] With wires 40 and terminals 18 aligned, and with the top of connector nest 72 engaging wires 40, actuator 80 is energized to lower wire insertion blades 76 (Figs. 4d, 4e). Wires 40 are severed by insertion blades 76 as they are pinched between the blades and the upper die-like portion of nest 72 (Fig. 4f). Thereafter, the second or trailing end of the newly formed wire segments are terminated in both rows of connector 14, simultaneously (Fig. 4e).

[0037] With the harness thereby being full formed, automatic ejection arms 100, 102 are cycled to extract connectors 14 from their respective nests 70, 72(Fig. 5) for transport along ejection tracks to remote work stations.

[0038] The second transport assembly 52 is thereafter retracted to the second loading station 56, leaving the free ends of wires 40 extending from supply 92, at the predetermined position above termination station 58, and harness machine 10 is ready to begin another harness making cycle.

[0039] Immediately after ejection, connectors 14 and the length of wires 40 extending therebetween, are transported to a conventional work station 107 (see Fig. 1) where the connectors 14 are rotated 90 degrees (as indicated in Fig. 5b), such that their mating ends 24 are upwardly directed as indicated in Figs. 7, 8. After being placed in their rotated position, connectors 14 are slid along transport tracks 110 which extend to a peg removal station indicated generally at 112 (Fig. 7), and a web removal station indicated generally at 114 (Fig. 8). At station 112, the upwardly directed locating pegs 116, projecting from mating end wall 24, are severed by a selected array of blades 118. Thereafter, while preserving the rotated orientation, connectors 14 are advanced to station 114 (Fig. 8) wherein the selected web portions are removed by blades 120 to form a plurality of finished harness products.

[0040] Referring briefly to Fig. 6, an optional wire preparation module 122 is shown carried on second carrier member 62. Although the optional transport assembly formed thereby, designated by the numeral 52', is movable to and from the second loading station 56, it has no useful interaction therewith, as it does not carry a connector. Instead, the optional transport assembly 52' is provided when only a single-ended harness is desired, the second or trailing end of the harness being prepared by only cutting, or alternatively, cutting and stripping, the trailing ends of wires 40 at termination station 58. After termination to a first connector 14, the first transport assembly 50 is returned to the first loading station 54, and conductors 40 are paid out, across termination station 58. Transport assembly 52', as before, follows the same path to termination station 58, and upon arrival, actuator 80' is energized to lower cutting and stripping blades 124, 126, respectively (Fig. 6d). With wires 40 cut by blades 124, and the insulation cladding thereof at least partially severed by blades 126, an actuator 128 is energized to extend movable wire clamp 130 toward the first transport assembly 50, thereby stripping the second end of the newly formed wire segments (Fig. 6). Alternatively, stripping blades 126, actuator 128, and wire clamp 130 may be omitted if only cutting, and not wire stripping, is required at the second end of the cable harness.

[0041] As has been outlined above, a choice of two wire preparation modules 68 or 122 is available for the second transport assembly 52 (see Fig. 10). Carriers, 60, 62 act as frame assemblies for locating (see pins 61) and locking (see bolt-receiving mounting holes 63) a selected wire preparation module for movement therewith. More elaborate frame assemblies 66', 68' and 122' are illustrated in Fig. 10.

[0042] The various module styles described herein provide a finished second harness end having either a connector mass terminated to the wires, or second wire ends which are either cut or cut-and-stripped, in whatever form is desired by the end user. Those skilled in the art will readily appreciate that other styles of wire preparation modules can be employed with the present invention. For example, a module for gang crimping of the second wire ends to a crimp-type connector can be provided. If the wires comprise a flat flexible cable for example, the wire preparation modules can provide clinching of suitably formed terminals to the flat flexible cable. Also, a cable notching module can he provided if the wires are associated in a conventional ribbon cable. No matter what style of wire preparation module is required, the particular module can be quickly and easily bolted and unbolted from the threaded mounting holes 63 of carriers 60, 62, by simply installing and removing four mounting bolts for each module.

[0043] Throughout this application, the term "wire preparation module" will be employed to describe any of the above mentioned different styles of modules including wire finishing assemblies which may comprise equipment for terminating the trailing wire ends to a connector. Even though the term "wire finishing assembly" may alternately be employed to avoid any suggestion of excluding a module style wherein the wires are terminated in a connector, for the sake of simplicity, the term "wire preparation module" will be employed to cover those styles of modules which not only cut, strip or notch and perform like operations on the second wire ends, but also terminate or otherwise prepare for termination of those ends to a connector. In either event, the feature highlighted here is that at each of the modules, whatever their style, be quickly and easily mounted to either carrier 60 or 62 by the simple installation and removal of four mounting bolts. It should be expressly understood that other particular combinations of modules and mounting frames other than those that set forth in Fig. 10, and elsewhere herein will become apparent to those skilled in the art upon studying the description herein, and such arrangements are regarded as being included in the present invention.

[0044] Further, it should also be expressly understood that the present invention includes not only modularization of the entire wire preparation module, but also any portion thereof. For example, the upper and/or a lower wire preparation portion. Alternatively, the concept also covers the modular interchangeability of wire insertion blades, wire clamping means, or other subparts of a transport assembly 50 or 52.

IV. First Modular Transport Assembly

[0045] Turning now to Figs. 1 and 2, the first modular transport assembly 50 receives a connector 14 from the first loading station 54, and is moved to termination station 58 by carrier 60. As can be seen in Fig. 1, the first loading station 54 comprises an accumulator track 140 which receives a single row of connectors, placed end-to-end, from a source not shown. The leading connector is moved by shuttle 142 to a delivery track 144 under the action of transfer solenoid 146. Thereafter, delivery solenoid 148 advances the connector along delivery track 144 to connector nest 70, where it is prepared for transfer to the termination station.

[0046] With reference to Fig. 2, the wire preparation module 66 of the first transport assembly 50 includes wire insertion blades 74 inserted in a movable head 150, which is mounted for reciprocation about guide pins 152 under the force of double acting air cylinder referred to above as actuator 78. Also mounted on head 150 are a series of wire separator blades 154 which align wires 40, just prior to termination.

[0047] The first modular transport assembly 50 is advanced to termination station 58 at a lower level than that of the wire feed of wires 40, as indicated in Figs. 2 and 3a. Wire supply 92 includes an associated power feed, for directing the wires 40 through a wire guide 162 having a delivery end located immediately adjacent termination station 58. Upon delivery of carrier 60 to the termination station 58, transport elevator 94 is activated to raise the rods 82, thereby elevating the lower wire preparation module portion 66L located thereon.

[0048] Other arrangements for elevating the wire preparation module portion 66L will become apparent to those skilled in the art, in the light of the description herein. For example, the entire wire preparation module may be raised a first amount with an optional double-acting solenoid 84 raising 60' an additional amount.

[0049] As connector nest 70 is raised, the upper surface of connector housing 16 carried therein contacts wires 40, deflecting every other wire with the upper row of terminals, to produce a predetermined angular deflection (see Fig. 3b). The upwardly deflected wires 40U are those aligned for termination in the upper row 28 of connector 14. The remaining set of wires 40L, to be terminated to the lower connector row 30, are positioned in channels 42, extending between the terminal receiving cavities of upper row 28. Channels 42 guide wires 40L to terminals located on the lower connector row 30.

[0050] Electrical sensors not shown in the figures, initiate energization of elevator 94, upon arrival of carrier 60 at termination station 58. Sequencing control 170 transmits the actuation signal to elevator 94. Further sensor switches, not shown in the figures, can be provided within solenoid 84, to indicate when carrier bed 60', and hence lower wire preparation module portion 66L, is raised to its uppermost height. These switches send a signal to sequencing control 170 which de-energizes elevator 94 and initiates downward movement of actuator 78, simultaneously inserting both sets of wires 40U, 40L in connector rows 28, 30. Wires 40L, upon full extension of insertion blades 74, take an equal but downwardly directed angular offset (see Fig. 3c). As indicated in the present embodiment of Fig. 3c, connector 14 is preferably centered about the level of wire feed, with the angular offsets of the upper and lower rows of wires being equally displaced from that level of wire feed.

[0051] After full downward extension of upper module portion 66U, sequencing control 170 initiates a retraction signal to double acting solenoid 78, whereupon moving head 150 is returned in an upward direction. Solenoid 84 is energized to pull down the lower wire preparation module portion to its original, lower, position. As carrier 60 returns wire preparation module 66 to the first loading station 54, wires 40 terminated to the connector 14 carried in nest 70 are dereeled as they pass through termination station 58. If the frictional forces of dereeling are too great, or if the distance between the first loading station 54 and termination station 58 is not great enough, additional power dereeling can be provided at wire supply 92. Cable loops can be conveniently downwardly directed between the termination and loading stations.

[0052] Shortly before the return of transport assembly 50 to the first loading station 54, a test cylinder 174 is automatically activated to extend movable bed 176 carrying test pobes 178 (see Fig. 2) in an extended position toward the connector carried in nest 70. The left-hand free end of test probes 178 are thereby inserted in connector 14 in preparation for electrical testing of the harness. The right-hand free end of probes 178 are mated with a stationary connector block 180 located adjacent loading station 54. Connector block 180 contains suitable socket terminals for reception of probe 178, providing connection to an electrical test apparatus not shown in the drawings. Preferably, each free end of test probes 178 is provided with retractable spring loading to provide easy mating between connector 14 and connector block 180. In the present embodiment, the electrical testing is performed only on single-ended harnesses (see Section VI, below) to detect any shorts between adjacent harness conductors. Other suitable electrical testing as is known in the art, may be performed on both single or double-ended harnesses being fabricated.

V. Second Modular Transport Assembly

[0053] The wire preparation module of the second modular transport assembly 52 can take at least three forms. If a double ended harness is required, a wire preparation module, similar in function to that described above, can be provided for mass termination to a second connector 14. However, if a single-ended harness is required, the wire preparation module need only contain a wire cutting device. Alternatively, if a single-ended harness having stripped electrical wires at its free end is required, wire cutting and stripping equipment can be mounted to the second carrier 62. The numeral 68 has been applied to the mass termination wire preparation module of the present embodiment. The other wire preparation module described hereinbelow is designated by numeral 122 and includes wire cutting and stripping features.

[0054] Referring now to Fig. 4, a second modular transport assembly 52, adapted for mass termination to a second connector 14, is shown comprising a carrier 62 and a wire preparation module 68. A connector nest 72 carries a connector 14 from second loading station 56 to termination station 58. The first and second connector loading stations 54, 56 are functionally similar. Accordingly, the numerals 140 to 148 used to describe the first loading station are repeated for the second station 56 but appear therein as primed numerals. For example, the accumulator track at the second connector loading station is designated by numeral 140'.

[0055] In addition to the second connector nest 72, wire preparation module 68 includes upper and lower wire clamps 200, 202, respectively. Lower wire clamp 202 is mounted for retraction toward carrier 62 by double acting pulldown actuator 85. Carrier bed 62' is mounted for vertical reciprocal movement by guide pins 83. Also mounted to the lower portion 68L of module 68 is a travelling wire comb 208, the function of which will be described later. The upper module portion 68U consists of the aforementioned upper wire clamp 200, wire separator blades 210, wire cut-off and insertion blades 76 and a wire clamp 214. The aforementioned components 76, 200 and 204-214 are mounted for common movement to a movable head 216 which is driven by actuator 80 for movement about guide pins 220. The leftmost wire clamp 214 is mounted for independent movement with respect to head 216, by actuator 222, to press wires 40 against surface 72' (see Fig. 4a).

[0056] With reference now to Figs. 4a to 4f, operation of the second transport assembly having a mass termination wire preparation module will be described. All operations take place at the common terminating station 58 whereat the first transport assembly 50 has dereeled wires 40 such that a continuous wire portion is positioned above termination station 58. Upon arrival of the second transport assembly 52 (Fig. 4a), carrier bed 62' is raised by elevator 94. Sensor switches associated with pull down solenoid 85 indicate to sequencing control 230 when carrier bed 62' has been elevated to a maximum height, whereat the top surface 72' of the connector nest 72 comes in contact with wires 40 (Fig. 4b). Thereupon, energization of elevator 94 is discontinued by control 230 which then initiates independent movement of lower wire clamp 202 until it also contacts wires 40, which are maintained at their level of wire feed set by wire guide 162 (Fig. 4c). At this point control 230 can initiate the lowering of wire clamp 214 by energizing actuator 222. Thereafter, as indicated in Fig. 4c, travelling wire comb 208 is moved to the left, toward second connector 14, is lowered so as to engage wires 40, and is thereafter retracted past lower wire clamp 202.

[0057] Upon completion of the wire comb cycle, sequencing control 230 energizes actuator 80, to initiate depression of tooling head 216. As indicated in Fig. 4e, the termination cycle is shown at a time just after contact of upper and lower wire clamp members 200, 202. The left hand edge 76c (see Fig. 4c) of wire cutting and insert blades 76 (see Fig. 4b) has just engaged a co-operating edge 72c (see Fig. 4c) of connector nest 72 so as to sever wires 40. Also, sequencing control 230 relieves back pressure on solenoid 85, to allow lower wire clamp 202 to be fully depressed by the downwardly moving wire clamp 200. Upon maximum downward extension of the upper module, as indicated by sensors located within solenoid 85, sequencing control 230 de-energizes solenoid 80 at a point where cut-off and insertion blades 212 have fully seated the newly formed wire segments in the terminals of the second connector 14. Immediately prior to the termination shown in Fig. 4d, wire separators 210 (see Fig. 4d) have engaged the freshly cut wire segments to aid in alignment with the terminals of connector 14. Thereafter, as shown in Fig. 4f, sequencing control 230 initiates raising of upper wire preparation module 68U, by energizing double acting solenoid 80. Simultaneously, or at a convenient time thereafter, sequencing control 230 energizes double acting solenoid 85 to retract lower wire clamp 202, thereby pulling the carrier bed 62', with lower module portion 68L and connector nest 72, below the newly formed free end of supply wires 40. At sometime prior to the step shown in Fig. 4f, elevator 94 is retracted so as to retract the toggle lock mechanism allowing downward movement of carrier bed 62'.

[0058] The termination of the second connector 14 forms a double-ended harness ready for ejection from the transport assemblies 50, 52. Referring to Figs. 1 and 5, ejection arms 100, are extended to overlie the connectors 14, their spring-loaded pawls 184 being retractable as they are passed over the connector housings. As pawls 184 clear the remote end of connectors 14, ejection arms 100 reverse direction and pawls 184 pull connectors 14 onto their respective eject tracks 104, for transport to 90 degree roll-over stations 107 (see Fig. 1).

[0059] An example of a roll-over station 107 is shown in Fig. 5a incorporated with an arm 100. In this figure, arm 100 is mounted for reciprocal extension and retraction indicated by arrow 240 under the driving force of actuator 242. In this optional arrangement of roll-over station 107, a second pawl 244 is provided to provide gripping of connector 14. The leading pawl 184 is preferably mounted on an extendible section 246 of ejection arm 100, while the second pawl 244 is fixed in a stationary position. After gripping of connector 14 between pawls 184, 244, a motor 251 is energized to drive the gear 252. Actuator 242 and ejection arm 100 are rotatably mounted at each end by rotatable supports 254, 256. As indicated, the leading support 254 is rotatably driven by gear 252. Accordingly, connector 14 is rotated 90 degrees in a plane extending perpendicular to eject track 104. Limit switches 260 de-energize motor 251, when the proper angular rotation is achieved. Upon rotation, actuator 242 is again energized to introduce connector 14 to a delivery track 110 (see Fig. 8a), which will be explained below with reference to Fig. 8a.

[0060] A second roll-over station 170 must be provided for a second connector 14, when a double-ended harness is produced. While a particular roll-over station 170 is shown in Fig. 5a, other arrangements will become apparent to those skilled in the art.

[0061] Upon leaving stations 107, connectors 14 are positioned with their mating ends 24 upwardly directed, and wires 12 extending between connectors 14 forming a downward loop, as shown in Fig. 7a.

VI. Alternative Second Modular Transport Assembly

[0062] As referred to above, an alternative embodiment of the second modular transport assembly, designated generally at 52', includes wire cutting and stripping tooling, rather than the mass termination tooling referred to above. Referring now to Figs. 6a to 6e, operation of the cut and strip wire preparation module 122 will be described. As referred to above with reference to Fig. 4, wires 40 have been extended past termination station 58 by the first transport assembly 50, upon its retraction to a point adjacent loading station 54. Thereafter, as shown in Fig. 6a, opposed moving wire comb members 130, 132 are extended toward the wire supply 92. As indicated in Fig. 6b, the wire combs are brought into engagement with each other, and are thereafter retracted to their initial position, being moved toward first transport assembly 50. With this operation, wires 40 have been combed and aligned, ready for cutting and stripping operations. Sensors located in wire combs 130, 132 send a cycle completion signal to sequencing control 240, upon returning to their initial position. Thereafter, sequencing control 240 energizes elevator 94, raising tooling head 246 to engage wires 40, and raising lower wire clamp 248 to also engage wire 40. Tooling head 246 and wire clamp 248 are both contained on a movable bed 250. Pull down solenoid 256 is in turn fastened to bed 250 to ensure retraction thereof at the proper time.

[0063] Sensors located within solenoid 256 indicating full upward extension of tooling head 246 send a signal to sequencing control 240, initiating downward extension of actuator 80' (Fig. 6c). At this time, control 240 energizes actuator 222 lowering wire clamp 214 to press wires 40 against the lower wire preparation module portion. Cutting blades 124 and stripping blades 126 are thereby lowered for engagement with cutting edge 246c and lower stripping blade 126', respectively. Also, upper wire clamp 249 is brought into engagement with its mating counterpart 248, so as to firmly engage wires 40. Upon the full downward extension of actuator 80', a signal is sent to sequencing control 240 to initiate the rightward extension of actuator 128. This action moves wire clamps 248, 249 toward the right, away from stripping blades 126, 126', to effectively strip the newly formed free ends of the harness wires, as indicated in Fig. 6e.

VII. Polarizing Peg Removal Station

[0064] Turning now to Fig. 7, connectors 14 are located at a peg removal station 112, whereat knife-like peg-removing blades 118 are lowered to sever selected polarizing pegs 116 from the upper and lower housing surfaces 20, 22 respectively. The pegs 116 have been positioned so as to extend beyond, but not overlie mating edge 24. The positioning of connectors 14, to withstand the force of severing blades 118, is ensured by delivery track 110. Blades 118 are mounted to a press-like actuator 119 for downward movement across top and bottom connector surfaces 20, 22. Accordingly, it is important that track 110 is more narrow than the body of connector 14, and prevents sideways rocking of that body during peg removal.

VIII. Delivery Track

[0065] Referring now to Fig. 8a, the delivery track 110 will be explained in greater detail. Connectors 14 have alignment tabs 260 extending from mating end 24 to form an alignment channel 262 extending therealong. Track 110 has an upper rail member 266 complementarily shaped with channel 262, for a close-fitting reception therein. Track 110 further includes second and third rail members 270, 272 which engage and support the wire receiving end 26 of connector 14 immediately adjacent the top and bottom connector surfaces 20, 22. In effect, lower rails 272, 270 oppose upper rail 266 to form a connector receiving cavity corresponding to the profile of connector 14. With upper rail 266 received in channel 262, and lower rails 270, 272 supporting the opposed end wall 26, the connector is supported by track 110 to prevent rocking movement during the sliding travel of the connector therealong. The rocking movement referred to occurs in a plane extending along the track, as well as the two directions mutually perpendicular thereto.

IX. Web Removal Station

[0066] Referring now to Fig. 8, connectors 14 are slid along track 110, for presentation to web removal station 114 which includes a predetermined plurality of web removing blades 120. As indicated in Fig. 8b, the web removal blades are lowered into the mating end of connector 14, so as to remove selected web portions 44, to form a plurality of connector modules 46 as indicated by the dotted lines of Fig. 8c. The phantom lines 280 (Fig. 8b) indicate the region of material removed from connector housing 16 by blades 120 corresponding to a web portion 44.

[0067] As indicated in Fig. 8c, the particular connector modules 46 formed by blades 120 have a vertically elongated side profile, particularly for a two-circuit connector comprising one upper terminal and one lower terminal. The arrangement of delivery track 110 is particularly advantageous in that it provides reliable sliding transport of the connector module, without rocking about any of its three mutually orthogonal axes, one of which lies in the direction of track 110.

Claims

1. A method of producing an electrical cable harness (12), including mass terminating the first ends of a plurality of double-ended insulation-clad wires (40) each to an insulation displacement terminal of a connector (14) the method including the steps of:
   loading a connector (14) onto a first transport assembly (50) at a first station (54) thereof, said first transport assembly (50) being operable to move said connector (14) between said first and a second station (58) of said first transport assembly (50),
   feeding and measuring wires (40) so that the first ends thereof are positioned adjacent said connector (14) at said second station (58) of said first transport assembly (50),
   terminating the first ends of said wires (40) to said connector (14) at said second station (58) of said first transport assembly (50) to form a first finished end of said harness (12) and then returning said first transport assembly (50) to said first station (54) thereof thereby drawing a predetermined length of said wires (40) past said second station (58) of said first transport assembly (50),
   removably mounting one of a plurality of different, selectively actuable, harness finishing modules (68; 122) on a frame assembly (62) of a second transport assembly (52; 52') having a first station (56) which may be a connector loading station and a second station (58) the same as said second station (58) of said first transport assembly (50),
   moving said second transport assembly (52, 52') with said frame assembly (62) and said module (68; 122) from said first station (56) of said second transport assembly (52, 52') to said second station (58),
   keeping said second transport assembly (52, 52') at said second station while actuating said module (68; 122) to simultaneously finish the second wire ends to form a second finished harness end thereby to form a single or a double-ended cable harness as desired depending upon the one of the harness finishing modules selected for finishing the second wire ends and then moving said second transport assembly (52, 52') together with said frame assembly and said module (68; 122) to said first station (56) of said second transport assembly (52, 52') to make ready for the production of another harness.

2. The method of claim 1 including:
   feeding the wires (40) to said second station (58) along a first level so that the first ends thereof are located at a predetermined position;
   loading said connector (14) to said first transport assembly (50) at a second lower level;
   moving said first transport assembly (50) along said second level to the predetermined position adjacent said first wire ends; and
   elevating at least a portion (66L) of said first transport assembly (50) so that said connector (14) loaded thereon is placed immediately under said wires (40), so as to position said first wire ends for mass termination to said connector (14).

3. The method of claim 2, including:
   moving said second transport assembly (52; 52') along said second lower level to position said one of said harness finishing modules (68; 122) adjacent said second wire ends; and
   elevating a portion (68L; 250) of said module (68; 122) to a position immediately adjacent said wires (40) for finishing said second wire ends upon further actuation of said module (68; 122).

4. The method of any preceding claim wherein:
   said one harness finishing module (68) comprises an arrangement for mass terminating the second ends of said wires (40) to a second connector (14) having a plurality of insulation displacement terminals, to form the second finished end of said harness,
   said one and said second connectors (14) each having an integrally formed housing (16) with opposed top and bottom surfaces (20, 22) extending in the axial direction between opposed forward mating and rearward end walls (24, 26) and at least two rows (28, 30) of axially extending terminal receiving cavities (32), said rows of cavities being stacked one on top of the other in a staggered fashion so that the cavities of one row (28) are positioned between the cavities of the other row (30), each cavity having an upwardly facing wire receiving slot opening to said top housing surface (20), so that all of said wires (40) can be inserted for termination from said top housing surface (20),
   the method including
   loading said one and said second connectors (14) so that the top connector surfaces (20) of the connectors (14) are maintained facing the same direction during termination; and
   terminating respective wire ends to the rows simultaneously (28, 30) of each connector (14).

5. The method of claim 4 including:
   rotating said one and said second connectors (14) upon termination thereof, so that the forward mating ends (24) thereof are upwardly directed, with the wires (40)of said harness (12) extending between said connectors (14) forming a downwardly extending loop; and
   transporting said harness (12) to a remote work station (112; 114) by sliding the rearward end walls (26) of said connectors along respective first and second transport tracks (110), each having slotted openings for receiving said wires (40).

6. A multi-station apparatus for automatically producing an electrical cable harness including mass terminating the first ends of a plurality of double-ended insulation-clad wires (40) each to an insulation displacement terminal (18) of a connector (14), the apparatus including
   a first connector transport assembly (50) for receiving and moving a connector (14) between two stations (54; 58),
   means (140, 142, 144, 146) for loading the connector (14) onto said first connector transport assembly (50) at a first station (54) thereof,
   wire feeding means (92, 162) for feeding and measuring the wires (40) so that the first ends thereof are associated with the connector (14) at the second station (58) of said first connector transport assembly (50),
   wire termination means (66) for terminating the first ends of the wires (40) to said connector (14) at said second station (58) to form a first finished end of said harness,
   a further transport assembly (52; 52') having a first station (56) which may be a connector loading station and a second station (58) the same as said second station (58) of said first connector transport assembly (50),
   said further transport assembly (52; 52') removably supporting one of a plurality of harness finishing modules (68; 122) on said apparatus,
   said harness finishing module (68; 122) being movable by said further transport assembly (52; 52') to said second station (58) to finish simultaneously second ends of the wires (40) to form the second finished harness end and being movable by said further transport assembly (52, 52') to said first station (56) of said further transport assembly (52, 52') to ready the machine to begin another harness making cycle, characterised in that the said further transport assembly (52, 52') has a frame assembly (62) removably supporting said one harness finishing module (68, 122),
   said further transport assembly (52, 52') is movable together with the frame assembly (62) and the harness finishing module (68, 122) from said first station (56) of the further transport assembly to the second station (58) thereof and, while the second transport assembly is kept at said second station, the harness finishing module (68, 122) is actuated to finish simultaneously said second ends, thereby to form a single or double-ended cable harness as desired, and
   said further transport assembly is movable together with the frame assembly (62) and said harness finishing module (68, 122) from said second station (58) of the further transport assembly (52, 52') to said first station (56) of the further transport assembly (52, 52') to ready the machine to begin another harness making cycle.

7. The apparatus of claim 6 wherein:
   said wire operation station of the module(68; 122) includes opposed upper and lower module portions (68U, 68L; 130, 132; 214, 124, 126, 249, 246, 248, 126') with a gap (98) therebetween for receiving said second wire ends, said opposed module portions being movable toward each other to finish the second ends of the wires, thereby forming the second finished harness end; and
   said apparatus further includes elevating means (94) at said second station (58) for elevating at least one of said lower module portions (68L; 246, 248) toward said second wire ends to facilitate the finishing thereof.

8. The apparatus of claim 7, wherein
   said first connector transport assembly (50) includes a connector nest (70) for receiving the connector (14) and the wire termination means (66) includes projecting means (74) for engaging and inserting the first ends of the wires into the terminals (18) of the connector (14) when those projecting means (74) are advanced toward the connector nest (70) and
   said connector nest (70) is positioned adjacent said elevating means (94) when said connector (14) is moved to said second station (58) and is engaged therewith for movement of said connector (14) toward said first wire ends.

9. The apparatus of claim 7 or 8, wherein said module portions respectively comprise second wire end clamping means (248, 249) and wire stripping blades (126, 126') movable toward one another to engage the wires, and actuator means (128) for displacing the clamping means (248, 249) to strip the insulation from the second ends of said wires.

10. The apparatus of claim 7 or 8 wherein
   one of said module portions (68L) includes a connector nest (72) for receiving a second connector (14) having a plurality of insulation displacement terminals (18);
   said other module portion (68U) comprises second wire termination means (76) for mass terminating the second end of the wires to said second connector (14) to form the second finished end of said harness; and
   means (140', 142', 144', 146') is provided for loading said second connector (14) onto said second connector nest (72).

11. The apparatus of any of claims 7 to 10 for producing harnesses comprising connectors (14) each having an integrally formed housing (16) with opposed top and bottom surfaces (20, 22) extending between opposed forward mating and rearward end walls (24, 26) and at least two rows (28, 30) of axially, extending terminal receiving cavities (32), said rows of cavities being stacked one on top of the other in a staggered fashion so that the cavities of one row (28) are positioned between the cavities of the other row (30), each cavity having an upwardly facing wire-receiving slot opening to said top housing surface (20), so that all of said wires (40) can be inserted for termination from said top housing surface (20), wherein
   said loading means (140 to 146; 140' to 146') is adapted to load connectors (14) so that a top surface (20) thereof is maintained in an upwardly facing direction during termination; and
   said wire termination means (66; 76) is operable to terminate all of said wire first ends simultaneously in terminals (18) of respective rows (28, 30) of said connector (14).

12. The apparatus of claim 11 when claim 11 is dependent upon claim 8 for producing harnesses comprising connectors as defined in claim 11 of which the housing sidewalls (34) of upper rows (28) of the connectors act as wire guides to aid in the passage of wires (40) to lower rows (30) for termination therein, such that all of said wire ends can be inserted for termination from said top housing surface (20), wherein said wire feeding means (92, 162, 50) is adapted for feeding and measuring said wires (40) so that said first wire ends when associated with a connector (14) at said second station (58) are arranged in a common plane, with adjacent wire ends to be terminated to terminals (18) of different rows (28, 30) of the connector (14) whereby when said connector is moved towards said first wire ends said connector bends the wires to be terminated in a first row with a predetermined upward angular deflection and causes the wires to be terminated to the other row to have an equal downwardly directed angular deflection when terminated by said wire termination means (66; 76).

13. The apparatus of claim 11, further comprising
   means (107; 170) for rotating each said connector (14) upon termination thereof, so that the forward mating end (24) thereof is upwardly directed, with the wires of said harness extending in a downward direction,
   a first transport track (110), having a slotted opening for receiving said wires (40), and surfaces (270, 272) for supporting the rearward end wall (26) of the connector (14) and
   means for transporting said harness to a remote station (112; 114) of said apparatus by sliding said connector along said track (110).

14. The apparatus of claim 13 for producing harnesses comprising connectors (14) as defined in claim 11 or claims 11 and 12, said rows (28, 30) of the connectors being at least partially joined together by selectively removable web portions (44) to form a plurality of commonly joined separable connector modules (46), each module including at least one upper row cavity (28) and at least one lower row cavity (30); wherein said remote station of said apparatus comprises a connector web removing station (114) and the apparatus further comprises
   means (120) at the web removing station for selectively removing at least one of said connector webs (44) in the axial direction so as to form a plurality of said connector modules (46), each connector module (46) thereby comprising a separate connector (14) terminated to a predetermined number of said wires (40) so as to form a separate harness (12) therewith.

15. The apparatus of claim 13 or 14 for producing harnesses comprising connectors (14) as defined in claim 11, 12 or 13, each said connector (14) further including a plurality of locating pegs (116) projecting from said top and bottom surfaces (20, 22) so as to extend beyond but not overlie said mating end wall (24); wherein the remote station of said apparatus further comprises a peg removal station (112), the apparatus further comprising
   means (118, 119) at said peg removal station (112) for selectively removing at least one of said connector pegs (116) in the axial direction, immediately adjacent one of said top and bottom surfaces (20, 22).

16. The apparatus of claim 13, 14 or 15 for producing harnesses comprising connectors (14) as defined in claim 11, 12, 13 or 14, each said connector (14) further including a plurality of aligning tabs (260) extending from said mating end wall (24) to form a channel (262) extending along said mating end wall; wherein
   said transport track (110) includes a first rail (266) complementarily shaped with and receivable in said channel (262), and second and third spaced-apart rail members (270, 272) opposing said first rail (266) engageable with said connector (14) for supporting said rearward end wall (26) thereof,
   whereby said connector (14) is supported by said track (110) to prevent rocking movement during travel therealong.

Ansprüche

1. Verfahren zur Herstellung eines elektrischen Kabelbaumes (12), bei dem ein Massenanschluß der ersten Enden einer Mehrzahl doppelendiger Drähte (40) mit Isolierungsmantel jeweils an einem Isolierungsverdrängeranschluß eines Verbinders (14) vorgenommen wird, wobei das Verfahren die Schritte umfaßt, daß
   ein Verbinder (14) auf eine erste Transporteinheit (50) in einer ersten Station (54) derselben aufgegeben wird, wobei die erste Transporteinheit (50) derart betätigbar ist, daß der Verbinder (14) zwischen der ersten und einer zweiten Station (58) der ersten Transporteinheit (50) bewegt wird,
   Drähte (40) derart zugeführt und bemessen werden, daß deren erste Enden angrenzend an den Verbinder (14) in der zweiten Station (58) der ersten Transporteinheit (50) positioniert werden,
   die ersten Enden der Drähte (40) an den Verbinder (14) in der zweiten Station (58) der ersten Transporteinheit (50) angeschlossen werden, um ein erstes fertiggestelltes Ende des Kabelbaums (12) zu bilden, und dann die erste Transporteinheit (50) zu deren erster Station (54) zurückgeführt wird, wodurch eine vorbestimmte Länge der Drähte (40) an der zweiten Station (58) der ersten Transporteinheit (50) vorbeigezogen wird,
   einer einer Mehrzahl verschiedener, wahlweise betätigbarer Module (68;122) zur Kabelbaumfertigstellung auf eine Rahmeneinheit (62) einer zweiten Transporteinheit (52;52') lösbar angebracht wird, die eine erste Station (56), die eine Verbinderaufgabestation sein kann, und eine zweite Station (58) besitzt, die die gleiche ist wie die zweite Station (58) der ersten Transporteinheit (50),
   die zweite Transporteinheit (52,52') mit der Rahmeneinheit (62) und dem Modul (68;122) von der ersten Station (56) der zweiten Transporteinheit (52,52') zu der zweiten Station (58) bewegt wird,
   die zweite Transporteinheit (52,52') in der zweiten Station gehalten wird, während der Modul (68,122) betätigt wird, um gleichzeitig die zweiten Drahtenden zur Bildung eines zweiten fertiggestellten Kabelbaumendes fertigzustellen und dadurch einen ein- oder einen doppelendigen Kabelbaum zu bilden, je nach Wunsch in Abhängigkeit von dem einen der Kabelbaumfertigstellungsmodule, der zur Fertigstellung der zweiten Drahtenden ausgewählt wird, und dann die zweite Transporteinheit (52,52') zusammen mit der Rahmeneinheit und dem Modul (68,122) zu der ersten Station (56) der zweiten Transporteinheit (52,52') für eine Bereitstellung zur Produktion eines weiteren Kabelbaums bewegt wird.

2. Verfahren nach Anspruch 1, bei dem
   die Drähte (40) der zweiten Station (58) entlang einer ersten Ebene zugeführt werden, so daß deren erste Enden in einer vorbestimmten Position angeordnet sind,
   der Verbinder (14) der ersten Transporteinheit (50) in einer zweiten niedrigeren Ebene aufgegeben wird,
   die erste Transporteinheit (50) entlang der zweiten Ebene zu der vorbestimmten, an die ersten Drahtenden angrenzenden Position bewegt wird und
   zumindest ein Bereich (66L) der ersten Transporteinheit (50) angehoben wird, so daß der darauf aufgegebene Verbinder (14) unmittelbar unter den Drähten (40) plaziert wird, derart, daß die ersten Drahtenden für einen Massenanschluß an den Verbinder (14) positioniert werden.

3. Verfahren nach Anspruch 2, bei dem
   die zweite Transporteinheit (52,52') entlang der zweiten niedrigeren Ebene bewegt wird, um den einen der Kabelbaumfertigstellungsmodule (68,122) angrenzend an die zweiten Drahtenden zu positionieren, und
   ein Bereich (68L,250) des Moduls (68,122) in eine unmittelbar an die Drähte (40) angrenzende Position angehoben wird, um die zweiten Drahtenden bei der weiteren Betätigung des Moduls (68,122) fertigzustellen.

4. Verfahren nach einem beliebigen vorhergehenden Anspruch, bei dem
   der eine Kabelbaumfertigstellungsmodul (68) eine Anordnung für einen Massenanschluß der zweiten Enden der Drähte (40) an einen zweiten Verbinder (14) umfaßt, der eine Mehrzahl von Isolierungsverdrängeranschlüssen besitzt, um das zweite fertiggestellte Ende des Kabelbaums zu bilden,
   der eine und der zweite Verbinder (14) jeweils ein einteilig gebildetes Gehäuse (16) mit gegenüberliegenden oberen und unteren Oberflächen (20,22), die sich in axialer Richtung zwischen einander gegenüberliegenden vorderen Verbindungs- und hinteren Endwänden (24,26) erstrecken, und zumindest zwei Reihen (28,30) axial verlaufender Anschlußaufnahmeräume (32) besitzt, wobei die Reihen von Räumen eine oben auf der anderen in versetzter Form gestapelt werden, so daß die Räume einer Reihe (28) zwischen den Räumen der anderen Reihe (30) angeordnet sind und jeder Raum einen nach oben weisenden Drahtaufnahmeschlitz aufweist, der sich zu der oberen Gehäuseoberfläche (20) öffnet, so daß sämtliche Drähte (40) für einen Anschluß von der oberen Gehäuseoberfläche (20) eingesetzt werden können, wobei das Verfahren vorsieht, daß
   der eine und der zweite Verbinder (14) so aufgegeben werden, daß die oberen Verbinderoherflächen (20) der Verbinder (14) in dieselbe Richtung weisend während des Anschlusses gehalten werden, und
   die jeweiligen Drahtenden an die Reihen (28,30) jedes Verbinders (14) gleichzeitig angeschlossen werden.

5. Verfahren nach Anspruch 4, bei dem
   der eine und der zweite Verbinder (14) bei deren Anschluß gedreht werden, so daß deren vordere Verbindungsenden (24) nach oben gerichtet werden, wobei die sich zwischen den Verbindern (14) erstreckenden Drähte (40) des Kabelbaums (12) eine nach unten verlaufende Schlaufe bilden, und
   der Kabelbaum (12) an eine entfernte Arbeitsstation (112,114) transportiert wird, indem die hinteren Endwände (26) der Verbinder entlang jeweiligen ersten und zweiten Transportbahnen (110) verschoben werden, die jeweils Schlitzöffnungen zur Aufnahme der Drähte (40) besitzen.

6. Mehrstationenvorrichtung zur automatischen Herstellung eines elektrischen Kabelbaumes mit einem Massenanschluß der ersten Enden einer Mehrzahl doppelendiger Drähte (40) mit Isolierungsmantel jeweils an einen Isolierungsverdrängeranschluß (18) eines Verbinders (14), bestehend aus
   einer ersten Verbindertransporteinheit (50) zur Aufnahme und zum Bewegen eines Verbinders (14) zwischen zwei Stationen (54,58),
   einer Einrichtung (140,142,144,146) zum Aufgeben des Verbinders (14) auf die erste Verbindertransporteinheit (50) in einer ersten Station (54) derselben,
   einer Drahtzuführeinrichtung (92,162) zur Zuführung und Bemessung der Drähte (40) derart, daß deren erste Enden dem Verbinder (14) in der zweiten Station (58) der ersten Verbindertransporteinheit (50) zugeordnet werden,
   einer Drahtanschlußeinrichtung (66) zum Anschließen der ersten Enden der Drähte (40) an den Verbinder (14) in der zweiten Station (58) zur Bildung eines ersten fertiggestellten Endes des Kabelbaums,
   einer weiteren Transporteinheit (52,52') mit einer ersten Station (56), die eine Verbinderaufgabestation sein kann, und einer zweiten Station (58), die die gleiche ist wie die zweite Station (58) der ersten Verbindertransporteinheit (50),
   wobei die weitere Transporteinheit (52,52') einen einer Mehrzahl von Kabelbaumfertigstellungsmodulen (68,122) auf der Vorrichtung lösbar abstützt,
   der Kabelbaumfertigstellungsmodul (68,122) von der weiteren Transporteinheit (52,52') in die zweite Station (58) bewegbar ist, um gleichzeitig die zweiten Enden der Drähte (40) zur Bildung der zweiten fertiggestellten Kabelbaumenden fertigzustellen, sowie von der weiteren Transporteinheit (52,52') in die erste Station (56) der weiteren Transporteinheit (52,52') bewegbar ist, um die Maschine für den Beginn eines weiteren Kabelbaumherstellungszyklus bereitzustellen, dadurch gekennzeichnet, daß die weitere Transporteinheit (52,52') eine Rahmeneinheit (62) besitzt, die den einen Kabelbaumfertigstellungsmodul (68,122) lösbar abstützt,
   die weitere Transporteinheit (52,52') zusammen mit der Rahmeneinheit (62) und dem Kabelbaumfertigstellungsmodul (68,122) von der ersten Station (56) der weiteren Transporteinheit zu deren zweiter Station (58) bewegbar ist und der Kabelbaumfertigstellungsmodul (68,122), während die zweite Transporteinheit in der zweiten Station gehalten wird, betätigt wird, derart, daß gleichzeitig die zweiten Enden fertiggestellt werden, wodurch ein ein- oder doppelendiger Kabelbaum, wie gewünscht, gebildet wird, und
   die weitere Transporteinheit zusammen mit der Rahmeneinheit (62) und dem Kabelbaumfertigstellungsmodul (68,122) von der zweiten Station (58) der weiteren Transporteinheit (52,52') in die erste Station (56) der weiteren Transporteinheit (52,52') bewegbar ist, um die Maschine für den Beginn eines weiteren Kabelbaumherstellungszyklus bereitzustellen.

7. Vorrichtung nach Anspruch 6, bei der
   die Drahtbearbeitungsstation des Moduls (68,122) einander gegenüberliegende obere und untere Modulbereiche (68U,68L,130,132,214,124,126,249,246,248,126') mit einem Spalt (98) zwischen diesen zur Aufnahme der zweiten Drahtenden aufweist, wobei die einander gegenüberliegenden Modulbereiche zur Fertigstellung der zweiten Enden der Drähte aufeinander zu bewegbar sind und dadurch die zweiten fertiggestellten Kabelbaumenden zu bilden, und
   die Vorrichtung ferner eine Hebeeinrichtung (94) in der zweiten Station (58) zum Anheben zumindest eines der unteren Modulbereiche (68L,246,248) zu den zweiten Drahtenden hin zur Ermöglichung deren Fertigbearbeitung aufweist.

8. Vorrichtung nach Anspruch 7, bei der die erste Verbindertransporteinheit (50) ein Verbindernest (70) zur Aufnahme des Verbinders (14) aufweist und die Drahtanschlußeinrichtung (66) eine vorspringende Einrichtung (74) für einen Eingriff mit den und Einsetzen der ersten Enden der Drähte in die Anschlüsse (18) des Verbinders (14) bei Vorbewegung dieser vorspringenden Einrichtung (74) zum Verbindernest (70) hin aufweist und
   das Verbindernest (70) eine Position angrenzend an die Hebeeinrichtung (94) einnimmt, wenn der Verbinder (14) zu der zweiten Station (58) bewegt wird, und mit dieser für eine Bewegung des Verbinders (14) zu den ersten Drahtenden hin in Eingriff kommt.

9. Vorrichtung nach Anspruch 7 oder 8, bei der die jeweiligen Modulbereiche Klemmeinrichtungen (248,249) für das zweite Drahtende und Drahtabisolierungsmesser (126,126'), die zum Erfassen der Drähte aufeinanderzubewegbar sind, und eine Betätigungseinrichtung (128) zum Verschieben der Klemmeinrichtung (248,249) zum Ablösen der Isolierung von den zweiten Enden der Drähte umfassen.

10. Vorrichtung nach Anspruch 7 oder 8, bei der
   einer der Modulbereiche (68L) ein Verbindernest (72) zur Aufnahme eines zweiten Verbinders (14) mit einer Mehrzahl von Isolierungsverdrängeranschlüssen (18) aufweist,
   der andere Modulbereich (68U) eine zweite Drahtanschlußeinrichtung (76) für einen Massenanschluß des zweiten Endes der Drähte an den zweiten Verbinder (14) zur Bildung des zweiten fertiggestellten Endes des Kabelbaums umfaßt und
   eine Einrichtung (140',142',144'146') zum Aufgeben des zweiten Verbinders (14) auf das zweite Verbindernest (72) vorgesehen ist.

11. Vorrichtung nach einem der Ansprüche 7 bis 10, zur Herstellung von Kabelbäumen mit Verbindern (14) jeweils mit einem einteilig geformten Gehäuse (16) mit einander gegenüberliegenden oberen und unteren Oberflächen (20,22), die sich zwischen einander gegenüberliegenden vorderen Verbindungs- und hinteren Endwänden (24,26) erstrecken, und zumindest zwei Reihen (28,30) axial verlaufender Anschlußaufnahmeräume (32), wobei die Raumreihen die eine auf der Oberseite der anderen in einer versetzten Form gestapelt sind, so daß die Räume einer Reihe (28) zwischen den Räumen der anderen Reihe (30) angeordnet sind, und jeder Raum einen nach oben weisenden Drahtaufnahmeschlitz besitzt, der sich zur oberen Gehäuseoberfläche (20) öffnet, so daß sämtliche Drähte (40) zum Anschluß von der oberen Gehäuseoberfläche (20) eingesetzt werden können, wobei
   die Aufgabeeinrichtung (140 - 146, 140' - 146') geeignet ist, Verbinder (14) derart aufzugeben, daß eine obere Oberfläche (20) von diesen in einer nach oben weisenden Richtung während des Anschlusses gehalten wird, und
   die Drahtanschlußeinrichtung (66,76) für einen Anschluß sämtlicher erster Drahtenden gleichzeitig in Anschlüssen (18) betreffender Reihen (28,30) des Verbinders (14) betätigbar ist.

12. Vorrichtung nach Anspruch 11, bei Abhängigkeit des Anspruchs 11 von Anspruch 8, zur Herstellung von Kabelbäumen mit Verbindern nach Anspruch 11, von denen die Gehäuseseitenwände (34) der oberen Reihen (28) der Verbinder als Drahtführungen zur Hilfe beim Durchgang der Drähte (40) zu unteren Reihen (30) für einen Anschluß in diesen wirken, derart, daß sämtliche Drahtenden für einen Anschluß von der oberen Gehäuseoberfläche (20) eingesetzt werden können, wobei die Drahtzuführeinrichtung (92,162,50) geeignet ist, die Drähte (40) derart zuzuführen und zu bemessen, daß die ersten Drahtenden bei Zuordnung zu einem Verbinder (14) in der zweiten Station (58) in einer gemeinsamen Ebene mit den anzuschließenden Drahtenden angrenzend an die Anschlüsse (18) verschiedener Reihen (28,30) des Verbinders (14) angeordnet sind, wodurch, wenn der Verbinder zu den ersten Drahtenden hin bewegt wird, der Verbinder die anzuschließenden Enden in einer ersten Reihe mit einer vorbestimmten aufwärtsgerichteten Winkelauslenkung verbiegt und bewirkt, daß die an die andere Reihe anzuschließenden Drähte eine gleiche abwärtsgerichtete Winkelauslenkung bei Anschluß durch die Drahtanschlußeinrichtung (66,76) besitzen.

13. Vorrichtung nach Anspruch 11, ferner bestehend aus
   einer Einrichtung (107,170) zum Drehen jedes Verbinders (14) bei dessen Anschluß, so daß dessen vorderes Verbindungsende (24) nach oben gerichtet ist, wobei die Drähte des Kabelbaums in Abwärtsrichtung verlaufen,
   einer ersten Transportbahn (110) mit einer geschlitzten Öffnung zur Aufnahme der Drähte (40) und Oberflächen (270,272) zum Abstützen der hinteren Endwand (26) des Verbinders (14) und
   einer Einrichtung zum Transportieren des Kabelbaums zu einer entfernten Station (112,114) der Vorrichtung durch Verschieben des Verbinders auf der Bahn (110).

14. Vorrichtung nach Anspruch 13, zur Herstellung von Kabelbäumen mit Verbindern (14) nach Anspruch 11 oder den Ansprüchen 11 und 12, wobei die Reihen (28,30) der Verbinder zumindest teilweise miteinander durch wahlweise entfernbare Stegbereiche (44) zur Bildung einer Mehrzahl gemeinsam verbundener brennbarer Verbindermodule (46) verbunden sind, wobei jeder Modul zumindest einen Raum (28) der oberen Reihe und zumindest
   einen Raum (30) der unteren Reihe aufweist, wobei die entfernte Station der Vorrichtung eine Verbindersteg-Entfernungsstation (114) umfaßt und die Vorrichtung ferner versehen ist mit
   einer Einrichtung (120) in der Stegentfernungsstation zum selektiven Entfernen zumindest eines der Verbinderstege (44) in der axialen Richtung, um so eine Mehrzahl der Verbindermodule (46) zu bilden, wobei jeder Verbindermodul (46) auf diese Weise einen gesonderten Verbinder (14) umfaßt, der an eine vorbestimmte Anzahl der Drähte (40) angeschlossen ist, um so einen gesonderten Kabelbaum (12) mit diesem zu bilden.

15. Vorrichtung nach Anspruch 13 oder 14 zur Herstellung von Kabelbäumen mit Verbindern (14) nach Anspruch 11, 12 oder 13, wobei jeder Verbinder (14) ferner eine Mehrzahl von Zentrierstiften (16) aufweist, die von den oberen und unteren Oberflächen (20,22) vorstehen, um sich so über die Verbindungsendwand (24) hinaus zu erstrecken, sie jedoch nicht zu überlagern, wobei die entfernte Station der Vorrichtung ferner eine Stiftentfernungsstation (112) umfaßt und die Vorrichtung ferner versehen ist mit
   einer Einrichtung (118,119) in der Stiftentfernungsstation (112) zum selektiven Entfernen zumindest eines der Verbinderstifte (116) in der axialen Richtung unmittelbar angrenzend an eine der oberen und unteren Oberflächen (20,22).

16. Vorrichtung nach Anspruch 13, 14 oder 15 zur Herstellung von Kabelbäumen mit Verbindern (14) nach Anspruch 11, 12, 13 oder 14, wobei jeder Verbinder (14) ferner eine Mehrzahl von Ausrichtlaschen (260) aufweist, die von der Verbindungsendwand (24) ausgehen, um einen entlang der Verbindungsendwand verlaufenden Kanal (262) zu bilden, wobei
   die Transportbahn (110) eine erste Schiene (266), die komplementär zu dem Kanal (222) geformt und in diesem aufnehmbar ist, und ein zweites und drittes beabstandetes Schienenteil (270,272) gegenüber der ersten Schiene (266) aufweist, das mit dem Verbinder (14) zur Abstützung dessen hinterer Endwand (26) in Eingriff bringbar ist,
   wodurch der Verbinder (14) von der Bahn (110) zur Verhinderung einer Schaukelbewegung während der Bewegung entlang dieser abgestützt ist.

Revendications

1. Procédé de fabrication d'un faisceau de câble électrique (12) dans lequel on raccorde en bloc chacune des premières extrémités d'une pluralité de fils à gaine isolante (40), à double extrémité, à une borne à déplacement d'isolation d'un connecteur (14), caractérisé en ce qu'il comprend les étapes consistant à charger un connecteur (14) sur un premier ensemble de transport (50), à l'endroit d'un premier poste (54) de celui-ci, ce premier ensemble de transport (50) pouvant intervenir pour déplacer le connecteur (14) entre le premier poste et un second poste (58) du premier ensemble de transport (50), à alimenter et mesurer les fils (40) de telle façon que les premières extrémités de ceux-ci soient placées dans une position adjacente au connecteur (14), à l'endroit du second poste (58) du premier ensemble de transport (50), à raccorder les premières extrémités des fils (40) au connecteur (14), à l'endroit du second poste (58) du premier ensemble de transport (50), afin de former une première extrémité finie du faisceau de câble (12), et à ramener ensuite le premier ensemble de transport (50) au premier poste (54) de celui-ci, en tirant ainsi une longueur prédéterminée des fils (40) en regard du second poste (58) du premier ensemble de transport (50), à monter d'une manière amovible l'un de plusieurs modules différents de finition du faisceau (68,122), actionnables sélectivement, sur un châssis (62) d'un second ensemble de transport (52;52') ayant un premier poste (56) qui peut être un poste de chargement de connecteurs et un second poste (58) qui peut être le même que le second poste (58) du premier ensemble de transport (50), à déplacer le second ensemble de transport (52;52'), avec le châssis (62) et le module (68;122), à partir du premier poste (56) du second ensemble de transport (52;52') vers le second poste (58), à maintenir le second ensemble de transport (52,52') à l'endroit du second poste tout en actionnant le module (68;122), afin de finir simultanément les secondes extrémités des fils, pour former ainsi une seconde extrémité finie du faisceau de câble, afin de fabriquer à volonté un faisceau de câble à une seule extrémité ou à double extrémité, suivant celui des modules de finition du faisceau de câble qui a été sélectionné pour la finition des secondes extrémités des fils, et à déplacer ensuite le second ensemble de transport (52;52'), conjointement avec le châssis et le module (68;122) vers le premier poste (56) du second ensemble de transport (52,52'), avant de le rendre prêt à la production d'un autre faisceau de câble.

2. Procédé suivant la revendication 1 caractérisé en ce qu'il comprend les étapes consistant à alimenter les fils (40) vers le second poste (58) le long d'un premier niveau de telle façon que les premières extrémités des fils soient situées dans une position prédéterminée, a charger le connecteur (14), à un second niveau inférieur, sur le premier ensemble de transport (50), à déplacer le premier ensemble de transport (50), le long du second niveau, jusqu'à la position prédéterminée adjacente aux premières extrémités des fils, et à élever au moins une partie (66L) du premier ensemble de transport (50) de telle façon que le connecteur (14) chargé sur lui soit placé immédiatement sous les fils (40) afin de mettre en position les premières extrémités des fils en vue d'un raccordement en bloc au connecteur (14).

3. Procédé suivant la revendication 2 caractérisé en ce qu'il compoere les étapes consistant à déplacer le second ensemble de transport (52,52') le long du second niveau intérieur, afin d'amener le module sélectionné parmi les modules de finition du faisceau de câble (68;122) à être adjacent aux secondes extrémités des fils, et à élever une portion (68L;250) du module (68;122) jusqu'à une position immédiatement adjacente aux fils (40), afin de finir les secondes extrémités des fils lors d'un actionnement additionnel du module (68;122).

4. Procédé suivant l'une quelconque des revendications précédentes dans lequel le module (68) de finition du faisceau de câble comprend une disposition pour le raccordement en bloc des secondes extrémités des fils (40) à un second connecteur (14) ayant une pluralité de bornes à déplacement d'isolation, afin de former la seconde extrémité finie du faisceau de câble, le premier connecteur et le second connecteur (14) comportant chacun un boîtier (16) formé d'une manière intégrale avec des surfaces supérieure et inférieure opposées (20,22), s'étendant dans la direction axiale entre des parois frontales opposées (24,26), à savoir une paroi antérieure d'accouplement ou d'embrochage et une paroi postérieure, et au moins deux rangées (28,30) de cavités (32) de réception de bornes, s'étendant axialement, ces rangées de cavité étant superposées l'une à l'autre, d'une manière décalée de telle façon que les cavités d'une rangée (28) soient situées entre les cavités de l'autre rangée (30), chaque cavité ayant une fente de réception d'un fil, tournée vers le haut, débouchant dans la surface supérieure du boîtier, si bien que tous les fils (40) peuvent être insérés, en vue de leur raccordement, à partir de la surface supérieure (20) du boîtier, caractérisé en de qu'il comprend des étapes consistant à charger les premier et second connecteurs (14) de telle façon que les surfaces supérieure (20) de ces connecteurs soient maintenues tournées dans la même direction pendant leur raccordement et à raccorder des extrémités respectives des fils simultanément aux rangées (28,30) de chaque connecteur (14).

5. Procédé suivant la revendication 4 caractérisé en ce qi'il comprend les étapes consistant à faire tourner les premier et second connecteurs (14), après leur raccordement, de telle façon que leurs extrémités d'accouplement ou d'embrochage antérieures (24) soient tournées vers le haut, les fils (40) du faisceau de câble (12) s'étendant entre les connecteurs (14) en formant une boucle s'étendant le bas, et à transporter le faisceau de câble (12) vers un poste de travail à distance (112,114) en faisant glisser les parois frontales postérieures (26) des connecteurs le long de première et seconde pistes de transport respectives (110), dont chacune présente une ouverture en forme de fente pour recevoir les fils (40).

6. Appareil à plusieurs postes pour la fabrication automatique d'un faisceau de câble électrique en raccordant en bloc chacune des premières extrémités de plusieurs fils à gaine isolante (40), à double extrémité, à une borne à déplacement d'isolation (18) d'un connecteur (14), comportant un premier ensemble de transport de connecteur (50) afin de recevoir et déplacer un connecteur (14) entre deux postes (54,58), des moyens (140;142;144;146) pour charger le connecteur (14) sur le premier ensemble de transport de connecteur (50), à l'endroit d'un premier poste (54) de celui-ci, des moyens d'alimentation en fils (92;162) pour alimenter et mesurer les fils (40) de telle façon que leurs premières extrémités soient associées au connecteur (14) à l'endroit du second poste (58) du premier ensemble de transport de connecteur (50), des moyens de raccordement des fils (66) pour raccorder les premières extrémités des fils (40) au connecteur (14), à l'endroit du second poste (58), afin de former une première extrémité finie du faisceau de câble, un second ensemble de transport (52;52') ayant un premier poste (56) qui peut être un poste de chargement du connecteur et un second poste (58) qui peut être le même que le second poste (58) du premier ensemble de transport de connecteur (50), ce second ensemble de transport (52,52') supportant d'une manière amovible l'un de plusieurs modules (68;122) de finition du faisceau de câble sur l'appareil, ce module (68;122) de finition de faisceau de câble pouvant être déplacé, par le second ensemble de transport (52,52'), vers le second poste (58), afin de finir simultanément les secondes extrémités des fils (40), pour former la seconde extrémité finie du faisceau de câble, et pouvant être déplacé, par le second ensemble de transport (52,52'), vers le premier poste (56) du second ensemble de transport (52,52') afin de préparer l'appareil à commencer un autre cycle de fabrication du faisceau de câble, caractérisé en ce que le second ensemble de transport (52,52') comporte un châssis (62) supportant d'une manière amovible le module (68;122) de finition du faisceau de câble, le second ensemble de transport (52,52') peut être déplacé, conjointement avec le châssis (62) et le module (68;122) de finition du faisceau de câble, à partir du premier poste (56) du second ensemble de transport vers le second poste de celui-ci, et, tandis que le second ensemble de transport est maintenu à l'endroit du second poste, le module (68;122) de finition du faisceau de câble est actionné afin de finir simultanément les secondes extrémités, pour former ainsi, suivant les besoins, un faisceau de câble à une seule extrémité ou à double extrémité, et le second ensemble de transport peut être déplacé, conjointement avec le châssis (62) et le module (68;122) de finition du faisceau de câble, à partir du second poste (58) du second ensemble de transport (52,52'), vers le premier poste (56) du second ensemble de transport (52,52'), afin de préparer l'appareil à commencer un autre cycle de fabrication d'un faisceau de câble.

7. Appareil suivant la revendication 6 caractérisé en ce que le poste d'opération du module (68,122) sur les fils comporte des portions de module opposées supérieure et inférieure (68U,68L;130,132,214,124,126,249,246,248,126') avec un intervalle (98) entre elles pour recevoir les secondes extrémités des fils, ces portions de module opposées pouvant être déplacées l'une vers l'autre afin de finir les secondes extrémités des fils, en formant ainsi la seconde extrémité finie du faisceau de câble, et il comporte en outre, à l'endroit du second poste (58), des moyens élévateurs (94) afin de soulever au moins une des portions de module inférieures (68L;246,248) en direction des secondes extrémités des fils, afin de faciliter la finition de celles-ci.

8. Appareil suivant la revendication 7 caractérisé en ce que le premier ensemble de transport de connecteur (50) comporte un berceau de connecteur (70) pour recevoir le connecteur (14) et les moyens (66) de raccordement des fils comportent des moyens en saillie (74) venant en contact avec les premières extrémités des fils et les insérant dans les bornes (18) du connecteur (14), lorsque ces moyens en saillie (74) sont avancés en direction du berceau de connecteur (70), et ce berceau de connecteur (70) est mis dans une position adjacente aux moyens élévateurs (94) lorsque le connecteur (14) est déplacé vers le second poste (58), et il est rencontré par ces moyens élévateurs afin de déplacer le connecteur (14) vers les premières extrémités des fils.

9. Appareil suivant l'une quelconque des revendications 7 ou 8 caractérisé en ce que les portions de module comprennent respectivement des moyens (248,249) de serrage des secondes extrémités des fils et des lames (126,126') de dénudage des fils, pouvant être déplacées l'une vers l'autre afin de venir en contact avec les fils, et un moyen d'actionnement (128) pour déplacer les moyens de serrage (248,249), afin de dénuder les secondes extrémités des fils.

10. Appareil suivant l'une quelconque des revendications 7 ou 8 caractérisé en ce que l'une des portions de module (68L) comporte un berceau de connecteur (72) pour recevoir un second connecteur (14) comportant une pluralité de bornes à déplacement d'isolation (18), l'autre portion de module (68U) comprend des moyens (76) de raccordement des secondes extrémités des fils afin de raccorder en bloc les secondes extrémités des fils au second connecteur (14), pour former la seconde extrémité finie de faisceau de câble, et des moyens (140',142',144',146') sont prévus pour charger le second connecteur (14) sur le second berceau de connecteur (72).

11. Appareil suivant l'une quelconque des revendications 7 à 10 pour la fabrication de faisceau de câble comportant des connecteurs (14) ayant chacun un boîtier (16) formé d'une manière intégrale avec des surfaces supérieure et inférieure opposées (20,22), s'étendant entre des parois frontales opposées (24,26), à savoir une paroi antérieure d'accouplement ou d'embrochage et une paroi postérieure, et au moins deux rangées (28,30) de cavités (32) de réception de bornes, s'étendant axialement, ces rangées de cavité étant superposées l'une à l'autre, d'une manière décalée de telle façon que les cavités d'une rangée (28) soient situées entre les cavités de l'autre rangée (30), chaque cavité ayant une fente de réception d'un fil, tournée vers le haut, débouchant dans la surface supérieure du boîtier, si bien que tous les fils (40) peuvent être insérés, en vue de leur raccordement, à partir de la surface supérieure (20) du boîtier, caractérisé en ce que les moyens de chargement (140 à 146; 140' à 146) sont adaptés de manière à charger des connecteurs (14) de telle façon qu'une surface supérieure (20) de ceux-ci soit maintenue tournée vers le haut pendant le raccordement, et les moyens de raccordement des fils (66,76) peuvent intervenir pour raccorder simultanément toutes les premières extrémités des fils dans les bornes (18) des rangées respectives (28,30) du connecteur (14).

12. Appareil suivant la revendication 11 lorsque cette revendication 11 est dépendante de la revendication 8, pour la fabrication de faisceaux de câble comprenant des connecteurs tels que définis dans la revendication 11, dont les parois latérales (34) du boîtier des rangées supérieures (28) des connecteurs agissent en tant que guides pour les fils afin de contribuer au passage des fils (40) vers les rangées inférieures (30), en vue de leur raccordement dans ces rangées, de telle façon que toutes les extrémités des fils puissent être insérées, en vue de leur raccordement, à partir de la surface supérieure (20) du boîtier, caractérisé en ce que les moyens d'alimentation des fils (92,162,50) sont adaptés pour alimenter et mesurer les fils (40) de telle façon que les premières extrémités des fils, alors qu'elles sont associées à un connecteur (14) à l'endroit du second poste (58), soient disposées dans un plan commun, les extrémités de fils adjacents devant être raccordées à des bornes (18) de différentes rangées (28,30) du connecteur (14) si bien que lorsque ce connecteur est déplacé vers les premières extrémités des fils, le connecteur cambre les fils devant être raccordés dans une première rangée, en leur donnant une inclinaison angulaire prédéterminée vers le haut, et il amène les fils qui doivent être raccordés à l'autre rangée, à avoir une flexion angulaire égale dirigée vers le bas, lorsqu'ils sont raccordés par les moyens de raccordement des fils (66,76).

13. Appareil suivant la revendication caractérisé en ce qu'il comprend en outre des moyens (107,170) pour faire tourner chaque connecteur, après son raccordement, de telle façon que l'extrémité d'accouplement d'embrochage antérieure (24) de ce connecteur soit dirigée vers le haut, les fils du faisceau de câble s'étendant vers le bas, une première piste de transport (110) présentant une ouverture en forme de fente pour recevoir les fils (40), et des surfaces (270,272) pour supporter la paroi frontale postérieure (26) du connecteur (14) et des moyens pour transporter ce faisceau de câble vers un poste situé à distance (112;114) de l'appareil, en faisant glisser le connecteur le long de la piste (110).

14. Appareil suivant la revendication 13 pour produire des faisceaux de câble comprenant des connecteurs (14) tels que définis dans la revendication 11 ou dans les revendications 11 et 12, les rangées (28,30) des connecteurs étant reliées entre elles, au moins partiellement, par des portions de languette de liaison (44) pouvant être enlevées sélectivement afin de former une pluralité de modules de connecteur séparables (46), reliés en commun, chaque module comportant au moins une cavité de la rangée supérieure (28) et au moins une cavité de la rangée inférieure (30), caractérisé en ce que le poste de l'appareil situé à distance constitue un poste (114) d'enlèvement des languettes de liaison des connecteurs et en ce que l'appareil comprend en outre des moyens (120), au poste d'enlèvement des languettes de liaison, pour enlever sélectivement au moins une des languettes de liaison (44) des connecteurs, dans la direction axiale, afin de former une pluralité de modules de connecteur (46), chaque module de connecteur (46) constituant ainsi un connecteur séparé raccordé à un nombre prédéterminé des fils (40), afin de former avec ceux-ci un faisceau de câble (12).

15. Appareil suivant la revendication 13 ou 14, pour la fabrication de faisceaux de câble comprenant des connecteurs (14) tels que définis dans la revendication 11,12 ou 13, chaque connecteur (14) comportant une pluralité de pions de mise en position (116) faisant saillie à partir des surfaces inférieure et supérieure (20,22) de manière à s'étendre au delà de la paroi frontale d'accouplement ou d'embrochage (24), sans surplomber celle-ci, caractérisé en ce que le poste de l'appareil situé à distance est constitué en outre par un poste (112) d'enlèvement des pions de mise en position et l'appareil comprend en outre des moyens (118,119), à l'endroit de ce poste (112) d'enlèvement des pions de mise en position, pour enlever sélectivement l'un au moins des pions (116) du connecteur dans la direction axiale, immédiatement adjacent à l'une des surfaces supérieure et inférieure (20,22).

16. Appareil suivant la revendication 13,14 ou 15, pour la fabrication de faisceaux de câble comprenant des connecteurs (14) tels que définis dans la revendication 11, 12, 13 ou 14, chacun de ces connecteurs (14) comportant en outre une pluralité de pattes d'alignement (260) s'étendant à partir de la paroi frontale d'accouplement ou d'embrochage (24), afin de former un canal (262) s'étendant le long de cette paroi frontale d'accouplement ou d'embrochage, caractérisé en ce que la piste de transport (110) comporte un premier rail (266) de forme complémentaire de celle du canal (262) et pouvant venir se loger dans ce canal, et des deuxième et troisième rails (270,272) espacés l'un de l'autre, opposés au premier rail (266) et pouvant venir en contact avec le connecteur (14) afin de supporter la paroi frontale postérieure (26) de celui-ci, si bien que le connecteur (14) se trouve être supporté par la piste (110) en étant afin de l'empêcher de basculer pendant son déplacement le long de cette piste.

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