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EP 0 216 464 B1 |
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EUROPEAN PATENT SPECIFICATION |
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Mention of the grant of the patent: |
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09.09.1992 Bulletin 1992/37 |
(22) |
Date of filing: 25.07.1986 |
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International Patent Classification (IPC)5: H01R 43/00 |
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(54) |
Electrical harness fabrication method and apparatus
Verfahren und Vorrichtung zur Herstellung eines elektrischen Kabelbaumes
Procédé et dispositif pour la fabrication d'un peigne de câble électrique
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Designated Contracting States: |
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DE FR GB |
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Priority: |
20.09.1985 US 778103
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Date of publication of application: |
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01.04.1987 Bulletin 1987/14 |
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Proprietor: MOLEX INCORPORATED |
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Lisle
Illinois 60532 (US) |
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Inventors: |
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- Nugarus, Anthony R.
Chicago, Illinois 60638 (US)
- Pellegrino, Thomas
Lisle, Illinois 60532 (US)
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(74) |
Representative: Slight, Geoffrey Charles et al |
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Graham Watt & Co.
Riverhead Sevenoaks
Kent TN13 2BN Sevenoaks
Kent TN13 2BN (GB) |
(56) |
References cited: :
AT-E- 5 287 AT-E- 9 423 US-A- 4 235 015
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AT-E- 6 181 US-A- 4 091 531
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Note: Within nine months from the publication of the mention of the grant of the European
patent, any person may give notice to the European Patent Office of opposition to
the European patent
granted. Notice of opposition shall be filed in a written reasoned statement. It shall
not be deemed to
have been filed until the opposition fee has been paid. (Art. 99(1) European Patent
Convention).
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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.
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.
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.
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.