[0001] This invention relates to the connection of conductors to terminals of a cross-connect
connector for communication lines.
[0002] In a telecommunications system, different cables are used for different purposes.
For instance, customers' premises are provided with an incoming cable from a central
office and this cable is referred to as a feeder cable. The conductors of the feeder
cable upon arrival at the customers' premises are connected either internally or externally
of the premises to the conductors of a distribution cable which are connected in turn
to the subscribers' apparatus. The cables are normally connected together with the
use of cross-connect connectors each of which comprises a body of dielectric material
and has a row of conductor terminals along each side of the connector. Each terminal
has opposed electrical conductor portions which cut into insulation of a conductor
forced between them thereby causing the conductor portions to electrically contact
the conductor. The terminals in one row are interconnected through the dielectric
material with terminals in the other row to enable the conductors of the two cables
to be interconnected. The cross-connect connectors are mounted for convenience in
a wall mounted unit which is a modular construction and is built to carry a plurality
(e.g. ten) of the cross-connect connectors.
[0003] It is usual for the cross-connect connectors to have fifty terminals along each row.
The forming of the connection between conductors and terminals of each row is a time
consuming operation. It is conventional practice to connect lengths of conductors
to the terminals along one row before insertion of the connector into the wall mounted
unit. These lengths of conductors are inserted into the terminals by a manual operation
which is tedious as well as time consuming. This manual method which involves the
drawing in sequence of conductors across the row of terminals and connecting them
to the terminals, this requires operator attention to conductors individually.
[0004] The present invention provides a method and apparatus for electrically connecting
a group of conductors along a row of terminals which substantially increases the rate
of assembly of the connectors and conductors.
[0005] According to one aspect of the present invention, apparatus is provided for electrically
connecting a group of insulated conductors to a row of terminals of a cross-connect
connector comprising means for holding the connector in an assembly station, guiding
and feeding means for feeding the group of conductors through the station and across
the connector with the conductors aligned with associated terminals and with lengths
of the conductors extending downstream along passlines from the assembly station,
means in the assembly station for inserting the conductors between opposed electrically
conductive portions of the terminals to enable said portions of each terminal to cut
into insulation on an associated conductor and electrically contact said conductor,
and severing means operable on the upstream side of the assembly station to sever
said lengths of conductors which are electrically connected to the terminals from
supplies of the conductors upstream from the station.
[0006] The invention also includes a method of electrically connecting a group of insulated
conductors to a row of terminals of a cross-connect connector comprising locating
the connector in an assembly station; feeding a group of insulated conductors together
along passlines and through the assembly station to provide lengths of the conductors
extending along the passlines downstream from the assembly station while guiding the
conductors so that they are aligned with terminals of the row; inserting the conductors
between opposed electrically conductive portions of the terminals to enable said portions
of each terminal to cut into insulation on an associated conductor and electrically
contact said conductor; and severing said lengths of conductors which are electrically
connected to the terminals from remainders of the conductors upstream from the station.
[0007] One embodiment of the invention will now be described, by way of example, with reference
to the accompanying drawings, in which:-
Figure 1 is a plan view of a cross-connect connector;
Figure 2 is a side elevational view of apparatus for electrically connecting a group
of conductors to the cross-connect connector with frame parts of the apparatus cut
away to show, in general manner, operational parts of the apparatus;
Figure 3, on a larger scale than Figure 2, is a side view in the same direction as
Figure 2 and showing a connector loading device;
Figure 4 is a view of part of the loading device in the direction of arrow IV in Figure
3;
Figure 5 is a view of part of the loading device taken in the direction of arrow V
in Figure 2;
Figure 6, on the same scale as Figure 3, is a view in the same direction as Figure
2, and shows means for inserting conductors into connectors in an assembly station;
Figure 7 is a cross-sectional view taken along line VII-VII in Figure 2;
Figure 8 is a view in the same direction as Figure 7 and on a larger scale to show
in greater detail an insertion tool operating means of the apparatus;
Figures 9 and 10 are cross-sectional views through the apparatus taken along lines
IX-IX and X-X in Figure 8;
Figures 11 and 12 are views similar to Figure 8 and showing stages in a conductor
insertion cycle;
Figure 13 is a view similar to Figure 8 and partly in cross-section to show detail
of part of the insertion means;
Figures 14 to 17 are views similar to Figure 8 and partly in cross-section to show
movement of a wire cutter during the insertion cycle;
Figures 18 and 19 are cross-sectional views taken along lines XVIII-XVIII and XIX-XIX
in Figure 13 and on a larger scale;
Figures 20 and 21 are views in the same direction as Figure 8, on the same scale as
Figure 18 and show operation of the insertion and cutting means in detail; and
Figures 22 to 28 are diagrammatic side elevational views of main functional parts
of the apparatus and showing the stages in its operation.
[0008] As shown in Figure 1, a cross-connect connector 10 comprises a substantially planar
strip 12 of dielectric material having along each edge a row of terminals 14. In this
known connector structure, each of the terminals comprises two opposed electrically
conductive portions (not shown) arranged on either side of a molded groove 15 in an
edge of the strip 12. These conductor portions act to cut into insulating material
surrounding a conductor when the conductor is forced into the groove so that the conductor
portions electrically contact the conductor.
[0009] As is exemplified by the embodiment of the invention to be described, apparatus is
provided for electrically connecting a group of conductors along one of the rows of
terminals 14 thereby eliminating the need for manual assembly of conductors to the
connector.
[0010] The apparatus for connecting the conductors to cross-connect connectors 10 comprises
a supply for insulated conductors 16 (Figure 2) this supply comprising a plurality
of storage reels (not shown) to deliver the conductors between two guide rollers 18
which form part of a guiding and feeding means of the apparatus. From the guide rollers,
the conductors 16 move along passlines and through a clamping means 20 of the guiding
and feeding means, before proceeding through an assembly station 22 for conductors
and connectors and then downstream from the station 22. This downstream movement is
performed by a clamping means 24 which is also part of the guiding and feeding means.
The clamping means 24 is movable between upstream and downstream positions, as will
be described, to move lengths of conductor downstream from the station 22 and to hold
these lengths securely in position while they are electrically connected and assembled
to connectors and are severed from the supplies of conductors extending upstream from
the assembly station. The apparatus also comprises a connector loading device shown
generally at 26 in Figures 2 and 7.
[0011] The apparatus will now be described in greater detail. As shown by Figure 2 and in
greater detail by Figure 6, the clamping means 20 lies in a fixed position upstream
from the assembly station 22. The clamping means 20 comprises a stationary support
block 28 which is secured to a frame 29 of the apparatus. As is clear from Figure
6 and Figure 9, clamping means 20 comprises a movable clamping member 30 having side
arms 31 each pivoted at an intermediate position 32 to the support block 28. A transverse
clamping bar 34 extending between the arms 31, moves up and down upon pivoting action
of the clamping member about its pivotal position. The clamping member 30 is controlled
in its pivotal movement by a pneumatic operated piston and cylinder assembly 36 which
is connected to an upstream end of the member 30 by an actuating rod 38. The guiding
and feeding means also comprises a conductor guide 40 disposed between the clamping
means 20 and a severing means 42 for conductors. The severing means will be described
below.
[0012] The guide 40 is mounted by a slide means comprising two laterally spaced-apart guide
shafts 44 which are slidably received within the block 28 (Figures 6 and 9). A compression
spring 46, engaging the upstream end of each shaft 44 within the block 28, is held
between its associated shaft 44 and an abutment member 48 which extends laterally
across the passlines slightly upstream from the block 28. The springs 46 form a spring
biasing means to urge the conductor guide into a normal or downstream position shown
in full outline in Figure 6 in which it lies closely adjacent to, but slightly upstream
from, the assembly station. The conductor guide is movable from its normal position
and against the springs to a retracted or upstream position shown in chain-dotted
outline also in Figure 6. Conductor guide 40 has upwardly extending projections 50
which act as guides for the passage of the conductors between the projections and
hold the conductors in their spaced-apart relationship.
[0013] The clamping means 24 (Figure 2) has two mutually opposed clamping jaws 52 which
are movable together in opening or closing directions. These jaws and their means
of operation may be of any suitable construction. For instance, the jaws may be of
an articulated structure operated from a single pneumatic operated cylinder (not shown)
or each jaw, as shown in Figure 2, may be moved by means of its own piston and cylinder
assembly 54. Clamping jaws 52 and their assemblies 54 are mounted upon a support structure
56 which is slidably mounted upon two guide shafts 58 extending in the direction of
the feedpaths of the conductors. The support structure 56 is movable along the guide
shafts 58 by any suitable means, for instance by a piston and cylinder assembly 60
which is secured to the frame of the apparatus. Movement of the support structure
56 carries the clamping means 24 between a downstream position as shown in Figure
2 and an upstream position as will be discussed. The downstream position is sufficiently
far downstream from the assembly station to provide the required conductor lengths
to be assembled to the connectors. The upstream position is upstream of the assembly
station 22 and during movement into this position, the clamping jaws cooperate with
the conductor guide 40 to urge it into its retracted position as will now be described.
The various piston and cylinder assemblies which have been and are to be discussed
operate in a certain rigid sequence, controlled electrically by microprocessor, to
cause the apparatus to operate in the required fashion. The operation of the guiding
and feeding means will now be discussed before describing the other operational parts
of the apparatus.
[0014] At commencement of operation of the guiding and feeding means for connecting the
conductors to a connector, the clamping means 20 is in its clamping position as shown
in Figures 2 and 22 with the clamping bar 34 gripping the conductors 16. Also, the
clamping means 24 is in the downstream position with the jaws 52 open as shown particularly
by Figure 22 with the conductor guide 40 lying in its normal full outline position
as in Figure 6. The normal position of guide 40 is also shown by Figure 22. The clamping
means 24 is operated to move the jaws 52 towards the upstream position and as the
jaws approach the upstream position they engage the opposing face of the guide 40
and move the guide to its retracted position as shown in chain-dotted outline in Figure
6. The piston and cylinder assemblies 54 are then operated to close the jaws 52. This
position of the guiding and feeding means is shown in Figure 24. The piston and cylinder
assembly 36 is then operated to raise the clamp bar 34 after which the closed jaws
52 are returned downstream to their downstream position (Figure 25). This also allows
the conductor guide 40 to return to its normal position. Before return of the clamping
jaws 52 to their upstream positions, the clamping means 20 is returned to its closed
condition and the jaws 52 are again opened thus giving the position shown in Figure
22.
[0015] The connector loading device 26 which is shown in Figures 2 and 7 is more clearly
shown in Figures 3, 4 and 5. The loading device comprises a means for holding a connector
in the assembly station and for moving it between the assembly station and a withdrawn
position. The connector holding means comprises a substantially U-shaped support 62
which, as shown in the Figures, comprises a base 64 for supporting one edge of a connector.
The support 62 also has two vertical sides 66 for slidably contacting the side surfaces
of the connector with the general plane of the connector extending vertically to provide
one of the rows of terminals facing upwardly from and beyond the support 62. The location
of the support 62 in the assembly station is as shown for instance in Figures 2, 6
and 26 to 28. The withdrawn position is shown for instance in Figures 3, 4 and 22
to 25.
[0016] The connector loading device includes a connector stacking means 68 (see Figures
2, 3, 4, 5 and 7). This stacking means is a vertical column which enables a plurality
of connectors to be stacked one above another with the connectors lying in substantially
horizontal planes, i.e. at right angles to the position they assume when in the support
62. A delivery means for the connectors to move them in succession from the vertical
stacking column into the support 62 is shown in Figures 3, 4 and 5. This delivery
means comprises a push rod 70 operated by a piston and cylinder 72 to urge the lowest
connector in the vertical stacking column outwards from the column and into a support
74 of similar structure to the support 62. The support 74 is mounted on an arm 76
with the support and arm pivoted about axis 78. A piston and cylinder assembly 82
attached to the arm, controls pivotal movement of the support and arm about axis 78.
The sequence of operation for delivery of connectors into the support 62 only commences
when the support lies in the withdrawn position. With the support 74 lying in the
horizontal position indicated by Figure 3, the push rod 70 is moved towards the left
to force the lowest connector from the stacking column 68 and into the support 74.
This support is then pivoted into a vertical position (shown with the arm 76 in chain-dotted
outline in Figure 3) by operation of the piston and cylinder assembly 82. In this
position, the support 74 (shown in full outline in Figure 5) is aligned with an intermediate
support 84 which lies between the support 74 and the support 62. A connector 10 held
in the support 74 is moved by operation of a further push rod 86 into the support
84, and under control of a piston and cylinder assembly 88. This movement causes a
preceding connector as will be described, to be moved from the support 84 into support
62. As shown by Figure 4, a tray 90 at the side of the apparatus is provided for collecting
connector and conductor assemblies.
[0017] The connector loading device also comprises means for moving the support 62 between
the assembly station and its withdrawn position. This moving means comprises a piston
and cylinder assembly 90 (Figure 7) which is disposed beneath a horizontal carrier
92 for the support 62 and moves the carrier 92 along horizontally spaced and vertically
disposed main guide shafts 94 of the apparatus. These main guide shafts are securely
mounted into the frame of the apparatus and are held for instance by an upper horizontal
frame member 96 which in turn is carried by vertical frame members 98 (Figure 2).
[0018] In the assembly station is disposed a means for inserting the conductors between
opposed electrically conductive portions of the terminals thereby permitting electrical
contact with the conductors. In this station the severing means 42 is provided to
sever lengths of the conductors extending downstream from the assembly station from
supplies of conductors extending upstream from the assembly station. The insertion
and severing means jointly comprise a main horizontal support 100 (see Figures 8 to
12 and 19). This support has two depending short sections 102 by which it is slidably
carried upon the main guide shafts 94. Extending between and across the support sections
102 is an insertion tool carrier 104. The insertion tool carrier comprises two parts,
namely a C-shaped upstream part 106 and a downstream part or cover plate 108 (see
Figures 6, 18 and 19). A plurality of conductor insertion tools 110 are carried by
the insertion tool carrier. Each insertion tool 110 has a shaft 112 of rectangular
section and at its lower end, each insertion tool has the conventional structure 114
(see particularly Figure 19) for inserting conductors into the terminals of a cross-connect
connector. As shown by the Figures (see also Figures 8, 11, 12, 19, 20 and 21) the
insertion tools are located in side-by-side relationship with the shafts 112 slidable
upon each other and guided between the C-shaped part 106 and cover plate 108 of the
carrier 104. To allow for the insertion of the tools 110, the cover plate 108 is provided
with a relieved section 116 along the part of its length corresponding to the positions
of the tools 110 (see Figure 19). The carrier 104 is mounted by means of the C-shaped
section 106 within two reverse C-shaped housings 117 (Figure 6) which are screwed
respectively, one to each of the support sections 102 as shown also by Figure 8 onwards.
For reasons to be discussed below, the C-shaped part 106 is slidable within the housings
117. The horizontal support 100 is vertically movable between the assembly station,
for instance as shown in Figure 8, and a withdrawn position vertically above it, for
instance as shown in Figures 22 to 25. This movement, which is along the main guide
shafts 94, is effected by a control rod 118 operated by a piston and cylinder assembly
120 vertically mounted upon the horizontal frame member 96.
[0019] An insertion tool operating means is provided for causing sliding movement of the
tools towards and away from the connector holding means, i.e. support 62, the movement
being in sequence along the tools from end-to-end of the tool assembly. This operating
means comprises an operating shaft 122 which is slidably received within the C-shaped
section 106 and is held in place by the cover plate 118 (see Figures 6, 18 and 19).
The shaft 122 is movable by a horizontally disposed piston and cylinder assembly 124
secured to the main horizontal support 100. A piston rod 126 of the assembly 124 is
connected to one end of the shaft 122 over which it extends, by a connecting block
128, for instance as shown in Figure 8. The operating shaft 122 and the tools 110
are operably connected together by a cam and cam follower means to effect the vertical
sliding movement of the insertion tools. The cam and cam follower means comprises
a cam slot 130 (see Figures 13, 18 and 19) which extends longitudinally of the operating
shaft 122 except for a longitudinally short outward and return section 132 (Figure
13) of the slot and which extends downwards and laterally of the slot 130 for a short
distance. In respect of each of the insertion tools 110, the cam and cam follower
means also comprises a rotatable cam follower roller 134 (Figure 19) which is rotatably
mounted upon one side of each of the shafts 112 so as to lie within the slot 130 in
engagement with both of its side surfaces during movement of the operating shaft in
either direction. As can be seen, movement of the operating shaft 122 in either horizontal
direction by means of the piston and cylinder assembly 124 causes the rollers 134,
in turn, to move along the outward and return section 132 of the slot 130. Such movement
as is indicated by Figures 13, 20 and 21, effect the downward movement of the insertion
tools towards the support 62, followed by the return or upward movement.
[0020] As may be seen from inspection of the various Figures, the insertion structures 114
of the insertion tools 110 are positioned a distance apart which is exactly double
that of the distance apart of the terminals along a row of terminals of a connector.
The reason for this is that the terminals are so close together that no practical
way has yet been found of assembling and designing the structures 114 with their distances
apart equaling that of the distances apart of the terminals while still being able
to operate the insertion tools properly during the insertion procedure. Hence, each
movement of the operating shaft 122 in operating the insertion tools 110 will only
urge those tools into engagement with alternate conductors of a group extending across
the terminals. Thus the remainder of the conductors are not connected to the terminals
during one direction of movement of the operating shaft 122. To overcome this problem,
a tool position shift means 136 (see Figure 8) is provided to move the tool insertion
carrier 104 within the housings 117 for a distance equal to the distance apart of
the terminals in the row on a connector. Hence one direction of movement of the operating
shaft 122 will connect alternate conductors of the group along the row of terminals,
as has just been indicated, while the return movement of the operating shaft will
connect the remaining terminals as will now be described.
[0021] The tool position shift means 136 comprises a thrust means in the form of an inclined
rib 138 having parallel side surfaces 140 (Figure 8), the rib extending outwardly
from an elongate plate 142. The plate 142 extends downwardly of one of the support
sections 102 and lies between that section and the C-shaped section 106 of the tool
carrier 104. To allow for this positioning of the plate, the section 106 is provided
with a complementary groove 144 (see Figure 10) with the rib 138 extending completely
along the groove from one end to the other. The rib is received with its side surfaces
140 in sliding and continuous engagement with the side surfaces of the groove as shown
by Figure 10. Vertical movement of the plate 142 will cause the rib 138 to translate
that movement into a horizontal movement of the C-shaped section 106 and the cover
plate 108 in the appropriate direction while the shaft 122 will remain stationary.
The plate 142 is movable in the vertical direction by operating means which is a piston
and cylinder assembly 146 which is secured in a vertical position to the upper side
of the main horizontal support 100. To control the horizontal movement in either direction
of the tool carrier 40, the cover plate 108 is flanked at each end with an abutment
plate 148. Each abutment plate 148 has a vertical end abutment surface 150 for engagement
with an adjacent housing 117 upon movement of the tool carrier in the appropriate
direction. The degree of movement permitted is of course that required to move the
tool carrier together with the insertion tools 110 for a distance corresponding to
half the distance between corresponding locations on adjacent tools. In other words,
the degree of movement in either direction is half the distance between adjacent structures
114 of the tools.
[0022] Operation of the piston and cylinder assemblies 124 and 146 is controllable to effect
the following operation of the insertion tools 110. At commencement of an insertion
operation, the plate 142 lies at its downward position (Figure 8) so that the rib
138 has moved the insertion tool carrier 104 towards the right whereby the abutment
150 of plate 148 on the right-hand side abuts the housing 117 at that side. In this
position, the operating shaft 122 lies towards its right-hand extreme limit shown
by Figure 8 with the outward and return section 132 of slot 130 lying to the right-hand
side of the group of insertion tools 110 (the section 132 of the slot is shown in
Figure 8). The assembly 124 is then operated to move the operating shaft 122 towards
the left. This movement causes the first of the insertion structures 114 to insert
a conductor 16 into the first terminal at the right-hand end of the row of terminals
on a connector 10 in the assembly station. This is shown by Figure 8. Continued movement
of the shaft 122 in the same direction then connects the alternate conductors to the
appropriate terminals whereby conductors are connected to the odd numbered terminals
counted from the right-hand side. Thus as can be seen by viewing the right-hand end
of Figure 8, and also Figure 20, the extreme left-hand structure 114 is aligned with
the conductor for the forty-ninth terminal and will proceed to insert the conductor
in that terminal when the insertion tool 110 is moved downwards by its follower roller
134 proceeding along the section 132 of the slot 130.
[0023] Upon the shaft 122 reaching the extreme of movement on the left-hand side, the assembly
146 operates to raise the plate 142. The difference in the plate positions is seen
by comparing Figure 8 with Figure 12. This movement takes place until the abutment
surface 150 of the left-hand side abutment plate 148 contacts its associated housing
117. The positional difference of the abutment plates which indicates the sideways
shift of the carrier 104 may also be seen by comparing Figure 8 with Figure 12. This
lateral movement of the tool carrier 104 causes the tools 110 and thus the structures
114 to move by a spacing equivalent to the distance apart of the row of terminals
in the connector. Hence instead of the left-hand structure being aligned with terminal
forty-nine as shown in Figure 8 (as measured from the right-hand side of the connector
10), this structure 114 is now aligned with the fiftieth or left-hand end terminal
as shown by Figure 12. This is also clear from a comparison of Figures 20 and 21.
Of course the other structures 114 have also moved by one terminal spacing towards
the left in conjunction with the movement of the left-hand structure 114. It follows
that upon return movement of the operating shaft 122 towards the right by operation
of the assembly 124, then the structures 114 move downwardly to insert the conductors
into the even numbered terminals as measured from the right-hand side of the connector
and commences with the fiftieth terminal which is on the left-hand end. The conductors
which were not inserted into the terminals during the movement to the left of the
operating shaft, are now being connected into the terminals.
[0024] The severing means 42 is of such a construction as to enable it to be moved between
a cutting position and a non-cutting position. As shown for instance by Figures 8,
12, 18 and 19, the severing means comprises a cutting blade 152 which is secured to
an arm 154 and the arm is pivoted at one end, i.e. the right-hand end in the Figures,
to the lower end of a downwards projection 156 of the operating shaft 122. This pivotal
connection is shown in detail in Figure 19. Thus as the operating shaft 122 moves
horizontally, it carries the arm 154 and blade 152 with it. The position of the blade
152 is such that its cutting edge is always slightly to the left of the mid position
of the return section 132 of the slot 130 (see Figures 8 and 13) to enable the insertion
tools 110 to insert conductors before a cutting stroke takes place, as will be described.
[0025] Means is provided to move the cutting blade into and out of its cutting position
and to hold it both in the cutting position and in the non-cutting position, this
moving means comprises a cam and cam follower means which is illustrated in Figures
14 to 17. As shown in those Figures, a cam slot 158 is formed in the inwardly facing
surface of the base of the C-shaped section 106 of the insertion tool carrier. This
slot has two parallel horizontal sections 160 and 162 which extend along sufficient
distance of the section 106 to accommodate the horizontal movement of the blade upon
operation of the shaft 122 while also controlling the position of the blade. A cam
follower roller 164 is received in the cam slot and is rotatably mounted upon a cam
follower arm 166 the lower end of which is secured to the left-hand end of the arm
154 (Figures 12 and 18). The arm 166 is vertically movable in a slot 167 formed in
the shaft 122 (Figure 18). It follows that when the roller 164 lies in the upper slot
section 160, then the arm 154 is held in an upward pivoted position (for instance
as shown in Figure 14) so that the cutting blade 152 lies in a non-cutting position
which is disposed above the terminals in a connector. This relationship of the cutting
blade to the terminals is illustrated in Figure 20. On the other hand with the roller
164 lying in the lower section 162, the cutting blade is in its cutting position with
the arm 154 pivoted downwards (for instance as shown in Figure 16). In this position,
as shown by Figure 21, the cutting blade extends across the line of the terminals
so as to perform a cutting operation as the cutting blade is moved from left to right
in the drawings.
[0026] The two slot sections 160 and 162 are interconnected at their ends by inclined slot
portions 168 and 170. Non-return devices are provided at the entrance of the slot
168 into the section 162 and also at the entrance of the slot portion 170 into the
section 160. Each non-return device comprises a gate 172 which is pivoted at one end
and normally lies in a position as shown by Figure 14 in which the gate does not obstruct
either of the sections 160 or 162 but, in fact, acts as part of a surface of the slot
section. Each gate is spring urged into this position in which it closes the slot
portion 168 or 170, as the case may be. By pressure exerted upon it by the roller
164 moving along a slot portion 168 or 170, a gate is pivoted into an open position
in which it allows the roller to move from one slot section, along the associated
slot portion and into the other slot section. The slot section 160 has a short end
section 174 which extends to the right slightly beyond the gate 172 to accommodate
the roller 164 and allow for return of the gate 172 into its closed position. Similarly
the slot section 162 has an end section 176 at its left-hand end which is in corresponding
relationship to the associated gate 172.
[0027] The complete operation of the severing means is as follows. With the operating shaft
122 at its right-hand end of movement as shown in Figure 8, the arm 154 lies in its
upward pivoted position with the blade in its non-cutting position. This corresponds
to the position of the severing means in Figure 14 with the roller 164 at the right-hand
end of the slot section 160 and lying in the end section 174. As the shaft 122 moves
towards the left it causes the severing means to move along the slot section 160,
because of the drive imparted to it by its connection to the projection 156 on the
operating shaft. As the right-hand gate 172 is in its closed position, the roller
164 will roll over the gate and proceed along the slot section 160 without difficulty.
When the roller 164 reaches the left-hand end of slot section 160, it proceeds to
move along the slot portion 168 and, upon contact with the gate 172 at that end, forces
the gate open as shown in Figure 15. Further movement of the shaft 122 then carries
the severing means to its left-hand limit with the roller 164 lying in the slot end
section 176. As the roller is now disengaged from the adjacent gate 172, this gate
is allowed to return to its closed position as shown in Figure 16. In this position
of the roller 164, the arm 154 has been pivoted downwards so that the blade lies in
its cutting position. The operating shaft 122 then proceeds towards the right-hand
side on its return movement. This is accompanied by movement of the roller 164 along
slot section 162 (see chain-dotted outline in Figure 16) to cause a cutting movement
of the cutting blade across the terminals of the connector. Upon reaching the right-hand
end of the section 162, the roller moves up the inclined slot portion 170 and forces
open the adjacent gate 172 (Figure 17) thereby returning to its position as shown
in Figure 14. In this position, the gate 172 is allowed to close and the cutter has
completed one cycle.
[0028] The complete operation of the machine is as follows.
[0029] At the end of one operation, conductor lengths 178 have been connected at their upstream
ends into terminals of a connector 10 held by holder 62. At this stage as shown in
Figure 22, the connector and conductor assembly lie in the withdrawn position with
the support 62 withdrawn downwardly from the assembly station. Also in this position,
the conductor guide 40 lies in its normal or downstream position adjacent the assembly
station with ends of the conductors 16 from the conductor supplies extending between
guide projections 50. The clamping means 20 is closed and the clamping means 24 is
open to allow the gripped downstream ends of conductor lengths 178 to move out of
the jaws 52 during movement of the holder into the withdrawn position. The horizontal
support 100 carrying the insertion tools and severing means is in its withdrawn or
upper position.
[0030] To commence a new cycle for inserting a succeeding connector into the assembly station
for inserting conductors into it, the connector loading device 26 is then actuated.
The push rod 70 moves towards the left (Figure 3) to urge the lowermost connector
in the stacking column 68 into the support 74 which lies in a horizontal position
as shown in Figure 3. The assembly 82 is then operated to swing the support 74 into
the vertical position, as has been described and this movement is followed by operation
of the push rod 86 (Figure 5) to urge the connector in the support 74 across and into
the intermediate support 84. This movement causes the connector moving into the support
84 to push a preceding connector 10 lying on that support into the support 62 thereby
pushing the previous connector with the conductors 178 attached out from the support
62 and into the collection tray 91. The connector and conductor assembly being removed
is shown with the connector in chain-dotted outline in Figure 4. The support 74 is
then returned into its horizontal position shown in Figure 3. After removal of the
finished connector and conductor assembly and insertion of the connector 10 from support
84 into support 62, the situation is as shown in Figure 23.
[0031] The guiding and feeding means then operate. The open jaws 52 are moved upstream,
as has previously been described, to their upstream position and during this movement
urge the guide 40 into its retracted position. This is as shown in Figure 24. This
movement of the guide 40 causes the leading ends of the conductors 16 to extend further
from the guide thereby enabling these leading ends to be gripped tightly by the jaws
52 when the jaws close as shown in Figure 24. Movement of the conductors up to this
stage is prevented because the clamping means 20 is closed. The clamping means 20
is then opened thereby releasing the conductors following which the clamping means
24 is returned to its downstream position, as shown in Figure 25, thereby drawing
the conductors downstream to provide new lengths 178 of conductor extending from the
guide 40 to the clamping means 24. Downstream movement of clamping means 24 allows
the guide to return to its normal position. Clamping means 20 is then closed so that
the conductors are gripped by both clamping means.
[0032] The horizontal support 100 is then lowered to bring the insertion tools 110 into
the operating or lower position together with the severing means. Also, the support
62 is raised into the assembly station. This is the position of the apparatus shown
in Figure 8 with the insertion tools disposed slightly above the upper terminals of
the connector held in the assembly station. In this position, the insertion tool carrier
lies towards its right-hand side with the abutment surface 150 of the right-hand abutment
plate 148 abutting the adjacent housing 117. Hence the insertion tools are aligned
with the odd numbered terminals commencing from the right-hand side in Figure 8.
[0033] With the clamping means 20 in the closed position and with the parts of the apparatus
in the position shown in Figure 27, the insertion of the upstream ends of the conductor
lengths 178 into the row of terminals and the severing operation then commences. Movement
of the operating shaft 122 causes the insertion tools 110 to move downwardly in sequence
as described by virtue of the reception of the cam follower rollers 134 in the cam
slot 130. Simultaneously with this, the operating shaft 122 moves the severing blade
152 across and above the row of terminals, i.e. in its non-cutting position, by the
reception of the roller 164 in the slot section 160. As shown by Figure 20, the odd
numbered conductor lengths 178 are moved into the terminal while the even numbered
conductors are not affected by the right to left movement of the shaft 122. As described
above the roller 164 then moves downwardly into the slot end section 176 to drop the
cutting blade into its cutting position. This is the position of the apparatus shown
by Figure 11. At this stage, the shaft 122 has moved to the limit in the left direction
of movement. The plate 142 is then raised from the position shown in Figure 11 to
that of Figure 12 which immediately causes the tool carrier 104 to move towards the
left until the abutment surface 150 of the left side abutment plate 148 contacts the
associated housing 117. This position is shown by Figure 12 in which the insertion
tools have also been moved towards the left so that they are then aligned vertically
above the even numbered terminals as counted from the right-hand end. A comparison
of Figures 11 and 12 and Figures 20 and 21 will show these differences. The shaft
122 then moves towards the right so that the conductors which have not been connected
to the terminals on the previous shaft movement are now forced into their associated
terminals. As shown by Figure 21, the position of the cam slot 130 is such that a
tool 110 is shown at its lowest position inserting two conductors into evenly numbered
terminals whereas an immediately adjacent right-hand tool 110 is just commencing its
insertion stroke and can be seen commencing to force two conductors into the terminals.
As the shaft 122 proceeds to the right the cutting blade 152 trails slightly behind
the vertical movement of the insertion tools 110 on the return stroke of the shaft.
Thus, upon the cutting blade reaching each particular conductor, that conductor is
already lying firmly held within its particular terminal and the cutter severs each
length of conductor 178 from the supply conductors 16. The connector held in the holder
62 then has all its conductor lengths assembled to it. Upon the shaft 122 reaching
its right-hand position illustrated by Figure 8, i.e. after its return stroke, then
the assembly 146 is operated to move the plate 142 downwards to return the carrier
104 to the initial position towards the right as shown in Figure 8. This is preparatory
to insertion of conductors into the next succeeding connector which is to be inserted
into the support 62.
[0034] The piston and cylinder assembly 90 then operates to return the support 62 to its
withdrawn position so as to complete the cycle. The whole cycle is then repeated to
assemble conductors into a succeeding connector and the just completed assembly is
ejected into the tray 91.
[0035] It should be realized that the steps discussed above may in some cases not be followed
rigidly in the order which has been discussed as some change in parts of the procedure
may be effected without changing the eventual product. For instance, the support 62
may be located in the assembly station either at the same time as or in sequence with
the movement of the main horizontal support 100 to perform the insertion operation.
Obviously, to perform the whole operation in the quickest time, it is preferable to
move both of the supports 62 and 100 towards the assembly station simultaneously.
Further to this, after the conductors have been inserted into the terminals and severed,
the return movement of the insertion tool carrier 104 towards the right may take place
either as described or at some other time while ensuring that the insertion tool carrier
is in the correct position when required for the next succeeding insertion operation.
[0036] The use of the apparatus and method according to the invention substantially increases
the quantities of assembled conductors and connectors for a given time. For instance,
when performed manually it has been shown that about one hundred connectors may be
connected to fifty conductor lengths in a two workday period by one operator. With
the machine according to the invention it is possible to connect conductors to at
least 1500 connectors during the same period.
1. Apparatus for electrically connecting a group of insulated conductors (19) to
a row of terminals (14) of a cross-connect connector (10) characterized in that it
comprises means (62) for holding the connector in an assembly station, guiding and
feeding means (18, 20, 24) for feeding the group of conductors through the station
and across the connector with the conductors aligned with associated terminals and
with lengths (178) of the conductors extending downstream along passlines from the
assembly station, means (106, 108, 110, 122, 124) for inserting the conductors in
the assembly station between opposed electrically conductive portions of the terminals
to enable said portions of each terminal to cut into insulation on an associated conductor
and electrically contact the conductor, and severing means (42) operable on the upstream
side of the assembly station to sever said lengths of conductors which are electrically
connected to the terminals from supplies of conductors upstream from the station.
2. Apparatus according to claim 1 characterized in that the guiding and feeding means
comprises a clamping means (24) movable between an upstream and a downstream position,
the downstream position being downstream of the assembly station, the clamping means
closable in the upstream position to grip the group of conductors, movable into the
downstream position in the closed condition and operable in the downstream position
to release the conductors.
3. Apparatus according to claim 1 characterized in that the guiding and feeding means
comprises a first clamping means (20) disposed along the feedpaths on the upstream
side of the assembly station and a second clamping means (24) downstream from the
first clamping means and movable between an upstream and downstream position, the
downstream position being downstream of the assembly station, the first clamping means
being in a closed condition to grip the group of conductors during movement of the
second clamping means towards the upstream position so as to hold leading ends of
the conductors in a specific location and being operable in an open position to release
the conductors before movement of the second clamping means towards the downstream
position, and the second clamping means closable in the upstream position to grip
the group of conductors and being movable into the downstream position in closed condition
to feed the group along the passlines and through the first clamping means to provide
said conductor lengths.
4. Apparatus according to claim 3 characterized in that both of the clamping means
(20,24) are in their closed conditions during operating of the inserting means and
the severing means to insert the conductors and sever said lengths from the conductor
supplies.
5. Apparatus according to claim 3 characterized in that the guiding and feeding means
further comprises a conductor guide (40) disposed between the first clamping means
and the severing means, the guide having a normal position in which it is disposed
adjacent the assembly station and a retracted position upstream from the normal position,
the first clamping means (20) being in its closed condition during the guide movement
to the retracted position and the guide being movable to the retracted position to
allow the second clamping means (24) to move into its upstream position and beyond
the assembly station from its downstream position to grip leading ends of conductors
extending from the guide.
6. Apparatus according to claim 5 characterized in that during its movement towards
its upstream position, the second clamping means (24) is engageable with the guide
(40) in its normal position, further upstream movement of the second clamping means
being with the second clamping means in an open condition and causing movement of
the guide into its retracted position.
7. Apparatus according to claim 6 characterized in that the first clamping means comprises
a stationary support block (28) for the group of conductors and a clamping member
(30) pivotally movable into and out of a clamping position in which the first clamping
means (20) is in a closed condition.
8. Apparatus according to claim 5 characterized in that the conductor guide (40) is
slidably mounted between its normal and retracted positions by a slide means (44)
and a spring biasing means (46) urges the guide towards its normal position.
9. Apparatus according to claim 1 characterized in that the guiding and feeding means
(18, 20, 24) comprises a first clamping means (20) and a conductor guide (40) disposed
along the feedpaths on the upstream side of the assembly station and a second clamping
means (24) downstream from the first clamping means with the guide intermediate the
two clamping means, and the guide is movable between a normal position in which it
is disposed adjacent the assembly station and a retracted position upstream from the
normal position; the second clamping means movable from a position downstream from
to a position upstream of the assembly station with the first clamping means in a
closed condition during said upstream movement, and during its upstream movement,
the second clamping means being engageable with the guide to cause movement of the
guide into its retracted position while the second clamping means is in an open condition;
the second clamping means operable in its closed condition in its upstream position
to grip the group of conductors; and with the first clamping means in an open condition,
the second clamping means is movable in the downstream direction and in closed condition
to feed the group through the first clamping means and along the passlines so as to
provide said conductor lengths.
10. Apparatus according to claim 5 characterized in that the inserting and severing
means has an operating position adjacent to the passlines and a withdrawn position,
the inserting and severing means being in the withdrawn position during movement of
the second clamping means through and beyond the assembly station.
11. Apparatus according to claim 5 characterized in that the means (62) for holding
the connector is movable between the assembly station and a withdrawn position, the
holding means being in the withdrawn position during movement of the second clamping
means through and beyond the assembly station.
12. Apparatus according to claim 11 characterized in that the holding means (62) forms
part of a connector loading device (26) which includes a connector stacking means
(68) and delivery means (70, 72, 74, 76, 82) for delivering a connector into the holding
means.
13. Apparatus according to claim 12 characterized in that the delivery means is operable
for delivering a connector into the holding means with the holding means in the withdrawn
position, the holding means then being movable into the assembly station.
14. A method of electrically connecting a group of insulated conductors (19) to a
row of terminals (14) of a cross-connect connector (10) characterized in that it comprises:-
locating the connector in an assembly station;
feeding the group of insulated conductors (19) together along passlines and through
the assembly station to provide lengths (178) of the conductors extending along the
passlines downstream from the assembly station while guiding the conductors so that
they align with terminals of the row;
inserting the conductors between opposed electrically conductive portions of the terminals
to enable said portions of each terminal to cut into insulation on an associated conductor
and electrically contact said conductor; and
severing said lengths of conductors which are electrically connected to the terminals
from conductor supplies upstream from the station.
15. A method according to claim 14 characterized in that before location of the connector
in the assembly station, the method comprises:-
gripping the group of conductors on the upstream side of the assembly station while
holding a guide (40) upstream from and adjacent the assembly station to guide leading
ends of the conductors of the group along their passlines;
gripping the leading ends of the conductors and drawing them along their passlines
to provide said conductor lengths (178); and
after location of the connector in the assembly station, continuing to grip the leading
ends of the conductors and the supply of conductors on the upstream side of the assembly
station during conductor insertion into the terminals and also during the severing
operation.