Abstract: A conveyor system that may be driven in a forward or a reverse direction is provided with jam detectors that are effective to interrupt the operation of the conveyor chain (10) upon encountering a jam condition in either direction of drive. The chain (10) is driven about idler sprockets (19 and 53) mounted in housings (21 and 51) that are slidably mounted on a T-bar frame (22). When the chain is driven in a forward direction A, a jam condition causes housings (21) to slide and operate a switch (23) to interrupt power to a motor (18). When the direction of drive is reversed, housing (21) is held from movement by a lock (47), and a lock (54) associated with housing (51) is released to allow the housing (51) to shift in response to a jam condition to operate a switch (58) to again interrupt the power applied to the motor (18).

Abstract: Connector housings (12) are pushed into a succession of nests (26) formed in workholders (17) mounted on an incrementally advanced turntable (15). Subsequent advance of a workhokder from the connector load station causes a cam follower (42) of a spring-biased lever arrangement (37) to react with a cam track (19) to pivot and move locating pins (31 and 32) into holes (13 and 14) formed in the connector housing. Further advance of the turntable (15) causes a cam follower (64) to ride onto a high portion of a cam track (21) to pivot a second lever arrangement (37) to move a spring-biased, pivotally mounted clamping arm (51) into engagement with the precisely positioned connector housing.

Abstract: A device for removing leads (14) of a circuit module (12) from sockets (16) mounted in a circuit board (18) includes a first assembly (51, 52 and 54) having two depending arrays of fingers which engage the socket (16) and a second assembly (34) having two arrays of pivotally mounted jaws (31 and 32) which are manipulated to grip opposite sides of the circuit module. The second assembly is movably mounted within the first assembly, and when moved upwardly away from the circuit board, acts to pull the circuit module to extract the leads from the sockets while the fingers hold the sockets from dislodgement from the board. The fingers are longitudinally grooved (61) to guide the leads during extraction from the sockets.

Abstract: An apparatus (10) and methods are disclosed for preparing the terminated end of a flat cable (25) for connectorization wherein the cable is of the type having two arrays of overlying/underlying conductors (27, 28) separated by an insulative center film (31), with each array being bonded directly to only the respectively adjacent one of two mutually disposed outer insulative films (33, 34), and wherein an aligned pair of isolating members (36, 37) are respectively positioned between, and transversely of, a different side of the center film the associated array of conductors at each predetermined terminating end of the cable, as fabricated. The apparatus includes a cross-slide assembly (12, 41), a flare-out die mechanism (14, 97), an optional trimming die mechanism (16, 134, 136) and a fold-back roller mechanism (18, 151, 167, 168).

Abstract: An apparatus is provided for applying lubricant to articles such as connectors. The connectors 10 with projecting terminals 12 are loaded into a holder 19 enclosed within a housing 16 having an entry door 23. The door is shut and lubricant is pumped into a tank 28 to overflow into a catch receptacle 66 whereafter the holder is moved to dip the terminal ends into the lubricant. During the dipping operation a pair of locking members 98 and 133 are positioned to block opening of the door. Following the dipping operation the locking member 98 is withdrawn while the lubricant is drained from the receptacle. Upon completion of the draining of the receptacle, facilities 126-132 are operated to withdraw the locking member 133 thus permitting an attending operator to open the door without exposure to any noxious frames emanating from the lubricant.

Abstract: Two spaced stacks of magnetically soft E-cores, (17 and 18) are supported in spaced relation by pairs of magnets (38 and 39) on opposite sides of each stack. A pair of shuttles (41 and 47) move alternately toward and away from each other and under the stacks to pick off the lower core in each stack. The shuttles alternately advance the cores into a transformer frame (10) where a pair of magnets (66 and 67) are effective to hold the cores in an assembled position within the frame while the shuttles return for another E-core feeding operation. Entry of the cores into the frame is facilitated by a pair of rotating drums (71 and 72) having staggered arrays of magnets (78 and 79) which act to rapidly vibrate the E-cores (17 and 18) and thus prevent lodging of the cores against the frame.

Abstract: In order to prevent cutting of inner windings of a film (39) wound on a pair of arbor halves (34 and 38) during sequential withdrawal of the arbor halves following a winding operation, the arbor halves are forge formed with rounded protuberant winding surfaces (51, 52 and 53). The rounded surfaces may be coated with a low friction plastic to enhance sequential arbor withdrawal without pulling the inner convolutions from the wound film plastic (39). Further, the arbor halves are provided with ends (36) bent beyond 90.degree. so that the arbor halves may force seat in holes (42) formed in holders. The arbor bent end construction will also allow an operator to strike the bent end of the arbor half in a hole to quickly remove a defective arbor to permit quick replacement with a new arbor half.

Abstract: Several flat cable embodiments (10, 10', 10", 10'", 10"") are disclosed, as are methods and apparatus (30) for the selective manufacture and connectorization of same. In accordance with one preferred flat cable embodiment (10), adapted for telephone under carpet applications, two precisely offset arrays of rectangularly shaped conductors (13, 14) are separated by a center film (16), with each array being adhesively bonded through an associated adhesive coating (21 or 22) to only the respectively adjacent one of two outer films (18 or 19).

Abstract: A connector housing (10) with projecting terminal pins (11) is moved through a set of blades (41-45) which act to align the columns of terminal pins. At an assembly area (38), a group of aligning pins (111) are advanced through openings in the blades to align the rows of terminal pins (11). A jaw device (62) advances an apertured block (13) into the position above the terminal pins, whereafter a pusher (103) advances an apertured retainer card (24) onto the block (13). A multi-fingered insertion tool (121) is moved to push the retainer card (24) and the block (13) onto the coordinately aligned terminal pins.

Abstract: A test device includes a pair of test probes (21 and 22) which are manipulated onto a succession of test sites (11, 13 and 16) formed on a complex circuit board, and the operator is visually apprised of test results without loss of eye contact with the test sites. Visual appraisal is provided by a small light emitting diode (46) which is activated in accordance with the probed test results. The diode is mounted on the operator's safety glasses (58) and is of such size as to be not discernible when positioned inside the normal focal point of the operator's eye, but a glow is discernible when the diode is operated upon a particular test condition being ascertained by the test probes.

Abstract: A strip (21) of pairs of terminals (13 and 14) are incrementally advanced into a bonding station (24) where electrical components, e.g., metallized film capacitors (10), are successively advanced adjacent to each pair of terminals. Each pair of terminals is bent into engagement with a pair of heat fusible end electrodes (11 and 12) on each electrical component. Sets of three welding pulses are respectively applied by a pair of welding devices (36 and 37) to each terminal. The welding pulses are monitored and if found to be below a predetermined magnitude, additional sets of welding pulses are applied to the electrodes. If a programmed control system ascertains that three successive welding attempts are unsatisfactory, or if five welding attempts are unsatisfactory in nine cycles of operation of the overall apparatus, further cyclic operation of the apparatus is interrupted. Facilities (38, 39 and 40) are provided to upset and reshape any metallic flash resulting from the welding operations.

Abstract: An electric soldering iron having an elongated heater barrel extending from a handle and a soldering tip projecting from the end of the barrel is provided with a thermally isolated fume exhausting attachment positioned coaxially of the barrel and surrounding the tip for withdrawing objectionable fumes, gases, smoke and other air-borne contaminants from the soldering site. The attachment includes a metallic shell having a forward hood portion, overlying the tip and forming a fume exhaust chamber connected to a vacuum source by an exhaust conduit including a flexible transparent plastic tube portion, and a rearward slotted clamping portion secured to the front end of the barrel by a clamping ring. A compressible thermally insulative sleeve of alumina silicate fibers is interposed between the clamping portion and the barrel for thermally insulating the attachment from the heated barrel to preclude burn injury to the user of the iron.

Abstract: A connector (10) having a socket-like opening (11) to be gauged is advanced into position to receive two sets of upright sensing legs (26 and 27) of L-shaped levers (28 and 29). The levers are moved upwardly to position the sensing legs within the connector opening, whereafter the levers are pivoted under urging of springs (57 and 58) to move the legs in opposite directions toward the opposing walls of the connector opening. Movement of the levers are monitored by two banks of linear transformers (72 and 73) to generate signals to actuate a pair of displays (116 and 117) to provide visual representations of the profiles of the opposing walls of the connector opening.

Abstract: A strip (11) of pairs of orthogonally projecting fragile terminals (14 and 16) with components (10) bonded therebetween is wound in a trackway (58) formed by a helical fin (57) extending from a cylinder (51). The cylinder (51) is mounted on a drum (52) that is intermittently driven by a constantly energized motor (36). Facilities (59) are provided to permit axial loading of the cylinder on the drum. A drive pin (67) arrangement provides a positive drive from the drum to the cylinder. The height of the helical fin is designed to be higher than the height of the strip of terminated components so that the confined strip of components may be transported without danger of damage.

Abstract: A contaminated solvent is first distilled in a distillation chamber (12) to drive off a substantial portion of the solvent which is condensed and recovered leaving a residual slurry (18) consisting of some solvent and the contaminants. A metering device (21) is cyclically operated to transfer precise amounts of slurry to a second distillation chamber where the slurry is deposited in an annular trough (26) formed in a heat plate (25). A spreader including a number of blades (27) moves the deposited slurry charge along the trough to an exit opening (44). The residual solvent in the slurry charge is vaporized, condensed and fed back into the first chamber (12). The remainder of the charge is exited through the trough opening (44) into a collection barrel (50) which is vented to pass back any solvent vapors to the second distillation chamber.

Abstract: A pulse generating circuit includes a first trigger circuit including a resistor (43) and transistors (34 and 42) for applying a current pulse to a resonant circuit (capacitor 31-inductor 32) to produce a sinusoidal output pulse having a predetermined width and amplitude, and a second trigger circuit including a resistor (64) and transistors (34 and 67) for applying current to a resonant circuit (capacitors 31 and 33-inductor 32) to produce a sinusoidal output pulse having a second predetermined width. In another embodiment, an inductor (76) contained in a resonant circuit (inductor 76-capacitor 77) is magnetically coupled to the base of a transistor (79) contained in an operate circuit.

Abstract: A weldment bulge (12) joining together two small diameter wire sections (10 and 11) is removed by a hand-held tool (16) having two facing file sections (24 and 34) which are moved back and forth along and about the weldment to abrade away the bulge portion without abrading the wire sections immediately adjacent to the weldment. The tool includes a U-shaped flexible band (16) for moving support blocks (22 and 31) and file sections (24 and 34) toward each other to engage opposite sides of a weldment bulge.

Abstract: A boxed and encapsulated rolled metallized film capacitor susceptible to facile machine insertion is fabricated by cyclically advancing a lead frame 32 through a number of stations (36,37) whereat pairs of leads (24,26) of the lead frame are bent downwardly and secured to end electrodes (22,23) formed on the capacitors, and then boxes (29) partially filled with encapsulant are moved over each capacitor secured to a pair of leads. Next, the lead frame is advanced to move each box and capacitor into position to receive additional encapsulant from a nozzle (38) which is projected through a feed hole (34) formed in the lead frame.

Abstract: A bulge (12) formed by coldwelding two wire sections (10-11) is removed by advancing the wire through a bore (91) formed in a split cutting tool (64) having a pair of stepped-back tapered surfaces (92,96) at one end. The tapered surfaces terminate along a diameter of the bore to form a pair of spaced semi-elliptical cutting surfaces (93,97) which are successively rendered effective to remove semi-circular sections of the bulge. The apparatus includes facilities (31,32) for temporarily holding the wire in place within the cutting tool (64) and a clamping arrangement (35,36) for securely holding the wire during the weld bulge removal operation.

Abstract: A protective coating (13) on a printed circuit board (10) is formed to extend into spaces (22) between spaced contact pads (16) adhered along an edge portion of the board. The protective coating is selected to be thicker than the thickness of the contact pads to provide fillets between the contact pads that function to form pockets (33) with the contact pads (16) being at the bottom of the pockets. When a multi-terminal connector (21) is assembled on the edge of the circuit board, the terminals (18) tend to fall into and seat within the pockets.