Abstract: A system for manufacturing wire harness assemblies is provided. Each wire harness includes a shielded cable having a plurality of insulated conductors therein, with each conductor being terminated at its respective opposed ends and with the terminated ends being mounted in connector housings. The system includes a plurality of pallets that are movable along a conveyor to work stations at which various assembly steps are carried out. A first station is provided for mounting the cables to the pallet, such that the wires at the opposed ends are mounted in fixtures. A second station may selectively deposit drop wires into fixtures on the pallets. A third station trims and strips the ends of the wires and aligns the drop wires with the cable wires. A fourth station sequentially crimps terminals to the ends of the wires, with the pallet being indexable between successive crimps.

Abstract: A work station is disclosed for dispensing electrical components (12) from a tape carrier (10) having a plurality of spaced component-containing cavities (14). During the dispensing operation, one side wall (18') of the cavity is opened by slitting the tape carrier with a dual-blade knife structure (46), such that a component-ejecting shuttle mechanism (40) can pass through an opening (50) in the cavity and guide the component into a fixture (52). The knife structure includes two knife blades (102, 104) arranged such that a V-shaped notch (100) is formed by two inwardly-facing single-bevel knife edges (112, 114). The improved knife structure positions and slits the tape carrier at the notch without causing the tape to buckle or tear.

Abstract: A modular application tooling machine includes a base unit with a delivery station for electrical connectors, a intermittently operated connector feed drive system and a continuously operated work station drive system. Feed track modules define a connector feed track along which connectors are fed by pusher modules driven by the feed drive system. Work station modules powered on demand by the work station drive system carry out cycles of operation to perform operations on connectors in the feed track. One work station module terminates conductors into insulation displacement terminals of the electrical connectors and another work station module breaks off a carrier strip connected to the terminals.

Abstract: A pitch transition wire guide apparatus for use in wire harness fabrication machines includes a plate member having a wire engaging edge and a corresponding number of open-ended wire guide channels, each extending inwardly from the edge to a closed end. The closed ends of said channels are spaced apart by a centerline spacing different from the centerline spacing of the open ends in said edge. The plate is reciprocably moveable between a first position wherein the open ends are in surrounding engagement with the wires adjacent the edge and a second wire-receiving position wherein said wires are disposed at the closed ends. The guide includes actuation means for moving the plate member between said first and second positions. Actuation of the wire guide causes movement of the wires within their respective channels to alter the centerline spacing thereof. The wire guide is useful for making smooth continuous transitions between production runs of different pitch wire harnesses.

Abstract: Disclosed is an apparatus for severing connector sticks into separate connector modules. A stick is formed by arranging individual connector housings in a serial row, and joining the connectors by a pair of L-shaped carriers. The carriers are arranged to overlie an outside corner of each housing, with one leg of the L-overlying a sidewall, and the other leg of the L-overlying the bottom wall. A tool bit is provided with first and second cutting surfaces, which sever respective legs of the carrier. The tool bit is configured to be received between individual connector housings, to provide alignment with the legs of the carrier member. The tool bit is arranged to sever a substantial portion of one carrier leg, and to thereafter sever both carrier leg portions.A method for severing the connector stick is also disclosed. According to the method, a substantial portion of the first carrier member is severed first, and the first and second carrier legs are thereafter simultaneously severed.