Abstract: An automated machine, such as a cable making machine, for terminating wires to terminals. The machine includes mechanisms for selecting a desired wire type and terminal applicator, and then for automatically setting the applicator to the proper insulation crimp height corresponding to the selected wire type and terminal type combination. The insulation crimp height may then be reset to another value for a subsequently selected different wire type.

Abstract: A connector, a termination of a conductor to a ground bus in a connector, and a method for effecting the termination is disclosed. The ground bus includes a series of openings in one edge thereof, each having a pair of parallel walls that are spaced apart a distance greater than the diameter of the conductor to be terminated. Each opening includes a constriction which positions and holds the conductor so that it is spaced from the walls of the opening during the soldering operation.

Abstract: An electronic component (16, 18) having contact pads (20) is surface mounted to a circuit board (27) by means of electrical terminals (1) each comprising a head (2) having a flat, contact pad engaging, face (6) and a shank (4), which may be in form of a compliant pin, extending normally of the pad engaging face (6). Each pad engaging surface (6) has a gold covering provided by electroplating or by inlaying. The circuit board (27) has metal lined through holes (30) in the same pattern as the pads (20) of the electronic component (16, 18). The shank (4) of each terminal (1) is inserted into the metal lining (36) of a respective hole (30) in the circuit board (27) so that the head (2) of the terminal (1) lies against a land (38) of one of the linings (36), after which the electronic component (16, 18) is seated on the circuit board (27) with each contact pad (20) of the electronic component (16, 18) in engagement with the gold covered face (6) a respective terminal (1).

Abstract: A contact module and method for making a connector for socketing an IC chip carrier is disclosed. The contact module comprised a relatively short body containing a plurality of contacts arranged on a standard center to center spacing, and a locking member. A positioning plate is fabricated having features, such as holes, along its edges for receiving other features, such as projections, formed in the contact modules. A number of the contact modules are assembled to the positioning plate to correspond to a particular chip carrier configuration. The plate and contact modules are then aligned with the pads of a substrate and terminal portions of the contacts are then soldered to the pads. The positioning plate is then removed. The chip carrier is then placed in the connector formed by the contact modules and a locking member inserted into each contact module for contacting the chip carrier leads.

Abstract: The present invention is an apparatus for and method of aligning the terminals of a group of connectors in side by side abutting relationship with tooling for terminating wires to the terminals thereof. The group of connectors is placed in a track with the first connector against a stop. A plurality of vertically reciprocal guide blades are arranged adjacent the track and are moved upwardly, one at a time, the first engaging the first connector and positioning it relative to the termination tooling followed by subsequent blades engaging the other connectors. These subsequent engagements occur one at a time in sequential order with increasing distance from the stop. When all connectors are positioned by engaging guide blades, wires are terminated to the connector terminals and the guide blades moved out of engagement so that the completed connector assembly can be removed and the process repeated.

Abstract: A small ferrule having inwardly projecting lances is clenched about a small coaxial cable. The tips of the lances pierce the outer plastic covering of the cable and mechanically engage the underlying metal shield layer. Each lance includes an opening adjacent thereto through which a laser beam is directed to disintegrate a portion of the plastic layer adjacent the lance. Solder paste is then deposited into the opening and heated to cause the solder to reflow and form a low-resistance contact between each lance and an adjacent portion of the shield.

Abstract: The present disclosure sets forth a unique contact structure for a separable electrical connector for carrying relatively high levels of current at high frequency in a high temperature environment. The contact utilizes a high loading spring design which permits a relatively low resistance and low inductance contact element. The contact element takes either of two forms. One form being a multiple wire spring formed in an open helical pattern and the other being a number of c-shaped contact elements arranged in concentric circles on a thin disk.

Abstract: An automated method of making an electrical harness of the type having a plurality of discrete wires includes one end of some or all of the wires terminating in a conductor. A wire of a desired type is automatically selected from a plurality of wires that are available for use. The wire is terminated with selected terminals and one end inserted into an appropriate cavity of a selected connector housing. Of the selected wires, at least one is of a different type than the others.

Abstract: The present invention sets forth a low height socket for an integrated circuit chip carrier of the "Tape Pak" type. The unique contact is arranged in the shape of a tuning fork. The chip carrier, having flexible leads projecting outwardly from its sides, is placed in the lower body of the socket with the leads resting on top of their respective tuning fork contacts. The cover, having locking members projecting downwardly and in alignment with the tuning fork contacts, is forced into engagement with the lower body so that the locking members deflect the leads downwardly, bending them about the contacting portion of the tuning fork shaped contacts. The two arms of each tuning fork then has the locking member and a respective lead wedged therebetween.

Abstract: The present invention relates to a wire selection and feed apparatus for use in an automated machine for making electrical cables. The apparatus includes a rotary turret having a plurality of wire holders angularly spaced about its periphery. The desired wire is selected by rotating the turret until the appropriate wire holder is in the feed, or select, position. The wire holder is then advanced thereby presenting the end of the selected wire to a work station for processing. At this point the wire may be fed a desired amount into the work station by bringing a wire feed until into feeding engagement with the wire.

Abstract: An electrical contact (100) formed as a monolithic element includes a cantilevered member (74), first and second contact portions (68 and 70), a C-shaped spring member (80), and a base (72). Three pivotal zones (79,84, and 102) are provided so that a relatively large deflection of the first contact portion (68) is transformed into a small deflection at the point where the spring action is effective so that a relatively flat force/deflection characteristic is attained. A kinematic model and five embodiments of the contact are disclosed, as well as a method of formation thereof.

Abstract: A connector feeding apparatus for an automated cable making machine is disclosed. The apparatus includes a pair of carousels each of which has a series of connector receiving units disposed about its periphery. Each carousel has a group of connector dispensing units arranged for selectively dispensing different types of connectors, under computer control, and inserting them into the connector receiving units. The carousels then deliver the connectors, in a desired order and a desired orientation to staging modules which, again under computer control, direct the connectors to a terminating station within the machine.

Abstract: An apparatus and method are disclosed for terminating a wire to a terminal having a metal contact that is partially assembled to an insulated housing. The apparatus includes a stop that abuttingly engages bulges in the contact after crimping and thereby prevents axial movement of the contact while sliding the insulated housing thereover. Both the crimping and assembly operations are performed in a single workstation.

Abstract: The present invention is an interposer connector assembly having a small contact grid spacing for interconnecting a relatively large integrated circuit chip carrier with a printed circuit board. The interposer connector assembly includes a holder which is composed of several thin plates having perforations arranged on the desired grid patterns. The thin plates are stacked with their perforations in alignment to form through openings in the holder. Contact modules are then inserted into the through openings to complete the connector assembly. The contact modules comprise a two part plastic housing with a contact member contained in a cavity formed by mating the two parts. The two parts are formed on continuous strips of extruded plastic.

Abstract: A method and apparatus for setting a plurality of print wheels, in an automated cable making machine for imprinting a desired set of characters onto a connector housing. The method includes a unique way of homing each of the print wheels to a known position prior to setting the print wheels to their desired print positions. This is a done by rotating each print wheel until a rod, which is constrained to move only along its longitudinal axis, can be inserted into an opening in the print wheel. This prevents further rotation of the print wheel thereby indicating that the wheel is in its home position.

Abstract: Apparatus for accurately aligning a cavity in a plastic connector housing for insertion of an electrical terminal and attached wire during a block loading operation. The apparatus includes a two part terminal guiding member having a funnel shaped hole through which the terminal and wire are passed. Features are included that engage the connector housing moving in until a selected cavity is in alignment with the funnel shaped hole which has the same shape as the cavity and is the same size or slightly smaller. The terminal and wire are then inserted into the selected cavity and the two part guiding member opened and withdrawn.

Abstract: The present invention is an apparatus and method of wrapping a binding tape about a bundle of wires in an automated environment. A tape handling system is provided that de-reels and stores slack tape prior to performing the tape wrap operation. This slack type is then provided to the tape wrapping mechanism at a controlled tension to avoid stretching or breaking the tape.

Abstract: The present invention is an automated method for making an electrical cable assembly including the automatic verification of insertion of each wire into its respective correct terminal and the automatic verification of the absence of short circuits. The overall system is controlled by a computer which is table driven by cable assembly parameters retained in a data base.

Abstract: Strip feed mechanism comprises an intermittently rotated sprocket wheel which engages the strip material. A guide plate extends tangentially past the sprocket wheel and serves to hold the strip material against the wheel and in engagement with the sprocket teeth. At the end of a feeding interval, the guide plate is moved away from the sprocket wheel by a bell crank mechanism. The bell crank mechanism comprises a bell crank having a movable axis which, in combination with other features of the mechanism, permits the guide plate to be moved away abruptly from the sprocket so that the feeding interval is brought to an abrupt halt without "chattering" or other slight uncontrolled movement of the strip.

Abstract: Stamping and forming machine of the type having opposed tooling assemblies which are reciprocable towards and away from each other has toggle mechanisms for moving the tooling assemblies along their paths of reciprocation. Each toggle mechanism has one toggle link pivoted to a tooling assembly and another toggle link pivoted at a fixed pivot location. The fixed location pivots are adjustable in order to control the position of the tooling assemblies when they are in their closed positions. Additionally, adjustable wear plates are provided in the passageway in which the tooling assemblies are mounted. Advantages achieved include reduced manufacturing cost for the machine, potential for high operating speeds, and compactness when desired.