Abstract: An applicator ram (8) driven by a press ram (46) drives an insulation barrel crimping die (10) which is adjustable lengthwise of the rams (8) and a wire barrel crimping die (14) fixed to the applicator ram (8), to crimp electrical terminals (T) to leads (L) in cooperation with an anvil (22). A crimp height adjustment disc (60) is rotatable about a shaft (104) on the applicator ram (8) selectively to interpose first projections (76) on one side of the disc (60) between the press ram (46) and the applicator ram (8) to adjust the shut height of the wire barrel crimping die (14) and selectively to interpose second projections (82) on the other side of the disc (60) between the applicator ram (8) and the insulation barrel crimping die (10) to adjust its shut height.

Abstract: Apparatus for breaking an optical fiber comprises fiber gripping units (2 and 4) each comprising a rigid block (6 or 6') having adhered thereto a strip (8 or 8') of a resilient material, for example a synthetic felt, the blocks (6 and 6') being relatively movable between an open position to receive an optical fiber (OF) between the resilient strips (8 and 8') and a closed position to clamp the fiber (OF) between the strips (8 and 8'). A fiber holder (9) is provided for applying a pulling force (P1) to the fiber (OF) to cause it to slide between the resilient strips (8 and 8') in the closed position of the blocks (6 and 6') Before being inserted between the strips (8 and 8'), the fiber is formed with a V-shaped notch (N) at which the fiber is to be broken.

Abstract: Apparatus for making electrical pins with frusto-conical end portions, comprises a wire feed station for the supply of a length of metal wire to a wire severing station at which a wire severing wheel severs the wire into pin blanks, in cooperation with a fixed bushing. The wheel pushes the blanks along a track to a pin blank rolling station at which the end portion of the pin blanks are rolled to frusto-conical shape between a pin rolling fixture and a pin rolling wheel having mounted for rotation relative thereto, a pin blank entraining ring having pin blank receiving grooves.

Abstract: A leading bung seal (BS1) in a magazine (4) is picked up by a bung seal transfer clamp (8) and is positioned between a bung seal receptacle (6) and a bung seal transfer device (10), which are axially aligned. A bung seal expansion pin (18) is advanced to drive the leading bung seal (BS1) into the bung seal receptacle (6), to force it against a resilient grommet (42) therein, and to extend through the bung seal (BS1) so as to expand it. A bung seal expansion sleeve (14) surrounding the expansion pin (18) is then advanced further to expand the bung seal (BS1) and the pin (18) is withdrawn leaving the bung seal (BS1) secured to the expansion sleeve (14) by its own resilience.

Abstract: Electrical connectors each having one row of electrical terminals, are joined together in end to end relationship by slugs formed integrally with end walls of the connectors. Lead receiving portions of the terminals of both of the connectors are loaded with electrical leads, which extend therefrom in the same direction. The slugs are then removed so as to separate the connectors. Dovetail cross section ribs on a side wall of one connector are then slid into complementary grooves in a side wall of the other connector so as to couple the connectors together in back to back relationship, with the leads projecting from opposite sides of the composite two row connector so provided. The invention enables the leads to be loaded into the connectors by means of a lead loading apparatus which is capable of loading electrical connectors only from one side thereof.

Abstract: A method of manufacturing electrical harnesses is disclosed in which wires are fed through a loading zone and then clamped in the loading zone in side-by-side parallel relationship in an array. The wires are then cut and the clamped array of wires is moved laterally of the axes of the wires past a succession of crimping machines or the like. At each of the machines, a preselected wire is moved axially from the array so that its end is presented to the machine and a terminal is crimped onto the wire. The method of the invention is capable of producing harnesses comprising a plurality of discrete wires having different types of discrete terminals on their ends.

Abstract: The assembly comprises a first slide (34) carrying a wire insertion tool (38) and a second slide (80) carrying support tools (92). As the slide (34) descends through a working stroke to cause the wire insertion tool (38) to insert a wire (W) into the wire slot (18) of an electrical terminal (10') of a multicontact electrical connector (2), support noses (96) of the support tools (92) which are in an open position, enter the mouths of the wire slots (18) of the next adjacent terminals. The wire insertion tool (38) continues to descend past the noses (96) to insert the wire (W) into the slot (18) of the terminal (10') and the support tools (92) close so that their noses (96) engage the terminals (10) on either side of the terminal (10') to be loaded with wire, thereby to restrain splaying of that terminal (10') as the wire (W) is inserted into its wire slot (18).

Abstract: The apparatus is for loading electrical terminals (T) on leads (L) into cavities (TC) in an electrical connector block (B). The apparatus comprises a lead clamp (240) which is actuable to clamp a lead (L). The lead clamp (240) is mounted on a first slide (369) which is movable along a vertical axis (Z--Z) relative to a second slide (408), which is in turn movable along a first horizontal axis (Y--Y) relative to a carriage (402) which is slidable along a second horizontal axis (X--X) at right angles to the first horizontal axis (Y--Y). Drive motors (414, 410 and 416) are actuable according to a harness making program, to cause the lead clamp (240) to insert a terminal (T) on a lead (L) gripped by the lead clamp (240), into any terminal receiving cavity (TC) which has been selected in accordance with a program.

Abstract: The connector has a body part (4) of good electrical conductivity and which is of U-shaped cross section. A pair of wings (18) extend from one or both ends of the side walls (16) of the body part (4) and define a wire slot (20). The wings (18) are not connected to the base (12) of the body part (4), so as to allow the side walls (16) of the body part (4) to be deflected away from each other. A U-section spring (10) receiving the part (4), and being separated therefrom, resiliently restrains deflection of the side walls (16) of the body part (4) away from each other, when a wire (W) is inserted into the wire slot or wire slots (20). The spring part (10) stores energy so as to maintain the integrity of the electrical connection between the edges of the slot or slots (20) and the core (C) of the wire (W), despite temperature cycling. The spring characteristics of the spring part (10) can be selected to achieve a desired contact force.

Abstract: An electrical connector housing (2 or 4) has through terminal receiving cavities (18) opening into a terminal receiving end (16), and mating end, of the housing (2 or 4). The terminal receiving end is surrounded by an axially projecting collar (34) having latching openings (36). A terminal antibackout cap (6) of cellular construction so as to be resiliently compressible has latching projections (66). When terminals have been inserted into the cavities (18), the cap (6) is forced into the collar (34) so that the latching projections (66) engage in the latching openings (36) in the collar (34).

Abstract: A one-piece, stamped and formed C-section locking clip for insertion into aligned holes (H1 and H2) in a superposed metal plate (P) and circuit board (CB) to secure them together for soldering the clip to the plate (P) and to a ground plane (G) on the board (CB) comprises a body (2) having a resilient and compliant larger diameter portion (6) for reception in the hole (H1) in plate (P), a smaller diameter portion (12) for reception in the hole (H2) in the board (CB). A spring (16) extending from the upper edge (8) of the body (2) extends for substantially the full length thereof and has at its lower end an outwardly bowed part (22) for engaging the ground plane (G) and holding the locking clip in position for the soldering operation.

Abstract: A device for adjusting the shut height of a press includes a rotatable dial (16) interposed between a ram mounting block (6) fixed to a press ram (2), and a tooling ram (14). The dial (16) is keyed to a screw bushing (12) which is rotatable in a screw threaded bore in the block (6) for vertical movement relative to the block (6). Facing surfaces (46 and 48) of the block (6) and the dial (16) are formed with opposed helical ramps (54 and 56, and 58 and 60). The angular position of the dial (16) is adjustable to cause the ramps (54 and 56, and 58 and 60) to cooperate to alter the distance between ramps (2) and 14) to adjust the shut height of the press.

Abstract: A wiring head (10) mounted for movement along coordinates (X, Y and Z) to insert electrical terminal (T) into selected cavities of electrical connector housings (CH), comprises rolls (38) for feeding a wire (W) in a wire feed direction (D) from a wire reel (20), a wire inserter (24) for inserting the wire (W) so fed, into a terminal (T) at a wire insertion station (54) and a terminal inserter (62, 63) for then inserting the terminal (T) into its cavity. Slides (32 and 34) are moveable towards each other to form a loop (L) in the wire (W), to be inserted into the terminal by the inserter (24), and wire severing blades (58 and 60) are also provided for severing either side of the loop (L), when required according to a wiring program, before a terminal (T) is inserted into its cavity. The inserted terminals (T) are thereby connected in daisy chain fashion, one side of the loop (L) being severed in the case of the end terminals (T) of the chain.

Abstract: An apparatus for heat staking plastic parts to other parts to form an assembly are featured, using multiple heating elements which are arranged in zones and which are separately programmable in terms of temperature and displacement to develop optimum deformation of plastic having different characteristics. The heating elements are isolated thermally to provide an improved conservation of heat energy.

Abstract: The present invention relates to a method through which a machine is enabled to feed a preloaded electrical connector (10) on appropriate spacings to allow the termination of individual wires (W) in terminals (13) in the connector through a novel indexing feed finger (120) which is capable of engaging surfaces (A-E) on the connector which are different relative to a constant indexing stroke. The indexing finger includes surfaces (126-132) capable of handling more than one set of dimensions of more than one style of connector without adjustment. The invention further includes a mechanism (180) for bending a scored portion of terminals to effect a later removal of the terminal carrier strips.

Abstract: A robotic pick up head for use in picking up electrical connectors (25 and 27) having top actuated rivets (176) and being of different lengths, placing them on a circuit board (19) and setting the rivets (176) to secure the connectors (25 or 27) to the board (19), comprises a body (28) having a top plate (30) for connection to the Z axis shaft (18) of a pick and place robot (2). Opposed piston and cylinder drive units (70 and 72) in the body (28) drive a toggle linkage (50, 54) to drive plungers (142) of riveting tools (26), first to cause the tools (26) to grip the rivets (176) when a connector (25 or 27) is to be picked up and then to set the rivets (176) when they have been inserted into holes (H) in the board (19), to secure the connector thereto.

Abstract: A heavy current electrical terminal (2) comprises a flat metal plate (4) having a wire slot (6) with a flared, insulation piercing, mouth (8) opening into an edge of the plate (4). An insulation piercing and wire support anvil (12) projects from base of the slot (6) which has an elongate constricted portion (18) between the mouth (8) and the anvil (12). The anvil (12) serves to support and to locate a heavy current wire (32) having insulation (34), when the wire (32) has been forced down into the portion (18) of the slot (6). The terminal (2) may be arranged in a housing having a cover with a wire stuffer bar for forcing the wire (32) into the slot (6). The walls (28) of the constricted slot portion (18) and the anvil (12) make contact with the wire (32) from three sides.

Abstract: Electrical continuity between the terminals of a multi-contact electrical connector and the cores of insulated leads that have been connected thereto, is tested for by engaging a respective electrical test probe with each of the terminals and using a multiplexer to connect each test probe in turn to a continuity testing circuit, under the control of a computer. Following the continuity test, a bank of analog switches also controlled by the computer is used to apply short circuit test electrical potential to energize selected terminals, and the presence of the test potential on adjacent unenergized terminals is tested for by the computer, to detect short circuiting between the terminals.

Abstract: A module (2) is connected to a multiplexing system by means of a printed circuit board (18) having thereon first conductors (14) each connected to a second conductor (22) by means of a spring clip (24) on the board (18). An edge connector (38) for mating with the board (18) has thereon projections (62) which can be selectively removed before the connector (38) is mated with the board (18). When the board (18) and the connector (38) are mated, the remaining projections (62) each left a respective clip (24) from its first conductor (14) and protrude between the clip (24) and the first conductor (14), thereby disconnecting them. The projections (62) and clips (24) thus provide a switching system which can be used to ensure that only selected second conductors (22) carry current.

Abstract: A pick-up head for picking up elongate electrical connectors having contact tails depending therefrom and for placing the connectors on circuit boards to insert the contact tails through holes therein, comprises a framework having a vertical shaft for attachment to the Z-axis shaft of a pick-and-place robot. Connector clamping bars on the framework are movable vertically with respect thereto by means of a first drive unit and are also movable towards and away from each other by means of second drive units. A contact tail comb assembly on the framework is movable towards and away from the clamping bars by means of third drive units. The clamping bars are adapted not only to grip a connector to be picked up, but to straighten it out to correct warpage, and the comb assembly is adapted to straighten out the contact tails of a connector which has been gripped by the bars and lifted from a connector pick-up station.