Abstract: A crimping apparatus is disclosed utilizing an angular motion actuator and a unique tooling bar arrangement to redirect the angular motion so that the crimping dies move along a straight line during the crimping process. Two identical tooling bars are utilized that interengage to form a sliding assembly so that the two crimping dies, formed in the tooling bars, move along the straight line. The tooling bars, which are operated by the actuator, have complementary recess and projected portions. The projected portion of each bar is nested within the recess of the other bar. Each tooling bar has an elongated opening and a pin that slidingly engages the elongated opening of the other tooling bar to limit the sliding motion to motion along a straight line.

Abstract: A machine and method are disclosed for attaching a coaxial connector to the end of a coaxial cable. The machine seats the cable end having a preassembled contact into the connector housing, latching the contact in place, then conducts a pull test to verify proper latching. The jaws that grip the cable during insertion of the contact and pull testing are used to push the ferrule over the braided signal conductor prior to crimping the ferrule. A single air cylinder is used, at a relatively low pressure, to seat the contact and at a relatively high pressure to seat the ferrule. A constant force return spring is used to apply a predetermined test force to the jaws during the pull test. A high voltage test may be conducted at two points in the operating cycle.

Abstract: A machine is disclosed for inserting terminals into cavities of a bobbin to terminate the ends of electrical windings. The machine includes a shear mechanism that separates the terminals from the carrier strip and then guides the terminals during insertion thereof. The shear mechanism includes a pair of links that form a toggle having a center pivot that is attached to the piston rod of an air cylinder. Movement of the toggle links in turn moves a pivoting lever that causes the shear blades to reciprocate. As the piston rod is made to extend, the links straighten and then pass center a small amount until a stop setscrew is engaged. As the links straighten the shear blades enter the die and sever the segments of carrier strip from the terminals. As the links pass over center the shear blade is partially withdrawn so that it clears features projecting from the sides of the terminals while a guide portion of the blade remains in guiding engagement with the severed terminals during insertion thereof.

Abstract: The present invention includes a lead sorting module in an automated lead making machine for segregating leads having defective terminations from the other leads. The module includes a lead deflecting door that is moved by an actuator to cause the leads having defective terminations to fall into one tray and the other leads to fall into another tray. The machine includes a crimp quality monitor which determines whether or not a termination is defective and then effects a corresponding control over the actuator.

Abstract: Insertion/extraction tool for inserting a substrate into, and extracting a substrate from, a socket assembly has a frame assembly containing force multiplying means and a yoke. Spaced-apart yoke arms extend from the yoke and have ends which will engage either the socket assembly or the underside of the substrate. First frame arms are fixed to the frame and have ends which are spaced from the ends of the yoke arms. Second frame arms are slidably mounted on the frame assembly for movement between extended positions and retracted positions. When inserting the substrate, the yoke arms are located between the underside of the socket and the surface of the circuit board on which the socket is mounted. The frame is moved towards the end of the yoke arms so that the first frame arms push the substrate into assembled relationship with the socket. When the tool is used for extraction, the second frame arms are moved to their extended positions and are located on the surface of the circuit board.

Abstract: In-line lead making machine (30) has a wire transferring mechanism (18) for shifting the leading end of the wire (11), which extends from a barrel or other endless source (12), from the vicinity of the cutting and stripping blades (21) to a terminating machine (28). The wire (11) is then shifted back to the vicinity of the cutting and stripping blades (21) and fed from the source (12). The wire is then cut to produce the electrical lead (2). During shifting of the wire (11) from the terminating machine (28) to the vicinity of the cutting and stripping blades (21), the transfer mechanism (18) is pivoted upwardly and the wire feeding operation is started during shifting of the transfer mechanism. The wire (11) is thus fed over and above the severing and insulation cutting blades (21) rather than between these blades and the feeding step is started earlier in the cycle than would otherwise be possible.

Abstract: Harness-making machine has a connector installing station, a staging zone adjacent to the installing station for holding a stack of connectors, and a cable dispensing or feeding unit adjacent to the staging zone. Cable is fed from the feeding unit through the staging zone to the installing station at which the leading connector on the stack is installed on the cable. The dispensing unit has a cable guide which extends through the staging zone to the installing station thereby to protect the cable from the terminals which extend from the connectors contained in the staging zone. This guide thereby prevents jamming of the machine which can occur if cable movement through the staging zone is impeded by the terminals.

Abstract: Electrical cable assemblies formed by joining two halves or sections with each section having grooves extending from end to end and outwardly projecting ribs alongside the grooves with the grooves and ribs on one section being laterally shifted relative to the other section so that when the sections are brought together, the ribs enter facing grooves on the opposing sections to cooperatively form passageways for electrical contacts positioned in the grooves. A fixture useful in assemblying the electrical members and a method are also disclosed.

Abstract: Apparatus for orienting elongate bodies, for example electrical connectors, comprises magazines for containing vertical stacks of the elongate bodies, escapement slides for releasing one body at a time from each magazine, as required, first and second slidable traps mounted beneath the escapement slides and having an advanced, body supporting position and a retracted body release position, and guide surfaces on the escapement slides for guiding each body as it falls from a magazine, so that it lies across both of the traps when they are in their body supporting position. A pair of receptacles are slidably mounted on a carriage beneath the traps so that either of these receptacles can be positioned to receive a body released by the traps. If one trap is first retracted, the body will fall into the receptacle in one vertical orientation and if the other trap is first retracted, the body will fall into the receptacle in the opposite vertical orientation.

Abstract: Method for replacing a single contact in an elongate connector having rows of right angle contacts with tails soldered in holes of a printed circuit board comprises steps of desoldering tail of contact, extracting the contact from the mating face, inserting a loop into the vacated contact passage from mounting face, inserting a replacement contact with a hooked tail into the vacated passage from mating face, and seating the replacement contact by using the loop to pull the hooked tail through the mounting face.

Abstract: Apparatus for connecting electrical connectors to a flat multi-conductor cable comprises a work table on which are arranged a connector orienting assembly for placing electrical connectors at loading locations in different selected vertical and lengthwise orientations, a press for connecting the connectors to the cable by forcing the cable conductors into conductor receiving portions of terminals of the connectors, an assembly for feeding the cable intermittently through the press, a shuttle for receiving connectors from the loading locations and being movable intermittently along a path extending between the orienting assembly and the press, rams for loading connectors from the loading locations into the shuttle and an insertion assembly for driving the connectors from the shuttle into the press.

Abstract: Apparatus for connecting individual wires to contact terminals contained in an insulating connector housing has a first wire insertion zone in which there is located a connector locator. The individual wires are fed from reels to the wire insertion zone and the ends of the wires are inserted into the terminals by individual inserters. The connector is thereafter moved away from the insertion zone and wire is withdrawn from the spools or reels. During movement of the connector, the wires are cut to produce a harness assembly. The apparatus also has a second insertion zone and a second connector locator therein. The apparatus can be operated in a mode such that a second connector is applied to the harness wires after the first connector has been moved away from the first insertion zone.

Abstract: Apparatus (26) for taping bundles of wires (4) into compact sheaves (8) comprises first and second bundling rolls (28, 30) having cylindrical surfaces (36, 38) which are in contact in a nip zone (40). First and second tapes (42, 46) are fed towards the rolls on one side of the nip zone and extend through the nip zone. Wires (4) are presented to the rolls on the one side (52) and passed through the nip zone during rotation of the rolls (28, 30). Tape is applied to each bundle from opposite sides of the bundle. On the other side (54) of the nip zone the tape is cut between adjacent bundles by knives (60) on a cutting wheel (56). A plurality of taping devices (26) can be provided on a harness making machine (12) so that the completed harnesses (2) are taped at several locations (10) along their lengths.