Abstract: The present invention constitutes an apparatus for assembling multiple electrical contacts and filler elements into an electrical connector. The apparatus includes a filler assembly for automatically installing filler elements into the holes within the electrical connector which are to be unoccupied by electrical contacts, and a guide assembly which is functional for assisting the operator in manually inserting the electrical contacts into the correct holes within the connector by providing a visual indication of the holes into which the contacts should be inserted. The filler and guide assemblies operate on connectors held into position on a turntable-like indexing plate which allows the connectors to be rotated alternatively into position with respect to each of the assemblies. The filler assembly includes one or more filler element inserter tools which are adapted for inserting filler material from strands of such material into the holes within the connectors so as to form installed filler elements.

Abstract: Apparatus for applying a pinch mark to a wire (10) at a selected target position along the length of the wire. The apparatus operates in response to a first signal (MARK) indicating that the target position is at a known upstream location. The apparatus includes pinch means (44) including dies (54,56) mounted for movement to and from a pinch station along the wire path. The apparatus includes coupling means responsive to the first signal for causing the dies to move to the pinch station when the target position is at the pinch station. The coupling means may comprise a servo motor (60), control means (70) for driving the servo motor at a selected speed with respect to the wire speed, and engagement means (62,64) responsive to the first signal for coupling the dies to the servo motor such that the dies and the target position arrive at the pinch station at the same time and traveling at the same speed. The dies thereby exert a minimum lengthwise force on the wire.

Abstract: A contact which is attached to a wire is fitted in a hole of a connector by first identifying the wire to which the contact is attached. The location of the hole that is to receive the contact is determined automatically from an electronic data lookup table, and a signal is provided which positions an end portion of a fiber optic rod in line with the correct hole of the connector. The opposite end of the fiber optic rod is optically coupled to a source of light. The fiber optic rod is advanced so that it enters the hole and projects from the opposite side of the connector identifying the correct hole. Light emitted from the fiber optic rod facilitates visual identification of the hole from which the rod is projecting. Therafter, the fiber optic rod is retracted, and the contact is inserted into the hole.