Abstract: A terminal crimping device includes crimp tooling comprising an anvil and a ram. A crimp zone is defined between the anvil and the ram. The crimp zone is configured to receive a wire and a terminal. The crimp tooling crimps the terminal to the wire during a crimp stroke. The terminal crimping device also includes an ultrasonic transducer module having at least one ultrasonic transducer held by at least one of the anvil or the ram. The ultrasonic transducer generates a plurality of ultrasonic pulses during the crimp stroke and directs the ultrasonic pluses through the terminal. The ultrasonic transducer receives the ultrasonic pulses and generates ultrasonic data based on the received ultrasonic pulses. The terminal crimp tooling also includes a crimp quality module communicatively coupled to the ultrasonic transducer module. The crimp quality module performs coherent processing of the ultrasonic data to determine a crimp quality.

Abstract: A terminal crimping device includes crimp tooling comprising an anvil and a ram movable toward the anvil with a crimp zone being defined between the anvil and the ram configured to receive a wire and a terminal configured to be crimped to the wire by the crimp tooling. An ultrasonic transmitting transducer is coupled to at least one of the anvil and the ram that transmits acoustic signals through the wire and terminal. A filter is provided on at least one of the anvil and the ram in the path of the acoustic signals that affects the acoustic signals.

Abstract: A fluid dispensing machine includes a frame and a fixture held by the frame. The fixture is configured to support a substrate. A positioning system is supported by the frame. A guidance system is supported by the positioning system. The guidance system has a camera viewing the fixture that is movable relative to the fixture. A fluid dispenser is supported by the positioning system and is moved by the positioning system relative to the fixture. The fluid dispenser is configured to dispense fluid onto the substrate. A controller communicates with the positioning system and the guidance system. The controller operates the positing system to control a position of the fluid dispenser relative to the fixture based on an image obtained by the camera.

Abstract: A heating device and method for providing temperature control in an additive manufacturing processes. The heating device is positioned circumferentially about a print head and proximate a top layer of a printed object. An area of the top layer of the printed object is heated by directing energy from the heating device to the top layer as material is deposited from the print head onto the printed object. The directed energy applied to the printed object reduces distortion of the printed object caused by temperature gradients and improves the layer-to-layer bonding of the printed object.

Abstract: An ultrasonic sensor array assembly includes a substrate having a plurality of contact pads, and a plurality of ultrasonic elements supported on the substrate. Each of the plurality of ultrasonic elements is independently electrically connected to a respective one of the plurality of contact pads. The plurality of ultrasonic elements are configured to emit an electrically phased ultrasonic beam.

Abstract: A connector and a method of retaining a contact in a housing. The method includes: inserting the contact into a contact receiving cavity of the housing; applying extruded material in layers into the contact receiving cavity with a precision controlled nozzle; filling voids in the contact receiving cavity layer by layer until the contact receiving cavity is filled; and cooling or curing the extruded material, allowing the extruded material to bond with a wall of the contact receiving cavity. The contact is securely maintained in the contact receiving cavity of the housing by the extruded material. The connector having a contact positioned in a contact receiving cavity of a housing. Extruded material is positioned in the contact receiving cavity. The extruded material is bond to walls of the contact receiving cavity, wherein the extruded material securely maintains the contact in the contact receiving cavity of the housing.

Abstract: A wire sorting fixture includes a cable support configured to support a multi-wire cable and a wire support configured to support wires of the cable. The wire support has a top surface. The wire support has cradles open at the top surface. The wire support has separating walls between corresponding cradles. A top plate is positioned above the wire support. The top plate is moved toward the wire support to a clamping position after the wires are positioned in the corresponding cradles. The top plate holds the wires between the top plate and the wire support in the clamping position.

Abstract: A connector mating assurance system includes a microphone configured to be located in a vicinity of a mating zone for electrical connectors. The microphone is configured to detect an audible sound when the electrical connectors are mated. An output unit is connected to the microphone and receives audio signals from the microphone. The output unit processes the audio signals for mating assurance. The output unit may provide feedback to an assembler based on the audio signals. The output unit may determine if the electrical connectors are properly mated based on the audio signals. The microphone may be held by the assembler proximate to the assembler's hand when assembling the electrical connectors.

Abstract: A terminal crimping device includes crimp tooling defining a crimp zone configured to receive a wire and a terminal. The terminal is configured to be crimped to the wire by the tooling during a crimp stroke of the crimp tooling to form a crimped terminal. The crimp tooling includes an ultrasound module ultrasonically coupled to the crimp tooling and the wire and the crimped terminal when present. The ultrasound module transmits acoustic signals through the crimped terminal and the wire. The ultrasound module also receives echo acoustic signals being reflected back to the ultrasound module. The ultrasound module generates echo signals based on the echo acoustic signals. The terminal crimping device also includes a crimp quality module that receives the echo signals from the ultrasound module and determines a crimp height of the crimped terminal based on the reflected echo acoustic signals received by the ultrasound module.

Abstract: A communication module adaptor adapted for mating with a device connector of a smart electronic device includes an adaptor circuit having a communication module and an adaptor connector coupled to the adaptor circuit. The communication module has a mating interface differing from a mating interface of the device connector such that the communication module is unable to directly connect to the device connector. The adaptor connector has a mating interface complementary to the mating interface of the device connector for mating with the device connector to electrically connect the communication module adaptor to the smart electronic device. The adaptor circuit electrically connects the adaptor connector and the communication module and control signals are transmitted from a controller of the communication module to the device connector of the smart electronic device via the adaptor connector.

Abstract: A wire sorting machine includes a frame and a fixture held by the frame. The fixture is configured to support a cable having a plurality of wires. A positioning system is supported by the frame. A guidance system is supported by the positioning system. The guidance system has a camera viewing the fixture that is movable relative to the fixture. A wire manipulator is supported by the positioning system and is moved by the positioning system relative to the fixture. The wire manipulator is configured to engage the wires of the cable to position the wires relative to the fixture. A controller communicates with the positioning system and the guidance system. The controller operates the positing system to control a position of the wire manipulator relative to the fixture based on an image obtained by the camera.

Abstract: A three-dimensional printing apparatus includes a material receiving area for receiving material, a plasticizer, a discharge pump and an auger. The material receiving area receives material to be used to be used in the three-dimensional printing process. The plasticizer includes a heating zone which places the material in shear. The discharge pump controls the flow of the material. The auger extends from the material receiving area through the plasticizer and terminates proximate the discharge pump. The material is maintained under pressure in the discharge pump until the material exits a nozzle provided at the end of the discharge pump for depositing on a build plate.

Abstract: A method and apparatus for the fabrication of an article made using a three-dimensional printing process. The invention includes depositing material from a print head onto a build plate located in a build chamber to form an article, heating ambient air in the build chamber to a first temperature which acts as a proper sink temperature for cooling of the article, and heating the build plate to a second temperature which is higher than the first temperature. The first and second temperatures are controlled to minimize warping and thermal stress of the article.

Abstract: A three-dimensional printing apparatus and method for inspecting an article during fabrication of the article. The material depositing device deposits layers of material to form a three-dimensional article. The build device receives the material deposited by the material depositing device. The inspection device is positioned proximate the build device and captures images of each respective layer of the article as the article is formed. The controller compares the images of each respective layer to a digital template to determine if the article is properly constructed. The article is inspected during the manufacture of the article with no need for destructive inspection.

Abstract: A bonded helical compression spring. The spring includes a plurality of layers having successive wave crests and troughs. First crests and first troughs of a first layer are aligned with respective second troughs and second crests of an adjacent second layer and with respective third troughs and third crests of an adjacent third layer. The first crests of the first layer are bonded to the second troughs of the adjacent second layer and the first troughs of the first layer are bonded to the third crests of the adjacent third layer. As the crests and troughs of adjacent layers are bonded together, friction between the crests and troughs is eliminated.

Abstract: An apparatus and method for fabricating a three-dimensional object. The apparatus includes a build rod for receiving successive layers of a build material therein. The apparatus also includes a drive mechanism to rotate the build rod and a print head disposed above the build rod. The print head is configured for dispensing a material onto the build rod to form a three-dimensional object.

Abstract: A terminal crimping device includes crimp tooling comprising an anvil and a ram. A crimp zone is defined between the anvil and the ram. The crimp zone is configured to receive a wire and a terminal. The crimp tooling crimps the terminal to the wire during a crimp stroke. The terminal crimping device also includes an ultrasonic transducer module having at least one ultrasonic transducer held by at least one of the anvil or the ram. The ultrasonic transducer generates a plurality of ultrasonic pulses during the crimp stroke and directs the ultrasonic pluses through the terminal. The ultrasonic transducer receives the ultrasonic pulses and generates ultrasonic data based on the received ultrasonic pulses. The terminal crimp tooling also includes a crimp quality module communicatively coupled to the ultrasonic transducer module. The crimp quality module performs coherent processing of the ultrasonic data to determine a crimp quality.

Abstract: A connector mating assurance system includes a microphone configured to be located in a vicinity of a mating zone for electrical connectors. The microphone is configured to detect an audible sound when the electrical connectors are mated. An output unit is connected to the microphone and receives audio signals from the microphone. The output unit processes the audio signals for mating assurance. The output unit may provide feedback to an assembler based on the audio signals. The output unit may determine if the electrical connectors are properly mated based on the audio signals. The microphone may be held by the assembler proximate to the assembler's hand when assembling the electrical connectors.

Abstract: A device control module for making a non-demand management system capable electrical device demand responsive to a demand management system includes a relay configured to be electrically connected to a power circuit of the electrical device to control power supply to a load device of the electrical device. The device control module includes a relay driver operated to open and close the relay and a controller operating the relay driver. The controller receives a demand state signal from the demand management system supplying power to the electrical device and operates the relay driver based on the demand state signal. The relay is configured to power off the load device of the electrical device irrespective of the main control operation of the electrical device.

Abstract: A contactless connector includes a transmitter having a first transmit integrated circuit generating a first signal and a second transmit integrated circuit generating a second signal. A first pick-up antenna is adjacent the first transmit integrated circuit and conveys the first signal along a first transmission line to a first propagation antenna. A second pick-up antenna is adjacent the second transmit integrated circuit and conveys the second signal along a second transmission line to a second propagation antenna. The first and second propagation antennas transmit the first and second signals to a propagation path at different and separable polarizations to allow duplex communication with the propagation path.