Abstract: The invention disclosed here is a pin hub that is to be used in conjunction with interchangeable wire reels for taking individual wire segments from a continuous wire feed. In use, an empty reel is first mounted to the pin hub. The pin hub has a plurality of pins which are arranged in a circular pattern, and are retracted relative to the hub at the time the reel is mounted. After mounting, the pins are extended through corresponding side openings in the reel, and thereby define a winding hub or circle within the reel itself. Instead of being wound directly against sidewall or hub structure of the reel itself, the wire is instead wound about the pins, and they take up the physical stresses associated with the winding process. After winding is completed, the pins are retracted, and the filled reel is thereafter removed from the pin hub.

Abstract: The invention disclosed here is a wire reel that is designed to be used in connection with an automated wire handling system. The reel has a generally planar stiffback, and a circular flange that is releasably connected to the stiffback. The stiffback and flange together define a circular winding space for coiling a wire onto the reel. The stiffback also carries two, spaced-apart clamps which are positioned outwardly with respect to the outer perimeter of the flange. These clamps hold the opposite ends of the coiled wire. The stiffback is shaped so that it is suitable for gripping and handling by a robotic arm or the like.

Abstract: The invention is an improved cutting blade for use in connection with a rotary wire stripper. The blade is notched in a manner so as to define one or more chipping points along the blade's edge. The notches are interconnected by sharp sections of the blade's edge. This configuration permits cutting through both hard and soft forms of wiring insulation. If the insulation is hard, the corners provided by the notches chip through it. If the insulation is soft, the sharp edges cut through it in conventional fashion.

Abstract: An open topped carrier (2) has a space (6) dimensioned to receive a plurality of coiled wire segments (100) hung on hangers (26) carried by upper portions of dividers (22). The dividers (22) are held in vertical, horizontally spaced use positions by slots (12) formed on the inner wall surfaces of the carrier (2). Each divider (22) may be independently grasped and slid into an elevated use position to facilitate hanging the coiled segment (100) on the hanger (26). A clamping device (32) extends along each of opposite side portions of an upper flange (14) of the carrier (2). The ends (102) of each segment (100) are clamped in an accessible transport position by the clamping device (32). The carrier (2) may have portions to facilitate handling of the segment ends (102) by an operator and/or an indicator bar (58) with a plurality of lights (62) aligned with the segment ends (102) for a human operator.

Abstract: A wire guide includes a notch cut in one face and a plurality of spaced webs oriented transversely in the notch to define a predetermined line for the wire at the bottom of a V-shaped valley fabricated into the webs. The webs support the wire so that a robot tool, having notches corresponding to the webs, can align with the webs along the line and can descend into the notches of the guide to acquire the wire in a retaining groove.

Abstract: The manufacturing system includes a wire segment preparation subsystem and a termination subsystem, each of which operates independently under the direction of local computer controllers. The preparation sybsystem measures and marks wire and cuts it into segments. The termination subsystem processes the ends of the wire segments. A transport subsystem selectively transports batches of wire segments from the preparation subsystem to the termination stations of the termination subsystem. A system controller oversees the operation of the system and transmits batches of computer process control data to the subsystems. The local controllers use the downloaded batches of data to direct the processing of batches of wire segments. The system may be entirely automated, or may include a mix of automated and manual work stations. The segments are preferably loaded in batches in carriers for transport between subsystems and work stations. The carriers may be transported by hand, along roller tables, and/or on conveyors.

Abstract: An open topped carrier (2) has a space (6) dimensioned to receive a plurality of coiled wire segments (100) hung on hangers (26) carried by upper portions of dividers (22). The dividers (22) are held in vertical, horizontally spaced use positions by slots (12) formed on the inner wall surfaces of the carrier (2). Each divider (22) may be independently grasped and slid into an elevated use position to facilitate hanging the coiled segment (100) on the hanger (26). A clamping device (32) extends along each of opposite side portions of an upper flange (14) of the carrier (2). The ends (102) of each segment (100) are clamped in an accessible transport position by the clamping device (32). The carrier (2) may have portions to facilitate handling of the segment ends (102) by an operator and/or an indicator bar (58) with a plurality of lights (62) aligned with the segment ends (102) for a human operator.

Abstract: A system for processing wire segments includes a wire segment transport subsystem and at least one automated termination station (2, 102). The station (2, 102) includes a robot (4, 104) with a work envelope (105) in which a plurality of wire segment end processing devices are positioned. A work depot (32, 132) is positioned within the envelope (105) and is dimensioned to receive a batch of wire segments (100) loaded in a carrier (72, 172). The depot (32, 132) is independent of the transport subsystem but accessible thereto via an input station (24, 124) and an output station (26, 126) in which carriers (72, 172) may be queued. The robot (4, 104) processes the ends of the segments (100) loaded in the carrier (72, 172), one at a time.

Abstract: A circuit is disclosed for detecting a conductive region in a body. The circuit includes a remote module (12) coupled to a driver and logic module (14). The remote module is mountable on a probe (16) and senses contact between a conductive detector electrode and the conductive region. The driver and logic module provides energy to the remote module and responds to the operation of the remote module by producing an output indicative of detection of the conductive region. In the preferred arrangement, current from a constant current source Q.sub.4 normally flows through a first transistor Q.sub.1, which is maintained in an "on" state by a charged capacitor C.sub.1. When the detector electrode contacts the conductive region, however, charge is bled from the capacitor, switching the first transistor to an "off" state and causing the current from the current source to be redirected to a switching transistor Q.sub.3.

Abstract: A wire stripper in accordance with the invention has a non-linear rate of blade closure where the stripper's blades first close quickly from an open position to near the wire that is to be stripped, followed by a slow rate of closure as the blades cut through the wire's insulation. The stripper also has a blade proximity sensor that involves placing a high voltage on the blades as they cut through the insulation so that a short-duration current pulse travels from the blades to the wire's center conductor as soon as the insulation is broken apart by the blades. Such pulse is sensed, and further inward movement of the blades toward the center conductor is immediately stopped, in order to prevent the blades from nicking or scraping the conductor.

Abstract: A pair of wire guides or "centering jaws" for use in connection with the blades of a rotary wire stripper. Each wire guide has a gripping leg which, in cooperation with a similar wire guide on the other side of the wire to be stripped, tightly grips the end of the wire, but only on the portion of the wire's insulation which is actually stripped. This enables the stripped portion to function as a centering guide thereby keeping the wire's center conductor from coming into contact with the stripper's rotating blades during the stripping operation.

Abstract: In the method of the present invention, a wire routing tool grasps a wire, inserts one end into a connector, routes the wire along a predetermined path to another end connector under the control of a robot, and inserts the second end into that connector. The trailing end of the wire is detected with a circuit using an electrostatic technique. The tool can move the wire along a predetermined linear path to effectuate the connection.

Abstract: To support robotic assembly of wire harnesses having wires with loop or lug terminals, a breakout dock includes a support for robotic breakout of the wire from the bundle and a clamp for receiving that wire from a wire routing tool on the robot. The clamp generally includes opposed spring leaves that are wedged apart by the lowering of the wire routing tool into the mouth of the clamp. Position indicators allow the robot to determine the precise orientation and location of the dock, including the location of the supports and clamps mounted on the dock.

Abstract: A wire routing tool grasps a wire, inserts one end into a connector, routes the wire along a predetermined path to another end connector under the control of a robot, and inserts the second end into that connector. The trailing end of the wire is detected with a circuit using an electrostatic technique. The tool can move the wire along a predetermined, linear path to effectuate the connection.

Abstract: A turn gate is used for receiving and supporting a plurality of wire segments that are successively guided laterally into contact with it by the robotic device during the assembly of the wire harness. The turn gate is positioned at bends in the wire harness and is configured so that each wire segment is positioned on a predetermined location on the inside radius of the curve.

Abstract: Disclosed is a connector block used for placing an electrical connector in precise position for receiving the ends of wire segments that are inserted therein by a robotic device. The connector block includes a socket upon which the connector is supported. The socket (hence the supported connector) can be selectively positioned in a plurality of positions relative to the robotic device. The connector block also includes a lock pin for both securing the socket in position and for providing a readily detectable indication of which particular rotational orientation in which the socket is disposed. The connector block also includes a reference pin usable for establishing the particular orientation of the connector block relative to the form board.

Abstract: Wire harnesses are automatically fabricated with pre-cut and preconfigured ends in a robotic wire harness assembly system including a wire preparation subsystem, a wire reeling subsystem, a wire terminating subsystem, a wire queuing subsystem, a layup subsystem, associated robots, and a logic controller.

Abstract: A wire canister capable of being used by robots during the assembly of a wire harness. The wire canister is capable of accepting, storing and dispensing random lengths of wire, i.e., a wire segment. The leading and trailing ends of the wire segment are constrained in such a way that the ends of the wire segment may be readily acquired by the manipulator of a robot and presented to other supporting equipment for purposes of performing operations on the ends of the wire segment.