Abstract: This invention relates to a contact system (50) which includes spring contacts (54, 56) of a geometry and position to mate with the contacts (26, 38) of differing geometries of plug (12) and receptacle (14) connectors and particularly to the use of such system to test connectors of different geometries.

Abstract: The insertion head of the present invention is for a wire trimming and inserting machine, i.e., a machine or apparatus for loading color-coded, or otherwise coded wires into a connector half. It includes a platform with an appendage coupled thereto. The appendage has a channel formed therein to receive and guide wire therethrough to a terminal of a connector half. The insertion head includes a spring biased guide, which bears against the channel-received wire, and imposes a movement-retarding force or drag on the wire to insure that the latter is held taut until engaged with the connector terminal.

Abstract: The present invention relates to a wire selection and feed apparatus for use in an automated machine for making electrical cables. The apparatus includes a rotary turret having a plurality of wire holders angularly spaced about its periphery. The desired wire is selected by rotating the turret until the appropriate wire holder is in the feed, or select, position. The wire holder is then advanced thereby presenting the end of the selected wire to a work station for processing. At this point the wire may be fed a desired amount into the work station by bringing a wire feed until into feeding engagement with the wire.

Abstract: An apparatus is disclosed for automatically making and testing electrical cable assemblies. A novel coupling is provided between the bulk cable contained on a large reel and the logic circuitry of the automated machine so that individual wires within the cable can be identified, inserted into a desired terminal of a connector, and tested. The coupling utilizes a slip ring assembly to communicate with the individual wires of the cable through a connector that has been previously terminated on a pigtail extending from the central core of the reel.

Abstract: A selective wire feed for feeding any one of a plurality of wires which are arranged in pairs, each pair having a first wire and a second wire. Each wire pair has a feeding unit associated therewith which comprises a driven belt and two idler belts. The idler belts are movable between a feeding position and a non-feeding position. A specific wire is fed by moving its associated feeding belt to its feeding position and actuating the driven belt so that the wire is fed by the two belts. A wire guide is provided and has convergent passageways which extend to a wire outlet. A cutter is provided adjacent to the outlet so that a wire which has been fed can be cut. Thereafter, the wire which has been fed can be retracted by reversing the direction of the driven belt.

Abstract: An electrical harness comprising a plurality of harness subassemblies is assembled by locating the subassembly leading ends of all of the subassemblies in a staging zone. The subassemblies are moved in succession along a transporting path which extends away from the staging zone in a succession which locates the subassembly leading ends of the several subassemblies at the required locations along the length of the harness. Bindings for the conductors in the harness subassemblies are applied where required. A fully automatic apparatus is disclosed for carrying out the process comprising individual transporters for each of the harness subassemblies which move the subassemblies individually along the transporting path.

Abstract: An electrical connector pick-up station for use in feeding electrical connectors from a magazine into an electrical connector transfer nest, for transfer to a work station, comprises a cable supporting the magazine, a seat for the nest having guide rollers for guiding the nest onto the seat, and a feed ram which is movable under the base of the magazine to insert a connector into the nest. The ram is provided with an end for engaging the connector to insert it, and a guide plate extending beyond that end for guiding the connector into a predetermined position in the nest, in which position it is releasably latched in the nest. Where the connectors are provided with mating covers, the guide plate acts as a separator which extends between the connector and its cover so that these are inserted into the nest in properly spaced relationship.

Abstract: A cable severing station for severing a flat cable at a position adjacent to electrical connectors to which the cable has been terminated, comprises a cable gripping unit having cable grippers which can be moved between an open position to allow the cable with the connectors thereon to be fed therethrough and a closed cable gripping position; and a cutting second unit for gripping the cable and the connectors and for severing the cable at positions close to the connectors. The cable is first fed through the grippers of the cable gripping unit when these are in an open position, and the cable cutting unit is then moved into the cable gripping unit to carry out the cable severing operations.

Abstract: In an assembly for connecting electrical connectors to flat multi-conductor cable, an arm of a robot is provided with a connector transfer nest into which a connector can be fed at a connector feed station, for transfer by the robot to a press through which the cable has been fed. The nest is inserted into the press by the robot so that the cable extends through the nest and the press is then operated to actuate means in the nest to force conductor receiving portions of terminals in the connector through the cable to receive the cable conductors. The robot is then operated to withdraw the nest from the press leaving the connector on the cable and the cable is fed forward to allow the robot to apply a further connector thereto and so on. Means may be provided for severing the cable with the connectors thereon to provide separate electrical harnesses.

Abstract: An electrical connector transfer nest for use in transferring an electrical connector from a connector pick-up station to a work station, comprises a frame in which are slidably mounted, a pair of plungers, one of these having means for releasably retaining a connector thereon. The nest is arranged to receive a flat cable between the plungers, so that by moving the plungers towards one another, against the action of a return spring, conductor receiving portions of terminals of the connector can be forced through the cable to receive the conductors. Means are provided for releasing the connector from the nest, after it has been terminated to the cable and as the plungers are moved apart by the return spring. The other plunger may be arranged, releasably to receive, a cover for the connector, the cover having means for stuffing the cable conductors into the wire receiving portions of the terminals.

Abstract: Apparatus for separating individual conductors of a ribbon cable comprises a pair of rollers having annular teeth which intermesh to split the cable as the rollers are moved together. The cable is clamped in a stationary frame and the rollers are mounted for rotation in a carriage which moves linearly in the frame to separate the conductors along a length of the cable.