Abstract: An apparatus for loading individual connectors into a wire-harness making machine includes a feed track which feeds a supply of connectors which have been separated from a connector supply chain. The lead connector is advanced into a feed channel whereupon a severing knife is advanced into the feed channel to separate the lead connector from an adjacent connector. The severing knife remains in place momentarily as a shuttle mechanism is actuated to move the severed lead connector along the feed channel, the severing knife blade forming a portion of the feed channel during the shuttling of the severed connector. Optical sensors may be mounted in proximity to the severing knife in order to verify the presence or absence of a connector prior to severing.

Abstract: A wire harness-making machine for producing wire harnesses of the type in which multiple wires extend between opposing first and second electrical connector elements. The machine includes a feeding assembly which separates successive first wire connectors and a transfer nest which shuttles the first array of connectors from a first connector advancement track to a first termination station. Multiple wires are fed to the first termination station where first free ends thereof are terminated to the first connector. Once terminated to the multiple wires, the first connector is shuttled back to the first connector advancement track. The first connector is then advanced along a feedpath and a set of second free ends of the wires are transferred to a second termination station while maintaining the order of the wires.

Abstract: Electrical connectors are slidably received in side-by-side serial array in elongated, hollow tubular cassettes. The cassettes are shaped to receive the connectors only in a single orientation, and protect terminals which partly extend from the connector housings in an intermediate assembly stage. Cassettes are vertically stacked in a feed system, and when the bottom cassette is emptied of connectors, it is released from the stack and replaced with a full cassette.