Abstract: A method of twisting a pair of wires includes the steps of arranging a first wire parallel to a second wire along a longitudinal axis, securing ends of the first and second wires, and gripping outer surfaces of central portions of the first and second wires. The inner surfaces of the central portions of the first and second wires are in contact with one another. The method further includes deflecting central portions of the first and second wires orthogonally from the longitudinal axis and rotating the central portions of the central portions of the first and second wires, thereby twisting the first and second wires about one another.

Abstract: An automated wire kitting system for assembling wire leads for a wired connector comprises a terminal delivery system configured to obtain a target terminal from a plurality of different types of terminals for wire leads and a crimp press comprising a plurality of dies and being configured to obtain a wire having an exposed portion where the wire's insulation has been removed, receive the target terminal from the terminal delivery system, engage a target die of the plurality of dies corresponding to a type of the target terminal, and crimp the target terminal onto the exposed portion of the wire using the target die of the plurality of dies to assemble a wire lead.

Abstract: A method of twisting a pair of wires includes the steps of arranging a first wire parallel to a second wire along a longitudinal axis, securing ends of the first and second wires, and gripping outer surfaces of central portions of the first and second wires. The inner surfaces of the central portions of the first and second wires are in contact with one another. The method further includes deflecting central portions of the first and second wires orthogonally from the longitudinal axis and rotating the central portions of the central portions of the first and second wires, thereby twisting the first and second wires about one another.

Abstract: A method of twisting a pair of wires includes the steps of arranging a first wire parallel to a second wire along a longitudinal axis, securing ends of the first and second wires, and gripping outer surfaces of central portions of the first and second wires. Inner surfaces of the central portions of the first and second wires are in contact with one another. The method further includes the step of rotating the central portions of the first and second wires, thereby twisting the first and second wires about one another.

Abstract: An apparatus configured to twist a first wire about a second wire is presented herein. The apparatus includes a securing mechanism configured to secure ends of the first wire and the second wire. The first wire is arranged parallel to the second wire along a longitudinal axis. The apparatus further includes a gripping mechanism configured to grip central portions of the first and second wires, a tensioning mechanism configured to apply a lateral offsetting force to the gripping mechanism, thereby deflecting the central portions of the first and second wires orthogonally from the longitudinal axis, and a rotating mechanism configured to rotate the gripping mechanism, thereby twisting the first and second wires about one another. A method of twisting a pair of wires is also presented.

Abstract: A method of twisting a pair of wires includes the steps of arranging a first wire parallel to a second wire along a longitudinal axis, securing ends of the first and second wires, and gripping outer surfaces of central portions of the first and second wires. Inner surfaces of the central portions of the first and second wires are in contact with one another. The method further includes the step of rotating the central portions of the central portions of the first and second wires, thereby twisting the first and second wires about one another.

Abstract: A modular retainer assembly is presented herein. The modular retainer assembly includes a first retainer module defining a flexible first retaining finger and a second retainer module that is distinct from and joined to the first retaining module. The second retainer module defines a flexible second retaining finger. When the first and second retainer modules are mated together, the first retaining finger is arranged opposite the second retaining finger. The first and second retaining fingers are configured to receive and retain an elongate article, such as a wire cable, between them.

Abstract: An apparatus configured to twist a first wire about a second wire is presented herein. The apparatus includes a securing mechanism configured to secure ends of the first wire and the second wire. The first wire is arranged parallel to the second wire along a longitudinal axis. The apparatus also includes a gripping mechanism configured to grip central portions of the first and second wires such that inner surfaces of the central portions of the first and second wires are in contact with one another and a rotating mechanism configured to rotate the gripping mechanism, thereby twisting the first and second wires about one another. A method of twisting a first wire about a second wire is also presented herein.

Abstract: An apparatus configured to twist a first wire about a second wire is presented herein. The apparatus includes a securing mechanism configured to secure ends of the first wire and the second wire. The first wire is arranged parallel to the second wire along a longitudinal axis. The apparatus further includes a gripping mechanism configured to grip central portions of the first and second wires, a tensioning mechanism configured to apply a lateral offsetting force to the gripping mechanism, thereby deflecting the central portions of the first and second wires orthogonally from the longitudinal axis, and a rotating mechanism configured to rotate the gripping mechanism, thereby twisting the first and second wires about one another. A method of twisting a pair of wires is also presented.

Abstract: A modular retainer assembly is presented herein. The modular retainer assembly includes a first retainer module defining a flexible first retaining finger and a second retainer module that is distinct from and joined to the first retaining module. The second retainer module defines a flexible second retaining finger. When the first and second retainer modules are mated together, the first retaining finger is arranged opposite the second retaining finger. The first and second retaining fingers are configured to receive and retain an elongate article, such as a wire cable, between them.

Abstract: An apparatus configured to twist a first wire about a second wire is presented herein. The apparatus includes a securing mechanism configured to secure ends of the first wire and the second wire. The first wire is arranged parallel to the second wire along a longitudinal axis. The apparatus further includes a gripping mechanism configured to grip central portions of the first and second wires, a tensioning mechanism configured to apply a lateral offsetting force to the gripping mechanism, thereby deflecting the central portions of the first and second wires orthogonally from the longitudinal axis, and a rotating mechanism configured to rotate the gripping mechanism, thereby twisting the first and second wires about one another. A method of twisting a pair of wires is also presented.

Abstract: A modular retainer assembly is presented herein. The modular retainer assembly, includes a first retainer module defining a flexible first retaining finger and a second retainer module that is distinct from and joined to the first retaining module. The second retainer module defines a flexible second retaining finger. When the first and second retainer modules are mated together, the first retaining finger is arranged opposite the second retaining finger. The first and second retaining fingers are configured to receive and retain an elongate article, such as a wire cable, between them.

Abstract: An apparatus configured to twist a first wire about a second wire is presented herein. The apparatus includes a securing mechanism configured to secure ends of the first wire and the second wire. The first wire is arranged parallel to the second wire along a longitudinal axis. The apparatus further includes a gripping mechanism configured to grip central portions of the first and second wires, a tensioning mechanism configured to apply a lateral offsetting force to the gripping mechanism, thereby deflecting the central portions of the first and second wires orthogonally from the longitudinal axis, and a rotating mechanism configured to rotate the gripping mechanism, thereby twisting the first and second wires about one another. A method of twisting a pair of wires is also presented.

Abstract: An apparatus configured to twist a first wire about a second wire is presented herein. The apparatus includes a securing mechanism configured to secure ends of the first wire and the second wire. The first wire is arranged parallel to the second wire along a longitudinal axis. The apparatus also includes a gripping mechanism configured to grip central portions of the first and second wires such that inner surfaces of the central portions of the first and second wires are in contact with one another and a rotating mechanism configured to rotate the gripping mechanism, thereby twisting the first and second wires about one another. A method of twisting a first wire about a second wire is also presented herein.

Abstract: A modular retainer assembly is presented herein. The modular retainer assembly, includes a first retainer module defining a flexible first retaining finger and a second retainer module that is distinct from and joined to the first retaining module. The second retainer module defines a flexible second retaining finger. When the first and second retainer modules are mated together, the first retaining finger is arranged opposite the second retaining finger. The first and second retaining fingers are configured to receive and retain an elongate article, such as a wire cable, between them.

Abstract: A method of nondestructive testing of a joint between an electrical terminal and a wire cable that is bonded to the electrical terminal is presented herein. This method includes the steps of providing an ultrasonic transducer in electrical communication with an electrical signal generator and signal analyzer, placing the transducer in ultrasonic communication with the joint, transmitting a first ultrasonic signal via stimulation of the transducer by a first electrical signal having a first frequency from the signal generator, receiving a first reflected signal of the first ultrasonic signal via the ultrasonic transducer, transmitting a second ultrasonic signal via stimulation of the transducer by a second electrical signal having a second frequency different than the first frequency from the signal generator, receiving a second reflected signal of the second ultrasonic signal via the transducer, and determining the quality of the joint by analyzing the first and second reflected signals.

Abstract: A wire cable configured to be attached to a wire cable terminal. An uninsulated end of the wire cable is formed into a nugget having a shape that generally defines a rectangular cuboid or rectangular prism. The nugget includes one face that defines a longitudinal concavity, indentation, or channel, which is oriented generally parallel to the longitudinal axis of the wire cable. The nugget may be formed by ultrasonically welding the wire strands together. The concavity reduces the occurrence of fracturing the nugget when it is attached to the terminal by wire crimping wings. The wire cable may be formed of aluminum-based material. An apparatus for forming an end of a wire cable into a nugget shape having a longitudinal concavity and a method of attaching a wire cable having an end formed into a nugget shape having a longitudinal concavity to a terminal is also presented.

Abstract: A wire cable configured to be attached to a wire cable terminal. An uninsulated end of the wire cable is formed into a nugget having a shape that generally defines a rectangular cuboid or rectangular prism. The nugget includes one face that defines a longitudinal concavity, indentation, or channel, which is oriented generally parallel to the longitudinal axis of the wire cable. The nugget may be formed by ultrasonically welding the wire strands together. The concavity reduces the occurrence of fracturing the nugget when it is attached to the terminal by wire crimping wings. The wire cable may be formed of aluminum-based material. An apparatus for forming an end of a wire cable into a nugget shape having a longitudinal concavity and a method of attaching a wire cable having an end formed into a nugget shape having a longitudinal concavity to a terminal is also presented.

Abstract: A method to electrically and mechanically connect at least one wire conductor to a terminal includes the steps of cutting and stripping a portion of an insulation outer layer along an end section of the at least one wire conductor to expose a lead of the at least one wire conductor. A further step includes applying a bonding process to the exposed lead to break down oxides disposed on the lead. A further step in the method is crimping the lead having the applied bonding process to the terminal to form a crimp connection connecting the at least one wire conductor to the terminal.

Abstract: A method to electrically and mechanically connect at least one wire conductor to a terminal includes the steps of cutting and stripping a portion of an insulation outer layer along an end section of the at least one wire conductor to expose a lead of the at least one wire conductor. A further step includes applying a bonding process to the exposed lead to break down oxides disposed on the lead. A further step in the method is crimping the lead having the applied bonding process to the terminal to form a crimp connection connecting the at least one wire conductor to the terminal.