Abstract: A modular application tooling machine includes a base unit with a delivery station for electrical connectors, a intermittently operated connector feed drive system and a continuously operated work station drive system. Feed track modules define a connector feed track along which connectors are fed by pusher modules driven by the feed drive system. Work station modules powered on demand by the work station drive system carry out cycles of operation to perform operations on connectors in the feed track. One work station module terminates conductors into insulation displacement terminals of the electrical connectors and another work station module breaks off a carrier strip connected to the terminals.

Abstract: A pitch transition wire guide apparatus for use in wire harness fabrication machines includes a plate member having a wire engaging edge and a corresponding number of open-ended wire guide channels, each extending inwardly from the edge to a closed end. The closed ends of said channels are spaced apart by a centerline spacing different from the centerline spacing of the open ends in said edge. The plate is reciprocably moveable between a first position wherein the open ends are in surrounding engagement with the wires adjacent the edge and a second wire-receiving position wherein said wires are disposed at the closed ends. The guide includes actuation means for moving the plate member between said first and second positions. Actuation of the wire guide causes movement of the wires within their respective channels to alter the centerline spacing thereof. The wire guide is useful for making smooth continuous transitions between production runs of different pitch wire harnesses.

Abstract: An electrical harness fabrication machine which produces harnesses which comprise ribbon cable having a connector at each end. Each connector has a housing with terminals loaded therein. Prior to termination to the cable, the terminals are partially preloaded into their respective housings so that conductor engaging ends thereof are presented to a termination station for mass termination. A conductor engaging end of the terminals are free standing sections which form an insulation displacement slot therebetween. The termination assembly has a portion adjacent conductor stuffing blades for laterally supporting the conductor engaging ends of the terminals during the termination operation. In addition, pilot members are provided to cooperate with a connector nest having a preloaded connector received therein and the conductors for accurately aligning the conductors, conductor engaging ends of the terminals and the termination assembly with respect to one another.