Abstract: A system for determining whether a lead is securely inserted into a connector includes an actuator for moving the lead to a plurality of positions, a position sensor for measuring a position of the lead relative to the connector, and a force sensor for measuring an actual force exerted on the lead at each of the plurality of positions to define an actual force signature. A processor compares the actual force signature to a predetermined force signature to determine whether the lead is disposed within the opening of the connector. The method includes the steps of moving the lead to a plurality of positions, establishing an actual force signature, and establishing a predetermined force signature. If the actual force signature is within the predetermined force signature, then the lead is securely inserted into the opening.

Abstract: A system for determining whether a lead is securely inserted into a connector includes an actuator for moving the lead to a plurality of positions, a position sensor for measuring a position of the lead relative to the connector, and a force sensor for measuring an actual force exerted on the lead at each of the plurality of positions to define an actual force signature. A processor compares the actual force signature to a predetermined force signature to determine whether the lead is disposed within the opening of the connector. The method includes the steps of moving the lead to a plurality of positions, establishing an actual force signature, and establishing a predetermined force signature. If the actual force signature is within the predetermined force signature, then the lead is securely inserted into the opening.

Abstract: Wire is routed onto a bus plate by a wire routing device that comprises a wire feed mechanism and a non-rotatable wire routing head. The wire routing head has a horn that includes an inverted funnel shaped orifice. The wire feed mechanism pushes wire into the inverted funnel shaped orifice which routes the wire in wire receiving channels and passages of the bus plate in linear and non-linear patterns without any need for rotating the horn with respect to the bus plate.

Abstract: Wire is routed onto a bus plate by a wire routing device that comprises a wire feed mechanism and a non-rotatable wire routing head. The wire routing head has a horn that includes an inverted funnel shaped orifice. The wire feed mechanism pushes wire into the inverted funnel shaped orifice which routes the wire in wire receiving channels and passages of the bus plate in linear and non-linear patterns without any need for rotating the horn with respect to the bus plate.

Abstract: An electrical connector assembly includes a bus assembly which comprises a bus insulation plate having a base which includes a plurality of terminal stations and a plurality of guide stations. The terminal stations and guide stations are separated from each other so as to provide a network of wire channels which communicate with wire passages which extend through the terminal and guide stations. The terminal stations also have terminal cavities which extends through the base to intersect the wire passages. The bus assembly further includes electrical busses comprising lengths of electrically conductive wire which pass through various terminal and guide stations via the network of wire channels.