Abstract: A wire harness handling and storage system particularly suitable for use in connection with automated harness making machines includes a harness unloading mechanism that unloads a completed wire harness from the harness-making machine and a storage cart that receives a plurality of completed wire harnesses in a plurality of storage racks maintained at different elevations on the storage cart. The handling and storage system is adaptable to handle both short wire harnesses about 6 inches in length) to longer wire harnesses (about 10 feet in length) without tangling or damage to connectors applied to the wires of the wire harnesses. For unloading and placing the longer wire harnesses, a gripping mechanism is provided that picks up the wire harnesses and places on the storage cart in a controlled movement. The unloading and gripping mechanisms are linked with a controller knows the length of the storage areas of the cart for proper, high-density loading thereof.

Abstract: A method for taping together a plurality of wires to create a plurality of individual multiple wire harnesses includes first providing a number of wires, each wire having an end connected to any one of a plurality of end connectors. Then feeding tape to a taping mechanism and applying the tape to the wires along a direction perpendicular to the axes of the wires to form a single bound multiple wire harness. Finally, the bound multiple wire harness is cut into a plurality of individual multiple wire harnesses, each one including an end connector. An apparatus includes a tape feed and application mechanism for applying the tape to the wires along a direction perpendicular to the wires axes; and a tape cutting mechanism to form the plurality of multiple wire harnesses.

Abstract: A machine for producing wire harnesses of the type having multiple connectors terminated to the wires of the harness, the connectors being arranged in serial order along the length of the wire harness and some of the connectors being of two-piece construction is disclosed. The machine includes a reciprocating carriage and a nest that retains a lead connector in place during termination and subsequent advancement of the harness wires. The carriage is received within a termination assembly which has different termination members for different connectors.

Abstract: A wire transferring assembly for a wire harness assembly machine has two adjoining termination stations. First connector elements are advanced in a reciprocating nest from a supply of connector elements into contact with wires extending from a positioning head and terminated thereto. After termination, to the wires, the connector elements are drawn away in the nest from the wire feed source and the wires are cut at their ends opposite the first connector elements. The cut wires are clamped onto a moveable clamping head and maintained in a preselected order while they are transferred to a second termination location, where a row of second connector elements are advanced into contact with the wire ends and terminated thereto.

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: An apparatus for taping wires of a wire harness includes first and second tape application heads interconnected together and disposed proximate to a wire guiding mechanism. Both of the first and second tape application heads have hollow inner cores which communicate with a source of negative air pressure to draw a vacuum in each tape application head which causes a strip of wire tape to adhere to the outer surfaces of the application heads. One of the application heads is brought into contact with a plurality of wires guided across the head, while the second application head rotates around a common axis shared by the two heads, whereby each of the first and second application heads generally oppose each other and apply the strip of tape to the wires.

Abstract: A wire-shifting apparatus particularly suited for use in assembling wire or cable harnesses includes a pedestal portion having a plurality of individual, elongated wire guide members thereon. The wire guide members have a channel-like cross-section and some of the wire guide members are fixed in the position upon the pedestal portion, while others of the wire guide members are mounted on the pedestal portion so as to pivot about a fixed point so that upon urging by an actuator, the movable wire guides shift laterally in unison. The shifted wire guides then convey wires between two opposing connector elements in a manner such that selected wires are terminated at locations in one connector element which are removed one location from the other connector element.

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: A wire holding device is disclosed for holding a plurality of discrete electrical wires in a side-by-side relationship and to facilitate providing longitudinal strain relief for the wires. The device includes a housing, and a plurality of generally parallel retaining passages through the housing for axially receiving and substantially surrounding the wires to retain the wires in substantially all radial directions. A plurality of access windows extend through the housing transversely of the retaining passages to provide access to the wires in the passages by an appropriate bending tool. Each retaining passage has a cavity opposite each respective window and into which a portion of a respective wire can be bent laterally of its axis so that the bent portion of the wire provides longitudinal strain relief for the wire.

Abstract: A system for manufacturing wire harness assemblies is provided. Each wire harness includes a shielded cable having a plurality of insulated conductors therein, with each conductor being terminated at its respective opposed ends and with the terminated ends being mounted in connector housings. The system includes a plurality of pallets that are movable along a conveyor to work stations at which various assembly steps are carried out. A first station is provided for mounting the cables to the pallet, such that the wires at the opposed ends are mounted in fixtures. A second station may selectively deposit drop wires into fixtures on the pallets. A third station trims and strips the ends of the wires and aligns the drop wires with the cable wires. A fourth station sequentially crimps terminals to the ends of the wires, with the pallet being indexable between successive crimps.

Abstract: A work station is disclosed for dispensing electrical components (12) from a tape carrier (10) having a plurality of spaced component-containing cavities (14). During the dispensing operation, one side wall (18') of the cavity is opened by slitting the tape carrier with a dual-blade knife structure (46), such that a component-ejecting shuttle mechanism (40) can pass through an opening (50) in the cavity and guide the component into a fixture (52). The knife structure includes two knife blades (102, 104) arranged such that a V-shaped notch (100) is formed by two inwardly-facing single-bevel knife edges (112, 114). The improved knife structure positions and slits the tape carrier at the notch without causing the tape to buckle or tear.

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: Disclosed is an apparatus for severing connector sticks into separate connector modules. A stick is formed by arranging individual connector housings in a serial row, and joining the connectors by a pair of L-shaped carriers. The carriers are arranged to overlie an outside corner of each housing, with one leg of the L-overlying a sidewall, and the other leg of the L-overlying the bottom wall. A tool bit is provided with first and second cutting surfaces, which sever respective legs of the carrier. The tool bit is configured to be received between individual connector housings, to provide alignment with the legs of the carrier member. The tool bit is arranged to sever a substantial portion of one carrier leg, and to thereafter sever both carrier leg portions.A method for severing the connector stick is also disclosed. According to the method, a substantial portion of the first carrier member is severed first, and the first and second carrier legs are thereafter simultaneously severed.