Abstract: A die clearance monitoring system includes a light source, a light detector, and a controller. The light source is disposed along a front side of a die set of a crimping device and emits light towards the die set. The die set includes a first crimp die and a second crimp die that engage and crimp an object along a crimp stroke. The light detector is disposed along a rear side of the die set. The light detector receives the emitted light from the light source that traverses across the die set through a gap defined between the first and second crimp dies and generates light absorption data based on the emitted light that is received. The controller is communicatively connected to the light detector. The controller processes the light absorption data to determine a relative spacing between the first crimp die and the second crimp die.

Abstract: A wire clamp includes a base and first and second jaws. The first jaw is pivotally mounted to a first upright portion of the base via a first pivot axle, and the second jaw is pivotally mounted to a second upright portion of the base via a second pivot axle. The first and second jaws crisscross each other at an overlap area, and are spring-biased to pivot relative to the base towards a closed position. Respective hook members of the first and second jaws define a mouth above the overlap area that is configured to receive a wire. A size of the mouth adjusts automatically to a size of the wire within the mouth as the first and second jaws pivot towards the closed position. The wire may be held within the mouth in an in-line orientation with a corresponding terminal to which the wire will be crimped.

Abstract: A die clearance monitoring system includes a light source, a light detector, and a controller. The light source is disposed along a front side of a die set of a crimping device and emits light towards the die set. The die set includes a first crimp die and a second crimp die that engage and crimp an object along a crimp stroke. The light detector is disposed along a rear side of the die set. The light detector receives the emitted light from the light source that traverses across the die set through a gap defined between the first and second crimp dies and generates light absorption data based on the emitted light that is received. The controller is communicatively connected to the light detector. The controller processes the light absorption data to determine a relative spacing between the first crimp die and the second crimp die.

Abstract: A wire clamp includes a base and first and second jaws. The first jaw is pivotally mounted to a first upright portion of the base via a first pivot axle, and the second jaw is pivotally mounted to a second upright portion of the base via a second pivot axle. The first and second jaws crisscross each other at an overlap area, and are spring-biased to pivot relative to the base towards a closed position. Respective hook members of the first and second jaws define a mouth above the overlap area that is configured to receive a wire. A size of the mouth adjusts automatically to a size of the wire within the mouth as the first and second jaws pivot towards the closed position. The wire may be held within the mouth in an in-line orientation with a corresponding terminal to which the wire will be crimped.

Abstract: A feed mechanism is provided for a terminal crimping machine that crimps a terminal to a wire. The feed mechanism includes a feed finger configured to move along a feed stroke in a feed direction to feed the terminal into a crimping zone. The feed mechanism also includes a cam having a lift profile, and a push rod that includes a cam follower engaged with the cam. The cam follower travels along the lift profile of the cam, moving the push rod in a lift direction. The push rod is mechanically connected to the feed finger and is configured to move the feed finger along the feed stroke in the feed direction when the push rod moves in the lift direction. A biasing mechanism is operatively connected to the push rod to exert a biasing force on the push rod that biases the cam follower into engagement with the cam.

Abstract: A feed mechanism is provided for a terminal crimping machine that crimps a terminal to a wire. The terminal crimping machine has a crimping zone. The feed mechanism includes a feed finger configured to move along a feed stroke. The feed finger is configured to move along the feed stroke in a feed direction to feed the terminal into the crimping zone. The feed mechanism also includes a cam having a lift profile, and a push rod that includes a cam follower engaged with the cam. The cam follower is configured to travel along the lift profile of the cam such that the push rod moves in a lift direction. The push rod is mechanically connected to the feed finger and is configured to move the feed finger along the feed stroke in the feed direction when the push rod moves in the lift direction. A biasing mechanism is operatively connected to the push rod to exert a biasing force on the push rod that biases the cam follower of the push rod into engagement with the cam.