Abstract: An electrical terminal is adapted for use with an electrical conductor. The terminal has a terminating portion with a generally U-shaped cross-section having a web and a pair of sidewalls extending from two opposite longitudinal edges of the web. The sidewalls are generally trapezoidally shaped with relatively wide bases, joined to the longitudinal edges of the web, and relatively narrow tips. The bases are transversely aligned across the web. The tips are offset across the web so that the tips are spaced longitudinally of the web. Therefore, the tips will bypass each other when crimped toward each other to terminate the electrical conductor, all within the longitudinal confines of the bases of the sidewalls.

Abstract: A tool is provided for crimping a sheet metal terminal onto an exposed conductor of an electrical wire. The terminal defines a longitudinal axis and includes a mating end, a terminating end and a transition section therebetween. The terminating end includes a pair of transversely spaced crimp walls, and the transition section includes a pair of transversely spaced transition walls coplanar with and joining the crimp walls to the mating end of the terminal. The tool includes a pair of opposed crimp jaws defined by an anvil for locating the terminal and a crimp die for crimping the crimp walls into generally semi-cylindrical configurations into engagement with the conductor of the electrical wire. The crimp die includes a portion for crimping the transition walls into generally semi-frusto-conical configurations toward the conductor.

Abstract: An elongated sheet metal terminal is adapted to be crimped onto an exposed conductor of an electrical wire, the conductor having a given cross-sectional area. The terminal defines a longitudinal axis and includes a mating end, a terminating end and a transition section therebetween. The terminating end has a pair of spaced crimped walls, and the transition section has a pair of spaced transition walls joining the crimp walls to the mating end. The transition section has a minimum cross-sectional area at any given axial location of at least sixty-five percent of the given cross-sectional area of the conductor. The crimp walls are adapted to be completely curled into generally semi-cylindrical configurations into crimping engagement with the conductor. The transition walls are adapted to be partially curled into generally semi-frusto-conical configurations toward the conductor.

Abstract: A terminal position assurance system is provided for an electrical connector which includes a dielectric housing having a terminal-receiving passage into which a terminal is inserted in an insertion direction to a fully inserted position. A latch surface is formed in the housing adjacent the passage and facing in the insertion direction. A bendable tab is provided on the terminal and is adapted to be bent against the latch surface. The bendable tab is structured to be bent about an axis generally parallel to the insertion direction to move an edge portion of the tab to a position over the latch surface when the terminal is in its fully inserted position.

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: An apparatus and a process are provided for assessing the quality of crimped electrical terminations of a terminal to a wire. The apparatus includes a strain gauge incorporated into a crimp press for measuring the strain generated in the press during each crimping cycle. The strain gauge is operatively connected to a controller which generates appropriate signals in response to strain measurements that are not within an acceptable range. The crimp press may further be operative to selectively adjust the crimp height or the length of the crimp stroke. The adjustment may be operatively connected to the controller, such that the crimp press is self-adjustiong and accommodates the gradual wearing of the crimp tools.

Abstract: A modular press block assembly for use in a press tool to mount an electrical connector assembly having a housing and depending terminal pins into a printed circuit board. The modular press block assembly includes a pair of end holders and at least one modular press block positioned between the end holders for engaging the connector assembly and pressing the terminals into the printed circuit board. The invention contemplates a plurality of the modular press blocks of different sizes to form a set thereof for accommodating a plurality of different sizes of connector assemblies. Complementary interengaging keys are provided between the end holders and the modular press blocks and between the press blocks themselves to define proper positioning of the press blocks between the end holders and to maintain that positioning when the end holders are held against the sides of the press block. Spacer blocks also can be used between adjacent press blocks.

Abstract: An improved apparatus and method for feeding a large volume of electrical components to a vision controlled robotic placement apparatus is provided. Electrical components in a reeled pocketed carrier tape are indexed along a dereeling component feeder to a pick up station. Forward advance of the carrier is stopped when an optical sensor in the feeder senses that a depending pocket in the carrier tape is generally positioned at the pick up station. The vision control system on the robot is relied upon to locate the pocket at the pick up station and to locate the individual components presented in the pocket. The components are robotically unloaded from the carrier one at a time and placed on a printed circuit board assembly at a second station with the guidance of the vision control system. As the last component is picked up for placement, the vision control system signals the carrier tape drive to index the next pocket to the pick up station.