WIRE GUIDANCE SYSTEM

Abstract

A wire guidance system includes a wire guide and a compressed air feeder. The wire guide has a wire guide channel extending between a wire entrance and a wire exit. The wire guide channel receives a wire through the wire entrance. A segment of the wire extends beyond the wire exit. The compressed air feeder supplies compressed air to the wire guide. The compressed air is supplied to the wire guide channel around the wire. The compressed air is discharged from the wire exit with the wire to support the segment of the wire extending beyond the wire exit.

Description

BACKGROUND OF THE INVENTION

The subject matter herein relates generally to a wire guidance system.

Lead maker devices and other processing equipment are used to process wire from a bulk wire source to produce electrical leads. For example, the wire may be fed by a belt or roller feed system through a series of rigid and/or flexible guide tubes that direct the wire to the processing equipment. The wire is presented to the lead maker and/or processing equipment which may be used to measure the wire to length, cut and strip the ends, crimp a terminal or other end piece to the wire, tin an end of the wire, seal an end of the wire, deposit a length of wire into a deposit tray, and/or the like. The guide tubes and/or feed system may be designed to rotate and/or translate in order to selectively provide the wire to one of multiple processing stations. For example, the wire may be fed to a cutting unit where the end of the wire is cut and/or stripped. Then, the guide tubes and/or feed system may be controlled to move in order to feed wire to one or more processing stations at which the wire is processed by applying a seal and terminal, for example. Therefore, the feed system and guide tubes may be used to present the wire to different processing stations for different wire processing applications.

Control of the position of the wire that is presented at a processing station relative to the processing equipment is important. For example, at a crimping station, the end of the wire must be positioned accurately within a crimping zone. If the wire is not positioned properly, the quality of the crimp suffers, and the lead may have to be discarded for not meeting strict quality standards. In addition, the guide tubes and/or feed system must be able to repeatably position the end of the wire accurately at the corresponding processing station for successive processing cycles (e.g., crimping cycles).

Small gauge discrete wire is difficult to process on lead makers and other processing equipment due to difficulty to control the feeding and positioning of the wire. Small gauge wire often lacks column strength and/or has a memory, which is a retained curl or camber from the spool or coil of the bulk wire source. Feeding the wire is difficult because the wire has a tendency to buckle in a guide tube due to the memory and/or low column strength of the wire, causing a jam or feed failure. Positioning the wire accurately at a processing station is difficult because the memory and/or low column strength of the wire may cause a freely-extending end segment of the wire that protrudes from the distal guide tube to move uncontrollably. For example, the end segment may move away from a controlled and/or desired position due to gravity, bends in the wire, or the memory of the wire, resulting in inaccurate positioning of the wire at a processing station. In some cases, the processing operation must be slowed considerably to reduce feed failures and/or improve positional accuracy. In addition to reduced productivity, quality may still be unacceptable even with slower operating speeds. A need remains for enhancing the feeding and control of wires for processing.

BRIEF DESCRIPTION OF THE INVENTION

In an embodiment, a wire guidance system is provided that includes a wire guide and a compressed air feeder. The wire guide has a wire guide channel extending between a wire entrance and a wire exit. The wire guide channel receives a wire through the wire entrance. A segment of the wire extends beyond the wire exit. The compressed air feeder supplies compressed air to the wire guide. The compressed air is supplied to the wire guide channel around the wire. The compressed air is discharged from the wire exit with the wire to support the segment of the wire extending beyond the wire exit.

In an embodiment, a wire guidance system is provided that includes a wire guide, a wire feeder, and a compressed air feeder. The wire guide has a wire guide channel between a wire entrance and a wire exit. The wire feeder supplies a wire to the wire guide channel through the wire entrance. A segment of the wire extends beyond the wire exit for presentation to a processing station of a lead maker device. The compressed air feeder supplies compressed air to the wire guide. The compressed air is supplied to the wire guide channel around the wire. The compressed air is discharged from the wire exit with the wire to support the segment of the wire extending beyond the wire exit for presentation to the processing station.

In an embodiment, a wire guidance system is provided that includes a wire guide. The wire guide has a holder and a nozzle that is received within a cavity of the holder. The wire guide defines a wire guide channel that extends along a wire guide axis through the holder and the nozzle between a wire entrance and a wire exit. The wire guide channel receives a wire through the wire entrance. A segment of the wire extends beyond the wire exit. The wire guide further defines an air supply channel extending through an aperture in a side wall of the holder to the wire guide channel. The aperture is at an axial location between the wire entrance and the wire exit. The air supply channel receives compressed air from a compressed air feeder and directs the compressed air to the wire guide channel around the wire. The compressed air is discharged from the wire exit with the wire to support the segment of the wire extending beyond the wire exit.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a wire guidance system in accordance with an exemplary embodiment.

FIG. 2 illustrates a segment of a wire extending beyond a wire guide of the wire guidance system according to an exemplary embodiment.

FIG. 3 is a perspective view of a wire guide and a wire of the wire guidance system according to an exemplary embodiment.

FIG. 4 is an exploded perspective view of the wire guide and wire of FIG. 3.

FIG. 5 is a cross-sectional view of a wire guide and a wire of the wire guidance system according to an exemplary embodiment.

FIG. 6 is a close-up cross-sectional view of the wire guide and wire of FIG. 5.

FIG. 7 is a cross-sectional view of a wire guide and a wire of the wire guidance system according to an exemplary embodiment.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 illustrates a wire guidance system 100 in accordance with an exemplary embodiment. The wire guidance system 100 is configured to control feeding of a wire 102 from a bulk wire source 104 and positioning of the wire 102 for processing at a wire processing device 106. In an embodiment, the wire guidance system 100 uses a compressed air stream to support the feeding and/or positioning of the wire 102.

The wire guidance system 100 includes a wire guide 108. The wire guide 108 has a wire guide channel 204 (shown in FIG. 2) that extends through the wire guide 108 between a wire entrance 110 and a wire exit 112 of the wire guide 108. The wire guide channel 204 receives the wire 102 through the wire entrance 110. The wire 102 extends through the wire guide channel 204 and a segment 114 of the wire 102 extends beyond the wire exit 112. In an embodiment, the segment 114 of the wire 102 extends beyond the wire guide 108 for presentation to the wire processing device 106 for processing. For example, the segment 114 may be cantilevered and extend freely from the wire exit 112 such that the segment 114 is only supported by the connection to the portion of the wire 102 within the wire guide channel 204 of the wire guide 108. Alternatively, the segment 114 may be at least partially supported by a surface of a processing station 116 at the wire processing device 106.

The wire processing device 106 may be a lead maker device or other wire processing equipment. For example, the wire processing device 106 may be configured to perform one or more processing operations, such as measuring lengths of the wire 102, cutting the wire 102, stripping the wire 102, applying a seal to an end of the wire 102, tinning the wire 102, crimping a terminal to the wire 102, depositing lengths of the wire 102 into a deposit tray, and/or the like. The wire processing device 106 includes one or more processing stations 116 that receive the segment 114 of the wire 102 and perform the processing operation on the wire 102. Many processing operations require accurate positioning of the wire 102 relative to the equipment at the processing station 116. For example, the processing station 116 may be a crimping station that includes an applicator (not shown) and a terminal feeder (not shown) that feeds terminals one by one to a crimping zone for crimping to the segment 114 of the wire 102. The wire guidance system 100 accurately positions the segment 114 in the crimping zone to produce a crimped lead that meets the stringent quality standards. In addition, the wire guidance system 100 is configured to present the segment 114 of the wire 102 repeatedly in an accurate position over many crimping cycles. In addition to crimping, the wire guidance system 100 is configured for repeatable accurate feeding and positioning of the wire 102 for other processing operations.

In addition to the wire guide 108, the wire guidance system 100 may also include a compressed air feeder 118. The compressed air feeder 118 supplies compressed air 202 (shown in FIG. 2) to the wire guide 108. The compressed air 202 is supplied to the wire guide channel 204 (shown in FIG. 2) around the wire 102. In an embodiment, the compressed air 202 flows through the wire guide channel 204 and is discharged from the wire exit 112 with the wire 102 to support the segment 114 of the wire 102 extending beyond the wire exit 112. The compressed air feeder 118 may be an air compressor that uses an electrical motor or a combustion engine to pressurize air. The compressed air feeder 118 may be coupled to the wire guide 108 by one or more air tubes 120. A valve 122 may be installed on the compressed air feeder 118 and/or the one or more air tubes 120 to selectively control the flow of compressed air 202 to the wire guide 108. The valve 122 may be controlled automatically and/or manually. For example, the valve 122 may be automatically controlled to allow the flow of compressed air 202 to the wire guide 108 when the wire processing device 106 (e.g., an automatic lead maker) is operating or at specific times during the processing cycle.

The wire guidance system 100 may also include a wire feeder 124 that feeds the wire 102 to the wire guide 108. The wire feeder 124 may include a belt, rollers, or the like that applies a force to the wire 102 via friction that propels the wire 102 in a direction towards the wire guide 108. The wire feeder 124 supplies the wire 102 to the wire guide 108 from the bulk wire source 104, which may include a coil of wire 102 around a spool. Optionally, one or more guide tubes 126 may be used to guide the wire 102 along a distance between the wire feeder 124 and the wire guide 108, such that the wire feeder 124 pushes or pulls the wire 102 through the guide tube(s) 126. The guide tube(s) 126 may be rigid or flexible. Optionally, a transfer arm 128 may be used to move the location of the wire guide 108 in order to present the wire 102 to different processing stations 116 and/or different wire processing devices 106 for different processing operations. The transfer arm 128 may be configured to rotate about a pivot axis and/or translate to extend or contract. For example, after one processing operation, the transfer arm 128 may rotate and/or translate to present the segment 114 to another processing station 116 at a different location for another processing operation. One or more flexible guide tubes 126 may be located on or proximate to the transfer arm 128 to allow for the movement of the transfer arm 128.

In the embodiment shown in FIG. 1, the wire feeder 124 is disposed between the bulk wire source 104 and the wire guide 108, and the transfer arm 128 is between the wire feeder 124 and the wire guide 108. However, the wire guidance system 100 may have other arrangements of components. In an alternative embodiment the wire guide 108 may be disposed between the wire feeder 124 and the transfer arm 128, with a guide tube 126 directing the wire 102 to the transfer arm 128 for presentation to the wire processing device 106. The wire guidance system 100 in other embodiments may include additional components not shown in FIG. 1 or may omit one or more of the components shown and described in FIG. 1.

FIG. 2 illustrates the segment 114 of the wire 102 extending beyond the wire guide 108 of the wire guidance system 100 shown in FIG. 1 according to an exemplary embodiment. Compressed air 202 that is received by the wire guide 108 is directed through the wire guide channel 204 around the wire 102 and is discharged from the wire exit 112 with the segment 114 of the wire 102. Optionally, the wire 102 may be entirely circumferentially surrounded by the compressed air 202 in the wire guide channel 204. For example, the compressed air 202 may surround the wire 102 such that no portion of the wire 102 touches the wire guide 108. In an embodiment, the compressed air 202 flows through the wire guide channel 204 with a high velocity (e.g., flow rate). The flow of compressed air 202 that is discharged from the wire exit 112 provides a low pressure air column 206 that surrounds the segment 114 of the wire 102. The air column 206 has a low pressure (e.g., relative to the surrounding air) due to the comparatively high velocity of the compressed air 202. The low pressure air column 206 may support the segment 114 because the air column 206 has a lower air pressure than stationary air 208 outside of the low pressure air column 206. The stationary air 208 provides a resistive force to resist movement of the segment 114 outside of the low pressure column 206.

The compressed air 202 in the air column 206 may have a lower pressure than the stationary air 208 surrounding the air column 206 because pressure decreases as the speed of horizontal flow of a fluid increases, and the compressed air 202 moves at a greater speed than the surrounding stationary air 208. Due to the pressure differential, the segment 114 of the wire 102 may experience resistive forces towards an interior region of the low pressure air column 206 when the segment 114 starts to move outside of the air column 206. The compressed air 202 “guides” the segment 114 of the wire 102 because the segment 114 is forcibly encouraged (e.g., by the stationary air 208) to stay within the air column 206 of moving compressed air 202 discharged from the wire guide 108. The resistive forces may, for example, resist the force of gravity on the segment 114, allowing the segment 114 to extend linearly from the wire exit 112 in-line with the wire guide channel 204 without drooping or sagging, which may otherwise happen with small wires lacking sufficient column strength. In addition, the resistive forces may resist internal memory forces of the wire 102, which would otherwise cause the segment 114 to curl in a way that the wire 102 was curled in the past (e.g., while in a bulk wire source). In addition, as shown in FIG. 2, the surrounding stationary air 208 may provide the resistive forces for the entire length of the segment 114 of the wire 102, providing guidance all the way to an end 210 of the wire 102.

The low pressure air column 206 of compressed air 202 may provide support and guidance for the segment 114 of the wire 102 for presentation of the wire 102 at the processing station 116 (shown in FIG. 1). For example, the air column 206 may improve the control and positional accuracy of the segment 114 relative to the processing equipment, such as within a crimping zone of a crimping station. The flow of compressed air 202 may be continued until the wire 102 is processed, or, alternatively, the flow of compressed air 202 may be controlled to stop once the wire 102 is positioned sufficiently within the processing station 116 but prior to the processing operation. The control provided by the low pressure air column 206 of compressed air 202 may allow for faster processing speeds due to, in part, reduced time spent positioning the segment 114 of the wire 102 for processing. In addition, the improved control of the segment 114 of the wire 102 may result in a higher quality product (e.g., lead).

FIG. 3 is a perspective view of an exemplary embodiment of the wire guide 108 and the wire 102 of the wire guidance system 100 shown in FIG. 1. The wire guide channel 204 extends through the wire guide 108 along a wire guide axis 302 between the wire entrance 110 and the wire exit 112. Although not shown in FIG. 3, the wire 102 optionally may be supplied to the wire entrance 110 within a guide tube 126 (shown in FIG. 1) that couples to the wire entrance 110 of the wire guide 108. The wire 102 and the compressed air 202 (shown in FIG. 2) within the wire guide channel 204 are guided along the wire guide axis 302 for discharge through the wire exit 112. The compressed air 202 is supplied to the wire guide channel 204 through an air supply channel 304. The air supply channel 304 is configured (e.g., shaped and oriented) to direct the compressed air 202 into the wire guide channel 204 and towards the wire exit 112 for discharge. In an exemplary embodiment, the air supply channel 304 extends through a side wall 306 of the wire guide 108 at an axial location (e.g., along the wire guide axis 302) between the wire entrance 110 and the wire exit 112. In an alternative embodiment, the air supply channel 304 may extend through the wire entrance 110 of the wire guide 108. An air tube 120 (shown in FIG. 1) from the compressed air feeder 118 (shown in FIG. 1) may couple to the wire guide 108 to provide compressed air 202 (shown in FIG. 2) to the air supply channel 304.

In an exemplary embodiment, the wire guide 108 includes a holder 308 and a nozzle 310. The nozzle 310 is held within the holder 308, although at least part of the nozzle 310 may extend beyond the holder 308, as shown in FIG. 3. The holder 308 and nozzle 310 may be oriented along the wire guide axis 302 with the wire guide channel 204 extending through both the holder 308 and the nozzle 310. In an embodiment, the side wall 306 of the wire guide 108, through which the air supply channel 304 extends, may be the side wall 306 of the holder 308. For example, the air supply channel 304 may include an aperture 312 in the side wall 306 of the holder 308, with the air supply channel 304 extending further into the wire guide 108 beyond the side wall 306. In an alternative embodiment, the air supply channel 304 may extend through a side wall 314 of the nozzle 310 instead of the side wall 306 of the holder 308. In an alternative embodiment, the wire guide 108 may have a one-piece construction with an air supply channel and wire guide channel formed therein instead of having separate holder 308 and nozzle 310 components.

FIG. 4 is an exploded perspective view of the wire guide 108 and the wire 102 shown in FIG. 3. The wire guide 108 (e.g., including any component parts such as the holder 308 and/or the nozzle 310) may be formed of metal (e.g., steel, aluminum, and the like), plastic, glass, wood, and/or the like. The wire 102 may include a conductive core 402 of copper, silver, or another metal. The wire 102 also may include an insulating layer 404 of rubber, plastic, or the like.

In an exemplary embodiment, the holder 308 includes a front 406 and a back 408. The holder 308 defines a cavity 410 that extends from a window 412 at the front 406 of the holder 308 into the holder 308 towards the back 408 for at least part of the length of the holder 308. The nozzle 310 includes a first end 414 and a second end 416. The nozzle 310 defines a channel 417 that extends through the length of the nozzle 310 between a first opening 418 at the first end 414 and a second opening 420 at the second end 416. The channel 417 may define at least part of the wire guide channel 204 (shown in FIG. 3). During assembly of the wire guide 108, the first end 414 of the nozzle 310 is loaded into the cavity 410 of the holder 308 in a loading direction 422 through the window 412 in the front 406 of the holder 308. The nozzle 310 may be retained within the cavity 410 of the holder 308 by an interference fit, by an adhesive (e.g., glue, epoxy, etc.), by soldering, by threading, and/or the like, to prohibit the nozzle 310 from moving relative to the holder 308 during use of the wire guide 108.

FIG. 5 is a cross-sectional view of an exemplary embodiment of the wire guide 108 and the wire 102 of the wire guidance system 100 shown in FIG. 1. Within the cavity 410 of the holder 308, the first end 414 of the nozzle 310 is disposed proximate to a back wall 502 of the holder 308. In the illustrated embodiment, the first end 414 of the nozzle 310 is separated from the back wall 502 by an axial gap 504 (e.g., along the wire guide axis 302). In other embodiments, however, the first end 414 of the nozzle 310 may contact the back wall 502 such that there is no axial gap 504. The wire guide channel 204 extends through the back wall 502 of the holder 308 and into the first opening 418 of the nozzle 310 at the first end 414. Therefore, the wire entrance 110 of the wire guide channel 204 is at an outer surface 506 of the back wall 502 of the holder 308. The wire exit 112 of the wire guide channel 204 is at the second end 416 of the nozzle 310.

As described above, the air supply channel 304 may include an aperture 312 through the holder 308. The air supply channel 304 may further include an annular chamber 508 and/or at least one port 510. The annular chamber 508 extends annularly between an outer surface 512 of the nozzle 310 and an inner surface 514 (e.g., of the side wall 306 shown in FIG. 3) of the holder 308. The annular chamber 508 is axially disposed with (e.g., is fluidly coupled to) the aperture 312 of the holder 308 such that the annular chamber 508 receives the compressed air 202 (shown in FIG. 2) that is supplied through the aperture 312. The annular chamber 508 extends around a perimeter of the nozzle 310. The annular chamber 508 may be at least partially defined by a groove 516 on the outer surface 512 of the nozzle 310 that extends annularly around the perimeter of the nozzle 310. Optionally, the inner surface 514 of the holder 308 may include a groove (not shown) in addition to, or instead of, the groove 516 in the nozzle 310 to define the annular chamber 508.

Although not shown in FIG. 5, the wire guide 108 may include at least one seal (e.g., compressive seal or gasket) between the outer surface 512 of the nozzle 310 and the inner surface 514 of the holder 308 along at least one edge of the annular chamber 508 to provide an air seal that prohibits compressed air 202 from leaking out of the air supply channel 304 between the nozzle 310 and the holder 308. In an alternative embodiment, the air supply channel 304 may include one or more ports that provide the compressed air 202 directly from the aperture 312 in the holder 308 to the wire guide channel 204 without including an annular chamber therebetween.

The at least one port 510 of the air supply channel 304 provides a fluid connection pathway between the annular chamber 508 and the wire guide channel 204 to supply the compressed air 202 from the annular chamber 508 to the wire guide channel 204. For example, as shown in FIG. 5, the at least one port 510 may be at least partially defined by the axial gap 504 between the back wall 502 of the holder 308 and the first end 414 of the nozzle 310. The at least one port 510 may be a pathway provided by the gap 504 that extends radially around the perimeter of the nozzle 310 at the first end 414.

In an alternative embodiment, the at least one port 510 may extend through the nozzle 310 to the wire guide channel 204 at an axial location between the first end 414 and the second end 416 of the nozzle 310, instead of being located between the first end 414 and the back wall 502 of the holder 308. The at least one port 510 may be configured (e.g., shaped and/or oriented) to direct the compressed air 202 towards the wire exit 112 for discharge from the wire guide 108, as described in FIG. 6. As described above, in an alternative embodiment, the wire guide 108 may have a single-piece construction (e.g., instead of both a holder 308 and a nozzle 310), such that the wire guide channel 204 and the air supply channel 304 (e.g., including the aperture 312, annular chamber 508, and/or one or more ports 510), are formed within the single piece, such as by molding, drilling, or the like.

FIG. 6 is a close-up cross-sectional view of the wire guide 108 and the wire 102 shown in FIG. 5. In an exemplary embodiment, the air supply channel 304 receives compressed air 202 from the compressed air feeder 118 (shown in FIG. 1) and directs the compressed air 202 to the wire guide channel 204 around the wire 102. The compressed air 202 may flow through the aperture 312 of the holder 308 into the annular chamber 508. From the annular chamber 508, the compressed air 202 may flow through the one or more ports 510 into the wire guide channel 204.

In the embodiment shown in FIGS. 5 and 6, the nozzle 310 may include a lip 604 at the first end 414. The lip 604 may define an edge of the annular chamber 508. A radial gap 606 may be formed between the lip 604 and the inner surface 514 of the holder 308 to provide a fluid pathway between the annular chamber 508 and the port 510 defined by the axial gap 504. The fluid pathway defined by the radial gap 606 may be considered part of the annular chamber 508 or part of the port 510 that connects the annular chamber 508 to the wire guide channel 204. The compressed air 202 that enters the annular chamber 508 may be forced to flow over the lip 604 before entering the port 510, which encourages at least some of the compressed air 202 to flow radially within the annular chamber 508 before entering the port 510. The lip 604 may also increase the velocity of airflow through the port 510 and the wire guide channel 204 by reducing the volume of space through which the compressed air 202 flows.

The port 510 shown in FIGS. 5 and 6 directs the compressed air 202 to enter the wire guide channel 204 through the first opening 418 of the nozzle 310. In an exemplary embodiment, an inner edge 602 of the nozzle 310 that defines the first opening 418 has a convex curve. As shown in FIGS. 5 and 6, the diameter of the first opening decreases along the convex curve of the inner edge 602 in the axial direction (e.g., along the wire guide axis 302) from the first end 414 of the nozzle 310 towards the second end 416 (shown in FIG. 5). The compressed air 202 that is directed through the port 510 between the first end 414 of the nozzle 310 and the back wall 502 of the holder 308 may flow along the convex curve of the inner edge 602 through the first opening 418 and into the wire guide channel 204 in a direction towards the wire exit 112 (shown in FIG. 5). Thus, the compressed air 202 may “adhere” to the convex curve, which directs the air 202 to flow towards the wire exit 112. In an alternative embodiment, the back wall 502 and/or the inner edge 602 of the nozzle 310 may be linearly angled towards the wire exit 112 instead of, or in addition to, the inner edge 602 having a convex curve.

In an exemplary embodiment, the flow of the compressed air 202 in the wire guide channel 204 towards the wire exit 112 (shown in FIG. 5) produces a low pressure region 608 in the wire guide channel 204 upstream of the air supply channel 304 between the air supply channel 304 and the wire entrance 110. For example, the low pressure region 608 may be defined axially between the one or more ports 510 (e.g., the port 510 shown in FIG. 6) and the wire entrance 110. The relatively high velocity flow of the compressed air 202 produces the low pressure region 608 in its wake, which provides a vacuum effect that draws ambient air 610 into the wire guide channel 204 through the wire entrance 110. The ambient air 610 that is drawn into the wire guide channel 204 may surround the wire 102 as the wire 102. Optionally, the back wall 502 of the holder 308 may be beveled or chamfered, as shown, such that the diameter of the wire guide channel 204 through the back wall 502 is greatest at the wire entrance 110 on the outer surface 506 and decreases along the axial width of the back wall 502. The back wall 502 may be beveled or chamfered in order to draw more ambient air 610 into the wire guide channel 204. In addition, as the cross-sectional area of the wire guide channel 204 decreases through the back wall 502, the velocity of the flow of incoming ambient air 610 may increase due to the reduced volume.

The low pressure region 608 may assist the wire feeder 124 shown in FIG. 1 in supplying the wire 102 to the wire guide 108 because the drawn-in ambient air 610 may propel the wire 102 (e.g., push or pull the wire 102 via friction or drag) towards the wire guide channel 204. The force on the wire may increase as the velocity of the ambient air 610 increases through the chamfered or beveled opening in the back wall 502 of the holder 308. In addition, the drawn ambient air 610 may surround the wire 102 upstream of the air supply channel 304 to guide the wire 102 into and through the wire guide channel 204 to prohibit the wire 102 from contacting surfaces of the nozzle 310 and/or holder 308 that define wire guide channel 204. Thus, the compressed air 202 may provide guidance to the wire segment 114 (shown in FIG. 2) extending beyond the wire exit 112 of the wire guide 108, and the ambient air 610 drawn into the wire guide channel 204 by the low pressure region 608 caused by the movement of the compressed air 202 may guide the wire 102 through at least the wire entrance 110 of the wire guide 108. Due to the propulsion and/or guidance provided by the drawn ambient air 610, the wire 102 may be less likely to buckle or jam (e.g., due to low column strength and/or retained memory) at the wire entrance 110 or within the wire guide channel 204. Due to the reduced likelihood of feed failures, less time would be wasted fixing such wire jams, and the speed of wire processing may be increased to enhance productivity. Therefore, the wire guidance system 100 (shown in FIG. 1) may also be used to improve wire feeding in addition to improving wire positioning for processing operations.

FIG. 7 is a cross-sectional view of an exemplary embodiment of the wire guide 108 and the wire 102 of the wire guidance system 100 shown in FIG. 1. The wire guide 108 shown in FIG. 7 may be an alternative embodiment of the wire guide 108 shown in FIGS. 5 and 6. For example, the at least one port 510 may include multiple radial ports 510 that extend through the nozzle 310 from the annular chamber 508 to the wire guide channel 204. Although the cross-section of two radial ports 510 are shown, the nozzle 310 may define any practical number of radial ports 510. The radial ports 510 may be radially spaced along the perimeter of the nozzle 310. The radial ports 510 may each have an inlet 702 at the annular chamber 508 and an outlet 704 at the wire guide channel 204. Optionally, the radial ports 510 are angled such that the outlet 704 of each radial port 510 is disposed at an axial location (e.g., along the wire guide axis 302 shown in FIG. 3) that is more proximate to the wire exit 112 than the axial location of the inlet 702. The radial ports 510 are angled to direct the compressed air 202 (shown in FIG. 2) that enters the wire guide 108 through the wire guide channel 204 towards the wire exit 112. The compressed air 202 is discharged from the wire exit 112 with the wire 102 to support positioning of the segment 114 of the wire 102 relative to the processing station 116 (shown in FIG. 1) for improved quality of a processing operation.

As shown in FIG. 7, because the radial ports 510 direct the compressed air 202 (shown in FIG. 2) to enter the wire guide channel 204 downstream of the first opening 418 of the nozzle 310, the wire guide 108 may include a first compressive seal 706 that provides an air seal between the nozzle 310 and the holder 308 at a back end 708 of the annular chamber 508. Likewise, the wire guide 108 may include a second compressive seal 710 that provides an air seal at a front end 712 of the annular chamber 508. The compressive seals 706, 710, may be ring-shaped gaskets that extend along the periphery of the nozzle 310. The compressive seals 706, 710 may provide barriers that force the compressed air 202 that enters the annular chamber 508 through the aperture 312 in the holder 308 to fill the annular chamber 508 and enter the wire guide channel 204 through the radial ports 510.

It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments, and are by no means limiting and are merely exemplary embodiments. Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means-plus-function format and are not intended to be interpreted based on 35 U.S.C. §112(f) unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.

Claims

1. A wire guidance system comprising:

a wire guide having a wire guide channel extending between a wire entrance and a wire exit, the wire guide channel receiving a wire through the wire entrance, a segment of the wire extending beyond the wire exit; and

a compressed air feeder supplying compressed air to the wire guide, the compressed air being supplied to the wire guide channel around the wire, the compressed air being discharged from the wire exit with the wire to support the segment of the wire extending beyond the wire exit.

2. The wire guidance system of claim 1, wherein the compressed air discharged from the wire exit provides a low pressure air column that surrounds the segment of the wire extending beyond the wire exit, the low pressure air column having an air pressure lower than stationary air outside of the low pressure air column.

3. The wire guidance system of claim 1, wherein the compressed air is supplied to the wire guide channel through an air supply channel extending through a side wall of the wire guide at an axial location between the wire entrance and the wire exit, the air supply channel directing the compressed air towards the wire exit for discharge.

4. The wire guidance system of claim 3, wherein flow of the compressed air in the wire guide channel towards the wire exit produces a low pressure region in the wire guide channel upstream of the air supply channel between the air supply channel and the wire entrance, the low pressure region drawing ambient air into the wire guide channel through the wire entrance.

5. The wire guidance system of claim 4, further comprising a wire feeder that feeds the wire to the wire guide, the low pressure region produced in the wire guide channel assisting the wire feeder.

6. The wire guidance system of claim 1, wherein the wire guide includes a holder and a nozzle that is received within a cavity of the holder, the compressed air supplied to the wire guide channel through an air supply channel that includes an aperture in a side wall of the holder.

7. The wire guidance system of claim 6, wherein the compressed air flows through the aperture of the holder into an annular chamber defined between an outer surface of the nozzle and an inner surface of the holder, the compressed air entering the wire guide channel via at least one port connecting the annular chamber and the wire guide channel.

8. A wire guidance system comprising:

a wire guide having a wire guide channel between a wire entrance and a wire exit;

a wire feeder supplying a wire to the wire guide channel through the wire entrance, a segment of the wire extending beyond the wire exit for presentation to a processing station of a processing device; and

a compressed air feeder supplying compressed air to the wire guide, the compressed air being supplied to the wire guide channel around the wire, the compressed air being discharged from the wire exit with the wire to support the segment of the wire extending beyond the wire exit for presentation to the processing station.

9. The wire guidance system of claim 8, wherein the compressed air discharged from the wire exit provides a low pressure air column that surrounds the segment of the wire extending beyond the wire exit, the low pressure air column surrounded by higher pressure stationary air that provides a resistive force to resist movement of the segment outside of the low pressure air column for improved control of the segment at the processing station.

10. The wire guidance system of claim 9, wherein the processing station is a crimping station, the resistive force allowing for improved accuracy in positioning the segment of the wire within a crimping zone of the crimping station.

11. The wire guidance system of claim 8, wherein the segment of the wire is presented to the processing station for at least one of cutting, stripping, crimping, tinning, or sealing.

12. The wire guidance system of claim 8, wherein the compressed air is supplied to the wire guide channel through an air supply channel extending through a side wall of the wire guide at an axial location between the wire entrance and the wire exit, the air supply channel configured to direct the compressed air towards the wire exit for discharge.

13. The wire guidance system of claim 12, wherein flow of the compressed air in the wire guide channel towards the wire exit produces a low pressure region in the wire guide channel upstream of the air supply channel between the air supply channel and the wire entrance, the low pressure region drawing ambient air into the wire guide channel through the wire entrance.

14. The wire guidance system of claim 8, wherein the wire guide includes a holder and a nozzle that is received within a cavity of the holder, a first end of the nozzle is disposed proximate to a back wall of the holder within the cavity of the holder, the wire guide channel extending through the back wall of the holder and into a first opening of the nozzle at the first end, the wire entrance of the wire guide channel at an outer surface of the back wall of the holder, the wire exit of the wire guide channel at a second end of the nozzle.

15. A wire guidance system comprising:

a wire guide having a holder and a nozzle that is received within a cavity of the holder, the wire guide defining a wire guide channel extending along a wire guide axis through the holder and the nozzle between a wire entrance and a wire exit, the wire guide channel receiving a wire through the wire entrance, a segment of the wire extending beyond the wire exit, the wire guide further defining an air supply channel extending through an aperture in a side wall of the holder to the wire guide channel, the aperture at an axial location between the wire entrance and the wire exit, the air supply channel receiving compressed air from a compressed air feeder and directing the compressed air to the wire guide channel around the wire, the compressed air being discharged from the wire exit with the wire to support the segment of the wire extending beyond the wire exit.

16. The wire guidance system of claim 15, wherein the compressed air discharged from the wire exit provides a low pressure air column that surrounds the segment of the wire extending beyond the wire exit, the low pressure air column having an air pressure lower than stationary air outside of the low pressure air column.

17. The wire guidance system of claim 15, wherein the air supply channel further includes an annular chamber and at least one port, the annular chamber extending annularly between an outer surface of the nozzle and an inner surface of the holder, the annular chamber receiving the compressed air through the aperture in the holder, the at least one port connecting the annular chamber to the wire guide channel to supply the compressed air to the wire guide channel.

18. The wire guidance system of claim 17, wherein a first end of the nozzle is disposed proximate to a back wall of the holder within the cavity of the holder, the wire guide channel extending through the back wall of the holder and into a first opening of the nozzle at the first end, the at least one port is defined by an axial gap between the back wall of the holder and the first end of the nozzle, the compressed air entering the wire guide channel from the at least one port through the first opening of the nozzle.

19. The wire guidance system of claim 18, wherein an inner edge of the nozzle defining the first opening has a convex curve, the diameter of the first opening decreasing along the convex curve in an axial direction from the first end towards the wire exit.

20. The wire guidance system of claim 17, wherein the at least one port includes multiple radial ports through the nozzle radially spaced along a perimeter of the nozzle, the radial ports having an inlet at the annular chamber and an outlet at the wire guide channel and angled with the outlet in an axial location more proximate to the wire exit than the inlet to direct the compressed air through the wire guide channel towards the wire exit.