Abstract: A retainer (A) aligns and retains ends (E) of branch wires (W1) and wires (W2) to be connected with the branch wires (W1) by means of a wire retaining portion (U). The wire retaining portion (U) is formed with cavities (42) which have a specified depth and into which the wires (W1,W2) are individually inserted, and contact members (60) for coming into contact with the wires (W1,W2) inserted into the cavities (42). The contact members (60) prevent the wires (W1,W2) from coming out of the cavities (42). The contact members (60) also move away from the wires (W1,W2) when necessary. The ends (E) of the branch wires (W1) and the wires (W2) to be connected with the branch wires (W1) can be aligned and retained during a wire arranging operation. After forming a bundle of wires, the wires (W1,W2) can be released from the retainer (A) with their ends (E) aligned. The aligned ends (E) can be easily processed at one time. The number of the wires (W1,W2) to be retained can be easily confirmed.

Abstract: A retainer (A) aligns and retains ends (E) of branch wires (W1) and wires (W2) to be connected with the branch wires (W1) through the use of a wire retaining portion (U). The wire retaining portion (U) is formed with cavities (42) which have a specified depth and into which the wires (W1, W2) are individually inserted, and contact members (60) for coming into contact with the wires (W1, W2) inserted into the cavities (42). The contact members (60) prevent the wires (W1, W2) from coming out of the cavities (42). The contact members (60) also move away from the wires (W1, W2) when necessary. The ends (E) of the branch wires (W1) and the wires (W2) to be connected with the branch wires (W1) can be aligned and retained during a wire arranging operation. After forming a bundle of wires, the wires (W1, W2) can be released from the retainer (A) with their ends (E) aligned. The aligned ends (E) can be easily processed at one time. The number of the wires (W1, W2) to be retained can be easily confirmed.

Abstract: A direct wind coil winding head assembly for depositing coil windings directly onto a coil support mandrel, comprising wire feed means having an input and an output, the wire feed means adapted to receive a continuous length of wire at the input and to cause the wire to exit the output at a first rate, mandrel positioning means for dynamically positioning the coil support mandrel beneath the output and control means coupled to the wire feed means and the mandrel positioning means, the control means operable to cause the mandrel positioning means to dynamically position the coil support mandrel beneath the output such that the exiting wire is deposited onto the mandrel in a predetermined pattern, and further operable to control the wire feed means such that the first rate is substantially equal to a second rate of movement of the coil support mandrel relative to the output, whereby the wire is deposited onto the coil support mandrel with substantially no residual winding stresses.

Abstract: A wire feeding device is for placing wire that is restrained in troughs. The device has a housing. A wire feeding assembly is mounted to the housing. The wire feeding assembly includes a feed tube for the wire to pass through. The feed tube directs the wire for placement in a trough. The trough extends at least one axial direction and has an opening for the wire to be placed in the trough, and the trough includes a restraining mechanism positioned over the opening to the trough. A wedge is adapted to be inserted into the trough to move the restraining mechanism for placement of wire into the trough. The wedge moves the restraining mechanism from a first position to a second position, the first position being over the opening to the trough and the second position being away from first position.

Abstract: To permit close positioning of a wire positioning finger (2) adjacent a slit blade insulation piercing connector, a pressing element (19) having a pressure surface (22) is movably located adjacent a wire outlet opening (10) of a wire guide duct (4) in the positioning finger. The pressing element (19) is movable, preferably longitudinally slidable on the finger, for movement transverse to the axis of the wire outlet opening between a quiescent position removed from the wire opening and a holding position to hold the wire (5) preparatory to cutting it off. A cutting knife (12) is movably located on the positioning finger (2), preferably slidable longitudinally, in the vicinity of the wire outlet opening (10) and movable between a rest position and cutting position in front of the wire opening. Respective pressing element control units (21) and knife operating control units (13) are provided, coupled to the pressing element (19) and to the knife (12) for programmed movement of the respective elements.

Abstract: A working apparatus includes a pair of supports which are provided on a base, and a pair of parallelly disposed linear servo-motors each of which is settled on each of the supports. Sliders of the linear servo-motors support the ends of a beam so that the beam extends perpendicular to the servo-motors and is moved according to the simultaneous movements of the sliders. Another linear servo-motor is provided on the beam, and the slider of this motor bears a working head. The working head is moved along the beam in accordance with the slider movement.

Abstract: A wire harness assembly arrangement acquires, prepares and routes various sections of wire by means of a wiring tool apparatus attached to a robotic manipulator. The tool apparatus moves coincident with an arm of the process controlled robotic manipulator and acquires the wire section through a front end portion. The first end of the wire section is fed into the tool apparatus and through a tail end portion of the tool apparatus. The next portion is wound around a spool member disposed within the tool apparatus and rotatable in response to a controlled motor operation. The front end portion is movable in relation to a wire feeding unit so that the wire section wound around the spool member is wound in a helical manner. The wire harness assembly arrangement can also include a strip/crimp station to prepare the acquired wire section for termination. The process controlled robotic manipulator then routes the acquired wire section along a predetermined path to form a part of the wire harness assembly.

Abstract: An automated flexible manufacturing system for fabricating electrical cable harness assemblies. The system includes a wire preparation system in which the wires are cut to length, provided with the desired electrical terminations and marked for identification under the control of computing means to which wire harness data is fed. The prepared wires are transported to an automated cable harness assembly system which is also controlled from computing means to which the wire harness data is fed.

Abstract: Apparatus for manufacturing wiring harnesses employs a robot mounted above a harness board with storage areas for jigs, connectors, wire dispensers, and insertion tooling about the periphery thereof for easy pickup by robotic gripper, which positions jigs and connectors and laces wire from a wire dispensing assembly through the jigs before terminating and severing wire. Dispensing assembly comprises a dispenser which gripper picks up from a bracket in a holder to draw wire from endless source to lace the harness. The holder has wire feed wheels and a severing mechanism therein which may be used with a choice of dispensers in order to use different color or size wire. After termination and severing, pivoted platforms on wire jigs eject wire scraps from around lacing posts fixed on the jigs.

Abstract: Apparatus for repositioning and adding or removing individual wires of a series of wires extending longitudinally in side-by-side relation in a row comprising a guide block formed with a cruciform slot defining a guide path and wire escapement; means to move the wires between the guide path and escapement and means to move the guide path along the row to align the escapement with a predetermined wire position in the row. In a method and apparatus for positioning wires, wires are fed from a supply through tubes having fixed wire entry ends and wire exit ends movable to vary the position of the leading ends of the wires.

Abstract: Apparatus for laying a filament includes a tool 10 moveable to follow a predetermined path, the tool comprising a storage chamber 12, 12', opposed outlets 30, 28, 16 and 116, 128 and clamp arrangements 19, 119 associated therewith. In use, filament is fed via outlet 30, 28, 16 through the chamber 12, 12' to protrude from outlet 116, 128. Clamp 119 is actuated and continued feeding causes the filament to be stored. Feeding is continued until the other end of the filament protrudes from outlet 116, 128. The tool is operable to define a gap through which filament may be bodily laterally withdrawn, once its free ends have been attached to respective attachment points.

Abstract: In a device for automatically looping a thread about a bundle of wires to form a continuous crocheted tying structure, a camming mechanism is provided for limiting the tying cycles to two and for adding a plurality of knotting cycles. A cutting knife and an intercept needle are reciprocatably mounted to the housing of the device and are shifted by a pneumatic cylinder under control of the camming mechanism. The knife cuts the thread after the formation of a plurality of knot loops, while the intercept needle catches the thread and holds it for the next work operation.

Abstract: In a method of manufacturing a saddle-shaped coil a wire supplied from a winding station is laid in a continuous process by means of a wire guide against a surface of a non-magnetic molding, which surface is concave in a first direction and convex in a direction transverse to the first direction to form a number of continuous turns defining a window, the wire, as soon as it has been laid, being fixed in position instantaneously or substantially instantaneously. In one example the surface of the moulding on which the wire is to be laid and fixed is provided, prior to laying the wire, with a thin layer of contact adhesive and the wire is previously provided with a coating of contact adhesive.

Abstract: A work piece 10 with projecting terminals 16, 17 and 18 on which are wrapped loose turns of wire 19, 20 and 21 is advanced into and held between arms of a yoke 30. Upper ends of the terminals are positioned between jaws 36, 37 and 38. A cam plate 49 is initially moved by fluid cylinders 53 and 54 to move V-shaped cam surfaces 48 against the jaws which partially close about the terminals. Next, fluid cylinders 65 and 66 are operated to move a slide 60 on which the jaws are mounted so that the now partially closed jaws engage and compact the loose wraps of wire against the work piece. Finally, the yoke 30 is withdrawn to permit stationary knockout pins 76 to dislodge the work piece into a discharge chute 79.

Abstract: Machine for interconnecting wire-in-slot type terminals in connectors mounted on a panel board utilizes a wire feed roll, rotatable insertion tooling, and an X-Y table. Wire is fed vertically through a rotation housing past wire inserters mounted above an aperture in a rotary plate. Wires are positioned for termination by wire feeding and movement of the X-Y table on which the panel board is mounted. Independently pivotable idler wheels cooperate with the feed roll to engage one or two wires. Insertion is effected by downward movement of the rotation housing which drives the inserters through the aperture in the rotary plate. The rotation housing is moved by pivoting a yoke with a variable pivot point to change limits of travel and therefore insertion depth. The plate, inserters, and rotation housing may be rotated to four orthogonal orientations to insert wires in terminals having like orientations.

Abstract: Apparatus for making loops in a metallic wire and for inserting successively formed loops into the pockets of discrete metallic components has a support for a pair of bending pins which define a gap for the passage of a reciprocable deforming ram. A wire feeder supplies a length of wire into and intermittently advances the wire in a channel at one side of the bending pins so that successive increments of the wire move first past one and thereupon past the other of the pins. The ram is movable from that side of the channel which faces away from the pins and into the gap to thereby deform a portion of the wire between successive intermittent actuations of the wire feeder. The other pin is thereupon retracted into its support to allow for movement of the wire in the channel and to thus place a fresh portion of the wire into the path of the ram. A duct stores a stack of metallic components in such positions that the pocket of the lowermost component registers with the gap and can receive a freshly formed loop.

Abstract: A wiring loom includes a multiplicity of shouldered pins and a table for receiving and releasably holding the pins in position to define paths for a wiring harness. The table includes a mesh which allows ends of the pins to pass and enter a resilient penetrable layer below the mesh. The mesh cooperates with the pins to prevent complete passage of the pins through it. Wires are held by injecting the leading end of a wire into the mesh, looping the wire around a start pin and then laying the wire along paths defined between pairs of pins. The wire may finely be looped around a terminating pin. Collars may be disposed over the pins to provide a platform for the wire. In a preferred form there is a further light nylon mesh above the first mesh. The pins can pass through this light mesh. When a wiring harness is completed, the light mesh is raised to free the harness from the pins and the table is inverted so that the harness falls onto a conveyor.

Abstract: A wire harness manufactured by a new method and a new apparatus is provided. A covered wire paid out from a selected one of reels is extended in a predetermined lay-out and fixed. The thus fixed wire is cut-off from the reel. Then, another wire is paid out from another reel for arranging it in a juxtaposing relation to the previously laid-out wire and cut off from the reel. After repeating the above steps, the arranged wires are tied up to form a wire harness. There is also provided a device which puts the above method into practice, thereby reducing complicated assorting work involved in the manufacture of a wire harness. A method and a device for automatically uncovering end portions of each wire of the wire harness and attaching terminals thereto are also provided to greatly increasing the productivity.

Abstract: In the wiring of connector plugs (18) to produce a wire mult, a wire (16) is first positioned in a terminal guide slot (32) on one side of a first connector plug (18) and then offset-dressed about a camming pin (52) of a wire insertion-and-slack forming tool (50) into alignment with a wire strain-relief slot (38) on an opposite side of the plug. Operation of the tool (50) then inserts the wire (16) into a terminal (24) on the one side of the first connector plug (18) and forms slack in the wire between the first connector plug and a second connector plug (18). The tool (50) next inserts the wire (16) into the wire strain-relief slot (38) of the first connector plug (18) and a terminal guide slot (38) on one side of the second connector plug (18) substantially simultaneously. The tool (50) includes dual air cylinders (64 and 66) and respective wire-engaging blades (54 and 56) which operate in sequence to perform the multing operation.

Abstract: A method of manufacturing an electrical interconnection assembly such as an automobile harness junction box, comprises laying a wire in a groove in a substrate; cutting the wire in the groove into a plurality of pieces; and then transferring the pieces of wire from the groove on to terminals carried by an insulating support to form the assembly.

Abstract: The wire cutting, skinning and wrapping tool includes a hollow sleeve, a knife carried by the sleeve, a bit provided with a longitudinal groove which is able to slide in a forward and backward direction in the sleeve, the bit and the knife skinning an insulated wire over a predetermined length and a means to move the bit from a backward to a forward position during the skinning operation. The sleeve is provided by normally closed sleeve halves with the insulated wire opening the sleeve halves during the skinning operation and with the sleeve halves closing again when the bit is in the forward position after each skinning operation. The length of skinned wire is captured between the bit groove and the closed sleeve halves.

Abstract: In the method, lengths of wire are drawn from wire supplies and cut, each end of each cut wire being stripped of insulation and terminated, and the cut wire then being laid along a predetermined path defined by guide pins on a loom board. The wire lengths are then bound together and removed from the board. The wire is handled by a mechanical gripper which moves and is actuated under preprogrammed electronic control.The apparatus comprises a loom board or the means by which such a loom board can be made, an automatic manipulator having a controlled gripper to draw wire from a preselected supply, a cutter to cut the wire, a wire stripper and insulative sleeve applicator and a terminal supply and crimper, both accessible to the gripper which can then lay the terminated wire lengths along predetermined paths on the loom board, and a tape binder which binds the laid wires together to form the required wiring loom.

Abstract: Cable harnesses are manufactured with a so-called cable head arranged on a able laying carriage. The cable head is controlled by an electronic data processor and continuously lays a cable running off a coil or spool, about pins on a cable laying table or pallet. A plurality of such coils or spools are mounted in a cable magazine arranged for cooperation with said cable laying table. Any one of the cables on the coils may be drawn into the cable head which is equipped with cable marking tools and with cable buffer tools. The cable being laid is marked and for this purpose it is "buffered" to such an extent, that a dwell time is obtained sufficient for the marking operation. The buffering takes place first to form a loop. The cable length stored in the loop is used up during the marking so as not to interrupt the feed advance of the cable during its marking.

Abstract: A backplane (32) supporting a plurality of pins (31) is clamped to a fixture (86) which is mounted on a movable platform (48). A pin straightening assembly (85) is attached to a movable holding bar (73) above the backplane-supported pins (31). By selective vertical movement of the straightening assembly (85), tips of the pins (31) are captured therein. The assembly (85) is then reciprocated horizontally in the plane of the assembly to straighten the pins (31) in a first plane. The tips of the pins (31) are then captured by other portions of the assembly (85). The platform (48) is reciprocated horizontally in the plane thereof to straighten the pins (31) in a second plane.

Abstract: The present disclosure describes a dressing finger assembly of advanced design for use on automatic wiring machines. Such machines make solderless wrapped electrical connections on pluralities of planar disposed terminals. A dressing finger is employed to form predetermined wire patterns in conjunction with a wrap tool which makes the actual connection. It has been observed that the design of dressing fingers used in present day machines is such that the insulation of the wire being wrapped may be pinched and cut, thereby necessitating its replacement to avoid electrical shorting. In accordance with the present invention, the assembly comprised of a newly designed finger and supporting guide, provide the required retention and support of the wire during wrapping while eliminating the aforementioned damage to the wire.

Abstract: A wire storage and wrapping tool for making wrapped wire connections on wrapping posts incorporates a portable housing having a front end and a rear end, a hollow open-ended sleeve shaft extending through the housing and rotatably mounted therein with its open ends exposed, and a drive motor mounted in the housing and connected to rotate the sleeve shaft. A hollow wrapping bit is removably engaged in the front end of the sleeve shaft with a wrapping post-engaging axial bore and an eccentric axial wire-delivery portal with an insulation-slitting axial edge. A hollow wire storage container encloses an extended length of wire wound in a succession of uniform layers concentric about a central axis, and has a wire exit portal disengageably secured to the rear open end of the sleeve shaft.

Abstract: Disclosed is an automatic wire handling and wrapping apparatus wherein wire from a continuous feed supply is sequentially prepared and wrapped between terminals of an electrical terminal board or the like to form a connection therebetween. The wrapping is accomplished for sequential terminals by a single wire wrapping head. The unique wire handling apparatus and bit accomplish the transfer of wire to the required positions to the right and left of the wrapping bit without wasteful loss of wire in control functions or loss of control of the wire ends. Further, the unique loading characteristic of the device allows for loading of the wire wrapping bit close to the terminal thereby avoiding excessive wire loop between the terminals. The wire wrapping head may be mounted on an X-Y table for transport between terminals and the wire wrapping device is capable of moving in the direction in and out or Z direction from the terminal to accomplish the wrap at any desired level on the terminal pin.

Abstract: Wire wrapping apparatus for use such as in the wrapping of an insulated single strand electrical wire around a rectangular cross-section terminal tag or post is disclosed. The present apparatus provides for the insulation to be cut or severed by an interaction between a cutting edge on the tool and a corner or ridge on the terminal tag.

Abstract: A wiring head housing, particularly adapted for use in an automatic cable harness forming machine, incorporates a uniquely mounted, resiliently locked and resettable guide tube assembly that allows a guide tube, while being moved horizontally in accordance with a programmed pattern along an X-Y coordinate plane, for example, to be tilted up to a predetermined maximum degree of inclination, upon hitting an obstruction, in any direction from the predetermined resiliently locked position, while remaining secured to the wiring head. The spring means for resiliently locking the guide tube assembly continuously engages a rotatable member thereof in such a way, and is of such a type, that it is expanded in response to the guide tube being tilted in any direction. Such spring expansion (or displacement) is optionally employed to actuate a machine turn-off switch positioned adjacent thereto.

Abstract: An automatic cable forming system incorporating an X-Y positioner for automatically laying a plurality of individual wires in a predetermined pattern to form a complex cable and including an array of individual spools each including a tensioning device to produce a predetermined tension on a wire as it is unspooled and to take up any slack in the wire. The system also includes a plurality of individual capstan pulleys each receiving an individual wire from one of the spools and with a single capstan drive for engaging one capstan pulley at a time for individually feeding the plurality of wires from the spools. The wires pass to a plurality of individual clamps for clamping the plurality of individual wires except the wire fed from the capstan pulley engaged by the capstan drive, and with a wire feed mechanism intermediate the capstan drive and the clamps for feeding the wires to a single wire head.

Abstract: An apparatus for splicing two rolls of tire cord fabric in axially aligned relation. A plurality of splicing rods are forced through overlapped ends of the rolls from opposing longitudinal sides of the fabric. The splicing rods are guided through the overlapped ends at successive points spaced along parallel lines angularly disposed to the parallel warp cords of the fabric and alternately pierce and pass through the pieces of fabric from the farthest spaced faces of the overlapped ends. The splicing rods are firmly snubbed together and held in position by the coaction of the warp cords and weft threads of the fabric, as the fabric is tensioned.

Abstract: The present disclosure describes an improved dressing finger for use with automatic wiring machines. Such machines are used to make solderless wrapped connections on terminals emanating from a common plane. The dressing finger which is used to form predetermined wire patterns is associated with a wrap tool which makes the actual connection. In present day machines, the distance relationship between wrap tool and dressing finger is fixed in one axis and the terminal grid arrangement which is dependent thereon is likewise fixed. The dressing finger of the present invention permits a combination of grids or fixed grids within a predetermined range, thereby providing greater flexibility in the design of the terminal panel.

Abstract: Apparaus for automatically bonding pre-twisted wires to a number of pairs of ground and current contact points on a workpiece or substrate is disclosed. The apparatus forms a loop in the pre-twisted wires and bonds each wire to a ground or current contact point. The pre-twisted wire is then routed to the next pair of ground and current contact point for bonding.

Abstract: An apparatus for the orderly dispensing of wire to form a harness, comprising a strand pay out head which is moved by an automated control unit in two dimensions over a layout table having strategically positioned pegs and wire gripping elements thereon such that the wire is engaged in one of the gripping elements, entrained around certain of the pegs, secured in another of the gripping elements and cut, the entire process being performed repeatedly and automatically to lay all of the wires of the particular harness in the required configuration. The wire pay out head has a swivel mounted feed unit which receives wire from a continuous source and ordinarily the end of the wire projects slightly from the feed and is automatically retained by any of the gripping elements upon the passage therethrough of the feed unit, subsequent to which a knife on the pay out device cuts the wire if such is required for the harness being made.