Gm Global Technolgoy Operations, Inc.

Delphi Technologies, Inc.

Delphi Automotive Systems Deutschland Gmbh

Edward M Bungo

Paul Gerhard Halbach

William T Madden

Anthony Joseph Corso

John M Chupak

Shao Chung Hsieh

Mark J Vanden Wymelenberg

Michael Model

Mark C Sellnau

Andrew Frank Rodondi

John Thomas Kightlinger

Andreas Sikora

John R Morello

Kenneth P Cope

Robert Alan McFall

Nick M Loprire

Ronald Allen Baldwin

John C McLane

James A Gourash

Melodee Ann Chapin

James M Drapcho

Ralph W Crouse

Ludwig Pauss

Thomas R Nichols

Robert J Stang

Jeanne E Staab

Thomas Borsuck

Jay Michael Sluss

Lloyd D Jack

Allan S Van Slyke

David K Sovacool

Robert A Mcfall

The present invention is an automated wire harness machine () capable of manufacturing a wire harness () unique in-part due to the automation process. The novel wire harness is generally a plurality of bundled, preferably un-stripped, insulated wires (). Each un-stripped end portion () of each wire is preferably terminated to one of a series of electrical connectors () of the wire harness. Each connector has at least one wafer () which houses a plurality of terminals () preferably crimped and electrically terminated to the ends of the wires. The wire harness machine preferably utilizes a pallet () which holds all of the wafers of one wire harness. A conveyor () transports the pallet and wafers through a series of stations which perform automated manufacturing steps. The first station is a terminal inserter () which inserts and locks the terminals within pre-assigned cavities () of the wafers. The next station is an automated wire loader () which measures, cuts and crimps the two ends of each wire into the respective terminals of the loaded wafer assembly. A third station, or ultrasonic welder (), the galls an un-stripped non-ferrous core () of the crimped wire to the terminal. The pallet with the loaded wafers, crimped terminals, and terminated wires are then transported to a wire marker station () which marks each wire, preferably via a laser (), for identification purposes.

Wire harness manufacturing machine

An electrical connector utilizing a plurality of terminals to which wires have been ultrasonically welded, most preferably via UWTI technology, wherein the terminals are aligned for the welding process and also aligned in the connector via one or more terminal carriers. Terminals are placed into respective seats in two terminal carriers, and wires are then ultrasonically welded to the terminals. The terminal carriers are then superposed and placed into a connector body of the electrical connector. The ultrasonic welding process is implemented by an anvil passing through an aperture in the terminal carriers at each terminal so that it is able to sonically and pressurably co-act with the tip of the ultrasonic welding apparatus to thereby effect an ultrasonic weld of the wire(s) to the respective terminals, preferably through the insulation thereof.

Electrical connector incorporating terminals having ultrasonically welded wires

A zero terminal insertion force electrical connection assembly. A female terminal features a barrel having a floor, a roof and an opening. Connected to the floor is a tongue which curves inwardly and upwardly into the barrel, and has an interface surface located adjacent the roof when the tongue is in a relaxed state. A boss feature is connected to the tongue and passes though an aperture in the roof when the tongue is in its relaxed state. A zero insertion force member is slidably interfaced with the barrel such that at a first position, the boss feature projects fully through the aperture. However, when slid to a second position, the zero insertion force member presses upon the boss feature so as to cause the tongue to be resiliently depressed toward the floor and allow a male terminal to be slid receivingly into the barrel without any contact with the tongue. Yet, when the zero insertion force member is returned to the first position the tongue resiliently rebounds such that the interface surface of the tongue is in good abutting electrical contact with the male terminal by virtue of the resilient normal force of the tongue.

Zero terminal insertion force electrical connection assembly

A vehicle wiring assembly for supplying power to a sliding door even when the door is open. The assembly includes a wire bundle having a first end attached to the vehicle and a second end attached to a predetermined position on the sliding door . The assembly also includes a spring mechanism attached at one end to the vehicle and at the other end to the wire bundle at a position spaced from the first end of the wire bundle. The basic assembly also includes a bundle guide &prime; disposed along the wire bundle between the spring mechanism and the second end of the wire bundle , where the bundle guide &prime; slidably supports the wire bundle as it extends from the vehicle to the door . The bundle guide &prime; attaches to the vehicle adjacent the sliding door

Wiring assembly for supplying power to a sliding door

An end fitting for a fiber optic cable for connection to a mating connector, said end fitting comprising a connector body surrounding an end of at least one fiber optic cable and an element movable relative to said connector body from the first position covering an end of said at least one fiber optic cable to a second position in which said end of said fiber optic cable is aligned with said mating connector and in which said movable element prevents separation of said end fitting and said mating connector.

Fiber optic cable for connection to a mating connector

Multiple annular electrical connectors are each positioned floatably through a respective aperture of a tray. A shield plate is secured over the tray by bolts which thread into a cylinder head. The shield plate has holes centered above the apertures for access to spark plugs disposed below. Each annular electrical connector is centered about an annular pressure sensing device which encompasses the spark plug. The inboard side of the electrical connector is in electrical contact with the outboard side of the sensing device beneath the tray. Insulated wires extend between the tray and shield plate from each electrical connector and connect to a common panel mounted electrical connector at one end of the tray.

Annular electrical connector assembly

A fiber optic connection system includes a connector body that has a socket at one end and a wire spring that has parallel retention legs that are spread apart against the self biasing forces of the wire spring. A pair of fiber optic cables are terminated in dovetailed ferrules that have up ramps at a forward end and down ramps at a rearward end. The dovetailed ferrules are inserted into the socket and retained by the parallel retention legs of the wire spring engaging the down ramps. The parallel retention legs engage the up ramps during insertion of the dovetailed ferrules into the socket to spread the parallel retention legs apart against the self biasing forces of the wire spring. The fiber optic connection system includes a ferrule position assurance device that is carried by the connector body for movement between a pre-stage position and a final position. The ferrule position assurance device allows the parallel retention legs to spread apart in the pre-stage position and prevents the parallel retention legs from being spread apart in the final position. The fiber optic connector system includes a strain relief handle that is attached to the dovetailed ferrules to provide a handle and a strain relief The fiber optic connector system has a chamber at an opposite end that receives a retainer and a pair of electro-optic devices. A modified fiber optic connector system has a second socket at an opposite end that receives a second pair of fiber optic cables that are terminated by dovetailed ferrules that are plugged into the second socket.

Fiber optic connection system

An optical star assembly having a ribbon fiber optic mixing element with the first and second ends. A first and second bundle of fiber optic cables are provided each with an engagement end for connection with a respective end of the ribbon fiber optic mixing element. The ribbon fiber optic mixing element and a portion of the fiber optic cables are carried in the housing so that the housing biases each end of the ribbon fiber optic mixing element towards an engagement end of the first and second bundles of fiber optic cables respectively. The fiber optic cables may be connected to a plurality of optical receivers so that the ribbon fiber optic mixing element distributes optical information from each of the fibers to all of the optical receivers in the assembly.

Optical star assembly

An adapter for interfacing, electrically and structurally, a flex-terminal receptacle to a barrel-terminal receptacle. The adapter has a first end configured as an inlaid pin terminal receptacle, and has a second end configured as a projecting pin terminal receptacle. The inlaid pin terminal receptacle includes a base plane having a plurality of pin slots having an inlaid pin forming thereat an inlaid pin terminal. Each pin slot is positioned so that the exposed contact surface thereof is interfaceable with the apex of a respective flex-terminal of a flex-terminal receptacle, and the dimension of the base plane is such as to interfit generally snugly within the flex-terminal receptacle. The projecting pin receptacle includes a shroud which is dimensioned to snugly receive therein a barrel-terminal receptacle, inclusive of the indexing tabs thereof. Each pin of each pin slot passes through a dividing wall of the adapter and therefrom projects as a projecting pin terminal within the shroud. Accordingly, when a barrel-pin receptacle is received into the shroud, each projecting pin terminal is received into the central bore of a respective barrel-terminal.

Adapter for interfacing a flex-terminal receptacle to a barrel-terminal receptacle

A sensor connection assembly for connection to a sensor in an internal combustion engine includes a connector housing and a flexible printed circuit disposed in the connector housing and having a plurality of legs to contact the sensor to provide an electrical connection thereto.

Sensor connection assembly

An electrical connection system for connecting an electrical device mounted on an instrument panel to an electrical circuit located behind the panel including a male plug mounted on the back wall of an instrument panel receptacle and a female socket mounted inside the electrical device adjacent an access hole. The male plug has a nonconductive connector body and a plurality of metal terminals that are retained in terminal cavities by flexible arms that project into tubular contact portions at the forward ends of the terminals. The connector body of the male plug has a platform at the forward end where the terminal cavities have channel shaped portions that have open exterior sides for exposing the tubular contact portions of the metal terminals. The tubular contact portions each include a lock aperture that cooperates with an associated flexible lock arm for retaining the terminals in the terminal cavities. The female socket has a nonconductive connector body and a plurality of compliant metal terminals. Each of the compliant metal terminals has a flexible tongue that projects into the slot for contacting the flat contact surface of a metal terminal of the male plug when the female socket is plugged onto the male plug.

Electrical connection system

The invention includes first and second electrical connectors and a connector position assurance member that is lockable in a pre-staged position. A first connector includes a pivotally connected pump handle lock arm positioned to lock on to a nub on the second connector. A connector position assurance member (CPA) is constructed for slidable movement on the first connector and includes two forward reaching arms each having a stop on a lower edge that engage a shoulder positioned on the first connector when the CPA is in a pre-staged position. In this pre-staged position, a lock arm of the CPA grabs into the pump handle on the first connector. The stop, shoulder and lock arm prevent forward or backward slidable movement of the CPA from this locked pre-staged position. As the first and second connectors are mated, a ridge on the second connector engages an angled portion of the forward reaching arms causing the arms to be lifted to raise the stop above the shoulder on the first connector and allowing the connector position assurance member to be moved forward to a final assembled position. Locking nubs on the CPA and the first connector may be positioned to keep the CPA in the final assembled position.

Electrical connector with locking connector position assurance member

A battery terminal connector has a hollow cylindrical gripping portion which is axially slit and which has raised radially inwardly extending pads which are knurled for biting into a top battery post when the gripping portion is tightened around the battery post.

Battery terminal connector having pad contacts

A connector assembly comprises a connector body having a plurality of cavities extending from a rearward conductor end to an intermediate location and an enlarged common opening along its forward end from the intermediate location to a forward end and with the intermediate location defining a transverse shoulder. It further comprises cylindrically shaped metal terminals having lands and each connected to a conductor. The terminals are inserted through the connector body and attach to a deflectable collar whose cross-sectional shape is like that of the common opening. The terminals are snap fittingly attached to the collar and then simultaneously pulled to seat via the lands on the collar engaging a shoulder on the collar and sliding the collar through the common opening of the connector body until the collar engages the transverse shoulder therein.

Pull-to-seat terminal collar

A two piece male terminal having a contact member and an attachment member. The contact member has a round solid pin at its forward end portion, an integral collar defining a radially extending abutment at its midportion and a round clamping portion behind the collar and a flattened rearward end portion. The attachment member has an attachment portion at its forward end portion that is tightly clamped around the clamping portion of the contact member and a cable attachment means at the rearward end portion which receives the flattened rearward end portion of the contact member so that the flattened end portion engages the cable at its core when the two piece terminal is attached to the cable. In addition, the clamping portion of the contact member is swedged to define a post extending radially outwardly of the outer surface of the clamping portion and the attachment member has a slot which receives the post when it is rolled onto the clamping portion. The post is coined to define a flange which engages the attachment member at locations surrounding the slot to securely retain the attachment member to the contact member.

Growing community of inventors

Cortland, OH, United States of America

Edward M Bungo