Molex Corporation

Jack F Funcik

Thomas E Schneider

Joseph T Tubbs

Joseph C Bennet

Joseph C Bennett

Clarence Kolanowski

Vito A Fusco

Kenneth L Kufner

Steven F Wright

Thomas P Pellegrino

Anthony R Nugarus

Frank P Chmela

Vito A Fusco, Deceased

A method and apparatus for manufacturing a plurality of electrical harnesses in a single machine cycle. A push bar device spaces a plurality of connectors in a predetermined, spaced relation one to another at a first station. The plurality of connectors are moved in longitudinal alignment from a first station to a second station where the connectors are each terminated to wires, for example ribbon cables. The terminated connectors then are moved back toward the first station pulling the cables with the connectors and then the cables are cut at the second station at a predetermined length. A second plurality of connectors can be loaded in predetermined spaced relation at the second station and terminated to the cut cable ends to manufacture a plurality of double-ended harnesses in a single machine cycle.

Electrical harnesses

A method and apparatus for fabricating a plurality of electrical harnesses is disclosed. Each electrical harness includes at least one connector defined by a housing with insulation displacement type contacts loaded therein. The apparatus sequentially feeds sets of connectors to a first station wherein each set includes a plurality of housings joined together by integral, severable connecting tabs. Each set of connectors is then moved to a second station and wires are inserted into the aligned contacts. Additional functions such as drawing lengths of the wires, forming loops of differing magnitudes in the wires and removing insulation from the wires may also be performed by the apparatus. At the completion of the desired functions, the apparatus is actuated to remove the connecting tabs from between the housings thereby forming a plurality of individual harnesses. The individual harnesses are then ejected.

Electrical harness fabrication method and apparatus

A method and apparatus for making an electrical harness. The harness generally includes at least one connector having a housing with insulation displacement type contacts loaded therein. Each contact is connected to an insulation clad multi-wire ribbon cable. The apparatus performs the functions of positioning a connector on a first station, holding the ribbon cable at a second station remote from the first station, moving the connector to the second station so that each contact is in alignment with each wire, moving the connector toward the ribbon cable so that each wire is simultaneously displaced into its corresponding contact, moving the connector back to the first station, holding the ribbon cable at the second station at the end of its length, cutting the insulation of a predetermined segment on the end of the length at the second station, cutting the ribbon cable held at the second station, imparting a longitudinal force upon the cut length of ribbon cable to pull the cable length from the second station and strip the cut insulation segment from the end thereof.

Electrical harness fabrication apparatus

A method and apparatus for making an electrical harness. The harness generally includes at least one connector having a housing with insulation displacement type contacts loaded therein. Each contact is connected to an insulation clad wire, said wires being of different lengths with different segments of insulation removed from the wire ends opposite the connector. The apparatus performs the functions of positioning a connector on a first station, holding the plurality of wires at a second station remote from the first station, moving the connector to the second station so that each contact is in alignment with each held wire, moving the connector toward the held wire so that each wire is simultaneously displaced into its corresponding contact, moving the connector back to the first station and simultaneously drawing a length of wire, forming loops of differing magnitudes in the wires, holding each wire at the second station at the end of each desired length, cutting the insulation of a predetermined segment on each end of each desired length at the second station, cutting all the wires held at the second station, imparting an axial force upon the cut lengths of wire to pull the wire lengths from the second station and strip the cut insulation segment from each end thereof, and ejecting the electrical harness from the first station.

Machine for making an electrical harness

Apparatus for electrical harness fabrication

A terminal crimping machine which, after crimping a terminal onto a wire lead, inserts the terminated wire lead into a terminal receiving recess of connector housing. The machine generally includes a press and die assembly mounted on the press. The die assembly includes a crimp station whereat terminal is crimped onto a wire lead, and insertion station whereat a terminated wire lead is presented, and a housing indexing assembly for supporting a plurality of connector housings and indexing a terminal receiving recess thereof at the insertion station. An insertion assembly is provided for inserting the terminated wire lead into a terminal receiving recess at the insertion station. The improvement in the insertion assembly includes a push member for engaging a terminal crimped on the end of a wire lead and inserting the terminal into the terminal receiving recess and providing guide means mounted on the punch holder above the insertion station for guiding a terminal into a terminal receiving recess.

Crimping and wire lead insertion machine having improved insertion means

A wire preparation machine for fabricating a continuous length of insulation clad wire into a plurality of cut and stripped wire leads. The machine includes a preparation station whereat the wire is cut and stripped. Located at the preparation station are a cutting mechanism for cutting the wire and a stripping mechanism spaced a given distance from the cutting mechanism for stripping insulation from the wire lead exposing a given length of conductor from the end of the wire lead. An intermittent wire drive mechanism is provided for moving the wire to the preparation station after each cutting and stripping operation. The stripping mechanism is mounted on a stripper mounting means for movement relative to the cutting mechanism so as to vary the distance therebetween. Control means is provided for programming the distance the stripper mounting means is allowed to move the cutting mechanism after each cutting and stripping operation. The machine will thus produce a plurality of wire leads in a predetermined sequence of exposed conductor lengths.

Wire preparation machine with variable insulation stripping mechanism

A connector harness assembly machine which includes a wire preparation assembly for cutting and stripping a reel of wire to provide a plurality of unterminated cut and stripped wire leads of various lengths. The cut and stripped wire lead is then transported by means of a wire transport assembly to a plurality of stations comprising a wire termination assembly. The wire termination assembly includes a wire pickup station whereat the cut and stripped wire lead is picked up, an insulation strip test station including an insulation strip sensor to check whether insulation has been stripped from the wire, a crimp station including crimping means for crimping a terminal onto a wire lead, a terminal test station including a terminal sensor to determine whether a terminal has been properly crimped, a wire reject station including means for releasing an improperly prepared wire lead, and an insertion station where a terminated wire lead is inserted into a connector housing.

Connector harness assembly machine

A connector harness assembly machine includes a wire transport assembly which further includes a conveyor mounted on a conveyor track and having a plurality of wire carriers mounted thereon in spaced relationship with respect to one another. Each wire carrier releasably holds a wire lead in a generally horizontal disposition. The wire carrier is pivotable so that the wire carrier can change positions to carry the wire lead in a substantially vertical disposition for insertion into a housing. The wire transport assembly is driven by an intermittent drive. The harness fabrication assembly has wire grippers for gripping and inserting a wire lead held in the wire carrier upwardly into a connector housing held at the insertion station. Associated with the insertion station is a test probe mechanism to check whether a terminated wire lead has been properly inserted into a connector housing and reject means for rejecting a connector harness assembly which has an improperly inserted terminated wire lead. A housing indexing assembly holds a connector at the insertion station and indexes the connector after each insertion. In addition, the housing indexing assembly transports housings from a housing load station spaced from the insertion station to said insertion station. The housings are automatically fed to the housing load station, one at a time, by means of a housing feed assembly.

Growing community of inventors

Downers Grove, IL, United States of America

Jack F Funcik