Delphi Technologies, Inc.

Mark J Vanden Wymelenberg

Edward M Bungo

Shao Chung Hsieh

Andrew Frank Rodondi

John Thomas Kightlinger

Robert Alan McFall

Nick M Loprire

John C McLane

James A Gourash

Shawn W Luich

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

The subject invention discloses a connector body positioning mechanism that pulls a pair of connector bodies together, against a high resistance force, to a fully seated position. A cam crank axially retained to one connector body turns in a plane normal to the direction of relative connector body motion, drawing a pair of helical grooves along an opposed pair of projections in the other connector body. A releasable latch retains the cam crank in a postion that properly registers the grooves and projections. Turning the handle back breaks the connection with the same highly leveraged force.

Connector bodies with high force positioning mechanism

Growing community of inventors

Girard, OH, United States of America

Mark J Vanden Wymelenberg