The Whitaker Corporation

Amp LLC

Other

Tyco Electronics Corporation

Michael D Strong

Michael Anthony Yeomans

Craig Warren Hornung

Gary Lee Deck

Douglas Sebastian Pfautz

Joseph R Keller

Alden Owen Long

Joseph M Bowling

Michael G Kiapokas

Charles E Zimmerman

Donald William Wright

Charles E Zimmermann

A single cycle positioning system utilizing a DC motor wherein a wide ranging incoming AC supply voltage is rectified and a fixed frequency variable duty cycle pulse width modulation is provided to apply a predetermined rms DC voltage to the motor for a single cycle of operation.

Single cycle positioning system utilizing a DC motor

A press (,) for operating a tooling unit in the performance of a manufacturing operation, such as crimping terminals onto a conductor. The press is adapted for attachment to the frame of a host machine (,), such as a lead maker, and for receiving a tooling unit, such as a terminal applicator (,). The press (,) includes a frame (,), a carriage (,) arranged for reciprocating motion with respect to the frame (,) and a ram (,) in sliding engagement with and carried by the carriage (,). A relatively low powered actuator (,) causes the ram (,) to move through a first incremental amount of movement during the first portion of the crimp cycle and a second, more powerful, actuator (,) causes the carriage (,) and ream (,) assembly to move through a second incremental amount of movement to complete the crimp cycle.

Two stage press

A magnetic press (10) for performing a manufacturing operation includes tooling (60) operatively connected to reciprocating parts comprising rods (22), and a magnet (41) connected to the rods (22) through a stationary plate (31). A control circuit (200) electrically operates a reciprocating magnet (41) and a stationary magnet (51) for inducing flux fields of attraction in the magnets (41,51), and for reversing the polarity of the flux fields to eliminate residual magnetism and for cushioning the landing of magnet (41) on a return stroke.

Magnetic press

Apparatus and method for evaluating a crimped electrical connection measures the crimping force over a range of positions of the crimping apparatus ram and derives a statistical envelope of acceptable forces. Each crimp is measured and the force measurements are compared against that envelope to determine the acceptability of the crimp. Acceptable crimps are then further evaluated to determine whether their data should be added to the data base.

Method of evaluating a crimped electrical connection

A machine (10) for receiving and operating a terminal applicator (12) in the attaching of an electrical terminal (14) to a conductor includes a magnetic power unit (28) having a fixed electromagnet (30) attached to the frame (20) and a movable electromagnet (32) coupled to the terminal applicator (12). The machine includes a cycling mechanism (86) for manually moving the movable electromagnet (32) through the power and return strokes of the terminal applicator (12). The cycling mechanism (86) includes a lead screw (88) having a nut (102) in threaded engagement therewith that moves vertically when the lead screw is rotated. A latch (110) attached to the nut (102) pivots into an opening (112) in the periphery (114) of the movable electromagnet (32) when the lead screw is rotated in one direction (130). As the lead screw (88) is rotated further the latch (110) carries the movable electromagnet (32) downwardly through its power stroke. When the lead screw (88) is rotated in the opposite direction the latch (110) carries the movable electromagnet (32) upwardly through its return stroke. When the movable electromagnet (32) nears its upper most position during the return stroke the latch (110) pivots, out of the opening (112) and disengages the movable electromagnet (32).

Manual cycling mechanism for a magnetically powered terminating machine

A magnetic press (10) for performing a manufacturing operation includes tooling (60) operatively connected to reciprocating parts comprising rods (22), and a magnet (41) connected to the rods (22) through a stationary plate (31). A control circuit (200) electrically operates a reciprocating magnet (41) and a stationary magnet (51) for inducing flux fields of attraction in the magnets (41,51), and for reversing the polarity of the flux fields to eliminate residual magnetism and for cushioning the landing of magnet (41) on a return stroke. FIGS. 2 and 4.

A magnet actuator assembly for reciprocating a ram shaft in a crimping press. The actuator assembly comprises stationary upper and lower electromagnet members and a movable central electromagnet member coupled to the ram shaft. The mating surfaces of the electromagnet members are formed of combinations of frusto-conical and planar regions so that an adequate force at a large separation between the upper and central electromagnet members is generated to raise the central electromagnet member and a relatively large force at a small separation between the central and lower electromagnet members is generated to effect the crimping function.

Crimping press actuator assembly

A single cycle positioning system utilizing a three phase wye connected induction motor (10) includes a three phase inverter (28) and a microprocessor (20) for controlling the inverter to generate three phases of power. Pulse width modulation techniques are utilized and in response to a start signal the frequency of the power to the motor is increased up to a running frequency, and in response to a stop signal the frequency of the power applied to the motor is decreased along with a corresponding reduction of the voltage applied to the motor.

Single cycle positioning system

An arrangement for enabling a sixteen bit microprocessor to transfer data to and from a peripheral unit operating in an eight bit mode includes a single OR gate for simulating an odd address so that only the low byte portion of the data bus is utilized. A subroutine in the microprocessor causes the microprocessor to act as if all addresses in the peripheral unit are even and to force the OR gate to an active state whenever the real address in the peripheral unit is odd.

Byte-swap hardware simulator for a sixteen bit microprocessor coupled to

The present invention is a method of determining the quality of a crimped electrical connection by collecting force and displacement data during the crimping cycle and comparing that data with data that represents standard crimped connections of known high quality. Of the collected data, selected portions are related to corresponding portions of the standard data and, if a deviation exists of more than a specific amount, a reject signal is generated and displayed to the machine operator. The standard data is continually updated to account for slowly changing environmental conditions that occur over a relatively long period of operation.

Method of determining the quality of a crimped electrical connection

The present invention is a method of determining the crimp height of an electrical terminal being crimped to a wire during the production crimping cycle. The method includes collecting a plurality of force and position data element pairs which are measured and sampled during the actual crimping operation. These data element pairs, representing the work curve of the operation and are analyzed to find the position of the ram when the crimping die set just disengages the terminal being crimped. The position of the ram at this point is then translated into the crimp height of the crimped connection. The analysis of the data element pairs includes a filter to remove inconsistent or extraneous data element pairs which could adversely affect the result by indicating an erroneous crimp height.

Method of determining the crimp height of a crimped electrical connection

A connector feeding apparatus for an automated cable making machine is disclosed. The apparatus includes a pair of carousels each of which has a series of connector receiving units disposed about its periphery. Each carousel has a group of connector dispensing units arranged for selectively dispensing different types of connectors, under computer control, and inserting them into the connector receiving units. The carousels then deliver the connectors, in a desired order and a desired orientation to staging modules which, again under computer control, direct the connectors to a terminating station within the machine.

Product feeding apparatus

A method and apparatus for setting a plurality of print wheels, in an automated cable making machine for imprinting a desired set of characters onto a connector housing. The method includes a unique way of homing each of the print wheels to a known position prior to setting the print wheels to their desired print positions. This is a done by rotating each print wheel until a rod, which is constrained to move only along its longitudinal axis, can be inserted into an opening in the print wheel. This prevents further rotation of the print wheel thereby indicating that the wheel is in its home position.

Print head setting apparatus

Electrical continuity between the terminals of a multi-contact electrical connector and the cores of insulated leads that have been connected thereto, is tested for by engaging a respective electrical test probe with each of the terminals and using a multiplexer to connect each test probe in turn to a continuity testing circuit, under the control of a computer. Following the continuity test, a bank of analog switches also controlled by the computer is used to apply short circuit test electrical potential to energize selected terminals, and the presence of the test potential on adjacent unenergized terminals is tested for by the computer, to detect short circuiting between the terminals.

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Mechanicsburg, PA, United States of America

Michael D Strong