Automated crimped wire harness fabricator

Abstract

An improved lead insertion apparatus for randomly inserting crimped wire leads one at a time into a multicircuit connector includes a pair of elongate insertion jaws for longitudinally surrounding and gripping a crimp terminated wire lead. The insertion jaws are actuable by a gripper control between a first open position, a second intermediate gripping position wherein the jaws are axially slideable along the gripped wire lead and a third closed position wherein the jaws firmly grip the lead in a non-slideable manner. The jaws and their gripper control are mounted for axial movement along the wire lead into the insertion station. A drive for the jaws moves the jaws in their intermediate wire gripping position along the wire segment until a proximity sensor senses the tips of the jaws abutting the rear end of the crimp terminal. In response to the sensor the gripper control changes the jaws to their closed position on the wire prior to insertion. The insertion jaws push on the rear end of the terminal and do not rely on the column strength of the wire during insertion of the lead into the connector housing cavity. In a preferred embodiment a programmable housing index module moveable along X, Y and Z axes and a terminal guide jaw assembly are provided for use with the insertion jaws to provide an apparatus capable of randomly inserting the leads into the housing cavities in any order.