DE19532130A1 - Contact harness mfg. appts. - Google Patents

Abstract

The appts. is comprised of wire rollers (7,8) which move horizontally in addition to a wire supply head (6) which moves between a pair of connector tables. The wire supply head supplies wires to the second table which are then cut by a contact blade (10). An inspection head inspects the wires that would be supplied to the wire rollers which are equipped with a wire guide (111). The wires are pulled back and shortened by the wire rollers. A wire stripping machine is set to strip a part of the wire insulation that would provide space for connectors.

Description

Field of the Invention

The present invention relates to a method to manufacture different types of wiring harnesses with different wire lengths between connectors, and on a device for performing the method.

State of the art

FIG. 32 shows a wire harness with contact pieces arranged in the press fit according to the prior art according to the unexamined Japanese patent application with publication number 60-14780. A guide 62 passes through it a plurality of parallel wires 61 . A jig 63 holds the front ends of the wires 61 . The clamping device 63 is seated on a carrier chain 64 , which moves the clamping device 63 back and forth. The wires 61 are cut off by means of a cutting device 65 . A pressure ram 67 and a printing form 68 simultaneously press the plurality of wires 61 into firm contact with connecting pieces, which in turn are press-fitted in a connector 66 . A retention cylinder 69 holds the rear end portion of the wires 61 .

The plurality of wires are cut at the front end of the wires so that the wire tips are aligned. Then the wires advance so that the front ends of the wires 61 are pressed into tight contact with connectors of the connector 66 ₁. Then the chain 64 pulls the connector 66 ₁ forward, such that then, as shown in Fig. 33, a second connector 66 ₂ connected to the center of the wires 61 and then a third connector 66 ₃ is connected to the wires 61 . Then the chain 64 drives the connector 66 ₁ further ahead, and the wires 61 are cut off at the rear end of the third connector 66 ₃. The above-described device 60 according to the prior art makes it possible to connect a plurality of plug connectors 66 one behind the other in the longitudinal direction of the wires 61 , as shown in FIG. 33.

However, the device is of no use if different connectors 2 ₁ to 2 ₂ or 2 ₁ 'to 2 ₃' are to be connected at any point in the longitudinal direction of the wires connected to a connector 3 or 3 'so that each connector with a desired number is connected by wires of different lengths. The device is also unable to produce a wire harness as shown in Fig. 34C, where a further connector 3 ₂ is connected to wires 13 which are connected to a connector 2 ₅ which in turn connects to some of the wires is connected, which are connected to a connector 3 ₁. In order to produce a wiring harness, as shown in FIGS. 34A to 34C, the wires 13 ₁ to 13 ₄ must be pressed manually into the respective connector.

Summary of the invention

An object of the invention is to manufacture a wiring harness with contact pieces arranged in the press fit to provide a method by which a plurality of Connectors over wires of different lengths to one or multiple connectors by automatically pushing the Wires connected in the contact pieces of the connectors can be. In addition, wires are said to be in various Arrangements can be connected to connectors.

A basic structure of a device according to the invention for producing a cable harness with contact pieces arranged in the press fit has the following features:
a pair of tables having a first table and a second table, which are arranged in a feed path of wires, the first table being arranged in the feed direction in front of the second table and each of the tables being designed to carry at least one connector, and at least one of the tables is configured to move across the path;
a first stuffing bar and a second stuffing bar, each having at least one stuffing blade and designed to move toward each of the tables to press-fit the wires to make electrical contact with the connector carried on the table, the stuffing bars being formed are to move across the path;
a pair of wire measuring rollers configured to move toward each other to hold the wires between them and rotate to measure the wires, and further configured to move apart to allow the wires to pass between them, at least one of the rollers is configured to move across the path;
a wire feed head configured to retractably move between the pair of tables and feed the wires to the connector located on the respective table.

In addition to the above In construction, the present invention provides a first construction ready, where the pair of roles between the first and second table is located. In addition, the present uses Invention a second construction in which the pair of rollers located in the feed direction in front of the first table.

Beyond the first and second construction, one of the third construction starting from the first construction advantageous in which the rollers have as many peripheral surfaces have how wires are present, and also a comb-like Wire guide is in place and is trained to work together with one of the rollers to move the wires and between to grasp the wires so that each wire is routed separately becomes. One is also based on the second construction fourth embodiment advantageous, in which the roles as well have many peripheral surfaces, such as wires, and a comb-like wire guide is also provided and is trained to move towards the wires and between to grasp the wires so that each wire is routed separately becomes. A fifth embodiment is also advantageous, in which there is also a holding pin which is retractable extends over the comb-like wire guide. A sixth embodiment is advantageous in which one comb-like wire guide with a plurality of separating strips is present and the wire guide swivels to the second  Table is movable in such a way that it each wire and each Darning blade of the darning strip between adjacent dividing strips the wire guide leads.

A seventh embodiment in which the wire feed head one biased on the second table Sliding head having a plurality of wire-guiding Has through holes, each facing the second table extend towards and at associated bore mouths with a wire cut edge are formed, the Wire feed head also a wire holding mechanism having.

An eighth embodiment is advantageous in which one first continuity tester is present to the Current continuity between the wires and that on the first Table connected connectors to check wherein the first continuity tester is a test head owns that extends retractably to the first table and has at least one test needle, and a second Continuity tester is present to determine current continuity between the wires and connected connectors, that were removed from the second table.

The present invention provides a first method for Making a wire harness with a press fit Contact pieces, with the following steps:

• (a) in a path where wires are fed at least a first connector on a first table placed and at least a second connector on one in Direction of conveyance behind the first table arranged second Table laid, with at least one of the tables formed is to move across the path;
• (b) the wires become that on the second table located second connector advanced;
• (c) the wires are placed under pressure on the second table inserted second connector, by a second stuffing bar with at least one stuffing blade is used;
• (d) The second table is left behind by the second Connector retracted across the path;  
• (e) the wires are moved forward or backward using a Pair of wire measuring rollers moved to a predetermined length of Measure wires;
• (f) the wires are placed under pressure on the first connector located on the first table, by a first stuffing bar with at least one stuffing blade is used.

The invention further provides a method of manufacturing a wiring harness with contact pieces arranged in the press fit, wherein step (a) has a substep in which a Plurality of first connectors on the first table and a second connector is placed on the second table, and step (f) has the following substeps:

• (f1) a number of wires are pressurized into a connector from the one on the first table Introduced a plurality of first connectors, including the first Stuffing board is used;
• (f2) the pair of wire measuring rollers is together with the first stuffing strip a predetermined distance across the path emotional;
• (f3) a number of wires is made by means of the pair of rollers either forward or backward by a predetermined distance emotional;
• (f4) Steps (f1) through (f3) are for everyone Connectors from the plurality of first connectors repeated.

The invention further provides a method of manufacturing a wiring harness with contact pieces arranged in the press fit, step (a) being on the first table first connector and one on the second table located plurality of second connectors and the Step (c) has the following substeps:

• (c1) a number of wires are pressurized into a connector from the one on the second table Introduced a plurality of second connectors, the second stuffing board is used;
• (c2) the pair of wire measuring rollers is together with the second stuffing strip a predetermined distance across the path  emotional;
• (c3) a number of wires is made using the pair of rollers either forward or backward by a predetermined distance emotional;
• (c4) steps (c1) to (c3) are for everyone Connectors from the plurality of second connectors repeated.

The invention further provides a method of manufacturing a wiring harness with contact pieces arranged in the press fit, wherein step (a) has a substep in which a Plurality of first connectors on the first table and a plurality of second connectors on the second table be placed, and step (c) following sub-steps having:

• (c1) a number of wires are pressurized into a connector from the one on the second table Introduced a plurality of second connectors, the second stuffing board is used;
• (c2) the pair of wire measuring rollers is together with the second stuffing strip a predetermined distance across the path emotional;
• (c3) a number of wires is made using the pair of rollers either forward or backward by a predetermined distance emotional;
• (c4) steps (c1) to (c3) are for everyone Connectors from the plurality of second connectors repeated; and

step (f) contains the following substeps:

• (f1) a number of wires are pressurized into a connector from the one on the first table Introduced a plurality of first connectors, including the first Stuffing board is used;
• (f2) the pair of wire measuring rollers is together with the first stuffing strip a predetermined distance across the path emotional;
• (f3) a number of wires is made by means of the pair of rollers either forward or backward by a predetermined distance emotional;  
• (f4) Steps (f1) through (f3) are for everyone Connectors from the plurality of first connectors repeated.

The present invention provides a method for producing a wire harness with press-fitted contact pieces, comprising the following steps:
a first table is arranged so that it can carry at least one first connector, and a second table is arranged so that it can carry at least one second connector, the first table being in a path through which the tables are wired are fed, is arranged in front of the second table;
Wires are advanced to the second connector located on the second table;
the wires are pressurized into the second connector located on the second table using a second plug connector;
the second table is retracted across the path leaving the second connector;
the wires are moved either forward or backward using a pair of wire measuring rollers to measure a predetermined length of the wires;
the wires are inserted under pressure into the first connector located on the first table using a first plug connector.

In addition to the aforementioned procedures, the present invention a method in which the first The darning strip comprises a single darning blade and either the first stuffing board or the first table is right across the path moved to press one or more wires under pressure to plug one of the first connectors.

In addition to the above methods, the present invention provides a method which further includes the step of:
the position of the first table or the first stuffing strip is offset by a predetermined distance, which is the same as the distance between adjacent connectors and / or the wall thickness of adjacent, mutually contacting connectors.

The present invention provides a method in which each of the second connector a plurality of Has connection recesses which are in a row, wherein half a recess at the end of each row and the first table or the first stuffing board a distance between adjacent wires or a multiple of that existing between adjacent wires Distance is moved.

The present invention provides a method for producing a wire harness with press-fitted contact pieces, comprising the following steps:
a wire feed head is positioned over a table on which a connector is placed;
wires are advanced from the wire feed head by a predetermined distance in the forward direction by means of measuring roller devices, the wire feed head being provided with a cutting edge at each wire outlet;
the wires are cut by moving a stuffing bar across the wires; and
the wires are inserted into the connector under pressure, thereby producing a cable harness having a free end with contact pieces arranged in the press fit.

The present invention provides a method for producing a wire harness with press-fitted contact pieces, which is based on a device which has the following features:
a first and a second sliding base body, each carrying a connector support table, the first sliding base body being arranged in a wire feed path in front of the second sliding base body,
a first and a second stuffing strip, which are each designed to move towards a connector in order to insert the wires under pressure into the connector located on the respective connector support table,
a wire feed head which is movable between the tables, and
a wire measuring roller device, which is arranged in the conveying direction in front of the tables,
the method comprising the following steps:
a wire stripping device is placed on the sliding base body for the second connector, the wire stripping device having an upper and a lower cutting edge;
the upper cutting edge is attached to a slider mounted on a jaw of the second stuffing bar, the jaw being designed to retractably advance toward the lower cutting edge;
the wires are fed through the wire feed head between the upper and lower cutting edges behind these two cutting edges, and then the upper cutting edge is moved towards the lower cutting edge so that the cutting edges penetrate the wire insulation;
the wires are moved backwards by means of the wire measuring roller device, whereby the wires are stripped;
End sections of the wires facing away from the stripped parts are inserted by means of the stuffing strips into the connector carried on the first table under pressure.

The present invention provides a method that further has a step that consists of the wires by means of the wire measuring roller device forward or backward be moved to the wires over a given length measure up.

Brief description of the drawings

The features and objects of the invention emerge from the detailed description of the preferred embodiments more clearly with reference to the accompanying drawings emerged; show in it

Figure 1 shows an essential part of a first embodiment of the invention of a device for producing a wiring harness with contact pieces arranged in the press fit.

Figs. 2A to 2B, the operation of the apparatus of Figure 1, wherein Figure 2A Figure 2B shows a plan view and a side view of FIG...;

.... 3A, when wires are inserted under application of pressure in a wide connector to 3B the operation of the apparatus of Figure 1, wherein Figure 3A is a plan view and Figure 3B is a side view;

... 4A to 4B, wherein 4A and 4B shows the operation of the apparatus of Figure 1, when the wires are measured using the Drahtmeßrollen shows a plan view and a side view of Fig.

.... 5A, when the wires are inserted under application of pressure in a first connector to 5B, the operation of the apparatus of Figure 1, wherein Figure 5A is a plan view and Figure 5B is a side view of FIG;

If the wires 6A to 6B, the operation of the apparatus of Figure 1 is inserted while applying pressure in a second connector, wherein FIG 6A is a plan view and Figure 6B shows a side view....;

. Fig. 7A is the operation of the apparatus of Figure 1, when the table is retracted transversely to the wire path to 7B;

Fig. 8 connectors which are formed at their adjacent ends to adjacent recesses with half recesses;

FIG. 9A-9B, a specific example of a Stopfleiste, FIG 9B is a Stopfleiste 75 with a plurality of Stopfklingen 75 and Figure 9A shows a Stopfleiste with a single Stopfklinge 76th.

FIG. 10 is a wiring harness through with intersecting cable branches;

Fig. 11 illustrates a specific configuration of a first embodiment of an inventive device for manufacturing a wire harness arranged in the press-fit contact pieces;

FIG. 12 shows a section along the line AA shown in FIG. 11;

FIG. 13 shows a cross section along the line BB shown in FIG. 11;

14 is a perspective view of the essential part of a second embodiment of the invention an apparatus for manufacturing a wire harness arranged with press fit contact pieces.

Figure 15 shows the operation of the device of Figure 14 when the wires are inserted into the second connector under pressure;

FIG. 16 shows the operation of the device according to FIG. 14 when the wires are conveyed forward by means of the wire measuring rollers;

Fig. The operation of the apparatus of Figure 14, if the wires are conveyed backwards by means Drahtmeßrollen. 17;

Figure 18 shows the operation of the device of Figure 14 when a short wire harness is being made;

Figs. 19 to 21 the operation of the device according to Fig. 14, when a wiring harness is manufactured with a free end, Fig. 19, an initial setting of the wires, FIG. 20, the feed of the wires through the Drahtmeßrollen and Fig. 21 the wire harness in a Shows situation in which one end of the wires is being inserted into a connector under pressure;

FIG. 22 is a specific configuration of the second embodiment of Fig. 14;

Figure 23 is a table to the second flap applied.

Fig. 24 is a perspective view of the essential part of the second embodiment in the case where a wire guide is provided;

FIG. 25 is a front view of the wire guide of Fig. 24;

Fig. 26 is a side view of the second embodiment in the case where a stripping device is provided;

Fig. 27 is a front view of the stripping device;

Figure 28A is a partially stripped wire, wherein a piece of the insulation is still on the conductor.

Figure 28B shows a fully stripped wire with a portion of the insulation completely removed from the conductor.

FIG. 29 is a perspective view for illustrating the operation of a Durchgangsprüfvorrichtung;

FIG. 30 is a side view of the second embodiment with an installed Durchgangsprüfvorrichtung;

FIG. 31 is a side view of Durchgangsprüfvorrichtung when the Prüfkopfnadel to the terminal, the connector is in contact;

Figure 32 is a side view of a formed according to the prior art apparatus for manufacturing a wire harness arranged in the press-fit contact pieces.

Figure 33 is a formed according to the prior art wiring harness arranged in the press-fit contact pieces. and

FIG. 34A to 34C with an inventive apparatus produced cable harnesses arranged with press fit contact pieces.

Detailed description of the preferred embodiments Mode of operation

The wire feed head moves between the separated wire measuring rollers. The sliding head of the Wire feed head abuts so that the front end portions the wires further forward, under that over the connector running guide flap. Then the wires inserted under pressure into the connector. Then the second table moves across the wire path and leaves the connector behind. This allows the Wire measuring rollers move the wires forward or backward. Of the Wire holding mechanism presses in such a way that it has a Prevents backward movement of the wires. The wires are from the comb-like wire guide, and the connector moves forward along with the wires. Then moves the wire feed head back. The stuffing strip moves together with the wire measuring rollers sideways on one on the first connector located on the first table, such that it pushes the wires into the connector. The Wire measuring rollers pull from the first connector to one second connector on the first table back, so that they are in the second connector move the wires to be pressed in forwards or backwards. Then the stuffing strip goes into action to the wires in the second Push connector. Both on the first and on the second table has one or more connectors, see above that a wire harness made with intersecting branches can be made independent by the tables or the stuffing strips are moved from each other across the wire path. The  Connectors are with connection sides facing upwards arranged so that the test needles of the continuity test arrangements into which connectors are inserted from one direction, in that the test needles do not interfere with the wire insertion process.

The wires are reversed using the wire measuring rollers moved, whereby a wire harness can be made, the is shorter than the distance between the tables. The Stripping device can be installed instead of the second table will. This arrangement enables the wire measuring rollers to themselves to strip the wires backwards, causing yourself results in a wire harness with a free end.

construction

Fig. 1 shows an essential part of a first embodiment of a device according to the invention for producing a cable harness with contact pieces arranged in the press fit, and Figs. 2A to 2B show the operation of this device.

First, the principle of the invention will be explained with reference to Figs. 1, 2A to 2B, 3A to 3B, 4A to 4B, 5A to 5B and 6A to 6B, and then the detailed structure will be described.

In Fig. 1, a pair of connector tables 4 and 5 are formed to receive a first narrow connector 21 and a second narrow connector 22 and a wide connector 3, respectively, and can move sideways independently of each other. A wire feed head 6 is configured to move from the narrow connector 2 side to a wide connector 3 side and vice versa. A pair of wire measuring rollers 7 and 8 are configured to move vertically to the point of mutual contact or to move vertically apart. The rollers 7 and 8 have a plurality of parallel peripheral surfaces 71 to 74 and 81 to 84, respectively. The roller 7 contacts the roller 8 in order to set the roller 8 in rotation. A motor 9 drives the upper roller 7 in rotation. A stuffing strip 10 has a plurality of stuffing blades for the narrow connectors 2 and is synchronously movable sideways with the upper roller 7 . A plug 11 is provided for the wide connector 3 .

In this embodiment, two narrow connectors 2 are placed side by side on the table 4 . The plug connectors 2 and the plug connector 3 each have pressure connections or contact pieces 12 which are each connected to external connections (not shown) arranged on the underside of the plug connectors.

When connecting wires to the connectors, the front ends of the wires 13 on the head 6 are aligned in a line as shown in Fig. 2A. Thereafter, 2B move as shown in Fig., The upper and lower rollers 7 and 8 apart, so that the head 6 between the rollers 7 and 8 can advance through the wide connector 3. Then the head 6 and the wires 13 move together and hit the table 5 as shown in Fig. 3A; the head 6 thereby comes to a standstill, while the wires 13 are advanced further through the head 6 to the wide connector 3 by means of a mechanism described below. The stuffing bar 11 lowers so that the stuffing blades 11 ₁ to 11 ₄ bring the wires 13 into contact with the pressure connections 12 of the wide connector 3 under pressure, as shown in Fig. 3B.

The head 6 has a plurality of parallel bores 14 through which the wires 13 run and is provided with wire cut edges 15 at the mouths of the bores 14 , as shown in FIG. 1.

Then the connector table 5 moves across the wires, namely in the direction of the arrow shown in FIGS . 4A and 7, leaving the wide connector 3 in place. The rollers 7 and 8 move vertically towards each other to hold the wires between them, and the roller 7 rotates the roller 8 to advance the wires 13 by a predetermined length as shown in Fig. 4A. Then, the stuffing strip 10 moves, as shown in Fig. 5A, together with the upper roller 7 to the first narrow connector 21 , and then the stuffing strip 10 lowers so that the wires 13 ₁ and 13 ₂ cut off at the cutting edges 15 be, and the stuffing blades 10 ₃ and 10 ₄ press the wires 13 ₁ and 13 ₂ in the first narrow connector 2 ₁. It should be noted that the lower roller 8 remains in a fixed position while the upper roller 7 moves transversely to the wires.

As shown in FIG. 6, the upper roller 7 separates vertically from contact with the lower roller 8 and then moves together with the stuffing strip 10 to the second narrow connector 22 . The roller 7 comes into contact with the roller 8 again , so that the peripheral surfaces 7 ₁ and 7 ₂ face the peripheral surfaces 8 ₄ and 8₄ to allow the wires 13 ₃ and 13 ₄ to advance further by a predetermined length, as in FIG. 6A. This causes the wires between the rollers and the wide connector 3 to become slack, as shown in Fig. 6B. The stuffing bar 10 lowers again so that the wires 13 ₃ and 13 ₄ are cut off at the cutting edges 15 , and then the stuffing blades 10 ₁ and 10₂ press the wires 13 ₃ and 13 ₄ into the second narrow connector 2 ₂.

The first embodiment has just been described as having two narrow connectors 2 connected to a wide connector 3 as shown in Fig. 34A. Likewise, as shown in FIG. 34B, more than two narrow connectors can also be connected to a wide connector 3 by moving the roller 7 and the stuffing strip 10 accordingly. Furthermore, as shown in Fig. 34C, the wires 13 can also be connected between connectors on the first connector table 4 and connectors on the second connector table 5 so that the wires originating from the connector 2 ₄ are connected to the connector 3 , and then from the connector 3 ₁ outgoing wires to connector 2 ₅ and finally from connector 2 ₅ outgoing wires to connector 3 ₂ are connected. If a higher number of bores 14 in the head 6 , a higher number of stuffing blades on the stuffing strips 10 and 11 and a higher number of peripheral surfaces on the rollers 7 and 8 are provided, a higher number of wires 13 - and thus a higher number of short connectors 2 - can be connected. The upper roller 7 can be movable together with the lower roller 8 . The stuffing strip 10 and the upper roller 7 can be moved sideways independently of one another. In Fig. 4, the table 5 can be in a fixed position, and the tables 4 and 5 can be positioned so that the distance between the tables 4 and 5 corresponds to the desired wire length between the connectors 2 and 3 .

In Fig. 1, the recesses 74 of the connector 2 ₁ and 2 ₂ are not in line with recesses in the connector 3 , since the distance between the adjacent recesses on the mutual contact surface of the connector 2 ₁ and 2 ₂ is larger by "L" . Therefore, the stuffing strip 10 and the table 4 by a distance "L", which corresponds to the wall thickness at the mutual contact surface of the connector 2 ₁ and 2 ₂, to move the recess 74 of the narrow connector 2 correctly under the wire 13 . Such a transverse movement of the stuffing strip 10 and the table 4 is advantageous for the production of intersecting wiring harness branches for the narrow connectors 2 ₁ and 2 ₂, as shown in Fig. 10. Alternatively, the connectors 2 ₁ and 2 ₂, as shown in Fig. 8, each be designed such that they have a half recess 72 at their opposite ends, so that two half recesses 72 together form a complete "pseudo recess" as soon as the Connectors 2 ₁ and 2 ₂ are placed side by side. The "pseudo-recess" formed by the two halves has a width L1 which is the same size as the width of the other recesses. The manufacturing device can be programmed to move sideways in the smallest increment that corresponds to the distance between adjacent wires. The stuffing bar 10 and / or the table 4 are moved by n increments such that the stuffing bar does not penetrate into the "pseudo-recess", thereby preventing a wire from getting into the "pseudo-recess".

FIG. 9A-9B illustrate a specific example of a Stopfleiste, FIG. 9B shows a Stopfleiste 75 consisting of a plurality of Stopfklingen 75, and Fig. 9A is a Stopfleiste shows that has only a single blade 76th As shown in FIG. 11, the stuffing strips 75 and 76 are fastened to a block 38 described below, for which purpose 77 bolts are inserted through bores.

The manufacture of the intricate wire harness shown in Fig. 10 requires repeated pressure on the same wires if the multiple plug stuffing bar 75 is to be used. Repeated pressure on the same wires is not harmful, but should be avoided. In such a case, a stuffing bar 76 with a single blade is advantageous. The stuffing bar 76 is, for. B. attached to the upper part of the table on which a plurality of narrow connectors 2 is placed. Then, the table 4 or the plug bar 76 is reciprocated several times across the wires 13 to form a complicated wire harness 78 with cross-connected wires as shown in FIG. 10. The use of the single blade stuffing bar 76 is also applicable to an arrangement as shown in FIG. 14, in which a pair of wire measuring rollers 80 and 81 measure the length of wires before the wires enter the stuffing bar 84 and head 86 be introduced.

Fig. 11 illustrates a specific configuration of a first embodiment of an inventive device for manufacturing a wire harness arranged in the press-fit contact pieces.

A pair of connector tables 4 and 5 carry the narrow connector 2 and the wide connector 3 on their upper side. The connector tables 4 and 5 are independent of one another transversely to the wires by means of rails 21 and 22 which are mounted on bases 19 and 20 which project vertically from a frame 18 , and by means of slide guides 23 and 24 which slide on the rails 21 and 22 , respectively slidable. The rollers 7 and 8 are arranged between the connector tables 4 and 5 and designed to move vertically in or out of mutual contact. The roller 8 is rotatably mounted on a substantially sideways articulated arm 25 and on a substantially vertically directed articulated arm 27 . The sideways-directed articulated arm 25 is pivotally articulated on a column 26 projecting from the frame 18 . The articulated arm 27 is pivoted on a piston rod 29 of a cylinder 28 . The cylinder 28 is fixed to the frame 18 and causes the piston rod 29 to extend or retract and thereby move the articulated arm 27 so that the lower roller 8 is displaced in the vertical direction. The articulated arm 25 has a comb-like wire guide 30 into which the peripheral surfaces of the rollers 7 and 8 extend, so that the wires 13 are properly guided through the rollers 7 and 8 , as shown in FIG . The wire guide 30 rises and falls together with the lower roller 8 in a fixed mutual association.

The upper roller 7 is rotatably mounted on a bracket 33 which is fastened to a piston rod 32 of a cylinder 31 and is driven by a motor (not shown). The bracket 33 has an arm 34 in order to push a partial wiring harness - that is to say wires 13 which have just been pressed in shortly before - out of the way. The upper roller 7 and the arm 34 are designed to move sideways together with the stuffing bar 10 . The carrier 35 , to which the cylinder 31 is attached, engages in a laterally displaceable manner a rail 37 which is attached to a ceiling structure 36 . The stuffing strip 10 is fastened to a block 38 separated from the carrier 35 and designed to move sideways along a rail 39 .

A rack 40 fastened to the carrier 35 is set in sliding motion by means of a motor 42 via a gear wheel 41 . The carrier 35 is designed to move laterally together with the block 38 by means of a coupling member (not shown). By means of a cylinder 43 , which is fastened to the ceiling structure 36 independently of the support 35 , the block 38 lowers and rises in order to insert the wires 13 into the narrow plug connectors 2 with the aid of the stuffing strip 10 while exerting pressure. The Stopfleiste 11 is connected to a cable attached to the ceiling structure 36 cylinders 44 to introduce by means of connectors arranged on the table 5 guide rails 45, the wires 13 while applying pressure in the narrow Connector 2.

The head 6 moves forward towards the connector table 5 . The head 6 has a slide head 47 with a pair of guide pins 46 and 46 , on each of which a coil spring 48 is seated, as shown in FIG. 13. The sliding head 47 is designed to move against the force of the coil springs 48 to a head part 49 . The head part 49 and the sliding head 47 are formed with a plurality of parallel bores 14 running through them, through which the wires 13 pass through guide rollers 55 . The mouths of the bores 14 also serve as wire cut edges 15 . The sliding head 47 abuts the connector table 5 and then slides back to the head part 49 ; thereby the wires 13 protrude to the wide connector 3 , where the front ends 13 a of the wires are inserted into the wide connector 3 under pressure by means of the stuffing strip 11 .

The head part 49 has as many cams 50 as there are wires; these cams 50 serve as a wire retention mechanism that prevents the wires from moving back. The head part 49 also contains a leaf spring 51 which presses the cams 50 onto the wires 13 . The head 6 slidably encompasses a rail 52 mounted on the frame 18 via an arm 53 and is connected to a cylinder 54 which drives the head 6 back and forth.

Fig. 14 is a perspective view of a second embodiment of an inventive device for manufacturing a wire harness arranged in the press-fit contact pieces.

The device 79 differs from the first embodiment in that the upper roller 80 and the lower roller 81 are arranged in front of the first connector table 82 instead of between the first and second connector tables 82 and 83 . This arrangement is very advantageous in that the wires 13 which are already moving forward can be withdrawn in the opposite direction. The rollers 80 and 81 , the tables 82 and 83 and the stuffing bar 84 are configured to move across the wires, and the rollers 80 and 81 and the stuffing bars 84 and 85 are designed to move vertically.

The Figs. 15 to 18 illustrate a method of manufacturing a wire harness arranged with press fit contact pieces using the device 79. As shown in FIG. 15, a head 86 described below is moved forward to feed the wires 13 to the second connector table 83 . The stuffing bar 85 lowers so that the wires 13 are pressed into a press fit electrically connected to the connector 3 . Then, as shown in Fig. 16, the second table 83 is shifted sideways with respect to the wires, and then the pair of rollers 80 and 81 hold the wires between them and feed them forward, the wires being additionally measured. The wide connector 3 and the wires connected to it lie on a wire guide 88 with a curved surface described below. The wire guide 88 guides the wires so that the connector 3 does not catch on the edge of the table 83 as soon as the wires are withdrawn. The connector 3 can either be a single, wide connector or consist of a plurality of narrow connectors. In this embodiment, the direction of rotation of the rollers 80 and 81 can be reversed so that the wires 13 , as shown in FIG. 17, are moved backward after they have been connected to the connector 3 or after the connector 3 has been moved to the position shown in FIG. 16 was promoted. The reversal of the direction of the rollers 80 and 81 enables nominal values for the wire lengths which are less than L2, ie shorter than the distance between the first and the second table, theoretically up to zero meters.

Thus, for example, one of two narrow connectors can be connected to wires that are longer than the distance L2, while the other connector is connected to wires that are shorter than the distance L2. Finally, the stuffing bar 84 lowers on the first table 82 to insert the wires into the connector 2 under pressure. The rest of the process corresponds to that described in the first embodiment.

Figs. 19 to 21 show further modes of operation. In the figures, the wires 13 are not conveyed by moving the head 86 . The connector 2 is brought to the first table 82 , as shown in FIG. 19, and the rollers 80 and 81 clamp the wires 13 between them. Then, the rollers 80 and 81 rotate as shown in Fig. 20 to push the wires 13 forward by a predetermined distance. Then the stuffing bar 84 lowers on the table 82 to bring the wires into electrical contact with the connector 2 under pressure, as shown in FIG. 21. The ends 13 a of the wires 13 are left as they are, creating a wire harness 140 with free wire ends.

Fig. 22 illustrates a specific configuration of a second embodiment of an inventive device for manufacturing a wire harness arranged in the press-fit contact pieces.

A pair of connector tables 82 and 83 are arranged on a base 90 . A pair of rollers 80 and 81 are arranged in front of the first table 82 . Each of the rollers 80 and 81 has peripheral surfaces 91 which correspond to the peripheral surfaces of the first embodiment. The upper roller 80 is driven by a motor 94 via reduction gears 92 and 93 so that it lowers and rises.

The tables 82 and 83 are designed to move across the wires by means of LM guides 95 and 96 or ball screws. In the figure, the first table 82 carries a wire feed head 86 which is designed to move back and forth by means of a cylinder (not shown), and the second table 83 carries a guide flap 97 which is pivotally mounted on the table and which is designed to open and close. Fig. 23 is a front view of the guide flap 97th The guide flap 97 has at its front portion a plurality of comb-like slots 98 through which wires are passed. The slots 98 ensure that the wires 13 are inserted under pressure into the connector 3 without position errors. A spring 99 biases the guide flap 97 in the opening direction, while a tip 100 a of a locking member 100 abuts a rear bottom 97 a of the guide flap 97 to close it. The locking member 100 is biased by a spring 101 in the closing direction of the flap 97 and is driven to open by a cylinder rod 102 . The guide flap 97 can also be used in the first embodiment.

In Fig. 23, the head is moved toward the guide flap 97 86 and abuts against a stop 103, where the wires disposed in the slots 98 13 are inserted by means of a Stopfleiste 85 under conditions of pressurizing and to produce electrical contact in the connector 3, which in a transverse connector receiving groove 104 is located. One end of the groove 104 is closed and the other end is open so that a piston rod 107 of a cylinder 106 can enter the groove 104 to bring the connector 3 into the required position. In Fig. 22 the second table 83 is formed integrally with the block 108. The block 108 and table 83 are removably mounted on a slide 110 of the LM guide 95 by inserting two bolts 109 into through holes (not shown) in a fixed plate 155 . This arrangement allows the table 83 together with the block 108 to be quickly replaced by other tooling devices in accordance with the type of connector to be manufactured.

In Fig. 22, a wire guide 111 is between the tables 82 and 83 close to the first table 82 is arranged. As shown in FIGS. 24 and 25, the wire guide 111 is connected to the tip of a piston rod 113 of a cylinder 112, to perform an upward or downward movement. The wire guide 111 carries the wires 13 running through slots 115 in order to keep the wires 13 horizontal with respect to the connector 2 located on the table 82 , so that the stuffing strip 84 presses in the wires precisely. As shown in Fig. 25, a retractable retention pin 117 is driven by a cylinder 116 so that the retention pin 117 extends across the slots and thus serves as a cover that prevents the wires 13 from escaping from the slots. Instead of the retaining pin 117 , a retractable flap (not shown) can be used. Pin 117 effectively prevents the wires from bulging once the wires are fed backward to measure wire lengths using a subtraction method. The wire guide 111 is moved down when the head 86 advances onto the second table 83 .

In Fig. 22, a curved, U-shaped wire guide 88 is substantially in the forward direction behind and close to the second table 83rd The guide 88 has a large downward curve portion 118 which prevents the connector attached to the wires from getting caught when the wires are moved backwards. Numeral 119 denotes a wire retainer, and 120 a stopper.

The Figs. 26 to 27 22 show the device 79 of FIG., With the difference that the second table 83 is replaced by a wire-stripping device 121st The wire stripping device 121 is fastened to the sliding carriage 110 with the aid of bolts 109 . The wire stripping device 121 has plate-shaped upper and lower cutting edges 122 and 123 . The lower cutting edge 123 is fastened to a frame 125 by means of bolts 124 , while the upper cutting edge 122 is fastened to a sliding piece 127 which is biased upwards by a spring 126 between the frame 125 and is designed to move vertically. The slide 127 is limited in its upward movement by a stop 128 . The head 86 moves over the first table 82 to the stop on the frame 125 , so that the front ends 13a of the parallel wires 13 advance between the cutting edges 122 and 123 until the wires abut a stop 129 which is from the center of the frame 125 protrudes and thus defines the wire length to be stripped. Then an upper block 130 descends so that an adapter piece 131 attached to the top of the block 130 depresses the slide piece 127 . Thus, the upper blade 122 until the shoulder 131 abuts a of the adapter piece 131 to the frame 125 and is thereby stopped, so that a gap remains open between the upper and the lower blade 122 and 123 lowers. The gap corresponds to the conductor diameter of the wire 13 . Thus, the upper and lower cutting edges 122 and 123 cut into the insulation of the wire, and then the rollers 80 and 81 grasp the wires 13 to pull them backward, thereby subtractively measuring the wires, the cutting edges stripping the wires .

The adapter piece 131 is fastened to the end region 132 of the block 130 and projects downward behind the stuffing strip 84 . Rollers 80 and 81 can be actuated to retract the wires approximately 2 mm to form a semi-stripped wire 134 as shown in Figure 28A. This is advantageous in that insulation 135 can be temporarily left on the wire to prevent the end of the wire from fraying; the insulation 135 is then only removed at a later stage. Rollers 80 and 81 are operated to pull the wires further backward and produce a fully stripped wire 137 , as shown in Fig. 28B. After stripping the wires, the fillet 84 lowers onto the connector 2 on the first table 82 to insert the wires into the connector, as shown in FIG. 26, with pressure and electrical contact, thereby creating a wire harness 140 with free wire ends form according to Fig. 21.

Figs. 29 to 31 illustrate a test apparatus 139 and a method for testing a wire harness 138 which has disposed in the press-fit contact pieces and prepared in the above-described apparatus 79, on passage of current.

The test device 139 includes a first continuity test arrangement 143 ( FIG. 30) and a second continuity test arrangement 145 ( FIG. 31). The first continuity test arrangement 143 has a test head 142 with a plurality of test needles 141 for connecting pieces 12 of the connector 2 on the first table 82 , as shown in FIG. 29. The second continuity test arrangement 145 has a test head 144 , into which the connector automatically ejected from the second table 83 is manually inserted. The test needles 141 are each provided with a spring so that they can be telescopically extended.

Fig. 30 shows the first Durchgangsprüfanordnung 143rd A horizontal rail 146 is attached to the machine frame. A slider 147 engages around the rail 146 to move back and forth on it. A vertical cylinder 148 is attached to the slider 147 . The test head 142 is attached to the end of the cylinder 148 . The second continuity test assembly 145 is mounted near the second table 83 in an area where the assembly does not interfere with the operation of the device. The test needles 141 are pressed against the connecting pieces 12 of the connector 3 by means of a cylinder 149 .

As shown in FIG. 29, the test head 144 of the second continuity test arrangement 145 has a rear plate 151 which is movably pressed against the connector 3 by a spring 150 . The connector 3 is inserted from above into an opening 152 between the test head 144 and the rear plate 151 . The connector 3 is positioned so that the test needles 141 are inserted horizontally into the connector 3 .

After the plug connector 3 has been brought into position in the second continuity test arrangement 145 , the test head 142 of the first continuity test arrangement 143 advances into a position above the first table 82 shown in broken lines in FIG. 30. Then, as shown in FIG. 31, the piston rod 153 of the cylinder 148 extends to place the test needles 141 on the connector 2 , thereby simultaneously checking the continuity between a plurality of wires 13 and the press-fit connectors 12 of the wire harness 138 becomes. The test device 139 can also be used in a device for producing a wire harness with contact pieces arranged in the press fit.

Claims (23)

1. Device ( 1 ) for producing a cable harness ( 78 , 138 , 140 ) with contact pieces ( 12 ) arranged in the press fit, the device having the following features:
a pair of tables with a first table ( 4 ) and a second table ( 5 ) arranged in a feed path of wires ( 13 ), the first table being arranged in the feed direction in front of the second table and each of the tables being formed, to carry at least one connector ( 2 , 3 ) and at least one of the tables is designed to move transversely to the path;
a first stuffing strip ( 10 ) and a second stuffing strip ( 11 ), each having at least one stuffing blade ( 10 ₁, 10 ₂, 10 ₃, 10 ₄; 11 ₁, 11 ₂, 11 ₃, 11 ₄; 75, 76 ) and are configured to move toward each of the tables to press-fit the wires to make electrical contact with the connector carried on the table, the stuffing strips being configured to move transverse to the path; a pair of wire measuring rollers ( 7 , 8 ) configured to move toward each other to hold the wires between them and rotate to measure the wires, and further configured to move apart to allow the wires to pass between them to leave, wherein at least one of the rollers is designed to move transversely to the path;
a wire feed head ( 6 ) configured to retractably move between the pair of tables and feed the wires to the connector located on the respective table. 2. Device according to claim 1, wherein the pair of rollers ( 7 , 8 ) is between the first and second table ( 4 , 5 ). 3. Apparatus according to claim 1, wherein the pair of rollers ( 80 , 81 ) is in the feed direction in front of the first table ( 82 ). 4. The device according to claim 2, wherein the rollers have as many peripheral surfaces ( 7 ₁, 7 ₂, 7 ₃, 7 ₄; 8 ₁, 8 ₂, 8 ₃, 8 ₄) as wires ( 13 ) are present, and there is also a comb-like wire guide ( 30 ) and is designed to move together with one ( 8 ) of the rollers onto the wires and to grip between the wires so that each wire is guided separately. 5. The apparatus of claim 3, wherein the rollers ( 80 , 81 ) have as many peripheral surfaces as there are wires ( 13 ), and further a comb-like wire guide ( 111 ) is provided and is designed to move towards the wires and between grasp the wires so that each wire is routed separately. 6. The apparatus of claim 5, further comprising a retaining pin ( 117 ) which retractably extends over the comb-like wire guide ( 111 ). 7. The device according to claim 1, wherein a comb-like wire guide ( 45 ) is provided with a plurality of separating strips and the wire guide is pivotally movable on the second table, such that it each wire and each stuffing blade of the stuffing strip ( 11 ) between adjacent separating strips Wire guide leads. 8. The device according to claim 1, wherein the wire feed head ( 6 ) has a sliding head ( 47 ) pretensioned on the second table and has a plurality of wire-guiding through bores ( 14 ), each of which extends towards the second table and at associated bore openings are formed with a wire cut edge ( 15 ), the wire feed head further comprising a wire holding mechanism ( 50 , 51 ). Apparatus according to claim 1, in which a first continuity test arrangement ( 143 ) is provided for testing the current continuity between the wires ( 13 ) and the connected connector ( 2 ) lying on the first table, the first continuity test arrangement comprising a test head ( 142 ), which extends retractably to the first table and has at least one test needle ( 141 ), and a second continuity test arrangement ( 145 ) is present in order to ensure the continuity of current between the wires ( 13 ) and the connectors ( 3 ) connected to them, which are from the second Table have been removed to check. 10. A method for producing a wiring harness with contact pieces arranged in the press fit, with the following steps:

• (a) in a path in which wires are fed, at least one first connector ( 2 ) is placed on a first table ( 4 ) and at least one second connector ( 3 ) is placed on a second table ( 5 ) placed, at least one of the tables being designed to move transversely to the path;
• (b) the wires are advanced to the second connector located on the second table;
• (c) the wires are inserted under pressure into the second connector located on the second table using a second stuffing bar ( 11 ) with at least one stuffing blade ( 11 ₁, 11 ₂, 11 ₃, 11 ₄);
• (d) the second table is retracted across the path leaving the second connector;
• (e) the wires are moved forward or backward by means of a pair of wire measuring rollers ( 7 , 8 ; 80 , 81 ) to measure a predetermined length of the wires;
• (f) the wires are inserted under pressure into the first connector located on the first table by using a first stuffing strip ( 10 ) with at least one stuffing blade ( 10 ₁, 10 ₂, 10 ₃, 10 ₄).

11. A method of manufacturing a wire harness with press-fitted contacts, according to claim 10, wherein step (a) comprises a partial step in which a plurality of first connectors are placed on the first table and a second connector on the second table, and step (f) has the following substeps:

• (f1) a number of wires are pressurized into a connector from the plurality of first connectors located on the first table using the first plug connector;
• (f2) the pair of wire measuring rollers are moved together with the first stuffing bar by a predetermined distance across the path;
• (f3) a number of wires are moved forwards or backwards by a predetermined distance by means of the pair of rollers;
• (f4) Steps (f1) to (f3) are repeated for each connector from the plurality of first connectors.

12. A method of manufacturing a wire harness with press-fitted contacts according to claim 10, wherein step (a) comprises a first connector located on the first table and a plurality of second connectors located on the second table, and step (c) follows Has partial steps:

• (c1) a number of wires are pressurized into a connector from the plurality of second connectors located on the second table using the second plug connector;
• (c2) the pair of wire measuring rollers are moved together with the second stuffing bar by a predetermined distance across the path;
• (c3) a number of wires are moved forwards or backwards by a predetermined distance by means of the pair of rollers;
• (c4) steps (c1) to (c3) are repeated for each connector from the plurality of second connectors.

13. A method of manufacturing a wire harness with press-fitted contact pieces according to claim 10, wherein step (a) has a partial step in which a plurality of first connectors are placed on the first table and a plurality of second connectors are placed on the second table , and step (c) has the following substeps:

• (c1) a number of wires are pressurized into a connector from the plurality of second connectors located on the second table using the second plug connector;
• (c2) the pair of wire measuring rollers are moved together with the second stuffing bar by a predetermined distance across the path;
• (c3) a number of wires are moved forwards or backwards by a predetermined distance by means of the pair of rollers;
• (c4) steps (c1) to (c3) are repeated for each connector from the plurality of second connectors; and

step (f) contains the following substeps:

• (f1) a number of wires are pressurized into a connector from the plurality of first connectors located on the first table using the first plug connector;
• (f2) the pair of wire measuring rollers are moved together with the first stuffing bar by a predetermined distance across the path;
• (f3) a number of wires are moved forwards or backwards by a predetermined distance by means of the pair of rollers;
• (f4) Steps (f1) to (f3) are repeated for each connector from the plurality of first connectors.

14. A method for producing a wiring harness with contact pieces arranged in the press fit, comprising the following steps:
a first table is arranged so that it can carry at least one first connector, and a second table is arranged so that it can carry at least one second connector, the first table being in a path through which the tables are wired are fed, is arranged in front of the second table;
Wires are advanced to the second connector located on the second table;
the wires are pressurized into the second connector located on the second table using a second plug connector;
the second table is retracted across the path leaving the second connector;
the wires are moved either forward or backward using a pair of wire measuring rollers to measure a predetermined length of the wires;
the wires are inserted under pressure into the first connector located on the first table using a first plug connector. 15. The method according to any one of claims 10 to 14, wherein the first stuffing bar ( 10 ) comprises a single stuffing blade ( 76 ) and either the first stuffing bar or the first table moves across the path to press one or more wires into one the first connector. 16. The method according to any one of claims 10 to 14, further comprising the step of:
the position of the first table or the first stuffing strip is offset by a predetermined distance, which is the same as the distance between adjacent connectors and / or the wall thickness (L) of adjacent, facing connectors. 17. The method according to any one of claims 10 to 14, further comprising the step of:
the position of the first table or the first stuffing strip is offset by a predetermined distance which is the same as the distance between adjacent connectors and / or the wall thickness (L) of adjacent, facing connectors; and each of the second connectors has a plurality of terminal recesses ( 74 ) in a row, with half a recess ( 72 ) at the end of each row, and the first table or plug strip around an existing one between adjacent wires Distance or a multiple of the distance between adjacent wires is moved. 18. A method for producing a wiring harness with contact pieces arranged in the press fit, comprising the following steps:
a wire feed head ( 6 ; 86 ) is positioned over a table on which a connector is located;
wires are advanced from the wire feed head by a predetermined distance in the forward direction by means of measuring roller devices ( 80 , 81 ), the wire feed head ( 86 ) being provided with a cutting edge ( 15 ) at each wire outlet;
the wires are cut by moving a stuffing bar across the wires; and
the wires are inserted into the connector under pressure, thereby producing a cable harness having a free end with contact pieces arranged in the press fit. 19. A method for producing a wire harness with contact pieces arranged in the press fit using a device ( 79 ) which has the following features:
a first and a second sliding base body, each carrying a connector support table ( 82 , 83 ), the first sliding base body being arranged in a wire feed path in front of the second sliding base body,
a first and a second stuffing strip ( 84 , 85 ), which are each designed to move towards a connector in order to insert the wires under pressure into the connector ( 2 , 3 ) located on the respective connector support table,
a wire feed head ( 86 ) which is movable between the tables ( 82 , 83 ), and
a wire measuring roller device ( 80 , 81 ) which is arranged in the conveying direction in front of the tables,
the method comprising the following steps:
a wire stripping device ( 121 ) is placed on the sliding base body for the second connector, the wire stripping device having an upper and a lower cutting edge ( 122 , 123 );
the upper edge is attached to a slider ( 127 ) mounted on a jaw ( 130 ) of the second stuffing bar, the jaw being adapted to retractably advance toward the lower edge;
the wires are fed through the wire feed head between the upper and lower cutting edges behind these two cutting edges, and then the upper cutting edge is moved towards the lower cutting edge so that the cutting edges penetrate the wire insulation;
the wires are moved backwards by means of the wire measuring roller device, whereby the wires are stripped; End sections of the wires facing away from the stripped parts are inserted by means of the stuffing strips into the connector ( 2 ) carried on the first table ( 82 ) under pressure. 20. The method of claim 19, further comprising a step  has, which consists in that the wires by means of Wire measuring roller device moved forward or backward to measure the wires over a given length. 21. The apparatus of claim 2, wherein the rollers ( 7 , 8 ) have as many peripheral surfaces ( 7 ₁, 7 ₂, 7 ₃, 7 ₄; 8 ₁, 8 ₂, 8 ₃, 8 ₄) as wires ( 13 ) are present, and further there is a comb-like wire guide ( 30 ) and is adapted to move upwards or downwards with one ( 8 ) of the rollers relative to the wires in order to reach between the wires in such a way that each of the wires is separated is led. 22. The apparatus of claim 3, wherein the rollers have as many circumferential surfaces as there are wires, and further a comb-like wire guide ( 111 ) is provided and is configured ( 112, 113 ) to move up or down relative to the wires to grip between the wires such that each of the wires is routed separately.