DE3686691T2 - METHOD AND DEVICE FOR PRODUCING AN ELECTRICAL WIRING HARNESS. - Google Patents

Description

1. Scope of the invention

The present invention relates generally to methods and apparatus for making an electrical wiring harness of the type including a connector having a housing with insulation displacement type contacts disposed therein, each contact being connected to an insulation-jacketed wire.

2. Brief description of the state of the art

Manufacturers of electronic products currently rely on electrical wiring harnesses that use insulation displacement type contacts to provide the performance and cost reductions required in a competitive market. A typical electrical wiring harness currently in use generally includes a connector with a housing in which insulation displacement type contacts are arranged. Each contact is connected to an insulation-jacketed wire. The wires may be a composite group or individual conductors, or may comprise a ribbon cable assembly with either flat or round conductors.

Since it is desirable to avoid labor costs, automated equipment is currently used to manufacture the type of electrical wiring harnesses described above.

US-A-4,441,251 describes a method and apparatus for manufacturing wire harness assemblies comprising two connectors with wires extending between the connectors. The two connectors are arranged adjacent to each other in an insertion area with the wire-receiving portions of the terminals aligned in the connectors. The wires are aligned with the terminals in two spaced planes and the wires are moved to the connectors and into the wire receiving portions of the terminals. Thereafter, one connector with the wires attached is removed and the other connector is moved through and beyond the insertion area and the wires are drawn off reels and placed in the insertion area in the spaced-apart planes. The cycle is then repeated by placing two additional connectors in the insertion area between the two wire planes. A special apparatus for automatically carrying out the process is also described. The connectors are two-row connectors but are essentially symmetrical in shape.

Another example of automatic equipment for producing electrical wire harnesses is described in US-A-4,235,015.

US-A-4,235,015 describes a method of manufacturing an electrical wiring harness in which a mass connection of the first ends of a plurality of double-ended wires with insulation jacket is made to an insulation displacement terminal of a connector, the method comprising the steps of loading a connector onto a first transport unit at a first station thereof, the first transport unit being operable to move the connector between the first and a second station of the first transport unit; feeding and sizing wires so that their first ends are positioned adjacent to the connector in the second station of the first transport unit; connecting the first ends of the wires to the connector in the second station of the first transport unit to form a first completed end of the wiring harness, and then returning the first transport unit to its first station, whereby a predetermined length of the wires is pulled past the second station of the first transport unit; a plurality of different optional operable harness completion modules for grounding the second ends of the wires are removably mounted on a second transport unit having a first station and a second station which is the same as the second station of the first transport unit; and the module is moved from the first station of the second transport unit to the second station to complete the second wire ends.

The apparatus of US-A-4,235,015 finishes the second wire ends at the second station by a pair of cooperating units which are moved in from opposite sides of the second station to perform the desired finishing operation, but changing the cooperating units to obtain a different finishing operation is cumbersome and time consuming.

In addition, adapting the device of US-A-4,235,015 to different connectors or wire structures requires considerable modification of the machine. Likewise, the wires of the rear end of the harness must be cut and then placed in position over the second connector.

This is sometimes undesirable, as for example when the connector of EP-A-0191977, published on 27 August 1986 (as described below) is used.

Another apparatus for making wire harnesses is described in commonly owned EP-A-0153387 filed January 4, 1985. Briefly, the apparatus comprises first and second connector nests, each movable from its respective connector loading station to a common termination station. Arrangements must be made for properly aligning the connector of each harness end with the ends of the harness wires to which it is to be connected. Considerations must also be made for aligning each connector with respect to the termination head to ensure to accommodate the opposite orientations of the connectors at each end of the harness. The apparatus currently used, although generally satisfactory, is not suitable for terminating double-ended harnesses in which the connectors are not symmetrical with respect to an axis of the wire assembly. An example of this type of connector is described below with reference to EP-A-0191977. Like the apparatus of US Patent No. 4,235,015, this apparatus cannot be easily reconstructed if the type of connector or the wire assembly is changed.

A particular type of electrical connector currently in use is described in the above-mentioned EP-A-0191977. Here, a modular multi-row electrical connector is described which mates with an array of pins. The connector has a one-piece molded housing with opposing upper and lower surfaces extending between opposing front connecting and rear end walls and two rows of axially extending terminal receiving spaces. Each space is defined by spaced-apart side walls extending between the front connecting and rear end walls, a lower wall and an upper wall opening to the upper housing surface so that all wires can be inserted for termination from the upper housing surface. The two rows of terminal receiving spaces are each stacked one on top of the other in a staggered configuration such that the terminal receiving spaces of the lower rows are located between the terminal receiving spaces of their upper rows. The rows are connected by selectively removable web portions to form a plurality of commonly connected, separable connector modules, each module having at least one upper row space and one lower row space.

In U.S. Patent No. 4,091,531, issued on 5/30/1978, a table tool is described for terminating a double row connector having opposing connecting and wire receiving ends. The terminals at the connecting end of the connector are oriented so that the upper and lower rows are directly above and below each other. However, the wire receiving ends of the terminals are oriented in staggered rows as described above so that wires from both rows can be inserted from a single direction. An arbor press is provided with upper and lower tooling elements, the upper element being moved toward the lower element during termination. The upper element receives a connector having terminals having insulation displacement slots which open downward. The lower tooling element has a series of staggered plates with specially shaped upper sawtooth-like edges. A ribbon cable is inserted between the upper and lower tool elements and the mandrel press is operated to connect both rows simultaneously. After the connection is made, an operator releases the press and pulls the connected cable harness out of the machine.

The device of U.S. Patent No. 4,091,531 is manually operated and requires an operator to feed the connectors and cables together for connection and to remove the wire harness.

It is therefore desired to provide an apparatus for manufacturing electrical wire harnesses which has fully automatic operation, can be more quickly converted to manufacture various wire harnesses using a method of the present invention, and is suitable for mass terminating connectors which are not symmetrical with respect to an axis of the wire assembly.

The present invention provides a method for producing an electrical wiring harness in which a mass connection of the first ends of a plurality of double-ended insulation-jacketed wires is made to an insulation displacement terminal of a connector, the method comprising the steps of loading a connector onto a first transport unit at a first station thereof, the first transport unit being operable to move the connector between the first and a second station of the first transport unit; feeding and sizing wires so that their first ends are positioned adjacent the connector in the second station of the first transport unit; connecting the first ends of the wires to the connector in the second station of the first transport unit to form a first completed end of the wire harness, and then returning the first transport unit to its first station, thereby pulling a predetermined length of the wires past the second station of the first transport unit; one of a plurality of different selectively operable harness completion modules is removably mounted on a frame unit of a second transport unit having a first station, which may be a connector loading station, and a second station which is the same as the second station of the first transport unit; moving the second transport unit with the frame unit and the module from the first station of the second transport unit to the second station; holding the second transport unit in the second station while the module is operated to simultaneously complete the second wire ends to form a second completed harness end and thereby form a single or double ended harness, as desired depending on the one of the harness completion modules selected to complete the second wire ends, and then moving the second transport unit to the first station of the second transport unit for provision for the production of another wiring harness.

The present invention also provides a multi-station apparatus for automatically manufacturing an electrical wiring harness with a mass connection of the first ends of a plurality of double-ended wires with insulation jacket each to an insulation displacement terminal of a connector, comprising a first connector transport unit for receiving and moving a connector between two stations; means for feeding the connector onto the first connector transport unit at a first station thereof; wire feeding means for feeding and sizing the wires so that their first ends are associated with the connector at the second station of the first connector transport unit; wire connecting means for connecting the first ends of the wires to the connector at the second station to form a first finished end of the wiring harness; a further transport unit having a first station, which may be a connector feeding station, and a second station which is the same as the second station of the first connector transport unit; the further transport unit releasably supporting one of a plurality of harness completion modules on the apparatus; the harness completion module is movable from the further transport unit into the station to simultaneously complete the second ends of the wires to form the second completed harness ends, and is movable from the further transport unit into the first station of the further transport unit to prepare the machine for the start of a further harness manufacturing cycle, characterized in that the further transport unit has a frame unit which detachably supports the one harness completion module; the further transport unit together with the frame unit and the harness completion module of the first station of the further transport unit is movable to the second station thereof and the harness completion module is actuated while the second transport unit is held in the second station such that the second ends are simultaneously completed, thereby forming a single or double ended harness as desired; and the further transport unit together with the frame unit and the harness completion module is movable from the second station of the further transport unit to the first station of the further transport unit to make the machine ready for the start of a further harness manufacturing cycle.

An embodiment of the apparatus of the present invention may include means for removing polarizing elements extending from a connector housing. The polarizing elements comprise centering pins projecting from the upper and lower surfaces of the above-described connector of EP-A-0191977 to extend beyond, but not overlie, the connector end wall. The apparatus may include means for presenting at least one rotated connector to a pin removal station and means for selectively removing at least one of the connector pins in the axial direction immediately adjacent one of the upper and lower surfaces.

A further embodiment of the apparatus of the present invention may also comprise means for machining the above-described connector of EP-A-0191977. Thus, the apparatus may comprise means for rotating the connector so that the front connection end is directed upwards, with the wires of a completed harness assembly running in a downward direction, and a series of knife-like, selectively programmable web separating means which are moved into the housing in an axial direction so that at least one of the webs connecting the connector rows Once completed, each connector module comprises a separate connector connected to a predetermined number of wires, thereby forming a separate wiring harness.

The apparatus according to another embodiment of the present invention may further comprise an arrangement for conveying connected wire harnesses from one work station to the next, the connectors having a plurality of alignment tabs extending from the connector end wall to form a channel running along the connector end wall. A track is provided with a first rail shaped complementarily to the channel and has second and third spaced rail members opposite the first rail. The connector is slid along the track so that the first rail is received in the channel and the second and third rails engage the rear connector end wall adjacent the upper and lower connector surfaces.

Embodiments of the present invention also provide a wire harness manufacturing machine for presenting the wires to the terminals in each of the staggered rows of a connector of EP-A-0191977 in a simple, fully automatic two-step process. The wires are fed along a first predetermined plane to the termination station and a wire preparation module having an upper and lower portion is disposed in the termination station so that the wire lies between the portions. The lower portion includes a connector nest which receives a connector of the type in which the rows of terminal receiving cavities are staggered and all cavities are open upwards so that all wires can be inserted for termination from the upper connector housing surface. The cavities of the lower rows are disposed between the cavities of their upper rows, the side walls of the cavities of the upper rows serve as wire guides to facilitate the passage of wires to the lower rows for connection there.

A lifting device is provided at the termination station so that when the module is placed over the lifting device, the connector nest can be raised to engage the wires on the connector housing so that the wires to be terminated in the upper row are bent with a predetermined upward angular deflection. The module also includes wire insertion blades positioned above the connector nest and aligned with the wires. As the insertion blades are lowered and the wires are subsequently connected to the terminals, the wires connected to the lower row are bent with the same but downward angular deflection.

Some embodiments of both the method and the apparatus of the present invention will now be described by way of example and not in a limiting sense with reference to the drawings which show certain embodiments of the apparatus of the present invention.

Of the drawings in which identical elements are provided with identical reference symbols,

Fig. 1 is a plan view of a device of the present invention;

Fig. 2 is an elevational view of the device of Fig. 1;

Figure 3 is a schematic flow diagram showing a process of the present invention wherein a connector is terminated in a first termination station;

Figure 4 is a schematic flow diagram showing a process of the present invention wherein a connector is terminated in a second termination station;

Fig. 5 is an illustration of the automatic harness ejection;

Fig. 6 is a view of an optional wire stripping arrangement for use in the second terminal station;

Fig. 7 is a view of a polarization overhang removal station;

Fig. 8 is a view of a web removal station for dividing a connector rod into separate connector modules;

Fig. 9 is a more detailed view of the connector rod of Fig. 8; and

Fig. 10 a view of the modular design of the connection stations.

DESCRIPTION OF THE SPECIAL EMBODIMENTS I. INTRODUCTION

Figures 1 to 5 show an electrical harness apparatus of the present invention, generally designated 10. The apparatus 10 automatically produces a complete electrical harness, generally designated 12, as shown in Figure 7a. The electrical harness 12 includes at least one connector, generally designated 14, and a plurality of wires with insulating jacket 40. The connector is described in the aforementioned EP-A-0191977, filed November 12, 1985, which is incorporated herein by reference to the extent necessary for an understanding of the present invention.

Referring to Figures 9a, 9b, the connector 14 includes an insulated housing 16 having a plurality of pre-loaded insulation displacement contacts 18. The housing 16 is integrally molded with opposing upper and lower surfaces 20, 22 extending between opposing front mating and rear end walls 24, 26. The connector includes an upper row 28 and a lower row 30 of axially extending terminal receiving cavities 32. Each compartment 32 is defined by spaced-apart side walls 34 extending between the front connecting and rear end walls 24, 26. Each compartment further includes a bottom wall 36 and an opposite top wall 38 opening to the upper housing surface 20 so that all wires 40 can be inserted for connection from the upper housing surface 20.

The rows 28, 30 are each stacked one on top of the other in a staggered configuration such that the terminal receiving spaces of the lower row 30 are located between the terminal receiving spaces of their upper row 28, with the side walls 34 of the upper row serving as wire guide channels 42 to facilitate the passage of wires to the lower row 30 for termination thereat.

As further described in EP-A-0191977, the rows 28, 30 are connected by selectively removable web portions 44 to form a plurality of commonly connected separable connector modules 46, each module having at least one upper row space 32U and at least one lower row space 32L.

The wires 40 may comprise an array of individual connectors with insulation jackets or may comprise conveniently manufactured ribbon cables as is known in the art.

Each compartment 32 receives a metallic terminal 18 having a conventional insulation displacement slot adapted to penetrate the insulation of insulation-jacketed wires 40. The connector modules, generally designated 46, may have any number of upper row compartments, which need not be equal to the number of lower row compartments. For example, to form a three-circuit connector, a connector module may include only a single upper row compartment located between two rooms of the lower row. Furthermore, if desired, several modules can remain attached to one another to form a larger circular connector.

II. Brief description of the device for producing an electrical wiring harness

Referring again to Figures 1 and 2, the apparatus 10 is generally shown as having first and second transport units 50, 52 that transport connectors 14 between first and second loading stations 54, 56 and a common termination station 58. The transport units include frames or supports 60, 62 on which optionally manually removable wire preparation modules, generally designated 66, 68, are provided for each unit 50, 52, respectively. As can be seen from Figures 2-4, each wire preparation module 66, 68 includes a connector nest 70, 72 that holds a connector 14 in a fixed, predetermined orientation. The wire preparation modules 66, 68 further include wire insertion blades 74, 76 facing the connector 14 and aligned with the terminals thereof. Each wire preparation module also includes means for actuating the insertion blades, typically in the form of an air cylinder, electric solenoid or other actuatable drive means 78, 80.

Referring to Fig. 1, each transport unit 50, 52 is mounted for movement between a corresponding connector loading station 54, 56 and a common terminal station 58. For example, the transport unit 50 is mounted for reciprocating movement along track rails 88 that extend between the loading station 54 and the terminal station 58. Likewise, the transport unit 52 is mounted for reciprocating movement on track rails 90 between the second loading station 56 and the terminal station 58.

Wires 40 extend from a wire feeder 92 to the termination station 58 where they are alternately connected to connectors carried by the two transport units 50, 52.

As shown in Figures 1 and 2, a clamp-type transport hoist 94 is the only operative device attached to the connection station 58; all other equipment is carried to the connection station by supports 60, 62. The transport hoist 94 alternately lifts each support 60, 62 and the wire preparation modules 66, 68 located thereon.

Each module 66, 68 includes spaced upper and lower wire preparation module sections identified by the suffix "U" and "L" respectively. Wire receiving gaps 96, 98 are formed between opposing upper and lower wire preparation module sections. When placed at the termination station 58, the carrier subframes 60', 62' are raised by the transport lift 94 so that the lower preparation module section is engaged with the wires 40 to facilitate termination. The carrier subframes 60', 62' are raised by guide rods 82, 83 in contact with the lift 94. For returning the lower wire preparation module sections in the downward direction, each lower section is equipped with a downward pull solenoid 84, 85.

III. Method for producing a wiring harness

With initial reference to Figs. 1-3, at the beginning of the harness manufacturing cycle, the wires 40 exit the wire feeder 92 with their free ends positioned as predetermined at the termination station 58 (see Figs. 1 and 2). A first transport unit 50, after receiving a connector 14, is moved from the loading station 54 to the termination station 58 so that the wires 40 are positioned in the gap 96. of the associated wire preparation module 66. The connector nest 70 is initially positioned below the wires 40 and the insertion blades 74 are positioned above and aligned with the wires (Fig. 2). Referring to Fig. 3a, the transport elevator 94 raises the lower portion of the wire preparation module 66 so that the connector nest 70 and the connector 14 therein are pushed upwardly toward the wires 40. At the highest point of the travel, the connector 14 displaces every other wire 40 with an upward angular deflection as shown in Fig. 3b. That is, the upwardly deflected wires 40U are captured by the side walls 34 of the upper terminal receiving cavities 32. The wires 40L to be terminated in the lower row 30 are received in channels formed between the adjacent cavities 32 of the upper row. Thereafter, the actuator 78 is energized to move the insertion blades 74 downwardly so that the wires 40 are inserted into the connector terminals 18 and thereby grounded. The transport unit 50 then moves back into the loading station 54 beyond the termination station 58, withdrawing a predetermined length of wire from the wire feeder 92.

Thereafter, a connector is loaded into the second transport unit 52 at the second loading station 56 and advanced to the termination station 58 where it is lifted by the transport lift unit 94. In this insertion, the second wire preparation module 68 can be considered to be functionally equivalent to the first module 66 in that it mass terminates the wires 40 to a second connector 14. As will be described in more detail below, the wire preparation module 68 differs in its wire handling and other related functions. For example, the second wire preparation module includes a movable wire comb for proper alignment between wires 40 and the terminals 18 of the connector thereon.

When the wires 40 and the terminals 18 are aligned and the top of the connector nest 72 is engaged with the wires 40, the actuator 80 is energized to lower the lower wire insertion blades 76 (Fig. 4d, 4e). The wires 40 are severed by the insertion blades 76 as they are compressed between the blades and the upper, die-shaped portion of the nest 72 (Fig. 4f). Thereafter, the second or trailing ends of the newly formed wire sections in both rows of the connector 14 are simultaneously terminated (Fig. 4e).

The harness is thus completed and automatic ejector arms 100, 102 are operated to extract the connectors 14 from their respective nests 70, 72 (Fig. 5) for conveyance on ejector tracks to remote work stations.

The second transport unit 52 is then retracted to the second loading station 56, leaving the free ends of the wires 40 extending from the feeder 92 in a predetermined position above the termination station 58 and the harness apparatus 10 ready for the start of another harness manufacturing cycle.

Immediately after ejection, the connectors 14 and the lengths of wires 40 extending therebetween are moved to a conventional work station 107 (see Fig. 1) where the connectors 14 are rotated 90 degrees (as shown in Fig. 5b) so that their connecting ends 24 face upwardly as shown in Figs. 7 and 8. After being placed in their rotated position, the connectors 14 are translated along conveyor tracks 110 which run to a pin removal station generally indicated at 112 (Fig. 7) and to a web removal station generally indicated at 114 (Fig. 8). At station 112, the upwardly facing centering pins 116 projecting from the connecting end wall 24 are by a selected array of knives 118. Thereafter, while maintaining the rotated orientation, the connectors 14 are advanced to station 114 (Fig. 8) where the selected web portions are removed by knives 120 to form a plurality of finished harness products.

Referring briefly to Fig. 6, an optional wire preparation module 122 is shown mounted on a second support frame member 62. The optional transport unit formed thereby and designated by the reference numeral 52', although movable to and from the second loading station 56, does not conveniently cooperate therewith since it does not carry a connector. Instead, the optional transport unit 52' is provided when only a single-ended harness is desired, with the second or rear end of the harness being formed only by cutting or cutting and stripping the rear ends of the wires 40 at the termination station 58. After termination to a first connector 14, the first transport unit 50 is moved back to the first loading station 54 and the connectors 40 are laid out over the termination station 58. The transport unit 52' follows the same path as before to the connection station 58 and on arrival the actuator 80' is energized to lower the lower cutting and stripping knives 124 and 126 respectively (Fig. 6d). As soon as the wires 40 are cut by the knives 124 and their insulation jackets are at least partially separated from the knives 126, an actuator 128 is energized to move a movable wire clamp 130 to the first transport unit 50, whereby the second end of the newly formed wire sections is stripped (Fig. 6). However, the stripping knives 126, the actuator 128 and the wire clamp 130 can also be omitted if at the second end of the wiring harness only cutting and no wire stripping is required.

As shown above, a choice of two wire preparation modules 68 or 122 are available for the second transport unit 52 (see Fig. 10). The support frames 60, 62 serve as frame units for locating (see pins 61) and locking (see screw-receiving openings 63) a selected wire preparation module for movement therewith. More elaborate frame units 66', 68' and 122' are shown in Fig. 10.

The various types of modules described herein result in a finished second harness end with either a connector grounded to the wires or the second wire ends either cut or cut and stripped to whatever shape is desired by the end user. Those skilled in the art will appreciate that other types of wire preparation modules can be used with the present invention. For example, a module can be provided for multi-crimping the second wire ends to a crimp connector. For example, if the wires comprise a flexible flat cable, the wire preparation modules can provide for clamping of appropriately shaped terminals to the flexible flat cable. A cable notching module can also be provided if the wires are assembled in a conventional ribbon cable. Whatever type of wire preparation module is required, the particular module can be quickly and easily screwed on and off the threaded mounting holes 63 of the support frames 60, 62 by simply inserting or removing four mounting screws for each module.

Throughout the application, the term "wire preparation module" is used to describe any of the above types of modules, including wire completion units that comprise equipment for terminating the rear wire ends to a connector. Although the term "wire completion unit" may also be used to avoid any perceived exclusion of a type of module in which the wires are terminated into a connector, for simplicity the term "wire preparation module" is used to encompass those types of modules which not only cut, strip or notch the second wire ends and perform similar operations, but also terminate or otherwise prepare those ends for termination to a connector. In any event, the feature emphasized here is that any of the modules, whatever their type, may be quickly and easily mounted to any support frame 60 or 62 by simply inserting or removing four mounting screws. It is expressly understood that other particular module combinations and mounting frames than those illustrated in Fig. 10 and elsewhere herein will be apparent to those skilled in the art upon studying the present specification, and such arrangements are considered part of the present invention.

Furthermore, it must be expressly assumed that the present invention not only includes the modular design of the entire wire preparation module, but also every part thereof. For example, the upper and/or lower wire production area. The term also includes the modular interchangeability of wire insertion knives, wire clamping devices or other components of a transport unit 50 or 52.

IV. First modular transport unit

With reference to Figs. 1 and 2, the first modular transport unit 50 receives a connector 14 from the first loading station 54 and is moved by the support frame 60 to the connection station 58. As can be seen from Fig. 1, the first loading station comprises 54, a collection line 140 which receives a single row of connectors arranged end-to-end from a source not shown. The first connector is moved to a delivery line 144 by the action of the conveying solenoid 146 on a reciprocating member 142. The conveying solenoid 146 then pushes the connector along the delivery line 144 to the connector nest 70 where it is prepared for conveyance to the termination station.

Referring to Figure 2, the wire preparation module 66 of the first transport unit 50 includes wire insertion knives 74 mounted in a movable head 150 which is moved for reciprocal movement about guide pins 152 by a double acting air cylinder referred to above as actuator 78. Also mounted on the head 150 are a series of wire severing knives 154 which align the wires 40 immediately prior to termination.

The first modular transport unit 50 is advanced to the termination station 58 at a lower level than that of the wire feed of the wires 40, as shown in Figures 2 and 3a. The wire feed 92 includes an associated mechanical feed for conveying the wires 40 through a wire guide 163 having a discharge end located immediately adjacent the termination station 58. Upon arrival of the support frame 60 at the termination station 58, the transport lift 94 is actuated to raise the rods 82, thereby raising the lower wire preparation module section 66L thereon.

Other arrangements for raising the wire preparation module portion 66L will be apparent to those skilled in the art in light of the present description. For example, the entire wire preparation module may be raised a first distance with an optional dual-acting solenoid 84, 60' lifting an additional distance.

When the connector nest 70 is raised, the upper surface of the connector housing 16 therein comes into contact with the wires 40, thereby deflecting every other wire of the upper row of terminals to produce a predetermined angular deflection (see Fig. 3b). The upwardly deflected wires 40U are those that have been aligned for termination in the upper row 28 of the connector 14. The remaining set of wires 40L to be terminated to the lower row of connectors 30 are placed in channels 42 that extend between the terminal receiving spaces of the upper row 28. The channels 42 guide the wires 40L to terminals located on the lower row of connectors 30.

Electrical sensors, not shown in the figures, trigger the energization of the elevator 94 upon arrival of the support frame 60 at the connection station 58. The sequencer 170 transmits the actuation signal to the elevator 94. Additional sensor switches, not shown in the figures, may be provided in the solenoid 84 for indicating when the support frame 60' and thus the lower wire preparation module section 66L is raised to its highest position. These switches output a signal to the sequencer 170 which interrupts the energization of the elevator 94 and triggers the downward movement of the actuator 78 simultaneously with the insertion of both sets of wires 40U, 40L into the connector rows 28, 30. The wires 40L are equally offset but angularly downward when the insertion blades 74 are fully extended (see Fig. 3c). As shown in the present embodiment of Fig. 3c, the connector 14 is preferably centered about the plane of the wire feed, with the angular offsets of the upper and lower rows of wires equally offset from this plane of the wire feed.

After the upper module section 66U is fully extended downward, the sequencer 170 initiates a retract signal to the double acting solenoid 78 so that the movable head 150 is moved back upward. The solenoid 84 is energized to retract the lower wire preparation module section to its original, lower position. As the support frame 60 moves the wire preparation module 66 back to the first loading station 54, the wires 40 connected to the connector 14 in the nest 70 are pulled off as they pass through the termination station 58. If the frictional forces of pulling off are too great, or if the distance between the first loading station 54 and the termination station 58 is not great enough, an additional mechanical pull can be provided at the wire feeder 92. Cable loops can easily be routed downwards between the connection and charging station.

Just before returning the transport unit 50 to the first loading station 54, a test cylinder 174 is automatically actuated to move the movable base 176 containing test probes 178 (see Fig. 2) into a disengaged position relative to the connector located in the nest 70. The left free end of the test probes 178 is thereby inserted into connector 14 in preparation for electrical testing of the wiring harness. The right free end of the probes 178 is connected to a fixed connector block 180 located adjacent the loading station 54. The connector block 180 contains suitable plug connectors for receiving the probes 178 which enable connection to an electrical test apparatus not shown in the drawings. Preferably, each free end of the test probes 178 is provided with retractable spring pressure so that an easy connection between the connector 14 and the connector block 180 is possible. In the present embodiment, the electrical test is only carried out on single-ended harnesses (see Section VI below) to detect short circuits between adjacent harness conductors. Other suitable electrical tests are known in the art and can be performed on both single-ended and double-ended harnesses.

V. Second modular transport unit

The wire preparation module of the second modular transport unit 52 may take at least three forms. If a double-ended harness is required, a wire preparation module similar in function to that described above may be provided for grounding to a second connector 14. However, if a single-ended harness is required, the wire preparation module need only include a wire cutting device. However, if a single-ended harness having stripped electrical wires at its free end is required, a cutting and stripping device may be attached to the second support frame 62. The reference numeral 68 has been used for the grounding wire preparation module of the present invention. The other wire preparation module, described below, is designated 122 and includes wire cutting and stripping means.

Referring to Fig. 4, a second modular transport unit 52 is shown which is suitable for mass termination of a second connector 14 and includes a support frame 62 and a wire preparation module 68. A connector nest 72 conveys a connector 14 from the second loading station 56 to the termination station 58. The first and second loading stations 54, 56 are similar in their operation. Therefore, the reference numerals 140 to 148 used to describe the first loading station are repeated for the second loading station 56, but are primed. For example, the collection track at the second connector charging station is provided with the reference number 140'.

In addition to the second connector nest 72, the wire preparation module 68 includes upper and lower wire clamps 200 and 202, respectively. The lower wire clamp 202 is adapted to be retracted to the support frame 62 by a double-acting, downward-pulling actuator 85. The support base 62' is mounted for vertical reciprocation by guide pins 83. Also mounted to the lower portion 68L of the module 68 is a movable wire comb 208, the function of which is described below. The upper module section 68U consists of the above-mentioned upper wire clamp 200, wire severing blades 210, wire cutting and inserting blades 76, and a wire clamp 214. The above-mentioned components 76, 200, and 204-214 are mounted for joint movement on a movable head 216 which is driven by the actuator 80 for movement about the guide pins 220. The leftmost wire clamp 214 is mounted for independent movement with respect to the head 216 by the actuator 222 to press the wires 40 against the surface 72' (see Fig. 4a).

Referring now to Figures 4a-4f, the operation of the second transport unit with a bulk termination wire preparation module will be described. All operations take place at the common termination station 58 where the first transport unit 50 has drawn wires 40 so that a continuous length of wire is disposed above the termination station 58. Upon arrival of the second transport unit 52 (Figure 4a), the carrier sub-frame 62' is raised by the elevator 94. Sensor switches connected to the pull-down solenoid 85 indicate to the sequencer 230 when the carrier sub-frame 62' has been raised to its highest position where the upper surface 72' of the connector nest 72 comes into contact with the wires 40 (Figure 4b). Thereafter, the power supply is of the lifting device 94 is interrupted by the controller 230 which then initiates the independent movement of the lower wire clamp 202 until it contacts the wires 40 which are held at their wire feed level set by the wire guide 162 (Fig. 4c). At this time, the controller 230 can initiate the lowering of the wire clamp 214 by energizing the actuator 222. Thereafter, as shown in Fig. 4c, the movable wire comb 208 is moved to the left toward the second connector 14 and lowered so that the wires 40 are engaged and is then retracted beyond the lower wire clamp 202.

Upon completion of the wire combing cycle, the sequencer 230 energizes the actuator 80 to initiate depression of the tool head 216. As shown in Fig. 4e, the termination cycle is illustrated at a time immediately after contact of the upper and lower wire clamps 200, 202. The left edge 76c (see Fig. 4c) of the wire cutting and inserting blades 76 (see Fig. 4b) has just engaged a cooperating edge 72c (see Fig. 4c) of the connector nest 72 to separate the wires 40. The sequencer 230 also releases the back pressure on the solenoid 85 so that the lower wire clamp 202 can be fully depressed by the downwardly moving wire clamp 200. At the maximum downward extension of the upper module, as indicated by sensors located in the solenoid 85, the sequencer 230 interrupts the power supply to the solenoid 80 at a time when the cutting and inserting blades 212 have completely inserted the newly formed wire sections into the terminals of the second connector 14. Immediately prior to termination, as shown in Fig. 4d, the wire separators 210 (see Fig. 4d) have sensed the wire sections just cut to ensure alignment with the terminals of the connector. 14. Thereafter, as shown in Fig. 4f, the sequencing controller 230 causes the upper wire preparation module 68U to be raised by energizing the double acting solenoid 80. Simultaneously or after an appropriate time, the sequencing controller 230 energizes the double acting solenoid 85 to retract the lower wire clamp 202, thereby drawing the carrier subframe 62' with the lower module portion 68L and the connector nest 72 under the newly formed free end of the feed wires 40. At some point prior to the step shown in Fig. 4f, the elevator 94 is retracted so that the clamping latch mechanism is retracted to permit the downward movement of the carrier subframe 62'.

The connection of the second connector 14 forms a double ended harness ready for ejection from the transport units 50, 52. Referring to Figs. 1 and 5, ejector arms 100 are extended to overlie the connectors 14 with their spring loaded latches 184 retractable as they are moved over the connector housings. When the latches 184 are moved past the distal end of the connectors 14, the ejector arms 100 are moved in the reverse direction and the latches 184 pull the connectors 14 into the respective ejector tracks 104 for conveyance to 90 degree rotary stations 107 (see Fig. 1).

An example of a rotary station 107 is shown in Fig. 5a in connection with an arm 100. In this figure, the arm 100 is arranged for alternately extending and retracting, as shown by arrow 240, by the driving force of the actuator 242. In this optional arrangement of the rotary station 107, a second latch 244 is provided for engaging the connector 14. The front latch 184 is preferably attached to an extendable portion 246 of the ejector arm 100, while the second latch 244 is in a fixed position. After the connector 14 is captured between the pawls 184, 244, a motor 251 is energized to drive the gear box 252. The actuator 242 and the ejector arm 100 are pivotally mounted at each end by pivotable supports 254, 256. Thus, the connector 14 is rotated 90 degrees in a plane extending perpendicular to the ejector path 104. Limit switches 260 interrupt the power supply to the motor 251 when the proper angular rotation is achieved. Upon rotation, the actuator 242 is re-energized to move the connector 14 to a dispensing path 110 (see Fig. 8a), which is explained in more detail below with reference to Fig. 8a.

A second turning station 170 must be provided for a second connector 14 when a double-ended harness is manufactured. Although a specific turning station 170 is shown in Fig. 5a, other arrangements will be apparent to those skilled in the art.

Upon leaving the stations 107, the connectors 14 are arranged with the connecting ends 24 pointing upwards and with wires 12 extending between the connectors 14 and forming a downward loop, as shown in Fig. 7a.

VI. Alternative second modular transport unit

As mentioned above, an alternative embodiment of the second modular transport unit, generally designated 52', includes a wire cutting and stripping tool in place of the above-mentioned mass termination tool. With reference to Figs. 6a-6e, the operation of the cutting and stripping wire preparation module 122 will be described. As mentioned above with reference to Fig. 4, the wires 40 were pulled past the termination station 58 by the first transport unit 50 as it was retracted to a point adjacent the loading station 54. Thereafter, as shown in Fig. 6a, counter-rotating wire comb members 130, 132 are extended to the wire feeder 92. As shown in Fig. 6b, the wire combs are engaged with each other and then retracted to their home position, being moved to the first transport unit 50. In this operation, the wires 40 have been combed and aligned so that they are ready for the cutting and stripping operations. Sensors located in the wire combs 130, 132 send a cycle completion signal to the sequencer 240 when they have returned to their home position. The sequencer 240 then energizes the elevator 94, thereby raising the tool head 246 for engagement with the wires 40 and lowering the lower wire clamp 248 for engagement with the wire 40. Both the tool head 246 and the wire clamp 248 are mounted on a movable base 250. The pull-down solenoid 256 is in turn attached to the base 250 so that it is retracted at the right time.

Sensors located in the solenoid 256 indicate when the tool head 146 is fully extended upward and output a signal to the sequencer 240, which initiates the downward movement of the actuator 80' (Fig. 6c). At this time, the controller 240 energizes the actuator 222 to lower the wire clamp 214 to press the wires 40 against the lower wire preparation module area. This lowers the cutting blades 124 and stripping blades 126 into engagement with the cutting edge 246c and the lower stripping blade 126', respectively. Likewise, the upper wire clamp 249 is engaged with the mating counterpart 248 so that the wires 40 are firmly grasped. When the actuator 80' is fully extended downward, a signal is sent to the sequencer 240 to initiate the movement of the actuator 128 to the right. This causes the wire clamps 248, 249 to be moved to the right, away from the stripping blades 126, 126', to actually strip the newly formed free ends of the harness wires, as shown in Fig. 6e.

VII. Polarization pin removal station

Referring to Fig. 7, the connectors 14 are positioned at a pin removal station 112 where blade-like pin removal knives 118 are lowered to separate certain polarization pins 116 from the upper and lower housing surfaces 20, 22, respectively. The pins 116 have been positioned to extend beyond, but not overlie, the connector edge 24. Orientation of the connectors 14 in a position to withstand the force of the removal knives 118 is accomplished by the delivery track 110. The knives 118 are mounted on a press-like actuator 119 for downward movement over the upper and lower connector surfaces 20, 22. Therefore, it is important that the track 110 be narrower than the body of the connector 14 and prevent lateral rocking of this body during pin removal.

VIII. Delivery track

Referring now to Fig. 8a, the delivery track 110 will be explained in more detail. The connectors 14 have alignment tabs 260 extending from the connection end 24 to form an alignment channel 262 therealong. The track 110 has an upper rail member 266 that is complementarily shaped to snugly receive the channel 262. The track 110 further includes second and third rail members 270, 272 that engage and support the wire receiving end 26 of the connector 14 immediately adjacent the upper and lower connector surfaces 20, 22. In fact, the lower rails 272, 270 face the upper rail 266 to form a connector receiving space that conforms to the profile of the connector 14. When the upper rail 266 is received in the channel 262 and the lower rails 270, 272 support the opposite end wall 26, the connector is supported by the track 110 to prevent rocking of the connector during sliding movement along the track. The rocking referred to here occurs in a plane extending along the track as well as in two directions perpendicular to either side thereof.

IX. Bridge removal station

Referring to Fig. 8, the connectors 14 slide along the track 110 and are brought to the land removal station 114 which includes a predetermined plurality of land removal knives 120. As shown in Fig. 8b, the land removal knives are lowered into the mating end of the connector 14 so that selected land portions 44 are removed to produce a plurality of connector modules 46 as shown by the dotted lines of Fig. 8c. The phantom lines 280 (Fig. 8b) show the area of material removed from the connector housing 16 by the knives 120 corresponding to a land portion 44.

As shown in Fig. 8c, the particular connector modules 46 formed by the blades 120 have a vertically elongated side profile, particularly in a dual circuit connector comprising an upper and a lower terminal. The arrangement of the delivery track 110 is particularly advantageous in that it ensures reliable sliding conveyance of the connector module without rocking about any of the three orthogonal axes, one of which lies in the direction of the track 110.

Claims (16)

1. A method for producing an electrical wiring harness (12) in which a ground connection of the first ends of a plurality of double-ended wires (40) with insulation sheath is made to an insulation displacement terminal of a connector (14), the method comprising the steps of a connector (14) is placed on a first transport unit (50) in a first station (54) thereof, the first transport unit (50) being operable in such a way that the connector (14) is moved between the first and a second station (58) of the first transport unit (50), Wires (40) are fed and dimensioned such that their first ends are positioned adjacent to the connector (14) in the second station (58) of the first transport unit (50), the first ends of the wires (40) are connected to the connector (14) in the second station (58) of the first transport unit (50) to form a first completed end of the wire harness (12), and then the first transport unit (50) is returned to its first station (54), whereby a predetermined length of the wires (40) is pulled past the second station (58) of the first transport unit (50), one of a plurality of different, selectively operable modules (68; 122) for wire harness completion is detachably mounted on a frame unit (62) of a second transport unit (52; 52') having a first station (56), which may be a connector application station, and a second station (58) which is the same as the second station (58) of the first transport unit (50), the second transport unit (52, 52') with the frame unit (62) and the module (68; 122) from the first station (56) of the second transport unit (52, 52') to the second Station (58) is moved, the second transport unit (52, 52') is held in the second station while the module (68, 122) is operated to simultaneously finish the second wire ends to form a second finished harness end and thereby form a single or double ended harness, as desired depending on the one of the harness finishing modules selected to finish the second wire ends, and then the second transport unit (52, 52') together with the frame unit and the module (68, 122) is moved to the first station (56) of the second transport unit (52, 52') for readiness for production of another harness. 2. The method according to claim 1, wherein the wires (40) are fed to the second station (58) along a first plane so that their first ends are arranged in a predetermined position, the connector (14) of the first transport unit (50) is placed in a second lower level, the first transport unit (50) is moved along the second plane to the predetermined position adjacent to the first wire ends and at least a portion (66L) of the first transport unit (50) is raised so that the connector (14) placed thereon is placed directly under the wires (40) such that the first wire ends are positioned for a ground connection to the connector (14). 3. Method according to claim 2, in which the second transport unit (52, 52') is moved along the second lower level to position the one of the wire harness completion modules (68, 122) adjacent to the second wire ends, and a portion (68L, 250) of the module (68, 122) is raised to a position immediately adjacent to the wires (40) to complete the second wire ends upon further actuation of the module (68, 122). 4. A method according to any preceding claim, in which a harness completion module (68) comprising an arrangement for grounding the second ends of the wires (40) to a second connector (14) having a plurality of insulation displacement terminals to form the second completed end of the harness, the one and second connectors (14) each comprise a unitary housing (16) having opposed upper and lower surfaces (20, 22) extending axially between opposed front connection and rear end walls (24, 26) and having at least two rows (28, 30) of axially extending terminal receiving spaces (32), the rows of spaces being stacked one on top of the other in a staggered fashion so that the spaces of one row (28) are disposed between the spaces of the other row (30) and each space having an upwardly facing wire receiving slot opening to the upper housing surface (20) so that all wires (40) for a connection can be inserted from the upper housing surface (20), the method comprising: the one and the second connector (14) are placed so that the upper connector surfaces (20) of the connectors (14) are kept pointing in the same direction during connection, and the respective wire ends are connected to the rows (28, 30) of each connector (14) simultaneously. 5. The method according to claim 4, wherein the one and the second connector (14) are rotated when they are connected so that their front connection ends (24) are directed upwards, the wires (40) of the cable harness (12) extending between the connectors (14') forming a downward loop, and the wire harness (12) is transported to a remote work station (112, 114) by sliding the rear end walls (26) of the connectors along respective first and second transport paths (110) each having slotted openings for receiving the wires (40). 6. Multi-station device for automatically producing an electrical cable harness with a ground connection of the first ends of a plurality of double-ended wires (40) with insulating sheath each to an insulation displacement connection (18) of a connector (14), consisting of a first connector transport unit (50) for receiving and moving a connector (14) between two stations (54, 58), a device (140, 142, 144, 146) for placing the connector (14) on the first connector transport unit (50) in a first station (54) thereof, a wire feed device (92, 162) for feeding and dimensioning the wires (40) such that their first ends are assigned to the connector (14) in the second station (58) of the first connector transport unit (50), a wire termination device (66) for connecting the first ends of the wires (40) to the connector (14) in the second station (58) to form a first finished end of the wire harness, a further transport unit (52, 52') with a first station (56), which can be a connector loading station, and a second station (58), which is the same as the second station (58) of the first connector transport unit (50), wherein the further transport unit (52, 52') releasably supports one of a plurality of cable harness completion modules (68, 122) on the device, the harness completion module (68, 122) is movable from the further transport unit (52, 52') into the second station (58) to simultaneously complete the second ends of the wires (40) to form the second completed harness ends, and is movable from the further transport unit (52, 52') into the first station (56) of the further transport unit (52, 52') to prepare the machine for the start of a further harness production cycle, characterized in that the further transport unit (52, 52') has a frame unit (62) which detachably supports the one harness completion module (68, 122), the further transport unit (52, 52') together with the frame unit (62) and the wire harness completion module (68, 122) is movable from the first station (56) of the further transport unit to its second station (58) and the wire harness completion module (68, 122) is actuated while the second transport unit is held in the second station such that the second ends are simultaneously completed, thereby forming a single or double-ended wire harness as desired, and the further transport unit together with the frame unit (62) and the wire harness completion module (68, 122) is movable from the second station (58) of the further transport unit (52, 52') to the first station (56) of the further transport unit (52, 52') in order to prepare the machine for the start of a further wire harness production cycle. 7. Device according to claim 6, in which the wire processing station of the module (68, 122) has opposing upper and lower module areas (68U, 68L, 130, 132, 214, 124, 126, 249, 246, 248, 126') with a gap (98) between them for receiving the second wire ends, wherein the opposing module areas are movable towards each other to complete the second ends of the wires and thereby form the second completed wire harness ends, and the device further comprises a lifting device (94) in the second station (58) for lifting at least one of the lower module areas (68L, 246, 248) towards the second wire ends to enable their finishing. 8. Apparatus according to claim 7, wherein the first connector transport unit (50) has a connector nest (70) for receiving the connector (14) and the wire connection device (66) has a projecting device (74) for engaging with and inserting the first ends of the wires into the terminals (18) of the connector (14) upon advancement of this projecting device (74) towards the connector nest (70) and the connector nest (70) has a position adjacent to the lifting device (94) when the connector (14) is moved to the second station (58) and engages therewith for movement of the connector (14) toward the first wire ends. 9. Device according to claim 7 or 8, in which the respective module areas comprise clamping devices (248, 249) for the second wire end and wire stripping knives (126, 126') which can be moved towards one another to grip the wires, and an actuating device (128) for displacing the clamping device (248, 249) to detach the insulation from the second ends of the wires. 10. Device according to claim 7 or 8, in which one of the module areas (68L) has a connector nest (72) for receiving a second connector (14) with a plurality of insulation displacement connections (18), the other module portion (68U) includes a second wire connection device (76) for grounding the second end of the wires to the second connector (14) to form the second finished end of the wiring harness and a device (140', 142', 144', 146') for placing the second connector (14) onto the second connector nest (72) is provided. 11. Apparatus according to any one of claims 7 to 10 for producing wire harnesses with connectors (14) each having a one-piece molded housing (16) with opposed upper and lower surfaces (20, 22) extending between opposed front connection and rear end walls (24, 26), and at least two rows (28, 30) of axially extending terminal receiving spaces (32), the space rows being stacked one on top of the other in a staggered configuration so that the spaces of one row (28) are disposed between the spaces of the other row (30), and each space having an upwardly facing wire receiving slot opening to the upper housing surface (20) so that all wires (40) for connection can be inserted from the upper housing surface (20), wherein the feed device (140-146, 140'-146') is adapted to feed connectors (14) such that an upper surface (20) thereof is held in an upward direction during connection, and the wire connection device (66, 76) can be actuated for connecting all first wire ends simultaneously in connections (18) of respective rows (28, 30) of the connector (14). 12. Apparatus according to claim 11, when claim 11 is dependent on claim 8, for producing wire harnesses with connectors according to claim 11, of which the housing side walls (34) of the upper rows (28) of connectors act as wire guides to assist in the passage of the wires (40) to lower rows (30) for termination therein, such that all of the wire ends for termination can be inserted from the upper housing surface (20), the wire feed device (92, 162, 50) being adapted to feed and dimension the wires (40) such that the first wire ends when associated with a connector (14) in the second station (58) are arranged in a common plane with the wire ends to be terminated adjacent the terminals (18) of different rows (28, 30) of the connector (14), whereby when the connector is moved towards the first wire ends the connector bends the ends to be connected in a first row with a predetermined upward angular deflection and causes the wires to be connected to the other row to have an equal downward angular deflection when connected by the wire connecting device (66, 76). 13. The device of claim 11, further comprising means (107, 170) for rotating each connector (14) during connection thereof so that its front connection end (24) is directed upwards, the wires of the cable harness extending downwards, a first transport path (110) with a slotted opening for receiving the wires (40) and surfaces (270, 272) for supporting the rear end wall (26) of the connector (14) and means for transporting the wire harness to a remote station (112, 114) of the apparatus by moving the connector on the track (110). 14. Apparatus according to claim 13 for producing cable harnesses with connectors (14) according to claim 11 or claims 11 and 12, wherein the rows (28, 30) of connectors are at least partially connected to one another by selectively removable web areas (44) to form a plurality of jointly connected separable connector modules (46), each module comprising at least one upper row space (28) and at least a lower row space (30), wherein the remote station of the device comprises a connector web removal station (114) and the device is further provided with means (120) in the web removal station for selectively removing at least one of the connector webs (44) in the axial direction so as to form a plurality of the connector modules (46), each connector module (46) thus comprising a separate connector (14) connected to a predetermined number of the wires (40) so as to form a separate wiring harness (12) therewith. 15. Apparatus according to claim 13 or 14 for producing wire harnesses with connectors (14) according to claim 11, 12 or 13, each connector (14) further comprising a plurality of centering pins (116) projecting from the upper and lower surfaces (20, 22) so as to extend beyond, but not overlie, the connection end wall (24), the removed station of the apparatus further comprising a pin removal station (112) and the apparatus is further provided with means (118, 119) in the pin removal station (112) for selectively removing at least one of the connector pins (116) in the axial direction immediately adjacent to one of the upper and lower surfaces (20, 22). 16. Device according to claim 13, 14 or 15 for producing of cable harnesses with connectors (14) according to claim 11, 12, 13 or 14, wherein each connector (14) further comprises a plurality of alignment tabs (260) extending from the connecting end wall (24) to form a channel (262) extending along the connecting end wall, wherein the transport path (110) has a first rail (266) shaped complementarily to the channel (222) and receivable therein, and a second and third spaced rail part (270, 272) opposite the first rail (266) engageable with the connector (14) for supporting the rear end wall (26) thereof, whereby the connector (14) is supported by the track (110) to prevent rocking motion during movement along it.