GB1564860A - Conductor terminating apparatus - Google Patents

Description

(54) CONDUCTOR TERMINATING APPARATUS (71) We, BUNKER RAMO CORPORA TION, a Corporation organised and existing under the laws of the State of Delaware, United States of America, of 900 Commerce Drive, Oak Brook, Illinois, United States of America, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: - This invention relates to an apparatus for terminating conductors in electrical connectors and, more particularly, to a device which facilitates and enhances the simultaneous trimming and insertion of insulated conductors in the individual contacts of multiple contact electrical connectors.

With the advent of miniaturized electronics and electrical components, connectors used in the electrical, communication and data handling industries have been reduced in size, making it more difficult to connect the individual conductors with the appropriate electrical terminal of the connector. Accordingly, a wide variety of tools and mechanical devices have been developed in recent years directed at simplifying and expediting the assembly or mounting of conductors in these small electrical connectors. The tools illustrated in United States Patents Nos. 3,742,571, 3.845,535.

3,952.392, 3,965,558 and 3,972,101 are tvDical examples of the kinds of apparatus developed to meet this need. Generallv.

these tools provide some mechanism whereby the insulation covered conductor is forced into the conventional insulation piercing terminals of the connector contact.

Prior art termination tools of the tvne disclosed in United States Patent No.

3.952,392 generally include a frame or sunnort structure having means for holding the connector in conductor receiving position and a pair of opnositely disposed, rota table arms, each of which includes an insertion tool for engaging and pressing a plurality of insulated conductors into the connector contacts. Such prior art devices are capable, therefore, of simultaneously terminating all of the conductors to be assembled with a given connector by virtue of a very simple sequence of operations.

While these prior art termination tools have met with some success, there are disadvantages associated with their manufacture and use which have limited their acceptance. For example, since the insertion tool. itself, moves through an arc in effecting the termination of the conductors it is not possible to achieve precise uniformity of termination force across the entire row of contacts in the connector. Moreover, in a given line of connectors the dimension between the oppositely facing rows of contacts will be less in the female connector than in the corresponding male connector.

Thus. the desired parallel relationship of the insertion tools as the rotatable arms reach the terminating position cannot be achieved for both female and male connectors. To overcome this disadvantage it has been suggested to provide an apparatus wherein the pivot of one of the rotatable arms is movable to accommodate connectors of different widths. This procedure is, however, time consuming and may not be entirely accurate.

A further disadvantage associated with prior art devices is that the means used, if 9ny, to align the conductors with the in- ç idual contacts prior to effecting their termination is generally constructed as an integral comDonent. These "comb elements" are not onlv expensive to manufacture, requiring milling and other machine tool oDerations, but also difficult to maintain in the field. since individual comb teeth are not replaceable and the shear edge typicallv disposed in these elements is difficult, if not imnossible, to resharpen.

Accordingly, a primary object of the invention is to provide a new and improved termination apparatus, particularly a field termination annaratus, for the readv termination of a plurality of conductors in the respective contacts of a multiple contact electrical connector.

Another object of the invention is to provide a termination apparatus wherein the insertion tool travels along a path substantially perpendicular to the planes defined by the rows of contacts in the connector.

According to the present invention there is provided an apparatus for simultaneously terminating a plurality of insulated conductors in the contacts of an electrical connector which has a row of contacts defining a contact plane, said apparatus comprising: a frame; means supported on said frame for mounting said connector in conductor receiving position; means for aligning individual conductors adjacent respective contacts of said connector; at least one rotatable arm mounted on said frame and adapted for arcuate movement from an open position remote from said connector to a closed position immediately adjacent said row of contacts; insertion means carried by said arm and adapted for reciprocatory and non-arcuate movement relative to the arm(s) substantially perpendicular to said contact plane for engaging and pressing said insulated conductors into the individual contacts of said connector; and means for applying an operating force to said insertion means to effect said perpendicular movement, thereby terminating each conductor in an individual contact of the connector.

The preferred embodiment of the apparatus which includes control means to ensure that the insertion tool travels the appropriate distance to effect proper conductor termination in both male and female connectors. The apparatus provides precise and uniform terminating forces to each of the contacts of either a male or female multiple contact connector regardless of dimensional variations across the width of the connectors.

The preferred embodiment also has an improved conductor aligning means which not only simplifies and reduces manufacturing costs but also facilitates and improves the terminating operation of the device.

The invention will be described in more detail, by way of example, with reference to the accompanying drawings, in which: FIGURE 1 is a perspective view illustrating the preferred embodiment of the invention with two rotatable arms, one in the open position and the other rotatable arm in the closed, termination position; FIGURE la is an enlarged perspective view illustrating in greater detail the insertion member employed in the embodiment of FIGURE 1 and showing its relationship with the camming element which applies to the termination member the appropriate termination force; FIGURE 2 is a plan view of the embodiment of FIGURE 1 illustrating, in solid lines, both rotatable arms in the closed position with the camming levers in the initial operating position and, in dotted lines, the camming levers at subsequent operating positions; FIGURE 3 is a plan view of the embodiment of FIGURE 1 showing both arms in the open position and, in partial cross-section, the structural arrangement of the rotatable arm, insertion member and camming element; FIGURE 3a is an enlarged cross-sectional view taken along line 3a-3a of FIGURE 3; FIGURE 3b is a side elevation taken along line 3b-3b of FIGURE 3 and showing the carriage and detent structure of the apparatus; FIGURE 3c is a cross-sectional view taken along line 3c-3c of FIGURE 3; FIGURE 4 is a cross-sectional view of the entire apparatus taken along line 4-4 of FIGURE 3 and showing the alignment of the insulated conductors adjacent the contacts of a male connector with the arms and their respective insertion members in a partially open position; FIGURE 5 is a perspective view of a preferred comb tooth utilized in the unique conductor aligning means of the present invention; FIGURE 6 is a cross-sectional view along line 66 of FIGURE 4, illustrating in greater detail the interrelationship of the connector, the conductors, the conductor aligning means and the blades of insertion members; FIGURE 6a is an enlarged partial crosssectional view illustrating the contact structure in greater detail and its relationship to the conductor and insertion blade; FIGURE 7 is a cross-sectional view similar to that of FIGURE 4 illustrating the arms in the closed, insertion position with the blades of the insertion members located at their respective positions immediately prior to the conductor trimming operation; FIGURE 8 is also a cross-sectional view similar to that of FIGURE 4 illustrating the blades of the insertion members in final position having effected the termination of the conductors in the contacts of a male connector; FIGURE 9 is a cross-sectional view identical to FIGURE 8 illustrating the termination of the conductors in the contacts of a female connector; and FIGURE 10 is a cross-sectional view taken along line 10-10 of FIGURE 3c illustrating in greater detail the ratchet arrangement employed with the camming elements of the present invention.

Referring to FIGURE 1, a preferred apparatus of the present invention, designated generally as 20, is shown to comprise a frame 22, a carriage 24 supported on the frame and adapted to mount a connector 26 in conductor receiving position, means 28 for aligning the conductors with respective contacts 30 of the connector, a pair of arms 32 used to position the insertion members 34 adjacent the rows of contacts 30, and a camming mechanism 36 used to transmit the appropriate termination force to the individual conductors.

The carriage 24 is the means by which the connector 26 is mounted within the apparatus 20 in the conductor receiving position. The carriage includes a base plate 38 and suitable locating means which cooperate with the connector to insure its proper location. In the illustrated embodiment the base plate 38 includes a pair of longitudinal slots 39 which cooperate with rails 41 mounted on the frame 22 (see FIGURE 3a), thereby enabling the carriage 24 to slide from an initial open position shown in FIGURE 1 to a final conductor receiving position shown in FIGURE 2.

Locating pins 40 are employed to engage apertures 42 in the opposite ends of the connector 26. Each of the pins 40 includes a shoulder 44 on which the connector 26 rides. Thus, the illustrated locating means ensures the proper lateral and vertical placement of the connector 26. As can be clearly seen in FIGURE 3b, the carriage 24 also includes a spring biased pin 46 which cooperates with an adjustable detent 48 to locate the connector longitudinally as well.

The detent 48 is threaded into the frame 22 to allow precise alignment of the connector with the conductor aligning means 28 and the insertion members 34.

The conductor aligning means 28 comprises a pair of comb elements 50 each including a plurality of comb teeth 52. The comb teeth define a plurality of conductor receiving slots 51 which are alignable with the contacts 30 of the connector 26. As shown in FIGURE 4, the comb teeth 52 are disposed in machined slots 53 formed in an inside member 54 of the comb element and securely clamped into position by an outside member 56 and bolts 58. The bolts 58 also serve to fix the comb elements 50 to the base 22. Each tooth 52 has a protuberant dimple extending into the adjacent slot to hold the corresponding conductor in place, as is apparent in Fig. 4.

The arms 32, rotatably mounted to the frame 22 by pins 68, are composed of upper and lower plates 70 and 72, respectively, which are configured to provide an intermediate arm slot 74 and an end arm slot 76. The intermediate slot 74 houses the insertion member 34 while the end slot 76 accommodates a pivotal and spring biased latch 78. As the arms 32 are rotated to the closed position their respective latches 78 engage the latch surfaces 80 to secure the arms in the closed, termination position adjacent the rows of contacts on the connector 26 in preparation for the termination operation. Guide surfaces 82 and 84 on the frame 22 serve as stops which abut the inside surfaces of the arms 32 to ensure the precise location of the arms immediately adjacent the oppositely facing rows of contacts 30 on the connector.

Each of the insertion members 34 includes a front face 86 having a series of insertion blades 88 extending outwardly therefrom. The member 34 also includes a pair of recesses 90 along the side faces 92 which mate with guide plates 93 and 94 as the arms 32 rotate toward their closed position.

The cooperation of the recesses 90 and plates 93 and 94 ensures the precise alignment of the members 34 even though, as described below, these members 34 are substantially free floating within the arms 32.

The insertion blades are configured along their engaging leading edge 95, in a manner well known in the art, to properly engage the specific dimensions and the geometric configuration of the contacts 30. In addition, the insertion blades 88 include a bottom shearing edge 97 which coacts with a stationary shear surface 55 formed in the inside members 54 of the comb elements 50.

As is clearly seen in FIGURES 7-9, the shear edge 97 and shear surface 55 act to trim the conductor C immediately prior to the insertion operation.

Each of the arms 32 also includes a clamp bar 96 which may be formed integral with the upper arm 70 or mounted to the upper arm by bolts 98 or other suitable fastening means. The clamp bars 96 extend outwardly from the upper surface of the arms 32 (see FIGURE 4) to a point beyond the engaging edges 95 of the insertion blades 88. As is illustrated in FIGURES 2 and 7-9, the clamp bars 96 engage the conductors C when the arms 32 reach their closed position and urge the conductors into the strain relief mechanism 98 (shown in FIGURE 6a) of the connector. This arrangement ensures that, even after the conductors have been trimmed and during the insertion operation, they will not be longitudinally displaced with respect to the contact 30. Of course, such a feature is highly desirable in that the possibility of a defective connection between the conductor C and the contact 30 is reduced.

The insertion members 34 are driven by camming elements 36 along a path substantially perpendicular to the contact planes defined by the rows of contacts 30 in the connector. Each camming element 36 is operatively associated with an arm 32 and includes a lever 100, a rotatable shaft 102, a cam member 104, and a cam following slot 105. A key pin 106 prevents relative rotation between the lever 100 and the shaft 102, the key being secured by the inside end 108 of the lever 100 which is threaded into the lever base 110. The eccentric cam member 104 is formed integrally with shaft 102 or may be keyed thereto by key pin 112. As is clearly seen the shaft 102 is journaled in both the upper and lower plates 70 and 72, respectively. The cam following slot 105 is formed in the insertion member 34 which slides freely within the intermediate arm slot 74. A small leaf spring 114 is mounted from a support 116 which depends from the upper arm plate 70, the spring engaging a small notch 118 to prevent insertion member 34 from floating in slot 74 to such an extent as to impede the proper engagement of recesses 90 and guide plates 93 and 94.

It will be apparent from the foregoing that as the lever 100 is rotated the shaft 102 and cam member 104 will also rotate thereby effecting a horizontal displacement of the insertion member 34 along guide plates 94. Moreover, when this operation is conducted with the arms 32 in the closed position, the members 32 will travel along a path substantially perpendicular to the planes defined by the rows of contacts 30.

In order to ensure that the insertion member 34 travels the required distance in terminating the conductors in the connector, each camming element 36 may also include a ratchet 120 and pawl 122 which coact to require full operative rotation of the levers 100. The ratchet 120 is mounted to the underside of the lever base 110 and secured to prevent relative rotation by key pin 124.

The pawl 122 is mounted on shaft 126 and is biased toward the ratchet 120 by a small compression spring 128. As is clearly illustrated in FIGURE 10, the ratchet 120 includes two release recesses 130 and 132, respectively, which allow the pawl to release from the ratchet in a manner well known in the art. The necessity for a plurality of release positions arises from the fact that connectors of different dimensions (i.e., male and female connectors) may be used with the present invention. Thus, a male connector, having a greater transverse dimension, requires less travel of insertion member 34 for proper termination than does a female connector. This difference in insertion member movement is accommodated by the recesses 130 and 132.

When connecting conductors to a male connector, the levers 100 are rotated from the initial position (FIGURE 2, solid lines) to position A (FIGURE 2, dotted lines) whereupon the operator will feel the ratchet release. The levers 100 may then be returned to the initial position. When a female connector is employed, the levers 100 will be rotated further to position B (FIGURE 2, dotted lines) whereupon the operator will again feel the ratchet release.

In this manner the apparatus will automatically accommodate either a male or female connector without any adjustment of the force transmitting components of the apparatus.

In the operation of the preferred embodiment, a connector 26 is mounted on pins 40 of the carriage 24 and a cable or bundle of conductors C are secured, such as by spring clamp 138, adjacent the connector. The carriage is then moved to the conductor receiving position, and each of the conductors C is threaded through the appropriate slot 51 and snapped passed the dimple 64 into alignment with an individual contact 30. Next, the arms 32 are rotated to the closed position whereupon the latches 78 lock into position. The levers 100 are then rotated to either position A or B (FIGURE 2) depending on whether a male or female connector is being assembled. The levers may then be returned to their initial position retracting the blades 88 from the contacts 30 of the connector. In this manner the conductors C may be expeditiously trimmed and inserted in each of the contacts 30.

WHAT WE CLAIM IS: 1. An apparatus for simultaneously terminating a plurality of insulated conductors in the contacts of an electrical connector which has a row of contacts defining a contact plane, said apparatus comprising: a frame; means supported on said frame for mounting said connector in conductor receiving position; means for aligning individual conductors adjacent respective contacts of said connector; at least one rotatable arm mounted on said frame and adapted for arcuate movement from an open position remote from said connector to a closed position immediately adjacent said row of contacts; insertion means carried by said arm and adapted for reciprocatory and nonarcuate movement relative to the arm(s) substantially perpendicular to said contact plane for engaging and pressing said insulated conductors into the individual contacts of said connector; and means for applying an operating force to said insertion means to effect said perpendicular movement, thereby terminating each conductor in an individual contact of the connector.

2. - The termination apparatus as claimed in Claim 1, wherein said conductor aligning means includes at least one comb element comprising a plurality of comb teeth which define a series of conductor receiving slots.

3. The termination apparatus as claimed in Claim 2, wherein said insertion means

**WARNING** end of DESC field may overlap start of CLMS **.

Claims (17)

**WARNING** start of CLMS field may overlap end of DESC **. a cam member 104, and a cam following slot 105. A key pin 106 prevents relative rotation between the lever 100 and the shaft 102, the key being secured by the inside end 108 of the lever 100 which is threaded into the lever base 110. The eccentric cam member 104 is formed integrally with shaft 102 or may be keyed thereto by key pin 112. As is clearly seen the shaft 102 is journaled in both the upper and lower plates 70 and 72, respectively. The cam following slot 105 is formed in the insertion member 34 which slides freely within the intermediate arm slot 74. A small leaf spring 114 is mounted from a support 116 which depends from the upper arm plate 70, the spring engaging a small notch 118 to prevent insertion member 34 from floating in slot 74 to such an extent as to impede the proper engagement of recesses 90 and guide plates 93 and 94. It will be apparent from the foregoing that as the lever 100 is rotated the shaft 102 and cam member 104 will also rotate thereby effecting a horizontal displacement of the insertion member 34 along guide plates 94. Moreover, when this operation is conducted with the arms 32 in the closed position, the members 32 will travel along a path substantially perpendicular to the planes defined by the rows of contacts 30. In order to ensure that the insertion member 34 travels the required distance in terminating the conductors in the connector, each camming element 36 may also include a ratchet 120 and pawl 122 which coact to require full operative rotation of the levers 100. The ratchet 120 is mounted to the underside of the lever base 110 and secured to prevent relative rotation by key pin 124. The pawl 122 is mounted on shaft 126 and is biased toward the ratchet 120 by a small compression spring 128. As is clearly illustrated in FIGURE 10, the ratchet 120 includes two release recesses 130 and 132, respectively, which allow the pawl to release from the ratchet in a manner well known in the art. The necessity for a plurality of release positions arises from the fact that connectors of different dimensions (i.e., male and female connectors) may be used with the present invention. Thus, a male connector, having a greater transverse dimension, requires less travel of insertion member 34 for proper termination than does a female connector. This difference in insertion member movement is accommodated by the recesses 130 and 132. When connecting conductors to a male connector, the levers 100 are rotated from the initial position (FIGURE 2, solid lines) to position A (FIGURE 2, dotted lines) whereupon the operator will feel the ratchet release. The levers 100 may then be returned to the initial position. When a female connector is employed, the levers 100 will be rotated further to position B (FIGURE 2, dotted lines) whereupon the operator will again feel the ratchet release. In this manner the apparatus will automatically accommodate either a male or female connector without any adjustment of the force transmitting components of the apparatus. In the operation of the preferred embodiment, a connector 26 is mounted on pins 40 of the carriage 24 and a cable or bundle of conductors C are secured, such as by spring clamp 138, adjacent the connector. The carriage is then moved to the conductor receiving position, and each of the conductors C is threaded through the appropriate slot 51 and snapped passed the dimple 64 into alignment with an individual contact 30. Next, the arms 32 are rotated to the closed position whereupon the latches 78 lock into position. The levers 100 are then rotated to either position A or B (FIGURE 2) depending on whether a male or female connector is being assembled. The levers may then be returned to their initial position retracting the blades 88 from the contacts 30 of the connector. In this manner the conductors C may be expeditiously trimmed and inserted in each of the contacts 30. WHAT WE CLAIM IS:

1. An apparatus for simultaneously terminating a plurality of insulated conductors in the contacts of an electrical connector which has a row of contacts defining a contact plane, said apparatus comprising: a frame; means supported on said frame for mounting said connector in conductor receiving position; means for aligning individual conductors adjacent respective contacts of said connector; at least one rotatable arm mounted on said frame and adapted for arcuate movement from an open position remote from said connector to a closed position immediately adjacent said row of contacts; insertion means carried by said arm and adapted for reciprocatory and nonarcuate movement relative to the arm(s) substantially perpendicular to said contact plane for engaging and pressing said insulated conductors into the individual contacts of said connector; and means for applying an operating force to said insertion means to effect said perpendicular movement, thereby terminating each conductor in an individual contact of the connector.

2. - The termination apparatus as claimed in Claim 1, wherein said conductor aligning means includes at least one comb element comprising a plurality of comb teeth which define a series of conductor receiving slots.

3. The termination apparatus as claimed in Claim 2, wherein said insertion means

comprises an elongated insertion member having a plurality of insertion blades extending from a lateral side thereof and adapted to align with said conductor receiving slots to engage and insert said insulated conductors into said contacts, said insertion member being movable both laterally and longitudinally with respect to said arm and adapted to engage guide means to thereby facilitate the alignment of said blades and said conductor receiving slots.

4. The termination apparatus as claimed in Claim 3, wherein said rotatable arm comprises an upper and a lower plate which define an intermediate slot adapted to receive said insertion member.

5. The termination apparatus as claimed in Claim 1, wherein said force applying means includes a camming element associated with said arm and comprising a rotatable camming member which cooperates with a cam following slot in said insertion means, whereby upon rotation of said camming member said substantially perpendicular movement of said insertion means is effected.

6. The termination apparatus as claimed in Claim 5, further including means for controlling the degree of rotation of said camming member such that said insertion means moves a predetermined distance relative to said arm and toward the row of contacts of the connector upon actuation of said camming element.

7. The termination apparatus as claimed in Claim 6, wherein said rotation controlling means is adapted to provide movement of said insertion means for a plurality of predetermined distances.

8. The termination apparatus as claimed in Claim 7, wherein said rotation controlling means comprises a ratchet operatively connected to said camming member and a pawl rotatably mounted on said arm, said ratchet having a plurality of release recesses.

9. The termination apparatus as claimed in Claim 1, further including means associated with said arm for urging said conductors into a strain relief mechanism of said contacts upon movement of said arm to the closed position adjacent said row of contacts.

10. The termination apparatus as claimed in Claim 9, wherein said conductor urging means comprises a clamp bar which extends outwardly from said arm to a point beyond said insertion means.

11. The termination apparatus as claimed in Claim 1 wherein said conductor aligning means includes at least one comb element comprising a plurality of comb teeth which define a series of conductor receiving slots, each of said comb teeth including a protuberance which extends into an adjacent slot, thereby providing means for retaining the individual conductors in alignment with the contacts of the connector.

12. The termination apparatus as claimed in Claim 11, further including shear means associated with each conductor receiving slot, said shear means coacting with said insertion means to trim the individual conductors immediately prior to insertion into the contacts of the connector.

13. The termination apparatus as claimed in Claim 12, wherein said protuberances are positioned toward the free end of said conductors relative to said shear means.

14. The termination apparatus as claimed in Claim 1, further including means for releasably securing said arm in the closed position.

15. The termination apparatus as claimed in Claim 4, wherein said securing means comprises a spring bias latch which cooperates with a latching surface on said frame.

16. The termination apparatus as claimed in Claim 1, wherein said connector mounting means comprises a movable carriage including fixed locating means for lateral and vertical positioning of the connector and adjustable locating means for longitudinal positioning of the locating means.

17. The termination apparatus as claimed in Claim 1 for use with connectors having two generally parallel rows of oppositely facing contacts defining respective parallel contact planes, wherein said at least one arm includes a pair of arms, each of said arms carrying a respective insertion means.