US3599800A

US3599800A - Station and method to store and dispense wiring components

Info

Publication number: US3599800A
Application number: US782145A
Authority: US
Inventors: Bernard J Durante
Original assignee: Hughes Aircraft Co
Current assignee: Raytheon Co
Priority date: 1968-12-09
Filing date: 1968-12-09
Publication date: 1971-08-17
Anticipated expiration: 1988-08-17

Abstract

A rack stacks rearwardly upward stepped rows of elongated openended rectangular boxes. A slidably removable divider partitions each box. From the removed divider rear along its undersurface, then around a front groove and then rearwardly over the divider is drawn a group of prepared wires. The loaded divider is inserted in the box for assembly of wires into equipment. One embodiment divider is rearwardly looped downwards to support one dangling end of long wires. The box row stepping enables separation of rows of overhanging wires into different planes. Another divider embodiment for shorter wires terminates with a box rear closure.

Description

United States Patent DISPENSE WIRING COMPONENTS 10 Claims, 10 Drawing Figs.

US. Cl 211/128, 2| 1/49, 21 1/60, 221/34, 221/46, 221/47 Int. Cl A471 3/14, A471" 7/00 Field olSenrch 211/128,

126,177, 60, 60 A, 148, 49, 49 D; 312/278, 198; 221/47, 46, 34; 206/64, 63.3; 242/127; 220/22, 22.5;108/9l93 Primary ExaminerRamon S. Britts Attorneys-James K. Haskell and Joseph P. Kates ABSTRACT: A rack stacks rearwardly upward stepped rows of elongated open-ended rectangular boxes. A slidably removable divider partitions each box. From the removed divider rear along its undersurface, then around a front groove and then rearwardly over the divider is drawn a group of prepared wires. The loaded divider is inserted in the box for assembly of wires into equipment. One embodiment divider is rearwardly looped downwards to support one dangling end of long wires. The box row stepping enables separation of rows of overhanging wires into different planes. Another divider embodiment for shorter wires terminates with a box rear closure.

PATENTED AUG] 7 I97! SHEET 1 OF 3 M04170: 514/410 Jade/r402;

STATION AND METHOD TO STORE AND DISPENSE WIRING COMPONENTS BACKGROUND OF THE INVENTION The present invention relates to apparatus and a method to package, store, and dispense groups of prepared wires in the assembly of units and equipments which include wire components.

In assembling units and equipments, for example, electronics apparatus and devices, the wires required to be installed into the electronics apparatus and devices are first prepared by a preparer at a preparing station. Preparation involves, for example, cutting the wires to length, color coding, stripping the insulation from a plurality of similar wires at both ends, tinning the stripped ends if required, and applying pigtails if required.

The wires necessary to build a unit of equipment are called a wire kit." A typical number of wires in a power harness wire kit, for example, is I50 wires. In the prior art methods, following the above-described operations at the preparing station, a number of wires equal to the number of equipments to be built, of each of the types of wire in the wire kit for that equipment is loaded into a separate plastic or paper bag or is bundles like wheat and confined by tape at the center and the bag or tape is identified. Groups of the bags of wires are then carted and sent to stores or sent for handling at the assembly station.

For example, assume 10 power harnesses are to he produced and each power harness is to contain 150 wires comprising a [-inch long wire of first characteristics, a 12- inch long wire of the first characteristics, a l0-inch long wire of second characteristics, etc. Then ten -inch first characteristics wires are loaded into one bag or are taped, ten l2- inch first characteristics wires are loaded into a second bag or are taped, ten l0-inch wires second characteristics wires are loaded into a third bag or are taped, etc. The bags are then each identified, and are sent to the assembly station or sent to stores and loaded into cartons or on shelves. When stored, upon commencing of assembly, the bags are drawn from stores and brought to the assembly station. A plurality of kits corresponding to the number of equipments to be built, e.g., 50 to I00 kits, are ordered and delivered to the assembly station in this manner.

At the assembly station, the individual groups of wires are removed from the bags. The dispatcher pushes a group of wires of a given characteristic into one or into two adjacent pigeonholes of an egg crate like structure. A typical such egg crate is a sheet metal rectangular box open at the front and back and divided by solid fiber partitions into 72 rectangular cavities or pigeonholes. Where the wires are less than pigeonhole length, a bag of wires or several wires of the bag at a time may be pushed into a single pigeonhole. Where the wires are longer than the pigeonholc depth the wires of a bag may be bent to form two legs and a bight or apex. One end or leg of the wire is pushed into the left side (facing the dispatcher) pigeonhole of a pair and the other end or leg of the wire pushed through the other pigeonhole of the pair and which is immediately to the right of the pigeonhole into which the first half of the wire was pushed. The apex or bight formed by folding each wire is positioned against the front divider between the pair of adjacent pigeonholes of the egg crate.

After the dispatcher has stored the wire into the individual adjacent egg crate pigeonholes, he identifies each pair of cavities into which a group of identical wires are positioned. The egg crates normally have 72 cavities or pigeonholes which form 36 pairs. After identifying each of the openings for short wires and pairs of openings for long wires by making or attaching labels to the partition material between and over the pairs of openings, to show identification of the separate groups of wires, the egg crates are carted to the using station. At the using station an assembly operator starts pulling out the different types of wires as needed for assembly into the electronic units to be assembled. Where the pigeonhole is not as deep as the length of the wires, the ends of the wires dangle behind the egg crate. This frequently results in problems of entanglement. Also in pushing the ends of the wires into the pair of cavities into which the wires fit they become twisted and bent or entangled. Often in trying to pull one wire from the group in the pair of cavities, because of entanglement within the cavities due to pulling bent, twisted or entangled wires and entanglement beyond the cavity, the assembler pulls more than one wire so that an additional wire is hanging loosely partly separated from the remainder. To rectify this the assembler normally tries to stuff one of the two wires which are usually pulled from the cabinet or egg crate back into the cabinet. Due to the entanglement and close grouping oftentimes the assembler cannot do this readily and she or he normally throws away the second wire (and any others pulled). This is wasteful of the wires which have been prepared adequately at the preparation station and imposes additional difficulties in handling the resulting scrap wire material.

Thus the prior art method and means requires cumbersome and time consuming bag packing and unpacking, and egg crate stuffing, and requires the handling of the egg crates or boxes of wires to be done at the assembly station where time and space are at a premium. By the prior art means and method there is caused disadvantageous wire entanglement, bending and distortion, loss of time, materials, and man hours due to difficulty of handling wires, and unnecessary waste and need for handling scrap. The prior art means and method is not sufficiently flexible and does not provide for ready rearrangement or change in assembled crates required to meet the needs of changing specifications, assembly operations or other changing conditions and the number of pairs of cavities in individual crates is fixed thereby causing insufficient flexibility and requiring an inventory greater than actually used of crates and types of crates to be on hand and sometimes use of crates which are not adapted to a particular project.

The present invention overcomes the above-enumerated and other disadvantages of the prior art and provides additional advantages.

SUMMARY OF THE INVENTION The apparatus of the invention comprises a rack and a predetermined plurality of wire holding and dispensing modules which the rack is structured to hold in a desired array, preferably in row-by-row rearwardly upward stepped cascaded relationship. Each module comprises an open-ended box, which may be of elongated substantially rectangular cross-sectional shape, and an elongated flat, generally rectangular-shaped divider. The box may further comprise means to removably retain the divider, for example, slidable means.

The divider in box inserted position partitions the box into chambers. When loaded and in box inserted position, the wires dispensed on the divider may be bifurcated, one end being in each chamber and the bight or bend apex being at the front of the divider. The divider may have wire bight retaining means at the front. For example, the divider front may be grooved. The upper chamber defining box sides may be bevelled to facilitate operator grasping of individual wire bights in pulling out wires for use in assembling a unit of apparatus. Identification tab holding or marking means may be provided at the top front of each module. In one embodiment, advantageous for wires longer than about twice the divider length, the divider is of flexible or resilient material and its rear portion is looped downwardly and forwardly terminating in a tongue. The box is slotted at the bottom to retain the tongue in divider locked condition. The loop is wider than the depth of the lower box chamber. The resilient material loop is contractable to a thickness less than lower box chamber depth by medium pressure exerted by the operators thumb and forefinger. This enables the operator to pinch the divider rear out of the tongue engagement in the slot when the divider is pulled out of the box or to compress the loop when the divider is slid into the box in tongue and slot locked engagement. In another embodiment, suitable for shorter wires, the divider may terminate in a box rear end cover having U-shaped spaced walls sized to interfit in the box inner walls and a flat end member sized to form a flange against which the rear box walls abut in divider retaining locked position.

In the inventive method, the assembler unlocks or disengages a divider from a box enclosing one, sliding the divider rearwardly out of the box. The assembler selects a group to be boxed, e.g., one of the types in the wire kit" to be assembled into an equipment. The assembler then draws the group of wires, with one wire end held from the divider rear underside, along the underside of the divider, and bends the group of wires over the wire holding means (groove) at the front end of the divider to form a bight. The assembler then draws the remainder of the length of the group of wires along the top side of the divider. Utilizing the above-mentioned first embodiment divider having the loop, where there is wire remaining to do so, the remaining wire is dangled over the rear bent over portion of the loop and allowed to hang downwardly. The divider is then reassembled into the tube with the wires inserted by pinching the loop and at the same time sliding with the grooved section forwardly disposed, from the box rear to the box front until the tongue is aligned with the groove. Locking is then effected by releasing the loop allowing the tongue to be depressed into the box slot. This group of wires is then ready for assembly. The wire group filled boxes required for a given assembly or subassembly are positioned in stepped row cascaded position in desired arrangement either as tilled or later. Assembly ofa unit or units may then be effected. Due to the stepped and cascaded arranging of boxes, the long wires will dangle over the rear divider loops, each row of wire ends resting on the loop dangling in a different plane.

The present invention provides the advantage ofelimination of two handling operations. By employing the wire storage and dispensing boxes of the invention at the preparation station the prepared wires may be loaded into the individual boxes by groups and the loaded wires are then ready to be used in assembly operations thereby eliminating the bag packing and the assembly into the egg crates operations of the prior art. Since the invention enables loading of one box at a time, the handling of boxes of wires is not required as in the case of the prior art egg crate assembly where done at the preparation station.

In the invention, the wire storing and dispensing boxes are stored in the rack in staggered array. Since the boxes may be made of equal lengths, the wires which are long enough to require positioning over the loop in the first above-enw merated embodiment may dangle behind the rack in different planes for different rows, thereby avoiding entanglement. Additionally, unless otherwise intended by the assembler, no more than one of the two ends will dangle over the divider rear end loop. Therefore, only one-half of the number of dangling wire ends for a given number of long wires are necessary as contrasted with handling of long wires in the egg crate prior art means.

In the prior art, the stuffing of groups of wires which were bent for assembly use had to be done by bending and forcing the unbent leg wire length down each cavity of pairs of egg crate cavities. This made bending and warping of the wire portions within the cavity almost inevitable. In the present invention, the divider around which the wire is to be bent is first withdrawn from the box and a group of wires are drawn from the divider rear along the underside, around the divider front and along the divider top. This wire drawing or pulling operation provided by the invention overcomes the difficulty of having to push the wires and the deleterious effect on the wires.

The modular nature of the assembly of wire holding boxes and the rack structure of the invention enables individual or several boxes to be disassembled or assembled in the rack readily without affecting the remainder of the assembled structure. This is advantageous where a group of wires is outmoded and a different group should be substituted. The different group of wires may be substituted in a box divider and the divider readily assembled back into the module or box. The arrangement or order of the individual wire holding modules may be changed. Modules may be inserted, may replace modules as a substitute or some of the modules may be removed, thereby facilitating changes in assembly corresponding to resequencing of assembly operations or redesign of the devices to be assembled.

In one embodiment, rack expansion or contraction of the rows of wire storage and dispensing modules may be more readily effected due to interfitting adjustability of the rack cover member. This is advantageous over the prior art egg crate wherein only a fixed number of the cavities provided may be used and the remainder left empty and unused. The invention provides better utilization and enables a lesser number of wire storage and dispensing boxes to be stocked. Also this adjustable interfitting rack and cover of the invention enables less bulk at an assembly station where less than the total number of modules assemblable into a rack need to be em ployed.

Accordingly, an object of the invention is to provide an improved apparatus and method to store, package, and handle component wires for assembly into fabricated units wherein handling is facilitated, and the elimination or reduction of handling operations in preparation, dispatching and assembly stations is provided.

Another object of the invention is to provide a wire storage and dispensing station and method for assembly of electronic, electromechanical, and mechanical units and devices which will enable a higher rate of available wires to be used for as sembly, which will lessen wire waste and scrap, wherein the wires are laid on and drawn into storage and dispensing module chambers wherein groups of ends of long wires may be dangled behind the station in separate planes, wherein a lesser number of wire storage and dispensing modules will be required, and which will facilitate handling of wires prior to and at assembly.

Another object of the invention is to provide an improved assembly station comprising an improved rack and wire storage and dispensing modular structure wherein ready rearrangement, adding to, subtracting from and/or substitution of modules in accordance with adjusting for changes in technical plans at any time prior to or during the electronic unit assembly process is facilitated, and wherein expansion or contraction of the number or types of wires utilized is facilitated.

Another object of the invention is to provide a means and a method for storage and dispensing of wires wherein the number of usable wires is increased and scrap reduced, facility is provided in handling, ready adaptability to changes in design or assembly of the wires into devices is enabled, wherein drawing of the wire to avoid damage to individua. wires by twisting or pushing at storage and at assembly is avoided to prevent wire entanglement, and wherein the number of dangling wires and frequency of possibility of intermingling of wires to provide unwanted entangling is avoided.

BRIEF DESCRIPTION OF THE DRAWINGS The above-mentioned and other features and objects will be apparent by reference to the following description taken in conjunction with the accompanying drawings in which:

H6. 1 is a view in perspective, as viewed by an operator from the left side at the front, of a first preferred illustrative embodiment of the wire dispensing and storing module of the invention showing an unloaded first preferred illustrative embodiment divider and box, the divider being inserted in locked position within the box, portions of the box being cut away for clarity of illustration;

FIG. 2 is a view in opposite perspective, as viewed from the right rear side by an operator, of the first preferred illustrative embodiment wire storing and dispensing module box of FIG. I with portions cut away for clarity of illustration and showing a rectangular, open-ended configuration terminated at one end by a bevelled portion to facilitate wire removal and a tab for facilitating stacking and at the other end of this view illustrating divider engaging rails and the bottom wall slot of the divider locking means;

FIG. 3 is a perspective view, as also viewed from the right rear side by an operator, of the first preferred illustrative embodiment wire storing and dispensing module divider of FIG. I, the divider being disengaged from the box and ready for mounting thereon of a group of component wires, and showing a wire apex retaining groove, a rear loop over which one end of long wires may be dangled, and a spring locking means; and a wire section supporting means, the divider being shown in position to be assembled into the box of FIG. 2;

FIG. 4 illustrates a second preferred illustrative embodi merit of the wire storing and dispensing module divider of the invention also having a wire apex receiving groove but terminating at the rear end, viewed to the right, in a box closure, this divider being adaptable for storing and dispensing wires which are shorter than or equal to the both side total length of the wire containing portion of the divider and wherein the wire storage and dispensing module box may be similar to that of FIG. 1 but preferably having an unslotted bottom wall;

FIG. 5 is an exploded view in perspective ofa first preferred illustrative embodiment of the assembly station of the present invention showing a first preferred illustrative embodiment of the rack of the invention with a cover member shown in full lines removed from the rack and in phantom being dropped to assembled position in the rack ready to be positioned in module array covering position and further showing a row of wire storage and dispensing boxes of the invention illustrated as loaded in the rack;

FIG. 6 is a view of an assembly station of the invention showing a side elevational view of the preferred embodiment rack of FIG. 5 but having a stack of modules mounted thereon comprising dividers of the embodiment of FIG. 3 loaded with wire components and locked in position in boxes such as shown in FIGS. 1 and 2, the rack cover being installed in the station in readiness for an apparatus assembly operation;

FIG. 7 is a view in perspective ofa second preferred illustrarive embodiment of the assembly station of the present invention illustrating a second preferred illustrative embodiment rack having an integral frame cover portion and illustrating a plurality of the boxes of the modules of the invention stacked in rows; and

FIGS. 8, 9 and [0 illustrate sequential steps of the method of the invention in mounting a group of wires on the divider, inserting the divider partially into the box, the divider then being positioned for retention in the box to form a loaded wire storage and dispensing module, the FIG. l module being shown for purposes of illustration, the module then being stacked or emplaced in desired position in the array in the rack as illustrated in FIGS. 5, 6 and 7.

Refer to FIGS. 1, 2 and 3. A wire storing and dispensing module 200 (see FIG. 3) which may comprise a box and a divider may be provided. The portion of the box 20 and of the divider 25 to the left as viewed in FIGS. 2 and 3. is nearest the assembly operator when removing wires for installation into equipments, and is designated the front and the portion to the right is designated the rear. Box 20 may be generally rectangular in longitudinal and in transverse cross section and may comprise sidewalls 2i and 22, a bottom wall 27 and a top wall 31. Box 20 may be made of a rigid metal or plastic. Divider 25 may comprise a front to rear extending elongated flat plate portion 39 generally rectangular in longitudinal and in transverse cross section and having a wire apex retaining front located groove 34 formed or machined in the general shape of a circular segment extending with the widest portion disposed toward the front and extending for the major portion of the divider width, a curved rear loop 35, a reversely bent angularly depending flat compressible spring section 36 which, when free from transverse compression by an operator, is bent angularly outward from flat portion 39 and a tongue 37 bent downwardly substantially normal to reversely bent section 36. Divider 25 may be formed of a rigid resilient material such that loop 35 and the bent over portion 36 will have spring like characteristics to enable withdrawing the tongue 37 from the slot 26 by compressing the loop 35. The material is rigid such that the wires may be mounted thereon without deforming the box 20 in assembling for operation. While nowise to be restricted thereto, one suitable material is polyvinyl chloride (PVC), a thermal plastic which has retentive memory such that upon forming when hot, the divider tends to be restored to original shape, that is, it is highly elastic. The tongue 37 extends substantially parallel to the loop 35 and is angularly bent outwardly with respect to the bottom side 82 of the divider 25 in order to impart a positive spring pressure like that of a hair pin to give positive pressure locking at tongue 37 into slot 26. Spring member 36 may alternatively be bent in the form of a slight ripple or wave (not shown) to provide additional elasticity. Divider 25 is of width slightly less than the distance between the inner surface of the side walls 21 and 22. Each of the sidewalls 2i and 22 may have formed thereon, integrally or otherwise attached, a pair of spaced protruberances or rails 23 and 24. The facing edges of

rails

23 and 24 are separated slightly more than the thickness of divider 25 to slidably support or retain divider 25. Transversely formed or machined through the bottom wall 27 at the rear is slot 26.

Refer to FIG. 1. At the front end, shown to the right in FIG. 1, of box 20 of module 200, the upper sidewall 21 and 22 may be chamfered by

chamfers

28 and 29 extending downwardly to the bottom side rails 24 at front terminations 43 and 44. A section of the top wall 31 is removed or top wall 3l is formed shorter than bottom wall 27 to provide receded edge 70 set back from the front edge 127 of bottom wall 27 to terminate the top of the bevels or

chamfers

28 and 29. An identification tab 32 may be provided. identification tab 32 may be flat, plate-shaped and rectangular in cross section and may be positioned about two-thirds of its width edges on the upper ends of the inclined chamfered surfaces 28 and 29 with the remaining width contiguous to and protruding above top wall 31. A cloth or paper marker 33 may be temporarily adhesively secured to tab 32 and may be marked with the identification of a group of wires temporarily stored or to be stored on the box 20 contained slidably divider 25. Groove 34 ofthe slidable divider 25 may comprise a flat recessed rear surface (not numbered) which is curved forwardly at the sides short of the side edges to form forwardly extending legs 41 and 42, the groove 34 being somewhat in the shape of a centrally flattened segment ofa circle. The divider 25 is made of width dimension slightly less than the distance between the walls 21 and 22 to enable divider 25 to easily slide within the

rails

23 and 24 of wall 2i and wall 22 throughout the length of the rectangular box or tube 20. The terms tube and box as used herein each mean an elongated open ended housing which may be square, rectangular, circular or otherwise shaped in cross section throughout most of its length. The length of the flat portion 39 of the divider member 25 may be longer than the length of box 20. When divider 25 is locked within box 20, the flat portion 39 may be thrust into the box 20 a distance such that the front projections 41 and 42 are substantially contiguous with the front faces of the

bevels

28 and 29 at their side rail front ter minations 43 and 44. The locked position of divider 25 within box 20 is reached when the tongue 37 is opposite the groove 26. The lengths and physical orientations of the flat spring 36 and of the loop 35 with relation to the length of the flat portion 39, including forward projections 41 and 42, of divider 25 are of appropriate dimensions to establish a divider 25 and a box 20 longitudinally aligned relationship wherein in assembled condition tongue 37 is depressed to engaged position in slot 26 and the forwardmost extended portion of the projection 4] and 42 is substantially contiguous with the side rail front terminations 43 and 44.

Refer to FIG. 4. A second preferred embodiment divider 65 is provided. Divider 65 may comprise a box terminating cover or box enclosure 75 and a front to rear extending elongated flat plate portion 66 generally rectangular in longitudinal and transverse cross section having a front groove 74 which may be disposed and shaped similar to groove 34 of the FIG. 2 embodiment. The divider 65 may be placed into a box 20 divider dimensioned to receive it but preferably a box 120 (see FIG. 7) not having a slot but otherwise similar in configuration to box 20 may be provided. Divider 65 is suitable for storing wires wherein the maximum amount of the length of the wire does not exceed approximately twice the length from the bottom of groove 74 to the inner bottoming surface 179 of the divider end closure 75. While the invention is nowise to be restricted by this exemplified dimension, a 14-inch long container 20 or 120 and a

divider

25 or 65 of according dimensions meets many requirements for housing wires of lengths suitable for all or a portion of many power harnesses of electronie equipments. For the longer length of wire, the open ended top chamber version such as that employing the divider 25 is desirable.

In flat slidable partition or divider 65 the front groove 74 is defined by a substantially flat bottomed curved portion (not numbered) substantially shaped as a segment of a circle the chord of which is almost the full width of divider 65 and a pair of projecting fingers 71 and 72 similar to the projecting fingers 41 and 42 respectively of the FIG. 3 embodiment. Similarly to flat plate portion 39 of the FIG. 3 embodiment, the flat plate portion 66 of FIG. 4 is dimensioned to slidably fit within the opposing rails 23, 24 of sidewalls 2] and 22 of the box 20 or corresponding side rails (not shown) of box 120. Box enclosure 75 may comprise a rectangular base 79 and a pair of separated generally U-shaped box interior engaging panel units 77. Each of panel units 77 may comprise a connecting panel 76 and a pair of end panels 78. The U-shaped panel units 77 are of dimensions and positioned such that the connecting panels 76 and end panels 78 fit in slidable and bearingly retained relationship within the upper, side and bottom walls 31, 21, 22 and 27 at the rear end (not numbered) of the box 20 illustrated in FIG. 1 or correspondingly within the walls at the rear of box 120. The rear end surface of the flat plate portion 66 may abut and may be permanently affixed to the inner surface 179 of the base 79 by conventional attachment such as adhesive, thermosetting or thermoplastic attachment. The panels 78 are spaced apart at their facing ends adjacent the ends of flat plate portion 66 to permit the

rails

23 and 24 or corresponding rails of box 120 to fit therewithin to permit closure of the divider 65 rear end into the box. The base 79 may be of cross-sectional dimensions to extend beyond the box interior engaging panel units 77, that is the underside of connecting panels 76 and end panels 78. The base 79 thus provides a flange (not numbered) on its inside box closure surface. The flange extends a distance sufficient to lock further sliding within the container to thereby form flange stop means in conjunction with the ends of walls of the container or box 20 or 120 into which the divider 65 is inserted. The space between panels 78 permits the rear ends of the

rails

23 and 24 of box 20 or corresponding rails of box 120 to be received therebetween and abut against the flange. Wires may be emplaced in one of the bins partitioned by divider 65 if short enough, e.g., under l4 inches. When the wires are too long for one bin and not long enough to extend more than the length of two bins, the wires may be drawn from the underside of flat portion 66, around the bottom edge defining groove 74, and above the top of flat portion 66 and divider 65 may be employed to mount such wires for storing in a module box 120.

Refer to FIG. 5. The wire storage and dispensing station provided in this embodiment of the invention may comprise a rack 100, a rack cover 61, and a plurality of wire storing and dispensing modules 20 or 120. The rack 100 and cover 61 may be of frame construction and may be formed of rods or of tubes of desired cross-sectional configuration. The words, top, bottom, upper, lower, vertical, horizontal, side, left side, right side, as used in the description of the rack 100 of FIGS. and 6 refer to the view as illustrated in FIGS. 5 and 6 of the drawings. The rods or tubes of the rack and cover may be secured together by conventional ways such as by welding or spot welding, bolts or screws and nuts, rivets, etc.

In the rack there may be provided a first rear frame rod 45 and a double angularly bent side frame rod 49 disposed in a first vertical frame, a second rear frame rod 46 and a double angularly bent side frame rod 50 disposed in a second vertical plane spaced from the first vertical plane to define the rack 100 width, a U-shaped frame 18 comprising a supporting rod 53 and two

side arm rods

51 and 52 and base frame rods 91, 92, 93 and 94, which, as will be described may alternatively be separately attached to the rear, side and U-shaped frame rods or may form an integral, rectangular base frame, for example with the base frame attached at its corners, for example to the rear, side and U-shaped frame rods. Double angularly

bent frame rods

49 and 50 each have a first lower bend and a second upper bend. Rod 91 is disposed horizontally across the front of rack 100. Rod 91 is connected at one end to the side frame rod 39 at the lower bend. Rod 91 is connected at its other end to the side frame rod 50 at the lower bend. Rod 92 is disposed horizontally extending from the front to the rear of the rack at right angles to rod 91. Rod 92 is connected at one end to the rear frame rod 46. Rod 92 is connected at the other end to the side frame rod 50 at the lower bend. Rod 93 is disposed in the horizontal plane of and parallel to rod 92 and spaced therefrom. Rod 93 is connected at one end to the rear frame rod 45. Rod 93 is connected at the other end to the side frame rod 49 at the lower end. Rod 94 is disposed in the horizontal plane of rods 91, 92 and 93 across the rear of rack 100 parallel to front rod 91. Rod 94 is connected at one end to the rear frame rod 45 and at the other end to the rear frame rod 46. Front base rod 91, side base rods 92 and 93 and rear base rod 94 and the interconnections thereto from a rectangular base frame 40. A portion of the rear frame rod 45 extends beneath the attachment to legs 93 and 94 and forms a rack supporting leg 145. A portion of the rear frame rod 46 extends beneath the attachment to legs 92 and 94 and forms supporting leg I46. Secured on the bottom ends of legs and 146 there may be provided flexible cups 47 upon which the

rack legs

145 and 146 may be frictionally supported on a surface. Double angularly bent

side frame rods

49 and 50 are each bent in the first direction vertically downwards perpendicular to the base 40 to form respective leg 149 and leg 150 which may be of equal length to that ofleg 145 and ofleg 146. Addi tional flexible cups 47 may also be provided and secured upon the supporting ends of each of legs I49 and 150. Additional flexible cups 47 may also be secured to the ends of

side frame rods

49 and 50 opposite respective legs 149 and 150. Cups 47 are of flexible material, rubber, for example, to protect the desk, bench or other surface upon which the rack 100 may rest and to provide a firm frictional antislip footing. The

side frame rods

49 and 50 each further comprises a respective angularly bent front frame side section 55 and 56. Sections 55 and 56 each are disposed in the vertical plane and slope rearwardly and upwardly from the legs 149 and 150 and are bent at respective

second bends

57 and 58 to third angularly extending side frame rod sections 59 and 60 respectively. Sections 59 and 60 extend substantially in the horizontal plane. Horizontal sections 59 and 60 are connected near but not at their ends to vertically extending

rear frame rods

45 and 46. Side frame rods 59 and 60 extend horizontally rearwardly beyond

rear frame rods

45 and 46 to form

side rod legs

159 and 160. Rod leg 159 and rod 160 may each terminate in an additional flexible cup 147.

Side rod legs

159 and 160 extend rearwardly beyond the rear base side 94 of the frame 40. The U- -shaped frame structure 18

side holding rods

51 and 52 are angularly sloped rearwardly upwards in the vertical plane at the angle that the front frame side sections 55 and 56 are sloped rearwardly upwards. Rod 51 is attached at its end opposite that connected to rod 53 at a point rearwardly disposed from the front to the rear along side frame rod section 59. Rod 52 is attached at its end opposite that connected to rod 53 at a point equally rearwardly disposed from the front to the rear along side frame rod section 60. The U-shaped structure 18 may be secured at the junction between the intermediate base support rod 53 and the side holding rod 52 to the leg 92 at a point approximately halfway from the front to the rear of leg 92. The junction between the

rods

51 and 53 may be secured at a corresponding point of leg 93 from the front of the leg 93 toward the back.

Cover 61 is structured to adjustably retain boxes 20 or 120 in tightly held or compressedly secured relationship within the rack 100. The frame cover 61 may be generally rectangular in shape and may comprise a first U-shaped frame comprising a pair of end box retaining rods 63 and 64, a rear box retaining rod 62, and may further comprise a closing U-shaped front box array retainer 162 parallel to rod 62 and secured to the ends of rods 63 and 64 to fonn the fourth side of rectangular frame cover 61. Box array retainer 162 may comprise a straight front top cover rod section 165 in the approximately same horizontal plane and parallel to rod 62 and may further comprise short vertically upward bent front frame side section engagers or cover retainers 163 and 164 at each end. Cover retainers 163 and 164 are spaced by rod 165 to closely and preferably bearingly engage the outer facing edges just outside of rods sections 55 and 56. This spacing and the structure of cover 61 enables rod 165 and hence cover 61 to be slidably mounted upon and be adjustably positioned on or be slid downwardly forwards along the side frame rod sections 55 and 56. The slidable retaining projections 163 and 164 enclose the angular rod sections 55 and 56. The uppermost position from which the cover is rested on or is slid downwardly depending upon the position of the upper walls 31 of the top row of boxes 20 is shown in phantom at locking engagement bends 57 and 58. The cover structure and spacing thereby provide a cam column compressing feature to retain the modules firmly but removably between the base and cover of the rack.

End box retaining rods 63 and 64 of cover frame 61 may be attached near the ends of front top cover rod section 165 at points opposite ends of rod 62. The spacing and dimensioning may be made such that rods 63 and 64 fit snugly within the

side frame rods

49 and 50 within the arm or box

side holding rods

51 and 52 such that the cover 61 may be positioned along sections 55 and 56 to rest upon the top surface of walls 31 of the boxes 20 or 120 stacked in rack 100. Shown in dashed lines in FIG. are the boxes or 120 aligned in the lowermost row of an array or matrix of boxes. The front ends of the lowermost row of boxes 20 or 120 rest upon their lower wall 27 or the corresponding box 120 lower wall under surfaces near its front, on the front base rod 91. The lower walls 27 or corresponding walls of the boxes 120 of the lowermost row of boxes 20 or 120 rest upon the intermediate base support rod 53 of the U-shaped rear support 18. The width of the rack 100 between the

side frame rods

49 and 50 and the widths of the modules are in interrelationship such that a predetermined number of modules, 200 per row, may be disposed between the

frames

49 and 50 in tightly held frictionally nonreadily module movable engagement. The rack boxes are preferably made of material such as polyvinyl to impart elasticity when compressed and the surface is such as to present some friction to non intended sliding between the surfaces of adjacent boxes 20.

It will be understood that either boxes 20 or 120 or corn binations thereof or other boxes in accordance with the invention may be stacked in the rack of FIGS. 5. 6 and 7. The description of FIGS. 5 and 6 mentions boxes 20 and its elements by way ofexample and is to be considered as applicable to and to include a description, emitted for brevity and clarity, of the boxes 120 and corresponding elements or other embodiments which may occur. The description of Fit]. 7 also mentions boxes 120 and its elements by way of example and is considered to be applicable and include also a description of the boxes 20 and corresponding elements, etc.

Refer to FIG. 6. Stacking is effected in an upwardly rearward stepped arrangement of rows of wire boxes 20 (or boxes 120). This is done by stacking each box 20 of each row except the bottom row such that the forward edge 127 of the bottom wall 27 of each such box 20 abuts the rear edge 30 of the identification tab 32 of the box 20 stacked immediately below. The box 20 front bottom edge 127 may be jammed or lightly wedged under the tab 32 at the niche 129. The material and securing of the tab 32 are made flexible and permit yielding such that some frictional and/or wedged holding together of boxes 20 is effected. This abutting and wedging affords the desired stepping angle and retains the boxes 20 in desired array with a locking feature afforded because force is necessary to overcome friction and to pry apart stacked and slightly wedged box edges 127 from the rear tab edge 30 and niche 129 defining sides comprising top wall 31 and the rear side 30 of tab 32. This enables and/or facilitates holding together in desired array of the boxes 20 whether standing as shown in FIGS. 5, 6 and 7 or resting on the rear in box front edge 127 upwardly facing array. The rack has additional versatility in that it may be either upended or placed on the bench or rack support (not shown) in the position shown in FIGS. 5, 6 and 7 so that access either from the front or from the top of the rack 100 may be had during assembly of wires into equipment by the operator. The rack 100 when in rack front upended position stands at a slight angle from the vertical resting upon the rear cups 147 and substantially tangential to the rack supporting surface upon side edge points of cups 47 of rack supporting legs and 146.

The angle with respect to the vertical plane of the side

frame rod sections

49 and 50 is preferably approximately the angle by which the boxes 20 are stepped in upwardly receding relationship as the rows are stacked. With the stacking in rack 100 of wire containers or modules the wires extending over the edge of the loops 35 will dangle downwardly in a successively receding plane for each row progressively upward in the column of rows such that entanglement of wires in the rear is reduced or avoided. This feature is illustrated at the right of FIG. 6 showing the rear of the therein illustrated modules 20. The feature of stepped rear terminations is unnecessary for rear enclosed boxes 120 and dividers 65.

The stepped array of boxes enables the operator, who is at the front of rack 100, shown to the left in FIG. 6 to have better access to the work. Access by the operator is also facilitated by the box front chamfers or bevels 28 and 29 in box 20. The inclined from upper chamber surface not only enhances accessibility by the fingers of the human hand of the operator. but better protects the operators fingers in reaching at as sembly for wires.

The cover member 61 may be positioned along the inclined sections 55 and 56 of

rods

49 and 50 downwardly and forwardly to a position where cover 61 rests upon the top row of the stacked boxes 20.

As seen by the dashed lines in the exploded view of FIG. 5, the cover 61 is readily removable. This permits ready removal of any one of the boxes 20 in the array of columns and rows, which box 20 is to be either deleted or substituted for or wherein a change of wire or of assembly sequence has been determined to be made. In that way, a change in accordance with desired design change of the device to be assembled or in accordance with manufacturing needs may more readily be made due to the modular construction of the wire storing and dispensing modules and due to the rack of the invention.

The spacing of the front box array retainer 162, front rod section and projections 163 and 164 in conjunction with the dimensions and construction of the end box retaining rods 63 and 64 and rear rod 62,

frame rods

49 and 50, and base support 18 facilitates positioning and permits additional sliding adjustability in emplacing the cover 61 to clampingly engage the boxes 20 at the upper walls 31 of the upper row.

Refer to FIG. 7. in this embodiment of the assembly station of the invention there may be provided a multipositionable fixed height rack 110 having an integral cover 111. Alternative use in the horizontal or vertical plane is provided. Cover 111 serves as a front member in upended position of the rack. The rack 110 and cover 111 may be formed of frame rods or tubes of any of various desired cross'sectional shapes. A side frame 140 and an opposite side frame (not shown) are provided. Each of the side frames 140 may have a long base side frame rod 142, a rear support rod 246, and a front double an gled side frame retaining rod 160. Front double-angled side frame retaining rod 160 may have a cover box retaining section 163 which extends horizontally rearward from an upper bend 158 at the rack upper front. From bend I58, rod 160 is bent to form a forwardly and downwardly extending angled side section 155. A second lower bend 157 is made in rod 160 at the lower end of section 155 to provide a vertical supporting leg section 150. As indicated hereinabove, boxes 20, 120 or other boxes and modules in accordance with the invention may be stacked in rack 110, boxes I20 being referred to by way of example. Base frame rods (not shown) support the bottom wall (not numbered) of the row of boxes 120 stacked in the rack 110. One of the base frame bottom box supporting rods (not shown) may be disposed underneath the lowermost row of boxes 120 near the front and may extend from the junction between the side frame rod 160 and the long base side frame rod 142 to the opposite corresponding junction of the opposite long base side frame and side frame rods (not shown). The other supporting frame rod (not shown) is disposed near the rear of and under the boxes of the bottom row to support the rows of boxes and may be connected between the rod 142 and its opposite rod (not shown). The rear support rod 246 may extend below the long base side frame rod 142 to form a supporting leg section I46. Leg sections I46 and 150 are preferably the same length. The long base side frame rod may extend rearwardly of rear support rod 246 to form a supporting leg section 245. beg sections 146 and 245 are perpendicular. The short base side frame rod 163 also may extend rearwardly of rear support rod 246 a distance preferably equal to the height of the leg section 245 to form a leg section 161. The supporting

leg sections

146, 150, 161 and 245 and the corresponding leg sections on the opposite side frame (not shown) each may be provided with fitted on flexible supports or cups 242. Cups 242 may be similar to and provide the functions of

cups

47 and 147 of FIGS. 5 and 6.

The

leg sections

146 and 150 and corresponding leg sections (not shown) on the opposite side enable the rack 110 to be supported in the position shown in FIG. 7. Alternatively, the legs 16] and 245 and corresponding legs of the opposite side may support the rack 110 in upended perpendicular position with the boxes I disposed vertically with the front (shown to the right in FIG. 7), then being in the position opening from the top. This is achieved by rotating the rack 110 counterclockwise 90 from the position illustrated adjacent the legend FIG. 7 of the drawings.

As shown in FIG. 7, the boxes 120 may be stacked in the rack 110 in rows and in stacking progressively upward may be stepped backwards. In each case the front edge of the bottom side of the box 120 is abutted against the rear edge of the identification tab (not numbered) of the next higher row box identification tab 32. This forms a stepped back nested array which preferably follows along the angle to the vertical of the front angled side frame retaining rod 160. The nesting facilitates the rack 110 functions wherein it serves as both a guide and to frictionally hold the nested rows of boxes together in the desired array in both horizontal and vertically disposed positions of the rack 110. The rack and module relative dimensions are preferably such that with a fully loaded complement of boxes 20 or 120 the pressure of the rack 110 cross bar 265 and the corresponding top rack cover 61 of the FIGS. 3 and 4 embodiment enables compressing the boxes 120 from top to bottom so as to releasably retain the boxes within the rack under retaining pressure.

Refer again to FIGS. 1-3 inclusive and refer to FIGS. 8 I0 inclusive. Straight portion 39 of divider has an under surface 82 and a top surface 83. A plurality of prepared wires 81 of a predetermined type may be provided at the preparing station sufficient in number to assemble a job order or a predetermined number of units to be manufactured. To commence the loading operation the operator obtains a wire storing and dispensing module divider 25 from its storage place either with other dividers 25 or form within a wire storage and dispensing module 200 which is unloaded. Refer to FIG. I. An unloaded divider 25 may be stored in the box 20 of a module 200. The outside surface 38 of spring section 36 may be grasped by the thumb and the approximately opposite upper surface 83 of straight portion 39 may be grasped by one or more of the index, second and third fingers, for example, as comfortable or more efiicient. Alternatively, the module 200 may be turned upside down and with the thumb engaging the upper surface 83, the surface 38 may be grasped by another finger or fingers. Grasping is effected with sufficient force to compress the spring section 36 toward straight portion 39 until the tongue 37 clears the slot 26. This pressure may be continued and the divider 25 may be withdrawn under this pressure rearwardly out of the box 20 of module 200. Alternatively divider 25 may be rearwardly withdrawn until the tongue 37 is beyond the rear of the slot 26 and the pressure then slackened with tongue 37 being slid along the bottom wall 27 until it clears the rear edge 48. Upon closing rear edge 48 the pressure may be further slackened to only enough grasping pressure so that the divider 25 may be withdrawn from box 20.

Refer to FIGS. 8 and 9. Prepared wires 81 may be positioned at the wire preparing station on the divider 25 with one end resting in the loop 80. Human fingers or a releasable clamp (not shown) may hold this end of wires 81 in position in loop 80. The remaining length of the wires 81 are drawn or wrapped along the divider undersurface 82 from the loop 80, then folded around the front of the groove 34 between fingers 41 and 42, then to extend over the upper side 83 and over the curved rear loop 35 to dangle downwardly thereover. The wires 81 form a bight or apex 86 at the folded and nested position in groove 34. While nowise to be limited to a particular number, by way of example, 35 wires of a particular type may be mounted upon the wire loaded divider 25. FIG. 9 illustrates, the wires 81 in mounted position on divider 25.

The front or grooved end (not numbered) of the divider and wire holding member 25 is then aligned with the rear face (not numbered) of the box 20 and positioned in a plane between the

rails

23 and 24 protruding from the sidewalls 21 and 22. The divider 25, with the apex or bight 86 of the group of wires 81 held within the groove 34, is then slid forwardly within and between the

rails

23 and 24 to the position illustrated in FIG. 10. At approximately this position of the divider 25 the tongue 37 and flat compressible spring section 36 are elevated with relation to the underside 82 of the divider 25 by squeezing the compressible flat spring section 36 and the rear end of the upper side 83 of the flat portion 39 between the thumb and index holding other finger(s) of the operator's hand, such that the tongue 37 clears the lower wall 27. The divider 25 is slid further forward within the box 20 until the tongue 37 has been positioned opposite the groove 26 in the bottom wall 27 of the module box 20. In this position, the tongue 37 is released and any required sight late and/or longitudinal adjustment of the divider 25 position is made until the spring action from the restoring force urging spring 36 downward causes the tongue 37 to be depressed into the slot 26 as illustrated in FIG. I. Upon depression to engage the tongue 37 into slot 26 the divider 25 is fixedly engaged within the box 20 in position for the wire assembly operation required for manufacturing a unit to be built. With the divider 25 locked into place, or at any other convenient time, the box 20 may be labeled for example, by attaching a cloth or paper adhesively backed appropriately marked marker 33 to the identification tab 32. The designation on marker 33 may, for example, characterize the particular wires 81 of identical characteristics such as particular lengths and types to be mounted upon a divider 25 and emplaced in box 20 of a particular wire dispensing and storing module 200 for later assembly into electronic or other units.

Refer to FIGS. 5, 6 and 7. Prior to assembly of equipment units. a plurality of loaded wire dispensing and storing modules 200 comprising boxes 20 and inserted dividers 25 each containing its complement of wires such as wires 81 mounted thereon are stacked, into the

rack

100 or 110. Stacking may optionally be done sequentially as the modules 200 are loaded in desired row and column positions to facilitate the assembly process. Alternatively, a complement of modules 200 may be loaded with the wires of the groups to make up the required number of power harnesses and the modules then stacked in desired positions in the

rack

100 or 1 10.

In the FIG. 3 divider, as shown in H6. 6, 9 and 10, the portions of wires 81 extending beyond the top surface 83 section opposite the loop 80 contained ends dangle behind and downwardly along the outside of loop 35 and therebelow in a plane behind the rack or 110. Thus a maximum of onehalf of the wires ends (one end for each wire) dangles behind a wire loaded module 200 in substantially a single vertical plane. The modules 200 are loaded in the

rack

100 or 110 by having successively upward rows of boxes stepped by dint of positioning each upper row box front 127 of bottom wall 27 against the back of the next lower row corresponding columnar positioned box identification tab 32. This provides the stepped arrangement illustrated in FIG. 6 wherein the ends of wires 81 in the module 200 upper chamber (not numbered) of each row above the lowest row dangle in substantially a single plane receded from the plane of dangling wire 81 ends in the row therebelow. The lowest row overhanging ends of wires 81 dangle in the frontmost plane of dangling wire planes.

The method steps of the invention of drawing of the wire around the divider instead of pushing of the wire ends into the front end of wire receiving chambers minimizes or reduces twisting or bending of the wire prior to unit assembly. By pulling the wire from the inner portion of the space 80 along the flat undersurface 82, over the groove 34 and along the top side 83 of dividers 25 and dangling the ends over loop 35 wire twisting is reduced or minimized. Less or minimum wire entanglement is caused in loading and assembling modules in accordance with the invention due to the stepped alignment of rows of modules 200 such that overhanging ends of different rows of wires 81 overhang in separate planes. The features that at most only one-half of the wire ends dangle, the wire drawing rather than wire pushing in wire storage and dispensing bin or chamber loading, and the resultant lack of twisting and bending of the wires, enable the individual wires 8! to be more readily pulled from the front of each of the modules in the assembly operation. In the assembly of units, one of the

divider

25 or 65 mounted wires 8! is grasped between the fingers of the operator at the apex or bight 86. The operator may optionally hold the remaining wires 81 in place. By virtue of the relative freedom of disentanglement afforded by the invention, one wire 81 may be readily separated from the others by the operator. As separated from the others, each wire 81 is installed in a predetermined position in the unit being assembled. The rack and box structure and the method of the invention facilitate installation at a bench where the rack is supported.

The invention thereby provides a means and a method whereby storage, packaging and handling of wire for assembly operations is facilitated, packaging and handling of wire for assembly operations is facilitated, elimination of handling operations in preparation, dispatching and assembly stations results, greater amounts of productive use of prepared wires is enabled and scrap reduced, the assembly of units of equipment is facilitated, the wires assembled into equipment are kept in better and less stressed and strained conditions and whereby the rack construction and the modular construction of wire containers enables ready rearrangement of modules, replacing of different modules, and adjusting for changes in equipment. The means and method of the invention enables a reduction in handling time to load wires into containers. The containers of the invention may be utilized as a combined shipping and packaging unit after preparation of wires. The invention further improves product reliability and enables avoiding damage to prepared ends of wires. The invention also provides for easier identification of individual wires or types of wires. Assembly and/or storing operations are facilitated by the invention since the racks may be stored and/or may be utilized at assembly in either a horizontal or a vertical position.

While salient features have been illustrated and described with respect to particular embodiments, it should be readily apparent that modifications can be made within the spirit and scope of the invention, and it is therefore not desired to limit the invention to the exact details shown and described.

What l claim is:

1. A modular wire storage and dispensing station to facilitate assembly of units having wire components comprismg:

a. a rack, said rack further comprising:

l a support base, 2. a pair of said enclosures, and 3. a cover,

b. a plurality of wire storage and dispensing modules removably stackable between said side enclosures and between said base and said cover of said rack, each of said modules further comprising:

1 an elongated box having an open front end,

2. a removable elongated wire supporting box divider contoured to fit in longitudinally extending relationship within said box, said divider having wire supporting and retaining means adapted to be loadable with and to retain wires in box removed condition, and

3. means to removably secure said divider in said box such that upon loading wires thereon said divider may be inserted into and retained in said box to divide said box into chambers to temporarily store said wires in position for removal through said box open front end; and wherein:

said rack support base and side enclosure are of frame construction,

. said modules are formed of elastic material and are of width with relation to said side enclosures such that a predetermined number of said modules are frictionally slidably contained in one of said rows,

said cover further comprises a cam interfitting means to compress said modules between said cover and said support base to clampingly secure said modules therebetween in releasable engagement,

said cam interfitting means further comprises a substantially U-shaped cover front frame member having a straight frame section terminated at each end by a cover retainer angularly bent with respect to said straight frame section,

. said side enclosures each further comprises:

1. a rear frame member having a normally vertically disposed leg,

2. a double angularly bent frame member having a normally horizontal upper side frame section and a normally rearwardly upward angled side frame section,

. said side enclosures, said straight frame section and said cover retainers are relatively spaced and dimensioned such that said cover retainers are adjustably engageable with said side frame sections to when positioned form said cam interfitting means to compress said modules between said cover and said support base in said releasable engagement, and

. said box of each of said modules further comprises:

1. a tab extending angularly vertically from said box to provide a surface against which a next vertically stackable module in said rack abuts to provide vertically stepped rows of said modules in said rack substantially angularly following the direction of said rearwardly upward angled frame section.

2. A modular wire storage and dispensing station to facilitate assembly of units having wire components comprismg:

a. a rack, said rack further comprising:

1 a support base, 2. a pair of side enclosures, and

3. a cover,

a plurality of wire storage and dispensing modules removably stackable between said side enclosures and between said base and said cover of said rack, each of said modules further comprising:

. an elongated box having an open front end,

3. means to removably secure said divider in said box such that upon loading wires thereon said divider may be inserted into and retained in said box to divide said box into chambers to temporarily store said wires in position for removal through said box open front end,

c. said box, divider, and means to movably retain said divider further comprising:

d. a box top,

e. a box bottom,

f. an elongated flat plate divider section having a bottom surface, a top surface and a front surface defining a wire bight receiving groove to enable drawing of said wire along said bottom surface. around said front groove defining surface and along said top surface for said wire loading and retaining,

g. a pair of rails protruding from the inside of each of an opposing two of said top, bottom and sides, said rails being separated to form a groove therebetween,

h. said divider being of dimensions with relation to the spacing between said opposing two insides and between said grooves to be slidably movable within the rails to divide said box into chambers such that said divider may be removed for loading, loaded, and reinserted within said box, and

i. means to lock said divider into position within said box where said front wire bight receiving groove is accessible by human fingers from said box front open end.

3. The modular wire storage and dispensing station of claim 2 wherein:

a. said box sides are forwardly downwardly chamfered from said top at the front and said top terminates at the front rearwardly of said bottom at the front thereby facilitating human finger accessibility and vision from the front,

b. said rails comprise top rails and bottom rails protruding from said box sides,

c. said box has an open rear end,

d. said divider when inserted into said box extends beyond said box open rear end,

e. said divider has a reversely downwardly bent loop disposed at its rear end to support wire ends extending thereover such that the wire ends dangle substantially in a plane immediately to the rear of the plane defined by the rear surface of said loop, said means to lock said divider further comprises a compressible spring section formed of elastic material and bent forwards from the lower end of said loop at an obtuse angle to said elongated divider section and bent substantially perpendicularly downwards at its forwardly terminating end to form a tongue, the spacing between said spring section in uncompressed condition and said elongated divider section being larger than the spacing between said bottom rails and said box bottom, said spring being compressible between human fingers such that said tongue clears said box bottom when said elongated divider section is slid in the groove between said top and bottom rails,

g. said box bottom has a slot rearwardly disposed, said tongue and said slot are parallel and said tongue and said slot are dimensioned and positioned to lockingly interfit when the divider is in operative inserted wire storing and dispensing position,

h. said box has an identification tab angularly disposed to its axis and protruding to enable rearwardly stepped stacking of superimposed modules.

2 wherein:

a. said box sides are forwardly downwardly chamfered from said box top at the front and said top terminates at the front rearwardly of said bottom at the front,

c. said means to secure said divider further comprises:

1. a box rear end enclosable wall having a dimension greater than the inner side spacing of said box,

2. means to attach said box enclosable wall perpendicularly to said flat plate divider section,

3. a first and a second U-shaped wall spaced to receive said flat divider section and the rear ends of said rails therebetween and dimensioned to bearingly slide within the rear top, bottom, and side portion within said box.

5. 1n station means to store prepared wires and to assemble said wires into equipment, a wire storage and dispensing module comprising:

a. an elongated box having top, side, and bottom walls and having open front and rear ends,

b. a box divider having supporting surfaces including a front surface to retain a wire bight and top and bottom supporting surfaces to support wire bifurcated ends,

. means to slide said divider selectively into box inserted condition wherein said wire bight retaining front surface is accessible from said box front end and said box is divided into wire end storing chambers, or to box removed condition to enable a wire to be drawn around said divider in bent wire configuration to fonn a bight and bifurcated ends such that said wire bight is disposed at said divider front surface and said wire ends are disposed along said bifurcated end top and bottom supporting surfaces,

d. means to secure said divider in said box in bight graspable position,

. said box front end sidewalls being bevelled downwardly and forwardly from said top wall, and said bottom wall extending forwardly of said top wall, to facilitate vision and grasping of said bight, and wherein said box bottom wall has a slot near its rear wall end,

. said divider further comprises:

1. a substantially rectangular elongated flat plate having opposite side edges and a rearwardly downwardly bent loop around which wires extending beyond said top surface are dangled,

2. a compressible material flat spring forwardly extending from the lower end of said loop to form an obtuse angle with said divider bottom supporting surface with the spring forward end positioned in spring uncompressed condition below said box bottom wall when said divider is aligned to be inserted into said box, and

3. A substantially downwardly extending tongue terminating said spring and of dimensions to be engagingly received in said slot,

. said means to slide said divider further comprises a pair of rails inwardly protruding from each said sidewall of said box and spaced to receive one of said side edges of said divider, said box inward sidewalls being spaced to receive said divider between said opposite side edges,

. said divider is of greater length than said box,

. said wire bight retaining front surface means further comprises a pair of forwardly extending fingers and a recessed center front section defining a groove in which wire bights are disposed, and

k. said divider fingers at the forward end are substantially contiguous with the adjacent box forward side edges when said tongue is engaged in said slot such that said bights disposed in said front section groove are in said bight graspable position.

6. A method of manufacturing a unit containing wires comprising the steps of:

a. preparing groups of the wires;

b. placing in proximity respectively each of said groups of wires, and for each of said groups a separable wire mountable box divider having first and second surfaces and a front end, and a divider retainable box having an open front end;

c, drawing the wires of each of said groups along said first surface, around said front end, and along said second surface of said group respective divider to form bights at the front end and bifurcated wire sections;

d. inserting each of said respective dividers into its said respective box to form therewith respective wire group storing and dispensing modules each having a first and a second chamber and a wire bight accessible open front; and

e. stacking said modules in a rack in rows comprising at least one row;

f. at least one of said dividers having a rear downwardly reversely bent loop, said drawing step further comprising:

g. positioning one end of the respective groups of wires of the at least one downwardly reversely bent box divider within the loop;

h. retaining said one end within the loop while drawing said last-named group of wires along said first surface, then around said front end, and then along said second surface of said box dividers; and

. draping any of said last-named wires which are longer than the length of said combined first and second bifurcated wire sections along said first and second surfaces and said bight, over said loop to dangle substantially in a plane rearwardly of said loop.

7. The method of claim 6, said stacking step further comprising:

a. arranging said modules in upward progressively stepped back rows such that said longer wires of each said row of modules dangles in a substantially separate plane.

8. A method of assembling a unit comprising the steps of:

a. preparing groups of wires at a wire preparing station,

b. mounting each of said groups at said preparing station upon a divider having first and second surfaces, a grooved front end, and a rear downwardly bent loop, said mounting further comprising:

1. positioning one end of the wires of said group within the loop,

2. retaining said end within the loop and drawing said wires along said first surface, around said grooved front end, along said second surface and any remaining wire length over said loop to form wire bights adjacent said grooved front surface, bifurcated wire ends along said surfaces, and remaining wire ends dangling in a plane behind the loop,

. inserting said divider to box loaded position into an openended box having a means to releasably receive said divider in loop protruding locked in relationship whereby said remaining wire lengths dangle substantially in a plane rearwardly immediately beyond said loop, and said bights are accessible from the front by the fingers of a hand, and having an angled angularly protruding tab,

. stacking in predetermined array a plurality of said loaded boxes in a rack in rows such that the end surfaces of the boxes of each row above the bottom row are stacked against one of the sides of the tabs of columnarly corresponding boxes of the next vertically disposed row to thereby stack the boxes in stepped backward relationship such that the remaining wires lengths dangle in separate planes for each row', and

compressingly securing said loaded boxes in the rack The method of claim 8 including:

selectively loading additional dividers into boxes, and deleting, inserting and rearranging said loaded boxes including said additional loaded boxes in accordance with currently changed composition, characteristics and numbers of wires required for said unit.

10. The method ofclaim 8 including:

"M050 UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent: No. 3, 599, 800 Dated August 17, 1971 Inventor(s) Bernard J. Durante It is certified that error appears in the above ide ntified atent and that said Letters Patent are hereby corrected as shown below? Col. 1, line 26, "bundles" should be -bundled. Col. 7, line 54, after "walls" insert 2l, 22, 27 and 31 or corresponding ends of walls.

Col. 8, line 19, after "rod, "39" should be 49--. Col. 13, line 58, after "facilitated," delete "packaging and handling of wire for assembly operations is facilitated,".

Signed and sealed this uth day of April 1 972.

(SEAL) Attest:

EDWARD M.FLETCHER,JR. ROBERT GOT'ISCHALK Attesting Officer Commissioner of Patents

Claims

1. A modular wire storage and dispensing station to facilitate assembly of units having wire components comprising: a. a rack, said rack further comprising: 1. a support base, 2. a pair of said enclosures, and 3. a cover, b. a plurality of wire storage and dispensing modules removably stackable between said side enclosures and between said base and said cover of said rack, each of said modules further comprising: 1. an elongated box having an open front end, 2. a removable elongated wire supporting box divider contoured to fit in longitudinally extending relationship within said box, said divider having wire supporting and retaining means adapted to be loadable with and to retain wires in box removed condition, and 3. means to removably secure said divider in said box such that upon loading wires thereon said divider may be inserted into and retained in said box to divide said box into chambers to temporarily store said wires in position for removal through said box open front end; and wherein: c. said rack support base and side enclosure are of frame construction, d. said modules are formed of elastic material and are of width with relation to said side enclosures such that a predetermined number of said modules are frictionally slidably contained in one of said rows, e. said cover further comprises a cam interfitting means to compress said modules between said cover and said support base to clampingly secure said modules therebetween in releasable engagement, f. said cam interfitting means further comprises a substantially U-shaped cover front frame member having a straight frame section terminated at each end by a cover retainer angularly bent with respect to said straight frame section, g. said side enclosures each further comprises: 1. a rear frame member having a normally vertically disposed leg, 2. a double angularly bent frame member having a normally horizontal upper side frame section and a normally rearwardly upward angled side frame section, h. said side enclosures, said straight frame section and said cover retainers are relatively spaced and dimenSioned such that said cover retainers are adjustably engageable with said side frame sections to when positioned form said cam interfitting means to compress said modules between said cover and said support base in said releasable engagement, and i. said box of each of said modules further comprises: 1. a tab extending angularly vertically from said box to provide a surface against which a next vertically stackable module in said rack abuts to provide vertically stepped rows of said modules in said rack substantially angularly following the direction of said rearwardly upward angled frame section.

2. a double angularly bent frame member having a normally horizontal upper side frame section and a normally rearwardly upward angled side frame section, h. said side enclosures, said straight frame section and said cover retainers are relatively spaced and dimenSioned such that said cover retainers are adjustably engageable with said side frame sections to when positioned form said cam interfitting means to compress said modules between said cover and said support base in said releasable engagement, and i. said box of each of said modules further comprises:

2. retaining said end within the loop and drawing said wires along said first surface, around said grooved front end, along said second surface and any remaining wire length over said loop to form wire bights adjacent said grooved front surface, bifurcated wire ends along said surfaces, and remaining wire ends dangling in a plane behind the loop, c. inserting said divider to box loaded position into an open-ended box having a means to releasably receive said divider in loop protruding locked in relationship whereby said remaining wire lengths dangle substantially in a plane rearwardly immediately beyond said loop, and said bights are accessible from the front by the fingers of a hand, and having an angled angularly protruding tab, d. stacking in predetermined array a plurality of said loaded boxes in a rack in rows such that the end surfaces of the boxes of each row above the bottom row are stacked against one of the sides of the tabs of columnarly corresponding boxes of the next vertically disposed row to thereby stack the boxes in stepped backward relationship such that the remaining wires lengths dangle in separate planes for each row; and e. compressingly securing said loaded boxes in the rack

2. A modular wire storage and dispensing station to facilitate assembly of units having wire components comprising: a. a rack, said rack further comprising:

2. a pair of side enclosures, and

2. a pair of said enclosures, and

3. The modular wire storage and dispensing station of claim 2 wherein: a. said box sides are forwardly downwardly chamfered from said top at the front and said top terminates at the front rearwardly of said bottom at the front thereby facilitating human finger accessibility and vision from the front, b. said rails comprise top rails and bottom rails protruding from said box sides, c. said box has an open rear end, d. said divider when inserted into said box extends beyond said box open rear end, e. said divider has a reversely downwardly bent loop disposed at its rear end to support wire ends extending thereover such that the wire ends dangle substantially in a plane immediately to the rear of the plane defined by the rear surface of said loop, f. said means to lock said divider further comprises a compressible spring section formed of elastic material and bent forwards from the lower end of said loop at an obtuse angle to said elongated divider section and bent substantially perpendicularly downwards at its forwardly terminating end to form a tongue, the spacing between said spring section in uncompressed condition and said elongated divider section being larger than the spacing between said bottom rails and said box bottom, said spriNg being compressible between human fingers such that said tongue clears said box bottom when said elongated divider section is slid in the groove between said top and bottom rails, g. said box bottom has a slot rearwardly disposed, said tongue and said slot are parallel and said tongue and said slot are dimensioned and positioned to lockingly interfit when the divider is in operative inserted wire storing and dispensing position, h. said box has an identification tab angularly disposed to its axis and protruding to enable rearwardly stepped stacking of superimposed modules.

3. A substantially downwardly extending tongue terminating said spring and of dimensions to be engagingly received in said slot, h. said means to slide said divider further comprises a pair of rails inwardly protruding from each said sidewall of said box and spaced to receive one of said side edges of said divider, said box inward sidewalls being spaced to receive said divider between said opposite side edges, i. said divider is of greater length than said box, j. said wire bight retaining front surface means further comprises a pair of forwardly extending fingers and a recessed center front section defining a groove in which wire bights are disposed, and k. said divider fingers at the forward end are substantiAlly contiguous with the adjacent box forward side edges when said tongue is engaged in said slot such that said bights disposed in said front section groove are in said bight graspable position.

3. means to removably secure said divider in said box such that upon loading wires thereon said divider may be inserted into and retained in said box to divide said box into chambers to temporarily store said wires in position for removal through said box open front end; and wherein: c. said rack support base and side enclosure are of frame construction, d. said modules are formed of elastic material and are of width with relation to said side enclosures such that a predetermined number of said modules are frictionally slidably contained in one of said rows, e. said cover further comprises a cam interfitting means to compress said modules between said cover and said support base to clampingly secure said modules therebetween in releasable engagement, f. said cam interfitting means further comprises a substantially U-shaped cover front frame member having a straight frame section terminated at each end by a cover retainer angularly bent with respect to said straight frame section, g. said side enclosures each further comprises:

3. a cover, b. a plurality of wire storage and dispensing modules removably stackable between said side enclosures and between said base and said cover of said rack, each of said modules further comprising:

3. a cover, a plurality of wire storage and dispensing modules removably stackable between said side enclosures and between said base and said cover of said rack, each of said modules further comprising:

3. means to removably secure said divider in said box such that upon loading wires thereon said divider may be inserted into and retained in said box to divide said box into chambers to temporarily store said wires in position for removal through said box open front end, c. said box, divider, and means to movably retain said divider further comprising: d. a box top, e. a box bottom, f. an elongated flat plate divider section having a bottom surface, a top surface and a front surface defining a wire bight receiving groove to enable drawing of said wire along said bottom surface, around said front groove defining surface and along said top surface for said wire loading and retaining, g. a pair of rails protruding from the inside of each of an opposing two of said top, bottom and sides, said rails being separated to form a groove therebetween, h. said divider being of dimensions with relation to the spacing between said opposing two insides and between said grooves to be slidably movable within the rails to divide said box into chambers such that said divider may be removed for loading, loaded, and reinserted within said box, and i. means to lock said divider into position within said box where said front wire bight receiving groove is accessible by human fingers from said box front open end.

4. The modular wire storage and dispensing station of claim 2 wherein: a. said box sides are forwardly downwardly chamfered from said box top at the front and said top terminates at the front rearwardly of said bottom at the front, b. said rails comprise top rails and bottom rails protruding from said box sides, c. said means to secure said divider further comprises:

5. In station means to store prepared wires and to assemble said wires into equipment, a wire storage and dispensing module comprising: a. an elongated box having top, side, and bottom walls and having open front and rear ends, b. a box divider having supporting surfaces including a front surface to retain a wire bight and top and bottom supporting surfaces to support wire bifurcated ends, c. means to slide said divider selectively into box inserted condition wherein said wire bight retaining front surface is accessible from said box front end and said box is divided into wire end storing chambers, or to box removed condition to enable a wire to be drawn around said divider in bent wire configuration to form a bight and bifurcated ends such that said wire bight is disposed at said divider front surface and said wire ends are disposed along said bifurcated end top and bottom supporting surfaces, d. means to secure said divider in said box in bight graspable position, e. said box front end sidewalls being bevelled downwardly and forwardly from said top wall, and said bottom wall extending forwardly of said top wall, to facilitate vision and grasping of said bight, f. and wherein said box bottom wall has a slot near its rear wall end, g. said divider further comprises:

6. A method of manufacturing a unit containing wires comprising the steps of: a. preparing groups of the wires; b. placing in proximity respectively each of said groups of wires, and for each of said groups a separable wire mountable box divider having first and second surfaces and a front end, and a divider retainable box having an open front end; c, drawing the wires of each of said groups along said first surface, around said front end, and along said second surface of said group respective divider to form bights at the front end and bifurcated wire sections; d. inserting each of said respective dividers into its said respective box to form therewith respective wire group storing and dispensing modules each having a first and a second chamber and a wire bight accessible open front; and e. stacking said modules in a rack in rows comprising at least one row; f. at least one of said dividers having a rear downwardly reversely bent loop, said drawing step further comprising: g. positioning one end of the respective groups of wires of the at least one downwardly reversely bent box divider within the loop; h. retaining said one end within the loop while drawing said last-named group of wires along said first surface, then around said front end, and then along said second surface of said box dividers; and i. draping any of said last-named wires which are longer than the length of said combined first and second bifurcated wire sections along said first and second surfaces and said bight, over said loop to dangle substantially in a plane rearwardly of said loop.

7. The method of claim 6, said stacking step further comprising: a. arranging said modules in upward progressively stepped back rows such that said longer wires of each said row of modules dangles in a substantially separate plane.

8. A method of assembling a unit comprising the steps of: a. preparing groups of wires at a wire preparing station, b. mounting each of said groups at said preparing station upon a divider having first and second surfaces, a grooved front end, and a rear downwardly bent loop, said mounting further comprising:

9. The method of claim 8 including: a. selectively loading additional dividers into boxes, and b. deleting, inserting and rearranging said loaded boxes including said additional loaded boxes in accordance with currently changed composition, characteristics and numbers of wires required for said unit.

10. The method of cLaim 8 including: a. marking indicia and placing such indicia upon said boxes in accordance with designation of the wires contained in said boxes.