US3713196A

US3713196A - Terminating machine for electrically connecting wire leads to posts on a terminal board

Info

Publication number: US3713196A
Application number: US00180677A
Authority: US
Inventors: P Garner
Original assignee: Thomas and Betts Corp
Current assignee: ABB Installation Products Inc
Priority date: 1971-09-15
Filing date: 1971-09-15
Publication date: 1973-01-30
Anticipated expiration: 1990-01-30

Abstract

A terminating machine comprises a combination of mechanism for effecting the connection of a stripped wire (either stranded or solid) to a terminal post of an integrated circuit panel board. The several mechanisms include sorting and feeding means for the electrical connectors, wire bearing and inserting means for inserting the wires into the connector preparatory to crimping about the terminal post, and extruding means for forming a gastight connection between the stripped wire and the terminal post to complete the electrical connection. The apparatus of the subject invention may be mounted on a convention x-y machine in order to enable semi-automatic operation of the machine during assembly of an interconnection panel.

Description

United States Patent m1 Garner 1 Jan. 30, 1973 [54] TERMINATING MACHINE FOR ELECTRICALLY CONNECTING WIRE LEADS TO POSTS ON A TERMINAL BOARD [75] Inventor: Peter Garner, Bernardsville,N.J.

[73] Assignee: Thomas & Betts Corporation,

Elizabeth, NJ.

221 Filed: Sept.l5, 197i 211 Appl.No.: 180,677

[56] References Cited UNITED STATES PATENTS Phelps et al ..29/203 D X Vickery, .Ir. ..29/203 B Primary ExaminerTh0ma s H. Eager Attorney-David Teschner, Esq.

[57] ABSTRACT A terminating machine comprises a combination of mechanism for effecting the connection of a stripped wire (either stranded or solid) to a terminal post of an integrated circuit panel board. The several mechanisms include sorting and feeding means for the electrical connectors, wire bearing and inserting means for inserting the wires into the connector preparatory to crimping about the terminal post, and extruding means for forming a gas-tight connection between the stripped wire and the terminal post to complete the electrical connection. The apparatus of the subject invention may be mounted on a convention x-y machine in order to enable semi-automatic operation of the machine during assembly of an interconnection panel.

11 Claims, 9 Drawing Figures PATENTEDJAN 30 I975 3,713, 11

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SHEET 3 [IF 3 84 I I: 44 67 55 64 FIG 4 Z0 2 INVENTORQZZ ATTOR/VEV TERMINATING MACHINE FOR ELECTRICALLY CONNECTING WIRE LEADS TO POSTS ON A TERMINAL BOARD The present invention relates to a machine, more specifically a semi-automatic machine for effecting the electrical connection between a stripped wire and a terminal post of an integrated circuit panel board.

The machine of the subject invention is adapted for use with an improved type of ductile electrical connector for providing a mechanical and electricalinterconnection between a conductor and, for example, a small terminal post of the type normally found in computers and other complex miniaturized electrical and electronic equipment. The use of the ductile connector is particularly suitable for forming a gas-tight connection, and for providing strain relief for the wires of the small insulated conductors. The type of extrudable electrical connector which is referred to is disclosed in U. S. Patent application Ser. No. 113,833, filed Feb. 9, 1971 by Francis A. OLoughlin and entitled Extrudable Electrical Connector and Connection, which application is assigned to the same assignee of the present invention and has been abandoned.

Before discussing the machine of the subject invention, it should be noted that a ductile electrical connector is preferably made of sintered powdered metal which is extremely ductile, and after compression forms a strong mechanical connection whereby it has particular application for electrical connecting means. A sintered powdered metal part can be made of copper, platinum, or stainless steel, along with other metals on which research is presently being conducted. Sintered powdered metal has almost a total lack of rebound or lack of memory, which makes it particularly easy for use in the connector field where the contact pressure between conductor elements is of primary importance. Along these lines, a sintered powdered metal electrical connector can be formed into nu-- merous shapes, this being inherent by virtue of the particular characteristics of powdered metal. This is a particularly important feature in that certain electronic systems are extremely small, whereby sintered powdered metal connectors may be readily formed and adapted for use in such applications.

The type of wire which is normally employed in integrated circuit panel boards is usually of 30 or 32 gauge wire. It is common to terminate wires to the terminal post of an integrated circuit panel, (said post being approximately 0.025 inches square) either by soldering or by wire wrapping wherein several turns of wire are wrapped around the post. As fully discussed in the above identified pending application, the use of a sintered powered metal connector provides greater reliability and ruggedness of the resulting connection, as well as good electrical connection characteristics of the connection.

The machine of the present invention includes a sorting and feeding system which automatically feeds the sintered powdered metal connectors into the extrusion tip of the machine, which system includes a hopper and air power means for feeding the sintered powdered metal part. In addition, the machine includes a suitable sensor means for determining when the sintered powdered metal part has been fed from the hopper to the extrusion tip. After a connector part has been seated in the extrusion tip, a wire inserting mechanism accepts a wire which has been both precut and pre-stripped, the wire being inserted manually into a groove of the wire inserted mechanism, after which the wire inserter mechanism is operated to cause the wire to bend upwardly and when in such position to be inserted into the bore of the sintered powdered metal connector. When forced into the bore of the connector, the wire is captivated by the extrusion means and is then ready for placement over the terminal post. Next, the machine is operated so as to move the extrusion means downwardly over a terminal post, and during this downward movement, the wire inserting mechanism is cammed out of the way of the downwardly moving extrusion means. When the connector and wire have been placed over the terminal post, the extrusion operation is commenced, thereby extruding the connector so as to form a mechanical and electrical connection between the post, the wire and the connector. The components of the machine are so arranged that during the extrusion operation, substantially no axial load is applied to the relatively fragile terminal post of the interconnecting panel by the extrusion tool. In addition, during the extrusion operation, an inner cylindrical plunger of the extrusion tool holds the sintered powdered metal connector in position while an outer cylindrical plunger is moved relative to the inner plunger and is effective to extrude the connector about the terminal post. In addition, during the extrusion operation it is of primary importance that there is no physical contact during the transmission of forces developed by the machine to the relatively delicate terminal post, and this is of particular importance especially in those cases where the terminal post is formed as part of a socket assembly which is held in the terminal board merely by frictional force.

Additional objects and advantages of the machine of the subject invention will become apparent from a reading of the following detailed description with reference to the drawings, in which:

FIG. 1 is a perspective view of the machine of the subject invention, and including a partial perspective view of a panel board;

FIG. 2 is a partial sectional view of the wire inserting mechanism, and extruding means of the machine of the subject invention;

FIG. 2A is a view taken along lines 2A-2A in FIG.

FIG. 3 is a figure similar to FIG. 2 but illustrating the components of the wire inserting mechanism during an intermediate operational mode thereof;

FIG. 4 is a view similar to FIG. 2 but illustrating the final position of the wire inserting mechanism of the subject invention during the operation thereof;

FIG. 4A is a view taken along lines 4A-4A in FIG. 4; and

FIGS. 5A, 5B and 5C illustrate the relative positions between the wire inserter mechanism and the extrusion means during the extrusion mode of operation of the machine of the subject invention.

Referring to FIG. 1, the terminating machine of the subject invention is generally designated by the numeral I0, and basically comprises a feeding and sorting means 12, a wire bending and inserting mechanism 14, and extruding means 16, along with suitable actuating and control means for coordinating the operation of said components of the terminating means, the actuating and control means being housed within housing 18.'.

portion 26' which isfextruded or caused to flow in order to effect the electrical connection.

In general, a plurality of electrical connectors 26 are fed into the hopper 30 of the feeding and sorting means 12, with the latter including a suitable air operated shuttle device, shown schematically as 32, which, when actuated, provides a single electrical connector 26, properly oriented for extruding, through tube 34 to the extruding means 16. In order to insure the proper feeding of a single electrical connector, it is suggested that an optical sensor 36 be provided intermediate the length of the tube 34 for providing the operator of the terminating machine with an indication that a connector has been fed to the extruding means 16.

With a connector properly disposed in the extruding means, the end of the wire 20, which has previously been stripped, is manually fed into the wire inserting mechanism 14, after which the latter mechanism is actuated so as to bend the end of said wire approximately 90, followed by the subsequently insertion of the stripped end of the wire into the bore of the generally cylindrical electrical connector 26. At this time, the combination of the ductile electrical connector and the wire 20 is ready for connection to the terminal post 22. The operator of the terminating machine 10 then rotates handle 40 in a downwardly direction, at which time the wire inserter mechanism is cammed laterally (as indicated by the dotted line position) as the extruding means 16 is moved downwardly over the terminal post 22. Next, the extruding means are actuated whereby the ductile electrical connector is extruded about the terminal post 22, with the wire 20 being disposed between said connector 26 and the terminal post 22. Hence, a gas-tight mechanical connection is formed between the connector 26, wire 20 and terminal post 22, and an electrical connection is effected between the stripped end of the wire and the terminal post. As the operator rotates the handle 40 upwardly, the extruding means 16 returns to its initial position, and the feeding and sorting means 12 is actuated to provide the next aligned electrical connector to the tip of the extruding means. As is readily apparent to those skilled in the art, the operation of the various mechanisms of'the terminating machine 10 may be individually controlled, through the use of suitable actuating switches, shown as elements 50 through 58 on the front face of the housing 18, or alternatively the control system of the terminating machine may be designed for semi-automatic operation to combine certain steps in the operation of the machine 10.

Reference will now be made to FIGS. 2 through 4A which illustrate in detail the components of the wire inserter mechanism and the extruding tip of the extruding means 16.

Referring to FIGS. 2 and. 2A, the wire inserter mechanism 14 includes a shaft 60 which is mounted at its upper end in housing 18 for vertical movement and for pivotal movement about an axis extending fore and aft of the housing 18 for lateral displacement relative to the extruding means 16. Rigidly secured to the lower end of shaft 60 is a flange 62 from which extends wire inserter pin 64. A groove 65 is formed in pin 64 to aid in the bending movement of the wire 20. A generally L- shaped member 66 is slidably mounted on the shaft 60 above the flange 62 and includes a leg portion 66', the forward end of which is formed with a cut-out 67 that is generally semi-conical in configuration. In addition, the leg portion 66 of L-shaped member 66 includes an aperature 67' through which the wire inserting pin 64 extends, as well as an enlarged recess 66", in which is placed a resilient pad 69, to be fully discussed hereinafter.

As illustrated in FlG. 2, in the initial position of the wire inserter mechanism 14, the wire inserter pin 64 extends to a point approximately level with the upper surface of the leg portion 66 of the L-shaped member 66. In addition, in this position, the L-shaped member 66 is spaced from the flange 62 by a distance d. The L- shaped member 66 is guided in its vertical movement along the shaft 60 by means of a guide pin-68 which extends through a guide slot 70 formed in a side portion 60' of the shaft 60. Disposed between a shoulder 60" of the shaft 60 and the upper surface of the L-shaped member 66 is a spring 72 to provide a constant downward biasing force on the L-shaped member 66. The cut-out 67 of the L-shaped member defines a funnel-shaped opening through which the pre-stripped wire 20*is positioned in the wire inserter mechanism 14. The other half of said funnel-shaped opening is defined by a pair of spring leaves 76 which are cantilevered from the L-shaped member 66 and connected thereto by screws 78, the upper surface of said spring leaves being defined with inclined surfaces 77. Each spring leave is generally triangular in cross-section at its forward end, and has integrally formed therewith a thin leaf portion 76' through which the screw 78 is mounted. Accordingly, each spring leaf may be readily deflected laterally, as illustrated in FIG. 4A.

The tip portion of the extruding means 16 is partially shown in FIGS. 2 and 2A and comprises an inner cylindrical plunger 80 concentric with an axially movable extruding sleeve 82 having an extruding tip portion 84 of slightly greater internal diameter than the outer diameter of plunger 80.'Formed adjacent the forward end of the extruding tip 84 is a keyhole slot 86 which is dimensioned to be slightly greater than the diameter of the insulation of wire 20 so as to grip the wire while the extruding means 16 is being lowered over a terminal post 22 preparatory to an extrusion operation.

As shown in FIG. 2, a ductile connector 26 is disposed at the tip of the extruding means 16, with the enlarged diameter portion 26 thereof being slightly greater than the internal diameter of the extruding tip portion 84. As is readily apparent, with the plunger 80 held in a stationary position, and with the movable sleeve 82 being withdrawn upwardly, the connector 26 is extruded and its internal diameter reduced by the flow of material of the connector so as to form a mechanical and electrical connection between a wire and a tenninal post.

Referring to FIG. 2, the position of the wire inserting means and the extruding means are shown preparatory to the manual insertion of a pre-stripped wire into plunger 80 is held in position thereby extruding the connector 26. More particularly, during the extrusion means 14. The pre-stripped wire is manually inserted into the funnel shaped opening defined by the conical cut-out 67 and the lower portions of the triangleshaped sections of the spring leaves 76, until the wire contacts the front face of the L-shaped member 66 at the point designated by letter f. The wire inserter mechanism 14 is then actuated thereby retracting the shaft 60 in a generally upwardly direction. The movement of the shaft 60 in the upward direction initially raises the flange 62 through the distance d without causing a corresponding movement of the slidably mounted L-shaped member 66. During this initial upward movement through the distance d, wire is positioned in groove 65 of pin 64 and is bent generally upwardly about the lower surfaces of the front portions of the spring leaves 76 to the generally vertical position illustrated in FIG. 3. After the wire 20 is bent through approximately a 90 angle, the entire wire inserter mechanism 14 continues to move upwardly to a predetermined point at which the insulated portion of wire 20 is forced into keyhole slot 86, and at which time the tip end of the extruding sleeve 82 is partially embedded in the resilient pad 69. Hence the pad 69 acts as a cushion to prevent mechanical interference between the metallic parts of the wire inserter mechanism and the extruding means. At this time, wire 20 is fully inserted into the bore of the sintered powdered metal connector 26. (See FIGS. 4 and 4A) It is noted that as shaft 60 is moved upwardly, the movable sleeve 82 of the extruding means rides on the inclined faces 77, 77 of the spring leaves 76, 76 thereby camming the latter outwardly relative to one another (see FIG. 4A), by virtue of the spring mounting thereof to the L-shaped member 66 to enable the bent portion of the wire 20 to be fully inserted into the connector 26. In the final position illustrated in FIGS. 4 and 4A, the stripped portion of the wire extends slightly beyond the upper end of the connector 26 and is generally disposed in the region of the enlarged diameter portion 26' of the connector 26, while the insulated portion of the wire has been forced into the keyhole slot 86 in the movable sleeve 82. The positioning of the insulated conductor in the keyhole slot 86 insures that the wire will not be inadvertently withdrawn from the connector 26 and the extruding tip when the wire inserter means is retracted to its initial position, preparatory to lowering the extruding means onto a terminal post.

Once the wire has been fully inserted into the powdered metal connector, the next step in the operation is to position the connector and wire about a terminal post preparatory to the extrusion operation. As previously mentioned shaft 60 is mounted for pivotal movement about a fore and aft axis whereby, as illustrated in FIGS. 5A and 58, as the extruding means is located over and onto terminal post 22, the shaft 60 is cammed laterally so as to prevent the wire inserter mechanism from contacting adjacent terminal posts and to be moved to a position out of the path of the extruding means. In the position of the elements illustrated in FIG. 5B, the extruding means has been lowered to the desired depth onto the terminal post and the extruding apparatus may then be actuated so as to cause the movable sleeve 82 to be withdrawn upwardly, while the operation, the extruding tip 84 forces the enlarged portion 26 of the connector 26 to flow radially inwardly whereby forming a gas-tight mechanical connection, as well as an electrical connection, between the exposed portion of the wire 20 and the terminal post 22.

After the extrusion operation is completed, the extruding tip is withdrawn upwardly, and simultaneously the wire inserting means is cammed laterally to its initial position. At the same time, the feeding and sorting means 12 is actuated so as to provide another connector 26 via the tube 34 and opening 34' to the extruding means (see FIG. 5C).

In the operation of the subject apparatus, assuming connector 26 is positioned in the extruding tip, the first operation would be for the operator to manually insert a pre-stripped wire into the funnel-shaped opening defined by the cut-out 67 and the spring leaves 76. The operator would then actuate a suitable switch so as to effect operation of the wire inserting means, after which the operator would manually operate handle 40 to cause the extruding means to be lowered over a terminal post. At such time, the wire inserting means would be rotated laterally so as to be positioned out of the path of the downwardly moving extruding means. The operator would then actuate a suitable switch to actuate the extrusion head thereby forming an electrical connection between the wire 20 and the terminal post 22.

In recycling the terminating machine of the subject invention, the operator rotates handle 40 upwardly, thereby actuating a suitable internal switch causing the cylindrical sleeve 82 to move downwardly relative to the plunger sleeve 80, and simultaneously actuate the plunger upwardly so as to create a sufficient clearance to enable another ductile connector to be fed into extruding head. As the plunger moves upwardly it actuates a suitable micro-switch closing the solenoid of the feeding and sorting means 12 to actuate same thereby causing the automatic feeding of a connector. At such times, the connector actuates the optical sensor 36, and the system is activated to the on or ready position.

As is readily apparent to those skilled in the art, the operation of these various mechanisms of the subject invention may be suitable controlled by an automatic control means so as to operate in a continuous manner, or alternatively, as described, the system may be operated in a semi-automatic manner. The terminating machine 10 of the subject invention may be readily mounted on a conventional X-Y assembly system to enable rapid assembly of an integrated circuit panel.

Although the invention has been described with reference to a specific embodiment, it will be obvious to those skilled in the art that modifications and variations thereof may be made without departing from the spirit of this invention, and such modifications are contemplated.

What is claimed is: l. A terminating machine for electrically connecting a wire to a terminal post comprising:

feeding and sorting means for orienting and feeding a series of ductile electrical connectors; extruding means for receiving one of said series of ductile electrical connectors and extruding same about a terminal post;

wire inserting means operative to insert a wire into the confines of each electrical connector preparatory to extrusion thereof to a terminal post; and

actuating and controlling means for operating said feeding and sorting means, said extruding means, and said wire inserting means in a sequential manner.

2. A'terminating machine as in claim 1 in which said feeding and sorting means includes a rotating hopper for aligning said electrical connectors, and an air operated shuttle device operatively connected via a tube to said extrusion means for feeding said electrical connectors.

3. A terminating machine as in claim 2 further including an optical sensor disposed intermediate the length of said tube for monitoring the feeding of an electrical connector.

4. A terminating machine as in claim 1 wherein said extruding means comprises two concentric sleeves, the inner sleeve being a stationary plunger, while the outer sleeve is vertically movable and includes therein a keyhole slot for maintaining said wire within the confines of the electrical connector during the extrusion operation.

5. A terminating machine as in claim 1 wherein said wire inserter means includes:

a vertically movable shaft extending from said actuating and controlling means;

a flange secured to the lower end of said shaft;

a generally L'-shaped member slidably mounted on said shaft and positioned above said flange, said L- shaped member having an aperture therein;

a wire inserting pin secured to said flange and projecting through said aperture in the L-shaped member, said L-shaped member including a conical-shaped recess disposed adjacent said operative thereof;

a pair of spring leaves cantilevered from said generally L-shaped member and defining with said conical-shaped recess a restricted opening through which the wire is inserted, said spring leaves cooperating with said L-shaped member to hold saidv wire upon upward movement of said shaft thereby enabling said wire inserter pin to bend the wire approximately 90, with further upward movement of said shaft causing said wire to be inserted within the confines of said electrical connector disposed within said extrusion means.

6. A terminating machine as in claim 5 wherein said wire inserting means is movable out of the path of the extruding means during the extrusion mode of operation of the terminating machine.

7. A terminating machine for electrically connecting an insulated wire to a terminal post comprising;

feeding and sorting means for orienting and feeding a series of ductile electrical connectors, each connector being generally cylindrical in configuration;

extruding means for receiving, one at a time, said series of connectors, and operative to extrude each connector to a terminal post, said extruding means being mounted for movement in a generally vertical direction;

wire inserter means for inserting one end of a wire partially pre-stripped of insulation, through the center of each connector preparatory to extrusion of said connector, said wire inserter means being mounted for movement from a position below sai extruding means during a wire insertion operation, to a position out of the path of movement of said extruding means; and

actuating and controlling means for operating said feeding and sorting means, said extruding means, and said wire inserter means in a sequential manner.

8. A terminating machine as in claim 7 in which said feeding and sorting means includes a rotating hopper for aligning said electrical connectors, and an air operated shuttle device operatively connected via a tube to said extrusion means for feeding said electrical connectors.

9. A terminating machine as in calim 8 further including an optical sensor disposed intermediate the length of said tube for monitoring the feeding of an electrical connector.

10. A terminating machine as in claim 7 wherein said extruding means comprises two concentric sleeves, the inner sleeve being a stationary plunger, while the outer sleeve is vertically movable and includes therein a keyhole slot for maintaining said wire within the confines of the electrical connector during the extrusion operation.

11. A terminating machine as in claim 7 wherein said wire inserter means includes:

a vertically movable shaft extending from said actuating and controlling means;

a flange secured to the lower end of said shaft;

a generally L-shaped member slidably mounted on said shaft and positioned above said flange, said L- shaped member having an aperture therein;

a wire inserting pin secured to said flange and pro jecting through said aperture in the L-shaped member, said L-shaped member including a conical-shaped recess disposed adjacent said operative thereof;

a pair of spring leaves cantilevered from said generally L-shaped member and defining with said conical-shaped recess a restricted opening through which the wire is inserted, said spring leaves cooperating with said L-shaped member to hold said wire upon upward movement of said shaft thereby enabling said wire inserter pin to bend the wire approximately with further upward movement of said shaft causing said wire to be inserted within the confines of said electrical connector disposed within said extrusion means.

* 1: 4- It t

Claims

1. A terminating machine for electrically connecting a wire to a terminal post comprising: feeding and sorting means for orienting and feeding a series of ductile electrical connectors; extruding means for receiving one of said series of ductile electrical connectors and extruding same about a terminal post; wire inserting means operative to insert a wire into the confines of each electrical connector preparatory to extrusion thereof to a terminal post; and actuating and controlling means for operating said feeding and sorting means, said extruding means, and said wire inserting means in a sequential manner.

2. A terminating machine as in claim 1 in which said feeding and sorting means includes a rotating hopper for aligning said electrical connectors, and an air operated shuttle device operatively connected via a tube to said extrusion means for feeding said electrical connectors.

5. A terminating machine as in claim 1 wherein said wire inserter means includes: a vertically movable shaft extending from said actuating and controlling means; a flange secured to the lower end of said shaft; a generally L-shaped member slidably mounted on said shaft and positioned above said flange, said L-shaped member having an aperture therein; a wire inserting pin secured to said flange and projecting through said aperture in the L-shaped member, said L-shaped member including a conical-shaped recess disposed adjacent said operative thereof; a pair of spring leaves cantilevered from said generally L-shaped member and defining with said conical-shaped recess a restricted opening through which the wire is inserted, said spring leaves cooperating with said L-shaped member to hold said wire upon upward movement of said shaft thereby enabling said wire inserter pin to bend the wire approximately 90*, with further upward movement of said shaft causing said wire to be inserted within the confines of said electrical connector disposed within said extrusion means.

7. A terminating machine for electrically connecting an insulated wire to a terminal post comprising; feeding and sorting means for orienting and feeding a series of ductile electrical connectors, each connector being generally cylindrical in configuration; extruding means for receiving, one at a time, said series of connectors, and operative to extrude each connector to a terminal post, said extruding means being mounted for movement in a generally vertical direction; wire inserter means for inserting one end of a wire partially pre-stripped of insulation, through the center of each connector preparatory to extrusion of said connector, said wire inserter means being mounted for movement from a position below said extruding means during a wire insertion operation, to a position out of the path of movement of said extruding means; and actuating and controlling means for operating said feeding and sorting means, said extruding means, and said wire inserter means in a sequential manner.