Insertion tool operable in accordance with a predetermined program to insert a plurality of conductors in insulation-piercing contacts disposed on opposite sides of an electrical connector
This is a continuation, of application Ser. No. 407,781 filed Oct. 19, 1973, now abandoned. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to conductor termination apparatus, and is more particularly concerned with the termination of conductors in insulation-piercing contacts of an electrical connector wherein a plurality of conductors, for example conductors of a similar color code, are inserted on each side of an electrical connector in accordance with a predetermined operational program. 
     2. Description of the Prior Art 
     The prior art recognizes numerous methods and apparatus for inserting insulated conductors into respective insulation-piercing contacts, including techniques for inserting insulated conductors into insulation-piercing contacts carried within said separate channels of an electrical connector. 
     Also, conductors have been terminated by means of a fluid controlled crimping process wherein conductors are fed to a station at which a contact, usually in the form of a terminal lug, is positioned about the connector and crimped to provide mechanical and electrical connection thereto. 
     The prior art also recognizes the utilization of mechanisms for aligning and inserting a plurality of strip conductors into electrical contacts, whereafter such conductors are soldered or crimped to the contacts. 
     SUMMARY OF THE INVENTION 
     The primary object of the present invention is to provide an apparatus whereby a plurality of conductors may be mechanically and electrically terminated in a corresponding plurality of insulation-piercing contacts in accordance with a predetermined sequence, such as may be dictated by conductor color coding. 
     Another object of the invention is to provide apparatus, as mentioned above, which in addition is almost completely automatic in operation, at least during a complete cycle operation which involves certain conductors of like identification. 
     An insertion apparatus, according to the present invention, comprises a base having a pair of upstanding plates carried thereon spaced forwardly and rearwardly with respect to the front end or operator&#39;s end of the apparatus. The forward upstanding member has a cable clamp mounted thereon for securing a cable so that the individual conductors thereof may be selected for insertion in an electrical connector in accordance with a predetermined schedule. The forward upstanding member is provided with a conductor support for mounting the conductor in a cantilevered manner extending forwardly of the forward support member. If, for example, five conductors of like identification are to be inserted on each side of the connector, an operator may select the conductors and dress the same two positions located immediately adjacent and parallel to the parallel channels of the connector which include therein respective insulation-piercing contacts. 
     The forward upstanding support member includes a pair of longitudinally disposed bearings each having disposed therein a carriage rod which supports a carriage frame which is designed to span the cantilever connector support. If five conductors are to be inserted on each side of the connector at one time, the carriage is indexed to have a total movement of five channel spaces during each sequential insertion operation. The carriage carries a pair of pivotally mounted insertion levers each of which mounts a multiple element insertion tool for performing the insertion operations at each rest position of the carriage. 
     The insertion mechanism includes a pair of pivotally mounted insertion levers carried by the carriage frame and having a cylinder and extensible rod carried in a pivotal suspended relationship to effect equalization of forces across the connector. In the particular embodiment disclosed, the cylinder for operating the insertion levers, and a cylinder for moving the carriage back and forth, are included in a fluid control circuit, in particular a pneumatic control circuit which is operable to effect carriage movement and insertion operations. 
     An indexing mechanism is also included for defining carriage movements two points which are spaced at least the spacing of the connector channels, or multiples thereof. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Other objects, features and advantages of the invention, its organization, construction and operation, will be best understood from the following detailed description taken in conjunction with the accompanying drawings, on which: 
     FIG. 1 is a pictorial representation of a pneumatically actuated and controlled termination apparatus constructed in accordance with the principles of the invention; 
     FIG. 2 is a detailed view of a portion of the apparatus of FIG. 1 shown generally from the top; 
     FIG. 3 is another detail view of a portion of the apparatus of FIG. 1 shown generally from the top; 
     FIG. 4 is a front view of a portion of the apparatus of FIG. 1; 
     FIG. 5 is a front view of the apparatus illustrated in FIG. 4 with a plate removed to better show a ratchet arrangement; 
     FIG. 6 is a sectional view taken generally along the line VI--VI of FIG. 2, with FIG. 6A showing a plan view of a coupling member; 
     FIG. 7 is a detail view of a cable clamp and connector support for use with the apparatus illustrated in the previous figures; 
     FIG. 8 is an elevational view of a portion of the apparatus of FIG. 1 as viewed from the opposite side and specifically showing a valve actuating mechanism; and 
     FIG. 9 is a schematic fluid circuit diagram of the pneumatic control apparatus for controlling the terminating apparatus illustrated in FIGS. 1-8. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to FIGS. 1-4, terminating apparatus is generally illustrated at 10 as comprising a base plate 12, a front support member 14 carried upright on the base plate 12, a rear support member 16 carried upright on the base plate 12, an aperture 18 in the base plate 12, and a plurality of control valves 20 mounted on the base plate 12 and extending through the aperture 18. 
     An air inlet 22 is adapted to supply shop air to a filter 24 and through a regulator 26 having an indicating meter 27 to a lubricator 28 and an air outlet 30. The air outlet 30 is connected to the valves 20 by way of a solenoid operated valve 32 mounted on the rear support member 16. The air supply is connected to the valves 20 by way of a plurality of air lines as will be readily apparent from the later description dealing with FIG. 9. 
     The front support member 14 mounts a pair of longitudinal bearings 34 and 36 which support respective shafts 38 and 40 for movement longitudinally of the apparatus 10. A frame 42 is mounted at the forward ends of the shafts 38 and 40 to form a carriage which is moved longitudinally of the apparatus 10 by a carriage air cylinder 44 mounted on the rear support member 16 and having an extensible member 46 which extends through the member 16 and is connected to the shaft 40. As will be explained below, the longitudinal movement of the carriage is performed in accordance with a predetermined sequential program. 
     The carriage frame 42 includes a pair of spaced plates 48 and 50 which are generally U-shaped so as to span and travel on each side of a cantilever mounted connector support 52 having a connector receiving slot 54 therein. 
     Referring to FIG. 7 for a moment, the cantilever 52 carries a pair of conductor spacing and dressing combs 56 and 58 on each side thereof having a plurality of conductor receiving comb slots 60 each having a sharp rear edge 62 which functions as a conductor cutting edge during conductor insertion. The distal end of the cantilever conductor support 52 carries a waste spring 64 for holding the free ends of the conductors as a housekeeping feature to prevent cluttering up of the work area. 
     Turning now to FIG. 4, the carriage frame 42 has a pair of insertion levers 66 and 68 pivotally mounted between the plates 48 and 50 at the pivots 70 and 72, which as shown in the drawing may advantageously include the carriage shafts 38 and 40. The levers 66 and 68 have respective upper ends which terminate in ball type pivots 74 and 76 for pivotally mounting a pair of insertion heads 78 and 80 which include insertion punches 82 and 84, respectively. The number of insertion punches may vary from one up to any desired number. For example, a 50 conductor cable may have 10 conductors of the same basic color code, of which 5 conductors are to be terminated on each side of a connector. In this case, the insertion heads would each include 5 punches. As will become apparent from the description of the indexing mechanism, however, any number of punches and longitudinal movement in any desired sequence may be effected in accordance with a predetermined program as dictated by a wiring schedule. 
     The insertion levers 66 and 68 have respective lower ends 86 and 88 which are pivotally connected to an insertion air cylinder 98 and its extensible piston rod 100. Extension of the rod 100 effects a parting of the lower ends, and thus a closing of the upper ends of the insertion levers 66 and 68 to cause the insertion heads 78 and 80 to move into a connector carried on the cantilevered connector support. As shown in the drawings, a connector 90 is mounted in the slot 54 and has a plurality of parallel vertically oriented channels 92. Each of the channels 92 has therein an insulation-piercing contact which mechanically and electrically terminates the respective conductors 96 of a cable 94 which is gripped by a cable clamp 97 mounted on the front support member 14. With a connector so mounted, the channels 92, the comb slots 60 and the insertion punches 82 and 84 are in alignment, and as the insertion heads are moved into engagement with the connector an equalization of insertion forces across the connector is effected due to the free pivotal suspension of the cylinder 98 and its rod 100 at the pivotal connections 102 and 104, in conjunction with the pivotal connections 70 and 72 of the levers and 74, 76 of the insertion heads. 
     As can be seen in FIG. 4, a pair of valves 106 and 108 are mounted for movement with the cylinder 98 and a valve actuating lever 110 having a pair of actuating members 112 and 114 is carried by the insertion lever 68 for effecting control operations upon initiation and termination of an insertion operation. These valves, and their specific functions, will become apparent from the description of operation offered in connection with FIG. 9. 
     The spaced plates 48 and 50 of the carriage frame 42 each carry a pair of insertion head guide members 116-122 for guiding the insertion heads in a horizontal line toward the connector. The pivotal connection of the insertion levers 66 and 68, constituted by the ball type pivots 74 and 76, together with the guiding action of the guide members 116--122, converts the arcuate movement of the levers into rectilinear movement of the insertion heads toward and away from the support connector. As the insertion heads extend beyond the guide members, particularly as the pivotal connections of the insertion heads extend beyond the guide members, the insertion heads may have a tendency to ride up on the conductors, rather than cooperate with the cutting edges 62 of the combs to sever the conductors. This action is more pronounced as larger numbers of conductors are inserted at the same time. Therefore, each insertion head is provided with a depending L-shaped member 123 for engaging the lower edge of the respective combs, or the lower surface of the cantilever support 52, to maintain a straight line horizontal movement of the insertion heads. 
     During a cycle of operation of the termination apparatus 10, a programming and indexing mechanism is provided for controlling the movement of the carriage from one insertion position to the next. In the particular embodiment illustrated in the drawings, particularly in FIGS. 2-6, a ratchet shaft 124 is mounted for rotation in a pair of bearings 126 and 128 and carries a ratchet 130 between the carriage frame plates 48 and 50. The ratchet 130 has a holding pawl carried by the frame 42 and biased to prevent movement of the ratchet in one direction. The insertion lever 66 carries an actuating pawl 134 and the insertion lever 68 carries an actuating pawl 136 in the form of a hook for rotating the ratchet 130. As the levers are operated to move toward each, the pawl 134 engages and initiates rotation of the ratchet 130 and as the levers move apart upon completion of insertion, the actuating pawl 136 pulls the ratchet 130 an additional amount whereupon the holding pawl 132 engages to prevent the ratchet from returning under the influence of a torsion spring 138 connected to the ratchet shaft 124. 
     The torsion spring 138 couples the shaft 124 to a drum 142 by means of a coupling member 140 having an arcuate limit stop mechanism defined by the arcuate slot 141 in the coupling 140 and a pin 143 carried by the drum 142. 
     The drum 142 is rotatably carried on the shaft 124 and includes a plurality of circumferentially spaced axially extending proram slots 146 each open to the rear end of the drum 142 and each having a closed end 148 which defines limits of carriage movement and the insertion positions assumed by the carriage. The carriage shaft 40 has a pin 144 extending therefrom for movement through a slot 146 to engage the closed slot end 148. The drum 142 is mounted for limited axial movement as defined by a space 150 between the drum 142 and the bearing 128. In FIG. 8, a valve 152 is carried by the front support member 14 and includes a ball-type actuator 154 which is spring loaded for extension, at least partially, into the space 150. As the drum 142 is brought into contact with the bearing 128, the valve 152 is operated to indicate completion of carriage movement toward the operator position and to effect further automatic control of an insertion operation which will be explained in detail below. 
     Up to this point, a termination apparatus has been described in which a carriage is movable back and forth along a connector support to predetermined positions at which conductor insertion operations are performed. The carriage carries a pair of pivotally mounted insertion levers, each of which has an insertion head at one end thereof and a pivotal connection to an insertion air cylinder at the other end thereof. The insertion mechanism is freely pivotal with the air cylinder suspended in a manner which provides for equalization of insertion forces across a connector. A programming and indexing mechanism includes a rotatable drum having a plurality of circumferentially spaced slots therein of different lengths for defining carriage rest positions for performing the insertion operations and is indexed from one position to the next by means of a ratchet mechanism to store energy in a torsion spring, the energy being released upon rearward movement of the carriage to disengage a pin from a program slot whereupon the drum is rotated to bring the next slot into alignment with the pin. 
     The control of carriage movement and insertion operations will now be explained with reference to FIG. 9. In FIG. 9, the shop air input 22, the air filter 24, the pressure regulator 26 and operating meter 27, the air lubricator 28 and the air output 30 have been schematically illustrated as connected to a solenoid control valve 32 having an energizing switch 33 connected to a commercial electrical supply, sequence as 120 VAC,60 Hz. The solenoid valve 32 permits disconnection of the air supply to the remainder of the circuit and provides that the circuit is set to a predetermined point in the operating cycle when the apparatus is turned on. 
     The control circuit 160 could, of course, be a hydraulic circuit, but has been illustrated herein as a pneumatic circuit including a pair of simultaneously operated manual valves 162 and 166 having hand operated plungers 164 and 168, respectively. Each of the valves illustrated, with the exception of the cylinder control valves, is spring loaded, as indicated by the S symbol opposite the actuating end thereof. Simultaneous actuation of the valves 162 and 166 provides air to charge a valve 170 and by way of a shuttle valve 172, a pulse valve 174 and a shuttle valve 176 provides an operating air pulse to a valve 178 which is already charged from the operated valve 32. Operation of the valve 178 provides an operating air supply to the pilot of the valve 170 to operate that valve. The valve 170 provides air to a pulse valve 180 which pulses a valve 182 to reverse that valve and cause the carriage air cylinder 44 to extend its rod 46. This movement of the carriage brings the pin 149 into a program slot 146, into engagement with the slot end 148 to close the space 150 depressing the ball actuator 154 to actuate the valve 152 indicating that the carriage has moved to an insertion position. 
     Actuation of the valve 152 causes connection of the air supply to a pulse valve 184 to effect an air pulse for reversing a valve 186. Reversal of the valve 186 causes the cylinder 98 to extend its rod 100 to release the normally operated valve 106 as the insertion levers are moved apart at their lower ends. Movement of the rod 100 to its fully extended position effects operation of the valve 108 by way of the valve actuating lever 110 and the actuating member 112. Operation of the valve 108 supplies air by way of a shuttle valve 190 to again reverse the valve 186 and retract the rod 100. 
     As the rod 100 moves back into the cylinder 98, the actuating member 112 disengages the valve 108 and upon completion of retraction the actuating member 114 engages and operates the valve 106 to supply air to a pulse valve 188 to reverse the valve 182 and cause retraction of the rod 46 into the cylinder 44. 
     As the insertion levers were operated, the ratchet 130 was rotated and held to store energy in the torsion spring 138. Upon retraction of the rod 46 and movement of the carriage rearwardly a sufficient amount for the pin 149 to clear the program slot 146, the drum 142 is rotated by the torsion spring to the next position. 
     A manually operated reset circuit is also provided to cause retraction of the rod 100 and disengagement of the insertion heads from the connector. This manual reset circuit comprises a valve 192 having an operatingc plunger 194 and connected to the shuttle valve 190. Depression of the plunger 194 causes the valve 192 to connect an air supply through the shuttle valve 190 to reverse the valve 186. This initiate of operation following reversal of the valve 186 is the same as described above. 
     Any suitable control valves may be employed for controlling the operation of the termination apparatus. The particular valves utilized in an operating embodiment of the invention were obtained from Clippard Module Controls, 7390 Colerain Road, Cincinnati, Ohio. 
     In the overall operation of the terminating apparatus, an operator first clamps a cable 94 into the cable clamp 97 and dresses the individual conductors 96 into the comb slots, and possibly into the connector if the connector is provided with dressing notches which communicate with the channels 92. The conductors may be dressed in groups, or the entire cable may be dressed, and the free ends inserted into the waste spring 64. The ratchet mechanism may be constructed for rotation in either direction and insertion from front to back, or back to front, may be provided as desired. For each insertion operation, the operator depresses the plungers 164 and 168 to initiate the automatic insertion sequence for each group of conductors. Programming of the drum 142 in accordance with a desired number of conductor insertions for each cycle determines the carriage position at the beginning of the next cycle. 
     The termination apparatus may be manually indexed to any desired position. In FIG. 4, for example, a portion of a cover plate 200 is illustrated as carrying an indicia of spaced marks 202. Diametrically opposed marks identify the same carriage position, as indicated by the double headed arrow 206 carried by a knob 204 mounted on the ratchet shaft 124. The knob 204; may be manually rotated to select a desired carriage position, for example, in accordance with a particular conductor color code, by manually positioning the double headed arrow 206 carried by the knob 204 with respect to the indicia 202. Upon retraction of the extensible rod 46 and disengagement of the pin 144 from a drum slot 146, the drum 142 rotates to the desired position and the next insertion cycle occurs at the selected position. 
     Although the invention has been described by reference to a specific illustrative embodiment thereof, many changes and modifications of the invention may become apparent to those skilled in the art without departing from the spirit and scope of the invention. It is therefore intended that the patent warranted hereon include all such changes and modifications as may reasonably and properly be included within the scope of this contribution to the art.