Wire jig intended for use in a harness-making machine or the like
This is a division of application Ser. No. 551,621 filed Nov. 14, 1983, now U.S. Pat. No. 4,559,702. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to wire jigs capable of holding a plurality of wires in side-by-side relationship and intended for use in a wire processing machine such as a harness-making machine. 
     BACKGROUND OF THE INVENTION 
     U.S. Pat. No. 4,372,041 shows a wire jig which is capable of holding a plurality of wires in side-by-side coplanar parallel relationship. Jigs of this type are commonly used in harness-making machines of the general type shown in U.S. Pat. No. 4,380,117. The harness-making machine of the latter U.S. patent comprises a conveyor having wire jigs secured thereto at spaced-apart intervals. A means is providing for feeding wires to the wire jigs at one station and as the conveyor is indexed, the ends of the wires held in the wire jigs are presented to wire processing machines such as connector assembly machines and insulation stripping machines. U.S. Pat. No. 4,380,117 also shows one type of jig in FIGS. 8A-8D which can be used on the harness-making machine. 
     Wire jigs of the type shown in the above-identified U.S. Pat. Nos. 4,372,041 and 4,380,117 comprise essentially clamps which clamp all of the wires in the array held in the jig. The processing machines, such as crimping machines or the like, which are used and form part of the harness-making machine must thus be designed such that they can perform operations on wires which are close together in side-by-side relationship with their ends in alignment. The number of operations and types of operations which can be carried out on wires in an array is therefore limited. For example, U.S. Pat. No. 4,372,041 suggests that all of the wires held in an individual clamp can be inserted into terminals in a multicontact electrical connector since it is commonly known to simultaneously attach the ends of wires to a plurality of terminals in a connector in the manner suggested in the patent. It is not, however, practical to perform an operation on an individual wire in the array held in a clamp because of the fact that the wires are close together with their ends in alignment. 
     The present invention is directed to the achievement of an improved wire jig which permits operations to be carried out on individual wires held in the jig without effecting the remaining wires held in the jig. Specifically, the invention is directed to the achievement of a wire jig which permits an individual wire to be selectively moved from the array of wires held in a jig so that its end is spaced fom the ends of the remaining wires. It then is possible to crimp a terminal onto the one wire without physical interference by the remaining wires in the jig. 
     THE INVENTION 
     The invention comprises a wire jig of the type comprising a frame having a wire clamping assembly thereon for clamping a plurality of wires in a coplanar array. A wire jig in accordance with the invention is characterized particularly in that the wire clamping assembly comprises a plurality of individual wire clamps, each of which is capable of holding at least one wire adjacent to its end. The clamps are in side-by-side aligned positions in a stack which is supported on the frame so that wires held in the stack extend laterally from the stack. The clamps are individually movable laterally from the stack in a direction parallel to the axes of the wires to extended positions, guide means being provided for guiding the individual clamps during movement between their aligned positions and their extended positions. By virtue of the fact that the clamps are individually movable from the stack, individual wires can be moved from the array of wires and presented to processing machines such as crimping machines. 
     The invention is further characterized in that each individual wire clamp has a first actuator engaging portion which is engageable by a first actuator for sliding the individual clamp from its aligned position to its extended position and returning the individual clamp to its aligned position. In accordance with further embodiments, each wire clamp comprises first and second clamping members which are movable with respect to each other between a wire-receiving position and a wire-clamping position, each clamp being receptive to a wire when the first and second clamping members are in their wire-receiving positions and are effective to clamp the wire when the first and second clamping members are in their wire-clamping positions. 
     In accordance with further embodiments, at least one of the wire-clamping members of each wire clamp has a second actuator engaging portion for engagement by a clamp opening actuator to move the first and second clamping members relative to each other. 
    
    
     DRAWING FIGURES 
     FIG. 1 is a frontal view of the harness making machine in accordance with the invention. 
     FIG. 2 is a top plan view of the machine of FIG. 1. 
     FIG. 3 is a view looking in the direction of the arrows 3--3 of FIG. 2. 
     FIG. 4 is a perspective view of an individual wire jig of the type provided on the machine of FIGS. 1-3. 
     FIG. 5 is a perspective view of a wire clamp. 
     FIG. 6 is a perspective view of the clamp with the parts exploded from each other. 
     FIG. 7 is a cross section looking in the direction of the arrows 7--7 of FIG. 4 and showing also portions of a clamp opening member, this view showing the positions of the parts when wires are clamped in the individual clamps of the wire jigs. 
     FIG. 8 is a view similar to FIG. 7 but showing the positions of the parts when the clamps are in their wire receiving positions. 
     FIG. 9 is a view looking in the direction of the arrows 9--9 of FIG. 2 and showing the manner in which wires are fed to the wire jigs. 
     FIG. 10 is a view looking in the direction of the arrows 10--10 of FIG. 2 and showing a mechanism for moving an individual wire clamp to its extended position. 
     FIG. 11 is an enlarged side view of the unloading station of the machine at which wires held in a wire jig are released. 
     FIG. 12 is a view looking in the direction of the arrows 12--12 of FIG. 11. 
     FIG. 13 is a perspective view of one type of harness. 
    
    
     THE PREFERRED EMBODIMENT 
     FIGS. 1 and 2 show a harness making machine 2 comprising a conveyor 4 which is indexed by a motor and drive train 5 and which has a plurality of wire jigs 6 thereon. Each of the wire jigs holds a purality of wires 8 in side-by-side parallel relationship with the wire ends extending to one side of the conveyor. The wires are fed to the wire jigs at a loading station 10 and the embodiment shown also has an applicator 12 for installing a multi-contact electrical connector 7 on the harness at one end thereof, see FIG. 13. The wire feeder 10 may be of the type shown in U.S. Pat. No. 4,043,494 and have the capability of feeding varying lengths of wires as indicated by the harness of FIG. 13. The applicator 12 may similarly be of any desired type. 
     The ends of the wires which are held in the wire jigs 6 are moved first to a wire stripper 13 at which insulation is stripped and are then moved to a purality of crimping machines 14 at which terminals 9 are crimped onto the ends of the wires. Different types of terminals can be crimped onto the wires at the several processing stations or crimping machines 14 as desired. 
     In the description which follows, an individual wire jig 6 will first be described in detail and the features of the harness making machine which are essential in an understanding of the invention will then be described. 
     As shown in FIGS. 4-8, each wire jig comprises a frame or support 16 having a wire clamping assembly 18 supported on its upper surface 20. The wire clamping assembly comprises a purality of individual wire clamps 22, each of which is capable of holding at least one wire with the wire end extending to the one side of the conveyor along which the processing machines 14 are located. 
     Each individual wire clamp 22 comprises a first wire clamping plate 24, a second wire clamping plate 26, a retaining plate 28, and a slide member 30, see FIG. 6. The first and second wire clamping plates 24, 26, and opposed surfaces 32, 34 and the upper portion of the surface 32 is beveled as shown at 36 adjacent to the top side edge 38 of plate 24. The surface 34 of the second plate 26 has a groove or pocket 40 extending thereacross at its upper end and a ledge 42 extends over this groove. As shown in FIGS. 7 and 8, the beveled surface 37 and the pocket or groove 40 provide wire clamping surfaces which are capable of clamping wires of varying diameters. 
     The retaining plate 28 is secured to the slider 30 and to the second clamping plate 26 by means of screws 46, 54. The screws 46 extend through holes 48 in plate 28, through slots 50 in the first clamping plate 24, and are threaded into opening 52 in the second clamping plate 26. The screws 54 extend through holes in retainer plate 28, through holes 56 in the slide 30, and are threaded into openings 58 in the second clamping plate 26. The first clamping plate 24 is loosely held between the retainer plate and the second clamping plate and is captured by the screws 46 which permit vertical movement of plate 24 relative to the other parts of the clamp. Plate 24 is biased upwardly by springs 60 which are received in notches 62 in the lower edge of plate 24 and by notches 64 in the upper edge of the slider 30. As indicated by FIGS. 7 and 8, the first clamping plate 24 can be moved downwardly to the position FIG. 8 to permit placement of the wires in the wire clamp. The wires are thus clamped by the springs 60 which biase the plates 24 upwardly. 
     As shown in FIGS. 4 and 9, the individual wire clamps are maintained in a stack on surface 20 by retaining their guide members 66, 68 which are bolted to the upper surface 20 of the frame 16. The retainer 66 has spaced apart slots 67 therein which receive the slide members 30, a shoulder 78 being provided on each slide to limit leftward movement of the clamps beyond the positions shown on FIG. 4. The guide 68 is fitted in a recess in the frame, see FIG. 9, and has upstanding ears between which the forward portions of the slides 30 are received. Each slide 30 has an elongated slot 70 extending parallel to its lower edge and a rod 72 which is supported in the guide 68 extends through this slot. This slot 70 therefore limits rightward movement of the individual clamps when they are moved to their extended positions as will be described below. 
     Each slide 30 has a notch 80 at its left-hand end as shown in FIG. 4 by means of which it is coupled by a clamp actuator shown in FIG. 10 and each slide has spaced apart notches 82, 84 in its lower edge which receives rails 102, 106 as shown in FIG. 9. The rails 102 extend along the entire conveyor path and maintain all of the wire clamps in a single stack when a wire jig is being moved between two adjacent processing machines 14. The rail 102 has an enlarged notch 104 at each of the processing machines so that all of the wire clamps 22 are free move to their extended positions. 
     Rails 106 are provided only at the processing machines 14 and are received in the notches 84 of the slides 30. The rails 106 are provided with a notch 108 which is in alignment with the slider 30 of the particular wire clamp which is to be moved to its extended position at a particular station. The rail 106 is thus programmed to prevent movement of those wire clamps which are to remain in the stack while one clamp is advanced as shown in FIG. 4. If desired, two or more clamps can be moved simultaneously at any one of the stations on the conveyor path. 
     The conveyor may be of any desired type and is shown and described only to the extent necessary for an understanding to present invention. The conveyor shown comprises a chain 86 having pins 88 which are received in slots in depending ears 90 on the underside of the frame 16. The chain 86 is supported on a support plate 92 which has opposed channel members 94, 96 on its side edges. Additional support for the frame 16 of the jig is provided by rollers 98 which are received in the channels and which are supported by ears 100 on the underside of frame 16. 
     Referring now to FIGS. 3 and 10, the actuator for moving an individual clamp to its extended position comprises an actuator rod 110 having a coupling 112 on its end which is received in the notch 80 of the appropriate slide member 30. The rod 110 is supported at 114 in a supporting frame 115 which in turn is secured to a tubular support 130 on which the plate 92 is supported. Rod 110 has a pin-slot coupling 116 to one arm 118 of a bell crank. The bell crank is pivoted at 120 and its other arm 121 is pivotally connected at 122 to a piston rod 124 which extends from a piston-cylinder 126. When the piston rod 124 is moved downwardly from the position shown in FIG. 10, actuator rod 110 is moved rightwardly and the wire clamp to which the rod is coupled is moved to its extended position. In this manner, the wire held in the clamp is selectively presented to a crimping machine or other wire processing machine 14. Limit switches as shown in 128 may be located adjacent to the moving parts to control the crimping press or otherwise control operation of the harness making machine. 
     Each of the actuators for advancing an individual wire clamp 22 is adjustably mounted on the machine by bolts 134 which extend through slots 132, see FIG. 1. The actuator can thus be moved by a slight distance so as to place it in alignment with the particular wire clamp 22 which is to be advanced. Additionally, the processing machines 14 can be adjustably mounted on rails 135 as shown in FIG. 2. 
     As mentioned previously, the wire feed 10 and the applicator 12 for installing the connector 7 on the wires can be any suitable type. FIGS. 7-9 show the manner in which the wires can be fed to the wire clamp and cut by a cutting means adjacent to the applicator 12. 
     To move the first clamping plates 24 downwardly, a depresser 136 is provided which has spaced apart projection 138 that engage the upper edges 38 of the first clamping plates 24 of each wire clamp. When this depresser 136 is in its lowered position. FIG. 8, a confined passageway is formed through which the wires can be fed. When the depresser 136 is moved upwardly to the position of FIG. 7, the first clamping plates 24 move upwardly and clamp the wires as shown in FIG. 7. The wires are guided by suitable guides 140, 142 and a cutting blade 144 is provided which cooperates with a cutting edge 146 to cut the wires at a location adjacent to the wire jig. In the embodiment shown, the depresser 136 is moved downwardly by the pressure plate 148. 
     The wire guides 140, 142 are capable of being opened or moved apart so that after cutting the wires, the conveyor can be indexed onto the wires moved latterally of their axes from the vicinity of the wire feed 10 and connector applicator 12 to the insulation stripper 13 and then to the processing machines 14. 
     FIGS. 11 and 12 show an unloading mechanism to open the wire clamps at an unloading station which is shown on the left in FIG. 1 adjacent to the conveyor drive 5. The unloading station is located on the underside or return side of the conveyor and comprises a pair of spaced apart cantilever members 154 which engage extentions 44 of the movable clamping plates 24. The bars 154 extend from a mounting plate 156 which is slideably supported on parallel rods or columns 158 that extend from a fixed support 160. The plate 156 can be moved upwardly a slide distance from the postion shown in FIG. 13 so that the movable clamping plates are moved upwardly by cantilever members 154 and the wires released. The wires will then fall downwardly and be collected in a suitable bin. 
     The finished harness can alternatively be removed from the wire jigs by a robot device which would open the wire clamps and transport the harness to a suitable receiving location. 
     It will be apparent from the foregoing description that harness making machines in accordance with the invention are capable of producing a wide variety of types of harnesses by virtue of the fact that the wires held in each wire jig can be selectively presented to processing machines located beside the conveyor. The above identified U.S. Pat. No. 41,614,808 shows a machine which has associated pairs of wire jigs in back-to-back relationship so that both ends of every wire are held in jigs and can be presented to processing machines. Wire jigs of the type described above can be used with this type of harness making machine and the harnesses produced can have different types of terminals on each end of each wire in the harness. As also mentioned above, one or more multi contact connectors can be provided on one or both ends of the harnesses so that the harness will have two or more connectors on each end and several different types of terminals on the remaining wires. 
     Wire jigs in accordance with the invention can be used with any of the commonly known types of conveyor type lead-making or harness-making machines and can be used under other circumstances where an array of wires must be held in the jig but individual wires must at some time or another be moved from the array for a processing operation.