Method of, and apparatus for, making electrical harnesses

Claim 3

A method according to Claim 1, characterised in that the position at which the insulation of the wire is severed, varies from wire to wire, in the axial direction of the wire, the wires being severed in a common plane perpendicular to the longitudinal axes of the wires.

Claim 4

A method according to Claim 1 or 2, characterised in that the one end portion (206) of each wire is fed axially into a template (10) at the first station (4), the one end portion (206) being moved into engagement with the wire receiving member of the terminal by means of a wire stuffer (8) moved through an opening (12) in the template laterally of the longitudinal axis of the wire (202).

Claim 5

Apparatus for making an electrical harness comprising an electrical connector provided with a plurality of electrical terminals having wire receiving members electrically connected to individual insulated wires, the apparatus comprising a shuttle (60); means (68) on the shuttle for gripping end portions of a plurality of insulated wires in juxtaposed relationship; a track (92) along which the shuttle is movable; a first station (4) having a support (26) for positioning the connector; a second station (6) spaced from the first station and having a blade (115) for severing each wire and a blade (42) for severing the insulation of each wire at a position between the wire severing blade and the first station; a wire lengthening assembly (14) movable through a working stroke to engage a wire to form a loop therein, means for imparting an axial force to each wire when it has been severed, to cause the insulation to be stripped therefrom between the insulation severing blade and the severed end of the wire, and a mechanism (64) for moving the shuttle along the track through the second station (6) to the first station (4) in a single pass; whereby each wire is connected to a terminal of the connector and the severed end portions of the wires are stripped of insulation; characterised in that the wire lengthening assembly (14), which is arranged to form the wires with loops (205) of different lengths, operates at a third station (15, 22) positioned between the first (4) and second (6) stations, a wire stuffer assembly (8) being arranged to engage the end portions (206) of the wires (202) with the wire receiving members of the terminals prior to the wire lengthening assembly (14) engaging the wires (202), the wire lengthening assembly (14) being driven by a predetermined distance into engagement with the wires (202) by a first mechanism (94, 100, 102) operated by the shuttle moving mechanism (62, 64) and being moved through a further increment of its working stroke by means of a second mechanism (16, 18, 20) to impart the axial force to the wires (202).

Claim 6

Apparatus for making an electrical harness comprising an electrical connector provided with a plurality of electrical terminals having wire receiving members electrically connected to individual insulated wires, the apparatus comprising a shuttle (60); means (68) on the shuttle for gripping end portions of a plurality of insulated wires in juxtaposed relationship; a track (92) along which the shuttle is movable; a first station (4) having a support (26) for positioning the connector; a second station (6) spaced from the first station and having a blade (115) for severing each wire and a blade (42) for severing the insulation of each wire at a position between the wire severing blade and the first station; a wire lengthening assembly (14) movable through a working stroke to engage a wire to form a loop therein, means for imparting an axial force to each wire when it has been severed, to cause the insulation to be stripped therefrom between the insulation severing blade and the severed end of the wire, and a mechanism (64) for moving the shuttle along the track through the second station (6) to the first station (4) in a single pass; whereby each wire is connected to a terminal of the connector and the severed end portions of the wires are stripped of insulation; characterised in that the wire lengthening assembly (14), which is arranged to form the wires with loops (205) of different lengths, operates at a third station (15, 22) positioned between the first (4) and second (6) stations, a wire stuffer assembly (8) being arranged to engage the end portions (206) of the wires (202) with the wire receiving members of the terminals prior to the wire lengthening assembly (14) engaging the wires (202), the wire lengthening assembly (14) being driven by a predetermined distance into engagement with the wires (202) by a first mechanism (94, 100, 102) operated by the shuttle moving mechanism (62, 64) and being moved through a further increment of its working stroke by means of a second mechanism (16, 18, 20) to impart the axial force to the wires (202).

Claim 7

Apparatus according to Claim 4, characterised in that the wire stuffer assembly (8), which is movable through a working stroke towards the support (21 ) and a return stroke away therefrom, is moved through its return stroke subsequently to the stripping of the insulation from the wires (202).

Claim 8

Apparatus according to Claim 4 or 5, characterised in that the insulation severing blades (42) are positioned at different distances from the first station (4).

Claim 9

Apparatus according to any one of Claims 4 to 6, characterised in that the shuttle (60) comprises a wire clamp (68) and a pair of wire guides (70 and 74) slidably connected to the wire clamp (68) between the wire clamp (68) and the connector support (26), the wire guides (70 and 74) abutting one another, and one (70) of the wire guides (70 and 74) abutting the clamp (68) when the shuttle (60) is at the first station (4), the wire guides (70 and 74) being spaced from one another in a retracted position of the shuttle (60) to guide the wires in relation to the insulation severing, and wire severing, blades (42 and 115).

Claim 10

Apparatus according to any one of Claims 4 to 7, characterised by a template (10) at the first station (4), the template (10) being arranged to guide the end portions (206) of the wires (202) to position them in alignment with the wire receiving members of the terminals and to guide each of a plurality of wire stuffers of the wire stuffer assembly (8) into engagement with one of the end portions (206) of the wires (202).