Apparatus for inserting terminals on the ends of wires into cavities in an electrical connector

Claim 2

A terminal inserting means for inserting an electrical terminal into a terminal receiving cavity in an electrical connector housing, the housing having a terminal receiving face, the cavity extending inwardly from the terminal receiving face, the terminal being on one end of an electrical conductor, the conductor and the terminal constituting an electrical lead, the inserting means being characterized in that: the terminal inserting means comprises terminal aligning means for aligning the terminal with the cavity and a terminal inserter for moving the terminal into the cavity, the terminal inserter comprising a first set of jaws, the terminal aligning means comprising a second set of jaws, the first and second sets of jaws being normally open and being normally in aligned, side-by-side, juxtaposed positions, the second set of jaws being between the first set of jaws and the cavity into which the terminal is to be inserted, the first and second sets of jaws being movable between their juxtaposed positions and extended positions in which the jaws are in aligned, spaced-apart relationship, the first and second sets of jaws are closable upon a lead located between the jaws of each set of jaws, the first set of jaws being in gripping engagement with the lead when in their closed positions, the second set of jaws being in surrounding and non-gripping relationship with the terminal when in their closed positions, actuating means are provided for closing the first and second sets of jaws, moving the second set of jaws to their extended position, and thereafter moving the first set of jaws relatively towards the second set of jaws and relatively towards the connector housing whereby, upon placing a lead between the jaws of each set of jaws and placing a connector housing adjacent to the lead with the cavity in approximate alignment with the lead, and upon closing the first and second sets of jaws and moving the second set of jaws to the extended position, the terminal will be precisely aligned with the cavity, and upon thereafter moving the first set of jaws relatively towards the second set of jaws and relatively towards the connector housing, the terminal will be inserted into the cavity, the second set of jaws serving as a terminal guide during insertion.

Claim 3

A terminal inserting means as set forth in claim 1 characterized in that the actuating means moves the first set of jaws towards the second set of jaws and towards the connector housing during insertion of the terminal into the cavity.

Claim 4

A terminal inserting means as set forth in claim 1 characterized in that the actuating means moves the connector housing towards the first set of jaws during insertion of the terminal into the cavity.

Claim 5

A terminal inserting means as set forth in claim 1 characterized in that a connector housing holding means is provided for holding a connector housing adjacent to the inserting means.

Claim 6

A terminal inserting means as set forth in claim 4 characterized in that the insertion means is intended to insert terminals into a connector housing having a plurality of terminal receiving cavities extending into its terminal receiving face, the terminal holding means having means for indexing the connector housing parallel to the place of the terminal receiving face thereby to position each of the cavities in approximate alignment with a lead located between the jaws of both sets of jaws.

Claim 7

A terminal inserting means as set forth in claim 5 characterized in that the connector holding means comprises a robot arm, the actuating means having means for indexing the robot arm thereby to index the connector housing.

Claim 8

A terminal inserting means as set forth in claim 1 characterized in that a lead delivery means is provided for delivering a succession of leads to a lead receiving zone, a lead positioned in the lead receiving zone being between the jaws of both sets of jaws when the jaws are in their normal positions.

Claim 9

A terminal inserting means as set forth in claim 7 characterized in that the lead delivery means comprises a lead conveyer.

Claim 10

A terminal inserting means as set forth in claim 7 characterized in that a connector holding means is provided for holding a connector housing adjacent to the inserting means.

Claim 11

A terminal inserting means as set forth in claim 9 characterized in that the inserting means is intended to insert terminals into a connector housing having a plurality of terminal receiving cavities extending into its terminal receiving face, the terminal holding means having means for indexing the connector housing parallel to the plane of the terminal receiving face thereby to position each of the cavities in approximate alignment with a lead located between the jaws of both sets of jaws.

Claim 12

A terminal inserting means as set forth in claim 10 characterized in that the connector holding means comprises a robot arm, the actuating means having means for indexing the robot arm.

Claim 13

A terminal inserting means as set forth in claim 1 characterized in that the inserting means is intended to insert terminals of the type having a retaining lance which is engageable with a retaining shoulder in the cavity thereby to prevent movement of the terminal from the cavity after insertion, the actuating means having means for moving the connector housing and the first set of jaws relatively away from each other after insertion of the terminal thereby to engage the retaining lance with the shoulder and ensure complete insertion of the terminal into the cavity, and sensing means are provided for sensing complete insertion of the terminal into the cavity.

Claim 14

A terminal insertion means as set forth in claim 4 characterized in that a lead receiving zone is provided which is angularly offset from the connector housing holding means, and means are provided for delivering an electrical lead to the lead receiving zone, the first and second sets of jaws being between the lead receiving zone and the connector housing holding means, the actuating means comprising jaw positioning means for moving the first and second sets of jaws between a loading position and a terminal inserting position, the first and second sets of jaws being positioned to receive a lead in the lead receiving zone when in the lead receiving position and being positioned to insert the terminal on the lead into the cavity in the connector housing when in the terminal inserting position.

Claim 15

A terminal inserting means as set forth in claim 13 characterized in that the jaw positioning means comprises means for pivotally moving the first and second sets of jaws between the lead receiving position and the terminal inserting position.

Claim 16

An assembling apparatus for assembling electrical leads to an electrical connector housing, each of the leads comprising a conductor having a terminal on one end thereof, the housing having a terminal receiving face and having terminal receiving cavities extending inwardly from the terminal receiving face, the apparatus comprising a connector loading zone and connector positioning means for positioning the connector in the loading zone, a lead receiving zone which is adjacent to, and spaced from, the terminal receiving face of a connector held in the connector loading zone, lead delivering means for delivering leads to the lead receiving zone, aligning means for aligning a terminal on a lead in the lead receiving zone with a cavity in a connector in the loading zone, and a terminal inserter for moving the lead axially from the lead receiving zone relatively towards the terminal receiving face of the connector housing whereby the terminal is inserted into the cavity, the apparatus being characterized in that: the terminal inserter comprises a first set of jaws and the aligning means comprises a second set of jaws, the first and second sets of jaws being normally open and being normally in aligned, side-by-side juxtaposed positions, the second set of jaws being between the first set of jaws and the terminal receiving face of a connector housing in the connector loading zone, the first and second sets of jaws being movable between their juxtaposed positions and extended positions in which the jaws are in aligned spaced-apart relationship, the first and second sets of jaws being closable upon a lead in the lead receiving zone, the first set of jaws being in gripping engagement with the lead when in their closed positions, the second set of jaws being in surrounding and non-gripping relationship with the terminal when in their closed positions, actuating means are provided for actuating the lead delivering means, thereby to deliver a lead to the lead receiving zone, for closing the first and second sets of jaws and moving the second set of jaws to its extended position, whereby the lead is gripped by the first set of jaws and the terminal will be precisely aligned with the cavity by the second set of jaws, and for thereafter moving the first set of jaws and the connector housing relatively towards each other whereby the terminal is inserted into the cavity.

Claim 17

An assembling apparatus for assembling electrical leads to an electrical connector housing, each of the leads comprising a conductor having a terminal on one end thereof, the housing having a terminal receiving face and having terminal receiving cavities extending inwardly from the terminal receiving face, the apparatus comprising a connector loading zone and connector positioning means for positioning the connector in the loading zone, a lead receiving zone which is adjacent to, and spaced from, the terminal receiving face of a connector held in the connector loading zone, lead delivering means for delivering leads to the lead receiving zone, aligning means for aligning a terminal on a lead in the lead receiving zone with a cavity in a connector in the loading zone, and a terminal inserter for moving the lead axially from the lead receiving zone relatively towards the terminal receiving face of the connector housing whereby the terminal is inserted into the cavity, the apparatus being characterized in that: the terminal inserter comprises a first set of jaws and the aligning means comprises a second set of jaws, the first and second sets of jaws being normally open and being normally in aligned, side-by-side juxtaposed positions, the second set of jaws being between the first set of jaws and the terminal receiving face of a connector housing in the connector loading zone, the first and second sets of jaws being movable between their juxtaposed positions and extended positions in which the jaws are in aligned spaced-apart relationship, the first and second sets of jaws being closable upon a lead in the lead receiving zone, the first set of jaws being in gripping engagement with the lead when in their closed positions, the second set of jaws being in surrounding and non-gripping relationship with the terminal when in their closed positions, actuating means are provided for actuating the lead delivering means, thereby to deliver a lead to the lead receiving zone, for closing the first and second sets of jaws and moving the second set of jaws to its extended position, whereby the lead is gripped by the first set of jaws and the terminal will be precisely aligned with the cavity by the second set of jaws, and for thereafter moving the first set of jaws and the connector housing relatively towards each other whereby the terminal is inserted into the cavity.

Claim 18

An assembling apparatus as set forth in claim 15 characterized in that the actuating means moves the first set of jaws towards the second set of jaws and towards the connector housing during insertion of the terminal into the cavity.

Claim 19

An assembling apparatus as set forth in claim 15 characterized in that the actuating means moves the connector housing towards the first set of jaws during insertion of the terminal into the cavity.

Claim 20

An assembling apparatus as set forth in claim 15 characterized in that the apparatus is intended to insert terminals of the type having a retaining lance which is engageable with a retaining shoulder in the cavity thereby to retain the terminal in the cavity, the actuating means having means for moving the connector housing and the first set of jaws away from each other after insertion of the terminal thereby to engage the retaining lance with the shoulder and ensure complete insertion of the terminal, and sensing means are provided for stopping movement of the connector housing and the first set of jaws away from each other when the lance engages the shoulder.

Claim 21

An assembling apparatus as set forth in claim 15 characterized in that the lead receiving zone and the connector loading zone are angularly offset from each other, the actuating means comprising jaw positioning means for moving the first and second sets of jaws between a lead receiving position and a terminal inserting position.

Claim 22

An assembling apparatus as set forth in claim 19 characterized in that the jaw positioning means comprises means for pivotally moving the first and second sets of jaws between the lead receiving position and the terminal inserting position.