Apparatus and method of manufacturing electrical cabling systems

Claim 3

The method defined by claim 1 wherein said method further comprises the steps of performing steps (a)-(e) a plurality of times for a plurality of main and secondary condcutors.

Claim 4

The method defined by claim 1 further comprising the step of inserting a pasty insulating material between said thimble and said band of insulating material.

Claim 5

The method defined by claim 3 wherein said pasty material is a silicone material.

Claim 6

An electrical cabling system manufactured by the method comprising the steps of: (a) stripping an intermediate portion of at least one pg,55 main conductor; (b) stripping at least one secondary conductor in the general vicinity of at least one of the ends of said at least one secondary conductor corresponding to said at least one main conductor; (c) positioning the stripped portions of said main and secondary conductors against one another tightly; (d) mounting a thimble on said two stripped portions; and (e) mounting a band of cold-deformable insulating material on said thimble.

Claim 7

An electrical cabling system manufactured by the method comprising the steps of: (a) stripping an intermediate portion of at least one pg,55 main conductor; (b) stripping at least one secondary conductor in the general vicinity of at least one of the ends of said at least one secondary conductor corresponding to said at least one main conductor; (c) positioning the stripped portions of said main and secondary conductors against one another tightly; (d) mounting a thimble on said two stripped portions; and (e) mounting a band of cold-deformable insulating material on said thimble.

Claim 8

The system defined by claim 5 wherein said system comprises: (a) said at least one main conductor having a plurality of ends and comprising: (i) a conductor core; (ii) an insulating sheath, wherein said conductor core is mounted in said insulating sheath; (iii) connection elements connected to said plurality of ends, wherein said connection elements comprise box elements comprising either male plugs or female sockets adapted to engage complementary elements; and (b) said at least one secondary conductor comprising: (i) a conductor core; and (ii) an insulating sheath, wherein said conductor core of said secondary conductor is mounted in said insulating sheath of said secondary conductor.

Claim 9

The system defined by claim 6 wherein said at least one main conductor and said at least one secondary conductor comprise, respectively, a plurality of main and secondary conductors, wherein said method is performed a plurality of times.

Claim 12

The apparatus defined by claim 8 wherein said at least one main conductor and said at least one secondary conductor comprise, respectively, a plurality of pairs of main and secondary conductors, wherein said plurality of main conductors comprises a bundle, wherein said stripping means (a) comprises means for stripping each main conductor of said pair, wherein said positioning means (b) comprises means for positioning said stripped portions of one member of each pair of said main conductor and said secondary conductor tightly against the other member of each pair of said main conductor and said secondary conductor, wherein said mounting means (c) comprises means for mounting a thimble on said stripped portions of each pair of said plurality of pairs of main and secondary conductors, and wherein said mounting means (d) comprises means for mounting a band of cold-deformable insulating material on each said thimble.

Claim 13

The apparatus defined by claim 9 further comprising: a frame; a loading station for receiving said stripped secondary conductors, wherein said station is supported by said frame; means for holding said bundle of main conductors for subsequent operations of said apparatus; means for driving said bundle of main conductors through said apparatus as operations are performed by said apparatus with respect to said bundle of main conductors; means for guiding said bundle of main conductors through said apparatus to maintain said bundle of main conductors properly positioned as they are driven through said apparatus; means for stopping the driving of said bundle of main conductors with respect to said apparatus; means for displacing said bundle of main conductors into a predetermined position for subsequent operation with respect thereto; means operatively associated with said loading station for extracting said secondary conductors from said loading station; means for positioning and maintaining at least one pair of main and secondary conductors side-by-side after said secondary conductors have been extracted from said loading station by said means for extracting and after stripping of said main conductor by said stripping means; means for firmly securing together the two stripped portions of said main conductor and said secondary conductor, wherein said securing means comprises a thimble; and means for enclosing said thimble in insulation after said thimble secures said two stripped portions.

Claim 14

The apparatus defined by claim 10 wherein said loading station comprises: a box comprising at least one pair of stirrups, wherein each stirrup comprises a web, wherein each web comprises a groove, wherein two corresponding grooves of said webs together comprise a substantially rectilinear throat adapted to accommodate a respective one of said at least one secondary conductor, wherein each said throat comprises a base, wherein each said stirrup is pivotally mounted on said apparatus; a restoring spring associated with each of said pair of stirrups for biasing said stirrups against said pivoting; a contact positioned in said base of each said throat; a control circuit, wherein said circuit closes in response to displacement of said contact; at least one jack associated with said box and actuated by said closing of said control circuit, wherein each said jack comprises a piston rod adapted to be displaced relative to said box from a retracted position into an extended position as said jack is actuated; at least one tubular element operatively associated with respective ones of said piston rod to move therewith and adapted to engage said webs of said stirrups as said piston rod is displaced toward said extended position to deflect said stirrups to form a slit in said substantially rectilinear throat of a size sufficient to accommodate said respective secondary conductor; and at least one pair of elastic metal rods affixed to said box and which extend through respective ones of each said tubular element, wherein said elastic metal rods each comprise a bent free end, wherein each pair of bent free ends of said elastic metal rods form a tong adapted to grip said respective secondary conductor, wherein each tong grips said respective secondary conductor before deflection of said stirrups, thereby guiding said respective secondary conductor through said slit formed in said throat in response to displacement of said piston rod into said extended position.

Claim 15

The apparatus defined by claim 11 wherein said at least one pair of stirrups comprise a plurality of pairs of stirrups, wherein said extended position of said piston rod is lower than said retracted position of said piston rod so that teach said tong grips said respective secondary conductor before deflection of said stirrups, thereby guiding said respective secondary conductor through said slit formed in said throat in response to descent of said piston rod into said extended position.

Claim 16

The apparatus defined by claim 10 wherein said driving means comprises a tape winding machine for winding tape around said bundle of main conductors, wherein said tape winding machine comprises: an endless chain comprising means for attachment to said bundle of main conductors; and a motor for driving said endless chain.

Claim 17

The apparatus defined by claim 10 wherein said guiding means comprises: a plurality of brakes adapted to engage said main conductors, wherein said plurality of brakes are pivotally mounted on said frame, wherein each said brake comprises two limbs; and a plurality of springs for biasing said plurality of brakes against said pivoting, wherein said plurality of brakes and said plurality of springs comprise means for elastically gripping said main conductors between said two limbs.

Claim 18

The apparatus defined by claim 10 wherein said driving means comprises a tape winding machine for winding tape around said bundle of main conductors, wherein said guiding means further comprises a wire guiding device retractably mounted on said apparatus and positioned upstream from said tape winding machine.

Claim 19

The apparatus defined by claim 15 wherein said guiding means further comprises: a shaft mounted on said frame; a sleeve supported by said shaft, wherein said wire guide is attached to said sleeve so that said wire guide is adapted to pivot between an operating position and a retracted position, wherein in said operating position said wire guide engages said main conductors, wherein in said retracted position said wire guide is disengaged from said main conductors; and a toggle biasing said wire guide against displacement out of said operating and retracted positions.

Claim 20

The apparatus defined by claim 10 wherein a plurality of said means of said apparatus operate in response to receiving current, wherein said guiding means comprises: an element pivotally mounted on said apparatus; a spring biasing said element against pivoting; a comb for guiding said bundle of main conductors, wherein said comb is supported by said element; and a circuit comprising a contact, wherein said element is adapted to bear against said contact, wherein said circuit comprises means for interrupting said current to said apparatus in response to pivoting of said element against the bias of said spring beyond a predetermined extent.

Claim 21

The apparatus defined by claim 17 wherein said guiding means further comprises: a plurality of brakes adapted to engage said main conductors, wherein said plurality of brakes are pivotally mounted on said frame, wherein each brake comprises two limbs; and a plurality of springs for biasing said plurality of brakes against said pivoting, wherein said plurality of brakes and springs comprise means for elastically gripping said main conductors between said two limbs.

Claim 22

The apparatus defined by claim 18 wherein said driving means comprises a tape winding machine for winding tape around said bundle of main conductors, wherein said guiding means further comprises a wire guide retractably mounted on said apparatus and positioned upstream from said tape winding machine.

Claim 23

The apparatus defined by claim 19 wherein said guiding means further comprises: a shaft mounted on said frame; a sleeve supported by said shaft, wherein said wire guide is attached to said sleeve so that said wire guide is adapted to pivot between an operating position and a retracted position, wherein in said operating position said wire guide engages said main conductors, wherein in said retracted position said wire guide is disengaged from said main conductors; and a toggle biasing said wire guide against displacement out of said operating and retracted positions.

Claim 24

The apparatus defined by claim 10 wherein said main conductor stripping means comprises: a securing clamp positioned in said apparatus to permit enclosing and clamping said main conductors to be stripped, wherein said securing clamp is adapted to be opened and closed; means connected to said securing clamp for displacing said clamp into said closed position in which said clamp clamps said main conductors; a stripping clamp positioned for operative association with said securing clamp for stripping said main conductors, wherein said stripping clamp comprises two knives for cutting said sheath of said main conductors, wherein said stripping clamp and said two knives are adapted to be displaced into a closed position in which said knives contact said sheath of said main conductors and into a retracted open position in which said knives are spaced from said sheath; and means connected to said stripping clamp for displacing said stripping clamp and said securing clamp into said opened positions.

Claim 25

The apparatus defined by claim 21 wherein said securing clamp and said stripping clamp each comprises first and second limbs, wherein said main conductor stripping means further comprises first, second, third, and fourth substantially parallel shafts, wherein said first limbs of said securing clamp and said stripping clamp are journalled, respectively, on said first and third shafts around first and third pivot axes, wherein said second limbs of said securing clamp and said stripping clamp are journalled, respectively, on said second and fourth shafts around second and fourth pivot axes, wherein said first and third pivot axes and shafts are coaxial, wherein said second and fourth shafts and pivot axes are coaxial, wherein said first limbs of said stripping clamp and said securing clamp are connected to each other and said second limbs of said stripping clamp and said securing clamp are connected to each other such that said opening and closing of said stripping clamp and said securing clamp are synchronized and interdependent.

Claim 26

The apparatus defined by claim 22 wherein said main conductor stripping means further comprises: a shaft attached to said apparatus and extending substantially orthogonal to said pivot axes of said clamp limbs; and a plate pivotally mounted on said shaft, wherein said stripping clamp is supported by said plate.

Claim 27

The apparatus defined by claim 23 wherein said securing clamp further comprises means for biasing said securing clamp into said open position and a plurality of rollers, one roller positioned on each limb of said securing clamp, wherein said means for displacing said securing clamp into said closed position comprises: a jack comprising a piston adapted to be displaced from a retracted position to a first intermediate position, a second intermediate position, and then to an extended position; and a first cam operatively associated with said piston comprising an inclined portion adapted to engage said rollers, wherein said first cam further comprises means for pivoting said securing clamp limbs into said closed position by means of contact between said inclined portion and said rollers in response to displacement of said piston to said first intermediate position, wherein said first cam further comprises means for displacing said inclined portion below said rollers so that said first cam is spaced from said rollers in response to displacement of said piston from said first intermediate position to said extended position, wherein said biasing means comprises said means for displacing said securing clamp into said open position in response to spacing of said first cam from said rollers.

Claim 28

The apparatus defined by claim 24 wherein said plate further has attached thereto a roller, wherein said piston rod is operatively associated with a second cam extending orthogonally to said first cam and adapted to engage said roller of said plate.

Claim 29

The apparatus defined by claim 25 wherein said jack comprises means for pressing said second cam against said roller of said plate in response to displacement of said piston into said second intermediate position, wherein said roller of said plate comprises means for pivoting said plate, wherein said plate comprises means for squeezing said knives into said sheath of said main conductors in response to pivoting of said plate by said roller.

Claim 30

The apparatus defined by claim 10 wherein said frame further comprises a plurality of substantially horizontally extending rails, wherein said apparatus further comprises: a first carriage mounted to slide on said plurality of rails; means for displacing said first carriage on said plurality of rails; and substantially vertically displaceable clamps supported on said first carriage for gripping one of said main conductors onto which a secondary conductor of said at least one secondary conductor is to be grafted, wherein said extracting means comprises substantially vertically displaceable tongs supported on said first carriage for extracting respective ones of said secondary conductors from said loading station, wherein said positioning and maintaining means comprises said clamps and said tongs.

Claim 31

The apparatus defined by claim 27 wherein said firmly securing means is supported on said first carriage and further comprises: a strip of thimbles; means supported by said first carriage for advancing said strip of thimbles through said apparatus; and means additionally supported by said first carriage for separating one of said thimbles from said strip and for tightly mounting said one of said thimbles on said conductors.

Claim 32

The apparatus defined by claim 28 wherein said separating means comprises an anvil against which one of said thimbles is pressed by said means for advancing to separate said one of said thimbles from said strip.

Claim 33

The apparatus defined by claim 29 wherein said first carriage further comprises a slit, wherein said separating means further comprises: a tool comprising: a displaceable lever; and a shaft attached to said first carriage, wherein said lever is journalled on said shaft; a jack supported by said first carriage comprising a piston rod for displacing said tool; and said slit, wherein said slit is adapted to accommodate said lever therein, wherein said piston rod comprises means for displacing said lever into said slit and for pressing said lever laterally against said one of said thimbles to exert lateral pressure against said one of said thimbles.

Claim 34

The apparatus defined by claim 30 wherein said advancing means comprises: a catch for engaging said strip of thimbles; and a jack supported on said first carriage comprising a piston rod for displacing said catch step-by-step, thereby displacing said strip of thimbles step-by-step.

Claim 35

The apparatus defined by claim 31 wherein said catch is attached to said rod of said jack of said advancing means, wherein said strip of thimbles comprises two flanges having two edges, wherein said advancing means further comprises: a slideway in which said strip advances; a slide integral with said rod of said jack of said advancing means; a spring on said slide; a shaft on said slide, wherein said shaft pivotally mounts said catch on said slide, wherein said spring biases said catch, wherein said advancing means comprises: means for engaging said catch with said two edges of said strip and for displacing said strip in said slideway in response to forward displacement of said rod of said jack of said advancing means; and means for displacing said catch in a rearward direction and for disengaging said catch from said strip in response to rearward displacement of said rod of said jack of said advancing means, wherein said slideway has an end, wherein said tool is positioned adjacent said end of said slideway.

Claim 36

The apparatus defined by claim 27 further comprising: a second carriage displaceable substantially horizontally on said frame; and means operatively associated with said frame for displacing said second carriage substantially horizontally on said frame; wherein said second carriage supports said main conductor stripping means, wherein said main conductor stripping means is mounted to slide substantially vertically on said second carriage, and wherein said apparatus further comprises a jack supported by said second carriage for substantially vertically displacing said main conductor stripping means.

Claim 37

The apparatus defined by claim 33 wherein said second carriage comprises a cavity adapted to receive said splice, wherein said apparatus further comprises: a reel supported by said second carriage; a strip of cold-deformable insulating material on said reel; means supported by said second carriage for advancing said strip of cold-deformable insulating material from said reel a distance corresponding to the length of insulation desired; means supported by said second carriage for cutting off a piece of said cold-deformable insulating material from said strip of cold-deformable insulating material; and means supported by said second carriage for tightly mounting said cut off piece of cold-deformable insulating material on said splice.

Claim 38

The apparatus defined by claim 34 wherein said apparatus further comprises: a jack supported by said second carriage comprising a piston; a slide for driving said strip of cold-deformable insulating material, wherein said slide is supported by said piston; and a non-return brake supported by said second carriage, wherein said strip of cold-deformable insulating material extends through said non-return brake, wherein said brake comprises means for permitting displacement of strip of cold-deformable insulating material in a first direction and for preventing displacement of said strip of cold-deformable insulating material in a second direction opposite from said first direction.

Claim 39

The apparatus defined by claim 35 wherein said slide comprises an aperture therein, wherein said apparatus further comprises: a cartridge supported by said second carriage; a pasty insulating product inside said cartridge; a distribution tube connected to said cartridge terminating at said strip of cold-deformable insulating material opposite from said aperture; and means operatively associated with said cartridge for conveying a drop of said pasty insulating product from said distribution tube to said strip of cold-deformable insulating material.

Claim 40

The apparatus defined by claim 36 wherein said means for conveying further comprises: a source of compressed air operatively associated with said cartridge; a tube connecting said source to said cartridge; and a timing device for controlling the length of time said compressed air is conveyed through said connecting tube to said cartridge, wherein said pasty insulating product is subjected to a predetermined quantity of compressed air for a predetermined period of time so as to convey a predetermined amount of said pasty insulating product through said distribution

Claim 41

The apparatus defined by claim 35 wherein said apparatus further comprises: a guide blade supported by said second carriage for guiding said strip of cold-deformable insulating material into said cavity, wherein said guide blade is supported by said slide.

Claim 42

The apparatus defined by claim 38 wherein said apparatus further comprises: a fixed knife positioned above said cavity; a passageway having a first portion extending in a direction from said cavity toward said loading station and said main conductor stripping means; and a displaceable knife positioned in said first portion of said passageway and adapted to be displaced in said first portion of said passageway toward said cavity to engage said fixed knife to cut said cold-deformable insulating material.

Claim 43

The apparatus defined by claim 39 wherein said passageway further comprises a second portion extending from said cavity in a direction opposite from said direction in which said first portion extends, wherein said apparatus further comprises: a die positioned in said first portion of said passageway; a punch positioned in said second portion of said passageway; a jack supported by said second carriage for displacing said punch in said second portion of said passageway; and a jack supported by said second carriage for displacing said die in said first portion of said passageway against said punch.

Claim 44

The apparatus defined by claim 40 wherein said die has connected thereto a push rod, wherein said jack for displacing said die is adapted to displace said push rod axially in said passageway.

Claim 45

The apparatus defined by claim 41 wherein said jack for displacing said die is adapted to displace said push rod axially in said passageway to hold said strip of cold-deformable material against said splice positioned in said cavity.

Claim 46

The apparatus defined by claim 34 wherein said apparatus further comprises: a cartridge supported by said second carriage; a pasty insulating product inside said cartridge; a distribution tube connected to said cartridge terminating at said strip of cold-deformable insulating material; means operatively associated with said cartridge for conveying a drop of said pasty insulating product from said distribution tube to said strip of cold-deformable insulating material.

Claim 47

The apparatus defined by claim 43 further comprising: a source of compressed air operatively associated with said cartridge; a tube connecting said source to said cartridge; and a timing device for controlling the length of time said compressed air is conveyed through said connecting tube to said cartridge, wherein said pasty insulating product is subjected to a predetermined quantity of compressed air for a predetermined period of time so as to convey a predetermined amount of said pasty insulating product through said distribution tube.

Claim 48

The apparatus defined by claim 10 further comprising: a carriage displaceable substantially horizontally on said frame; means operatively associated with said carriage for displacing said carriage substantially horizontally on said frame; wherein said carriage supports said main conductor stripping means, wherein said main conductor stripping means is mounted to slide substantially vertically on said carriage, and wherein said apparatus further comprises a jack supported by said carriage for substantially vertically displacing said main conductor stripping means.

Claim 49

The apparatus defined by claim 45 wherein said carriage comprises a cavity adapted to receive said splice, wherein said apparatus further comprises: a reel supported by said carriage; a strip of cold-deformable insulating material on said reel; means supported by said carriage for advancing said strip of cold-deformable insulating material a distance corresponding to the length of insulation desired; means supported by said carriage for cutting off a piece of said cold-deformable insulating material from said strip of cold-deformable insulating material; and means supported by said carriage for tightly mounting said cut off piece of cold-deformable insulating material on said splice.

Claim 50

The apparatus defined by claim 46 wherein said apparatus further comprises: a jack supported by said carriage comprising a piston; a slide for driving said strip of cold-deformable insulating material, wherein said slide is supported by said piston; and a non-return brake supported by said carriage, wherein said strip of cold-deformable insulating material extends through said non-return brake, wherein said brake comprises means for permitting displacement of said strip of cold-deformable insulating material in a first direction and for preventing displacement of said strip of cold-deformable insulating material in a second direction opposite from said first direction.

Claim 51

The apparatus defined by claim 47 wherein said slide comprises an aperture therein, wherein said apparatus further comprises: a cartridge supported by said carriage; a pasty insulating product inside said cartridge; a distribution tube connected to said carriage terminating at said strip of cold-deformable insulating material opposite from said aperture; means operatively associated with said cartridge for conveying a drop of said pasty insulating product from said distribution tube to said strip of cold-deformable insulating material.

Claim 52

The apparatus defined by claim 48 wherein said means for conveying further comprises: a source of compressed air operatively associated with said cartridge; a tube connecting said source of compressed air to said cartridge; and a timing device for controlling the length of time said compressed air is conveyed through said connecting tube to said cartridge, wherein said pasty insulating product is subjected to a predetermined quantity of compressed air for a predetermined period of time so as to convey a predetermined amount of said pasty insulating product through said distribution tube.

Claim 53

The apparatus defined by claim 47 wherein said apparatus further comprises: a guide blade supported by said carriage for guiding said strip of cold-deformable insulating material into said cavity, wherein said guide blade is supported by said slide.

Claim 54

The apparatus defined by claim 50 wherein said apparatus further comprises: a fixed knife positioned above said cavity; and a passageway having a first portion extending in a direction from said cavity toward said loading station and said main conductor stripping means; and a displaceable knife positioned in said first portion of said passageway and adapted to be displaced in said first portion of said passageway toward said cavity to engage said fixed knife to cut said cold-deformable insulating material.

Claim 55

The apparatus defined by claim 51 wherein said passageway further comprises a second portion extending from said cavity in a direction opposite from said direction in which said first portion extends, wherein said apparatus further comprises: a die positioned in said first portion of said passageway; a punch positioned in said second portion of said passageway; a jack supported by said carriage for displacing said punch in said second portion of said passageway; a jack supported by said carriage for displacing said die in said first portion of said passageway against said punch.

Claim 56

The apparatus defined by claim 10 further comprising a tape winding machine for winding tape around said bundle of main conductors, wherein said tape winding machine comprises: a channel for grouping said main conductors together; a tape winding head operatively associated with said channel; a roll of tape supported by said head; means for rotating said head and for winding said tape onto said bundle of main conductors as said bundle of main conductors advance relative to said tape winding head; an endless chain; a motor for rotatably driving said endless chain; means for connecting said motor to said endless chain for driving said endless chain; a claw attached to said endless chain, wherein said claw comprises means for attaching a box element of said bundle of main conductors to said endless chain; and an ejector operatively associated with said claw and said endless chain for expelling said box element after said bundle is wound with said tape.