Wire Processing Device

Abstract

To provide an improved system for attaching a terminal to the wires of multi-wire cables such as twisted pair cables.SOLUTION: A wire holding device includes a base 210 and a clamp assembly 230. The clamp assembly is attached to the base, and includes a first gripper adapted to grip a first wire 12 of a cable 10, and a second gripper 250 adapted to grip a second wire 14 of the cable. The second gripper is movable relative to the first gripper and operable independently of the first gripper.SELECTED DRAWING: Figure 3A

Description

[Technical Field]

[0001] The present subject matter relates to the fabrication of wires or cables and associated terminals, and more particularly to an improved system for attaching terminals to wires of multi-wire cables such as twisted pair cables. [Background technology]

[0002] Crimping or termination systems for securing terminals to elements such as electrical conductors typically include an applicator configured to feed a strip of terminals from a reel into position for crimping onto the conductors, more specifically, into a position above a lower crimping tool or die. Once the terminals are in position, the ends of the wires or cables to be terminated are fed into a position above or within the terminals. The terminals may be separated from the strip of terminals using a shear depressor attached to the movable end of an applicator ram used to drive the upper crimping die. As the applicator ram moves, the depressor engages a passive terminal shear or shearing device that shears the terminals from the strip shortly after they are captured by the crimping tool.

[0003] While the above-described configurations are effective for use with single wires, they are less suitable for use with multi-wire cables, such as twisted-pair cables. Specifically, in multi-wire cable applications, the wire ends may extend a relatively short distance beyond the cable (e.g., its jacket) due to the requirements of the final terminated assembly. This makes it difficult to position the individual ends within the applicator during the crimping operation. Further challenges arise due to the requirement that the separate wires of a pair must be kept in close proximity to each other to prevent signal noise. Specifically, during the above-described crimping process, the pair of wires may be pre-formed into a shape that provides sufficient space for the crimping tool. However, this separation is greater than the final spacing in the connector and greater than the allowable spacing between wires for signal integrity. Therefore, the wires must be reshaped after crimping to position them closer together. This forming and reshaping process can create length differences between wire pairs, or internal stresses can cause the wires to bend too far apart. Furthermore, because the grip is against the cable jacket behind the formed wires, the formed wires are not individually supported or controlled during crimping. Depending on the wire stiffness, sagging can occur, which can affect the repeatability of precise wire placement within the terminal. Summary of the Invention [Problem to be solved by the invention]

[0004] Improved systems and methods that address these shortcomings are desirable. [Means for solving the problem]

[0005] In one embodiment of the present disclosure, a wire holding device includes a base and a clamping assembly. The clamping assembly includes a first gripper mounted to the base and adapted to grip a first wire of a cable, and a second gripper adapted to grip a second wire of the cable. The second gripper is movable relative to the first gripper and operable independently of the first gripper.

[0006] The invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0007] [Figure 1] FIG. 1 is a front perspective view of a terminal applicator useful for illustrating embodiments of the present disclosure. [Figure 2] 2 is a side perspective view of the terminal applicator of FIG. 1 including a portion of a wire positioning device according to an embodiment of the present disclosure. [Figure 3A] FIG. 1 is a top perspective view of a wire positioning device according to an embodiment of the present disclosure. [Figure 3B] FIG. 3B is a partial top perspective view of the wire positioning device of FIG. 3A. [Figure 4] FIG. 10 is a front perspective view of the wire positioning device of the previous figure. [Figure 5] FIG. 10 is another top perspective view of the wire positioning device of the previous figure. [Figure 6] FIG. 10 is another front perspective view of the wire positioning device of the previous figure. [Figure 7] FIG. 10 is a bottom perspective view of the wire positioning device of the previous figure. DETAILED DESCRIPTION OF THE INVENTION

[0008] 1 and 2, embodiments of the present disclosure will be described for use with an exemplary crimping system 100. Crimping system 100 generally includes an applicator or applicator assembly 110, a ram assembly 120, a terminal shear 130, and opposing crimping tools or dies 141, 142. System 100 is adapted to crimp terminals 152 sheared from a terminal strip or carrier 150 containing a plurality of interconnected terminals onto the end of a wire or cable. Specifically, terminal applicator 110 is adapted to feed terminals 152 of terminal strip 150 into a crimping position between a movable upper crimping die 141 and an opposing fixed lower die 142. In the discussed embodiment, terminal strip 150 is forward of terminals 152. However, alternative embodiments are possible in which the carrier strip 150 is behind the terminals 152. The upper crimping die 141 is fixedly connected to the movable end of the applicator ram 122. The crimping system 100 may include one or more pneumatic or hydraulic cylinders or motor-driven mechanisms for selectively moving the ram assembly 120, including the applicator ram 122 and the crimping die 141 attached thereto, in a longitudinal direction, for example. During a termination sequence, the ram assembly 120 lowers, causing the terminal shears 130 to separate the terminals 152 from the strip 150, and the crimping dies 141, 142 to crimp the terminals 152 onto the free ends of the wires or cables inserted therein. When the terminal shears are behind the anvil, as is the case with rear carrier strip embodiments (not shown), the present invention may be positioned closer to the crimping dies 141, 142 to maintain the shortest possible wire extension. Alternatively, the present invention may be used with a front carrier strip and front strip shears and longer wire extensions, as shown. As specifically shown in FIG. 2 , a portion of a wire processing or positioning device or assembly 200 according to one embodiment of the present disclosure is shown directing wire 12 of a pair of wires 12, 14 of cable 10 into a crimping position between the upper crimping die 141 and the lower crimping die 142 described above. As shown, the positioning device 200 biases or displaces the other wire 14 outside the crimping area. The biasing or displacement of the wire is preferably not to the extent that it permanently deforms the wire.

[0009] 3A-7 generally, and FIGS. 6 and 7 in particular, wire positioning assembly 200 includes a movable first base or platform 210 and a movable second base or platform 211. Base 210 may be movable in a longitudinal direction V relative to platform 211, for example, by at least one actuator 212 (e.g., a linear actuator). Additional linear supports or guides 213, 214 may be provided between bases 210, 211 to improve stability and translational accuracy. In one embodiment, rod eye 215 is used to connect actuator 212 between bases 210 and 211. Movable base 211 may be moved in directions I and D in a plane perpendicular to the V direction by actuators and mechanisms (not shown).

[0010] As shown in FIG. 6, a cable clamp 220 may be mounted to the base 210 and adapted to selectively grip the cable 10 therein for processing. An actuator 221 (e.g., a pneumatic gripper, see FIG. 7) is adapted to operate the clamp 220. Specifically, the clamp 220 includes a first clamp half 222 pivotally connected to a second clamp half 224. The actuator 221 is adapted to selectively rotate the second half 224 relative to the first half 222 to secure the cable 10 within the illustrated opening between the first and second halves 222 and 224. For clarity, the cable clamp 220 has been removed from FIGS. 3A-5.

[0011] As shown most clearly in FIGS. 3A-5, the first gripper or clamp assembly 230 includes a fixed member 231 and a movable member 232. The movable member 232 is movable in a cam slot relative to the fixed member 231 as guided by a pin 233 (see FIG. 4). A linear actuator 234 operates with a cam 235 attached to the linear actuator 234 to articulate the movable member 232 relative to the fixed member 231. Specifically, the cam 235 engages a corresponding cam surface or slot 232′ in the movable member 232 to displace the movable member relative to the fixed member 231 and selectively clamp individual wires 14 of the cable 10 between their opposing clamping surfaces. Movement between the members 231, 232 may be achieved by the linear position of the cam 235 and actuation of the actuator 234 relative to the slot 232′.

[0012] Similarly, second gripper or clamp assembly 250 includes a fixed member 251 and a movable member 252. Similar to first clamp 230, movable member 252 is movable in a cam slot relative to fixed member 251 as guided by pin 253. A linear actuator 254 operates with a cam 255 attached to linear actuator 254 to articulate movable member 252 relative to fixed member 251. Cam 255 engages a corresponding cam surface or slot 252' in movable member 252 to move the movable member relative to fixed member 251 and selectively clamp wire 12 between their opposing clamping surfaces. While the use of a linear actuator is shown to enable selective gripping of each of wires 12, 14, other types of actuators may similarly be used (e.g., a rotary actuator) without departing from the scope of this disclosure.

[0013] The second gripper or assembly 250 is pivotally connected to the first gripper 230, for example, via a connecting pin 260 extending through each of the fixed members 231, 251. A linear actuator 261 is provided for selectively rotating the second gripper 250 relative to the first gripper 230. In one embodiment, a movable end of the actuator 261 is connected to the fixed member 251, although other configurations for achieving relative rotation between the assemblies are contemplated. Rotation between the assemblies 230, 250 selectively spreads or separates the wires 12, 14 of the cable 10, as shown in FIGS. 4 and 5. This allows one of the two wires (e.g., wire 14 in FIG. 5) to be inserted into a crimping location within the applicator assembly 110, while the other wire (e.g., wire 12 in FIG. 5) is temporarily removed from the crimping area to avoid interference with associated processing or crimping equipment. In one embodiment, a wire spreader pin or protrusion 265 extends from between the assemblies 230, 250 and operates to maintain a desired separation distance between the wires 12, 14 of the cable 10. The pin 265 may be integrally formed with the connecting pin 260 that is disposed between the first securing member 231 and the second securing member 251.

[0014] 7, assembly 230 may be pivotally engaged with bracket 226. Bracket 226 may be movably mounted to base 210. Specifically, bracket 226 may be movable or slidable relative to base 210 in at least one direction. In the exemplary embodiment, bracket 226 is movable in a fore-and-aft direction D (i.e., the direction of axial insertion of the wire into the terminal) by a linear actuator 228. A pair of sensors 227 are provided to detect this movement in the insertion direction D. Movement of wire positioning assembly 200 in an indexing direction, or lateral direction I, may be achieved, by way of example only, by translating bases 210, 211 by a linear actuator.

[0015] As will be appreciated by those skilled in the art, control of each of the actuators described herein may be programmable in nature (i.e., under the control of at least one processor and associated memory device). This control is achieved by a plurality of position sensors for detecting the state or position of each of the actuators described herein. For example, as shown in FIGS. 4 and 6, a plurality of sensors 270 are provided to monitor and / or control the position of, for example, cams 235, 255 and cable clamp 220. A control system including these sensors may be used to automate the operation of the above-described system (e.g., the movement of each of the actuators). Thus, a system according to embodiments of the present disclosure may be used in conjunction with a terminal applicator to terminate cables or wires under computer control and without operator input, and for the sake of brevity, further details of this control system are omitted herein.

[0016] It should be understood by those skilled in the art that the above embodiments are intended to be illustrative rather than limiting. For example, numerous modifications may be made to the above embodiments by those skilled in the art, and various features described in the various embodiments may be freely combined with each other unless they are inconsistent in structure or principle.

Claims

1. A base (210), a first gripper (230) attached to the base (210) and adapted to grip a first wire (14) of the cable (10); and a second gripper (250) adapted to grip a second wire (12) of the cable (10), the second gripper (250) being movable relative to the first gripper (230) and operable independently of the first gripper (230); a clamp assembly including Equipped with each gripper (230, 250) includes a plurality of oppositely disposable clamping members (231, 232, 251, 252), at least one of the clamping members (232, 252) being movable relative to the other of the clamping members (231, 251) to independently grip a respective one of the first wire (14) and the second wire (12) of the cable (10); each gripper (230, 250) includes a gripping actuator (234, 254) operative to bias at least one of the opposing clamping members (231, 232, 251, 252) against the other of the clamping members (231, 232, 251, 252); Each gripping actuator (234, 254) comprises a linear actuator having an end fixedly attached to a cam (235, 255); The cam (235, 255) engages a surface of at least one of the clamping members (232, 252).

2. A wire holding device as described in claim 1, wherein the second gripper (250) is rotatable relative to the first gripper (230) around an axis perpendicular to the central axis of the cable (10).

3. The wire holding device of claim 2, wherein the second gripper (250) is rotatable at least 20 degrees relative to the first gripper (230).

4. A wire holding device as described in claim 2, further comprising a wire separation actuator (261) that rotates the second gripper (250) relative to the first gripper (230).

5. The wire holding device of claim 2, wherein the first gripper (230) and the second gripper (250) are movable with the base (210) in a vertical direction (V).

6. a bracket (226), the base (210) and the first gripper (230) being attached to the bracket (226); a first actuator (228) for moving the bracket (226) in an insertion direction (D) perpendicular to the longitudinal direction (V); The wire retention device of claim 5 further comprising:

7. 2. The wire holding device of claim 1, further comprising a protrusion (265) extending between the first gripper (230) and the second gripper (250) in a direction perpendicular to the central axis of the cable (10), the protrusion (265) being positioned between the first wire (14) and the second wire (12) of the cable (10) and sized to separate the first wire (14) and the second wire (12).

8. The wire retention device of claim 1, further comprising a cable clamp (220) for selectively clamping the cable (10) in place relative to the clamp assembly.

9. 2. The wire holding device of claim 1, wherein the clamping assembly is movable along three mutually perpendicular axes, and the clamping assembly is configured such that movement along any one of the three axes is independent of movement along any other of the three axes.

10. an applicator (110) including a crimping ram (122) and a pair of opposing crimping dies (141, 142); mounted adjacent to the opposing crimping dies (141, 142); a first gripper (230) attached to the base (210) and adapted to grip a first wire (14) of the cable (10); and a second gripper (250) movable relative to the first gripper (230) and operable independently of the first gripper (230) to grip a second wire (12) of the cable (10); a clamp assembly including Equipped with the clamp assembly is positioned relative to the crimping dies (141, 142) of the applicator (110) to selectively place one of the first wire (14) or the second wire (12) into a crimped position between the opposing crimping dies (141, 142) and urge the other of the first wire (14) and the second wire (12) into a uncrimped position.

11. 11. The terminal applicator system of claim 10, wherein the clamping assembly is movable along three mutually perpendicular axes, and the clamping assembly is configured such that movement along any one of the three axes is independent of movement along any other of the three axes.

12. 12. The terminal applicator system of claim 11, wherein the second gripper (250) is rotatable relative to the first gripper (230) about an axis perpendicular to a central axis of the cable (10).

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