Machine and method for producing hybrid electrical wiring

Abstract

The present invention relates to a method and a machine for producing hybrid electrical wiring comprising electrical wires terminated by insulation displacement connection connectors and crimp connection connectors. Said method and said machine optimize the standard processing cycle, since, during the crimping of an electrical wire at a crimping station, another electrical wire is collected at a first feeding station and transferred to the crimping station. In this way, it is not necessary to wait for all the wires to be processed to be sequentially loaded at the first feeding station and then all the wires to be sequentially crimped at the crimping station, but for two wires fed in succession, the feeding and crimping operations are carried out substantially simultaneously.

Description

Technical Field

[0001] This invention relates to the field of electrical connector technology. Specifically, this invention relates to a machine and method for producing hybrid electrical wiring including insulation-displacement connectors and crimp connectors. Background Technology

[0002] This invention relates to a machine and method for producing a hybrid electrical wiring structure comprising electrical conductors and crimp terminals inserted into corresponding sockets of a connector, the connector being provided with corresponding electrical terminals to which the conductors are connected. At least one end of the electrical conductor is terminated by an insulation displacement connection (IDC) and inserted into a corresponding socket of the connector provided with the corresponding electrical terminal; the other end of the electrical conductor may instead be terminated by a crimp connector.

[0003] The present invention also allows for the production of electrical wiring structures consisting of connector pairs interconnected by wires, where the two ends of the electrical conductors present IDC connections.

[0004] An IDC connection is a permanent electrical connection between an electrical conductor and terminals housed in a specific housing or connector made of plastic. In the process of inserting the electrical conductor into the connector, the terminal tabs cut through the insulating shell of the conductor, establishing an electrical connection between the terminal and the conductor.

[0005] A crimp connection is a permanent electrical connection between a wire and a terminal. This connection requires a crimping tool using a die to clamp the terminal onto the wire. Therefore, the initial step before crimping the wire is to remove the insulation (stripping) of the wire, allowing the conductive parts to be directly connected to the terminal. In this way, a stable mechanical and electrical connection is ensured because the wire is held in place by the crimping tool against the terminal.

[0006] The various devices currently available are suitable for creating mixed electrical wiring between conductors and electrical terminals, which are equipped with connectors made of plastic material and are suitable for terminating electrical conductors by crimping connectors.

[0007] In the prior art, automated termination machines are known for producing electrical wiring with configurations including parallel and cross conductors, loops, and / or single-sided conductor connections. These machines are adapted to terminate electrical wires via IDC connectors, and they also include crimping units for terminating electrical wires via crimp connectors.

[0008] Document EP 1 775 804 B1 discloses an apparatus for performing electrical wiring of the type consisting of electrical wires inserted into corresponding electrical terminals connected to wires, or electrical wiring of the type consisting of connector pairs interconnected by wires. The apparatus includes two areas: a wire loading area, wherein the wires are loaded in predetermined sockets selected from a plurality of sockets defined on a comb-shaped loader; and an area for inserting the wires into predetermined housings defined in one or more predetermined connectors to be wired.

[0009] In the area where the wire is inserted into the connector, one or two clamping units are provided. Each clamping unit includes two clamping parts for blocking a wire from being inserted into the loader and bending it into a U-shape after its first insertion into the comb loader, so that it can be inserted into the same comb loader a second time. These clamping and insertion units are controlled by an electronically programmable device to perform automatic loading of the comb loader according to a programmed sequence of preferred positions corresponding to the same number of predetermined housings of the connector.

[0010] Regarding the productivity of wired connectors, existing machines ensure the production of electrical wiring at a limited speed compared to today's demand, while the proliferation of wired connectors continues to increase. Therefore, this invention reduces the complexity of current machines and increases productivity by reducing the time per processing cycle. Summary of the Invention

[0011] This invention is based on the concept of a method and machine for producing a hybrid electrical cabling structure combining crimping and IDC connectors. The method and machine optimize the processing cycle because, while the wires are being crimped at the crimping station, holding and conveying devices at different workstations collect new wires at a first supply station and convey them to the crimping station. In this way, waiting time is significantly reduced because it is not necessary to wait for all the wires to be processed to be sequentially loaded onto the holding and conveying devices and then for all the wires to be sequentially crimped at the crimping station; instead, for two consecutively supplied wires, the supply and crimping operations are performed substantially simultaneously.

[0012] According to an embodiment of the present invention, a method for producing electrical wiring consisting of at least two wires is provided, wherein each wire includes two ends, one end of each wire is inserted into a corresponding socket of a connector having a corresponding electrical terminal, and the other end of each wire is connected to a crimp terminal. The method includes the following steps:

[0013] a) Supplying the first conductor to the holding and conveying device at the first supply station;

[0014] b) The first wire held in the holding and conveying device is conveyed to the crimping station, and the first wire is released to the crimping station;

[0015] c) Crimping one end of the first conductor at the crimping station;

[0016] d) Supply the second wire to the holding and conveying device at the first supply station;

[0017] e) The second wire, held in the holding and conveying device, is fed to the crimping station;

[0018] f) Supply the first wire of the crimping to the holding and conveying device, and release the second wire from the holding and conveying device to the crimping station;

[0019] g) Crimping one end of the second conductor at the crimping station;

[0020] h) The crimped second wire is supplied to the holding and conveying device such that the holding and conveying device together accommodates both the crimped first wire and the crimped second wire;

[0021] i) The crimped first and second wires are transmitted to the IDC connection station via the holding and conveying device;

[0022] j) The IDC is connected to the free ends of the crimped first and second conductors.

[0023] The advantage of this method is that it generates electrical wiring structures quickly and simply, and it reduces the processing cycle.

[0024] In the preferred configuration, steps d) and e) are performed during step c). This configuration is particularly advantageous because, while the first conductor is being processed at the crimping station, the holding and conveying device is repositioned to collect the second conductor at the first supply station and convey it to the crimping station for crimping processing. This reduces each processing cycle and increases the machine's productivity.

[0025] The advantage of this method is that the loading operation is optimized because a single conductor is initially loaded onto the holding and conveying device and immediately conveyed to the crimping station for crimping, without waiting for the second conductor to be loaded at the first supply station. While the first conductor is being crimped, the holding and conveying device can repeat the loading and conveying operation on the second conductor, reducing waiting time, and a new conductor is conveyed to the crimping station. Preferably, the holding and conveying devices are empty when they return to the first supply station after releasing the first conductor to the crimping station.

[0026] In a further preferred configuration, steps f) and g) are performed such that the second wire is not released to the crimping station until the first crimped wire has been conveyed to the holding and conveying device, and therefore crimping of the second wire begins after the first crimped wire has been supplied to the holding and conveying device. Preferably, during the crimping of the second wire, the crimped first wire is transported back to the first supply station via the holding and conveying device. This reduces waiting time and increases machine productivity.

[0027] In a further preferred configuration, after the second wire has been crimped at the crimping station, it is also supplied to the holding and conveying device together with the first crimped wire. Thus, both crimped wires are collected together on the holding and conveying device and conveyed together to the IDC station for IDC connection.

[0028] Preferably, an IDC connection is made on the wire after one end of the wire is crimped.

[0029] According to another embodiment of the present invention, a method is provided, the method further comprising the following steps:

[0030] k) Corresponding to the second supply station supplying the third wire to the holding and conveying device;

[0031] l) Corresponding to the IDC connection station, the IDC connects to the two ends of the third conductor;

[0032] Step k) is performed during step I) such that the holding and conveying device together accommodates the crimped first wire, the crimped second wire, and the third wire.

[0033] The third electrical wire that needs to be terminated by the IDC connector is provided to the holding and conveying device at the second supply station and then conveyed to the IDC connection station. This solution is particularly advantageous because all electrical wires that need to be terminated by the IDC connector at one or both ends are transported together to the IDC connection station, thereby speeding up processing time.

[0034] For example, the holding and conveying device with crimped wire leaving the crimping station stops at the second supply station to collect the third wire before moving toward the IDC connection station.

[0035] All electrical wires transmitted to the IDC connection station via the holding and transmitting device are then terminated by the IDC connector, resulting in different electrical cabling configurations.

[0036] For example, a third conductor can be terminated by an IDC connector to connect two terminals of two connectors located in front of another. For example, a third conductor can be terminated by an IDC connector to connect two terminals placed within the same connector. For example, this can create configurations with parallel and crossing conductors, loops, and / or single-sided conductor connections.

[0037] According to another embodiment of the invention, a method is provided in which step k) is repeated multiple times in order to supply multiple conductors corresponding to a second supply station.

[0038] Repeat step k) so that multiple wires requiring termination by the IDC connector are supplied to the holding and conveying device at the second supply station, and are all housed on the same holding and conveying device that also carries two crimped wires, before being conveyed to the IDC connection station. This solution is particularly advantageous because all wires requiring termination by the IDC connector at one or both ends are transported together to the IDC connection station, thereby speeding up processing time.

[0039] In another preferred embodiment, the holding and conveying device with the crimped wire leaving the crimping station stops at the second supply station to collect additional wires before reaching the IDC connection station.

[0040] For example, after leaving the second supply station, the holding and conveying device may include: one or more electrical wires whose two ends need to be terminated by IDC connectors; and at least two electrical wires whose one end has been terminated by a crimp connector and whose other end still needs to be terminated by an IDC connector.

[0041] According to another embodiment of the present invention, a method is provided, the method further comprising the following steps:

[0042] m) Bending one or more wires supplied at the second supply station such that they form a U-shape, and such that both ends of the one or more wires are accommodated within the holding and conveying device.

[0043] Step m) is executed during step k).

[0044] The advantage of this method is that when the conductor is bent into a U-shape, both ends are readily available to other processing devices at the IDC connection station. In fact, conductors are often quite long, and it is difficult to process them if one end hangs down from the holding and conveying device and is not held by it. Therefore, this step simplifies further processing operations.

[0045] In another preferred embodiment, each wire supplied from the second supply station is bent into a U-shape. In a more preferred embodiment, each wire is placed on a holding and conveying device such that its two ends are received in different seats of the holding and conveying device.

[0046] For example, the wire can be bent into a U-shape so that when it is provided to a device for inserting it into the corresponding socket of a connector at an IDC connection station, the distance between the two ends of the U-shaped wire matches the distance between the corresponding sockets, which include predetermined terminals.

[0047] According to another embodiment of the present invention, a method is provided, the method further comprising the following steps:

[0048] n) Corresponding to the first supply station supplying another wire to the holding and conveying device, and conveying the other wire held in the holding and conveying device to the crimping station;

[0049] o) Release the other conductor to the crimping station;

[0050] p) Crimping one end of the other conductor at the crimping station;

[0051] q) The other crimped wire is then fed to the IDC connection station;

[0052] r) The IDC terminal is connected to the free end of the other crimped wire.

[0053] Step n) is performed during step g), and steps q) and r) are performed simultaneously with steps I) and j), respectively, so that steps q) and I) are performed by means of a holding and conveying device to convey all the crimped wires together.

[0054] Another wire is supplied to the holding and conveying device at the first supply station, then conveyed to the crimping station and released there. After the second crimped wire has been conveyed to the holding and conveying device, another wire is released to the crimping station. Another wire is collected at the first supply station and conveyed to the crimping station, while other wires previously supplied to the crimping station are being crimped. The first crimped wire, previously loaded onto and held in position on the holding and conveying device, is also conveyed between the crimping station and the first supply station, then returned to the crimping station. Another wire is conveyed from the holding and conveying device to the crimping device, while the previously crimped wire is loaded onto the holding and conveying device.

[0055] The advantage of this method is that it significantly reduces waiting time because it eliminates the need to wait for all the wires to be processed to be sequentially loaded onto the holding and conveying devices, and then for all the wires to be sequentially crimped at the crimping station. Instead, for two consecutively supplied wires, the supply and crimping operations are essentially simultaneous. The processing cycle is fast and efficient.

[0056] Then, all the crimped wires are housed together in the same holding and conveying device and transported to the IDC connection station for termination via the IDC connector. This configuration is particularly advantageous because the step of conveying the crimped wires to the IDC connection station is performed only once, which speeds up production time.

[0057] According to another embodiment of the present invention, a method is provided, the method further comprising the following steps:

[0058] s) Repeat steps n) to p) multiple times to supply multiple wires at the first supply station, thereby performing steps n) and o) on the new wires supplied at the first supply station, while performing step p) on the previous wire supplied to the first supply station just before the new wires;

[0059] t) The multiple crimped wires are conveyed together to the IDC connection station via the holding and conveying device;

[0060] u) The IDC terminal is connected to the free ends of the multiple crimped wires.

[0061] The advantage of this method is that it significantly reduces waiting time because it eliminates the need to wait for all the wires to be processed to be sequentially loaded onto the holding and conveying devices, and then for all the wires to be sequentially crimped at the crimping station. Instead, for two consecutively supplied wires, the supply and crimping operations are essentially simultaneous. The processing cycle is fast and efficient.

[0062] In another preferred embodiment, multiple wires are supplied to a holding and conveying device at a first supply station. The method is designed to reduce waiting time and to allow another wire to be loaded onto the holding and conveying device and conveyed to a crimping station while other wires previously supplied at the first supply station are being crimped. The holding and conveying device continuously moves from the first supply station to the crimping station, thereby collecting another wire at the first supply station and conveying it to the crimping station while crimping the previous wire. The crimped wire is then supplied to the holding and conveying device again and stored there, while the holding and conveying device moves back to the first supply station to repeat the operation.

[0063] Preferably, the crimping wire is loaded onto the holding and conveying device while another wire is being supplied to the crimping device of the crimping station. This further optimizes production time.

[0064] Then, multiple crimped wires are housed together in the same holding and conveying device and transported to the IDC connection station for termination by the IDC connector. This solution is particularly advantageous because the step of transporting the crimped wires to the IDC connection station is performed only once, which speeds up production time.

[0065] This method allows for the production of various electrical conductor configurations. For example, it can produce configurations with parallel and crossing conductors, loops, and / or single-sided conductor connections.

[0066] According to another embodiment of the present invention, a method is provided, the method further comprising the following steps:

[0067] v) Strip one end of one or more wires supplied at the first supply station while the one or more wires are supplied to the holding and conveying device.

[0068] This solution is particularly advantageous because when the conductor arrives at the crimping station, it already includes a stripped end that can be directly inserted into the terminal for crimping. Therefore, there is no need to introduce any additional stripping station to strip one end of the conductor in preparation for further crimping. In fact, the insulating shell on the end of the conductor supplied at the first supply station is immediately removed when the conductor is inserted into the holding and conveying device.

[0069] In another preferred embodiment, one end of the conductor is fed to the conductor stripping blade at a first supply station, and the insulating shell at that end is removed when the conductor is pulled back. In an alternative preferred embodiment, one end of the conductor is fed to the conductor stripping blade at a first supply station, and the insulating shell at that end is removed by moving the conductor stripping blade.

[0070] According to another embodiment of the present invention, a method is provided, the method further comprising the following steps:

[0071] w) Bend one or more wires supplied at the first supply station such that they form a U-shape, and such that both ends of the one or more wires are accommodated within the holding and conveying device.

[0072] Step w) is performed in one or more of steps a), d), and n).

[0073] The advantage of this method is that when the conductor is bent into a U-shape, both ends are readily available to other processing devices at the crimping station. In fact, conductors are often quite long, and it is difficult to process them if one end hangs down from the holding and conveying device and is not held by it. This simplifies further processing operations.

[0074] In another preferred embodiment, each wire supplied at the first supply station is bent into a U-shape. In a more preferred embodiment, the wire is placed on a holding and conveying device such that both ends are received in different seats of the holding and conveying device.

[0075] According to another embodiment of the invention, a machine is provided for producing electrical wiring comprising at least two wires, wherein each wire includes two ends, one end of each wire is inserted into a corresponding socket of a connector having a corresponding electrical terminal, and the other end of each wire is connected to a crimp terminal. The machine includes the following components:

[0076] - First supply station, used to supply the electrical conductors;

[0077] - A crimping station for crimping one end of each of the electrical conductors;

[0078] -IDC connection station, used to terminate the other end of each of the wires via IDC;

[0079] - A holding and conveying device is configured to receive the wires at the first supply station and convey them to the crimping station and the IDC connection station.

[0080] The machine is configured as a mobile holding and conveying device such that when the first wire is crimped at the crimping station, the holding and conveying device is moved to a first supply station to receive the second wire, and is moved back to the crimping station to crimp the second wire. The machine is also configured to release the crimped first wire to the holding and conveying device, and subsequently release the crimped second wire to the holding and conveying device, so as to provide the crimped first wire and the crimped second wire together to the IDC connection station via the holding and conveying device.

[0081] This configuration is particularly advantageous because, during the processing of the first conductor at the crimping station, the holding and conveying device is repositioned to collect the second conductor at the first supply station and convey it to the crimping station for crimping. This reduces each processing cycle and increases the machine's productivity.

[0082] Preferably, the machine is configured to operate with multiple wires supplied at the first supply station, such that when the wires are loaded onto a holding and conveying device at the first supply station and then conveyed to a crimping station, the previously supplied wires are crimped at the crimping station. The crimped wires are then released to the holding and conveying device and stored there, while new wires are supplied to the crimping station. During the crimping of the new wire, the holding and conveying device is moved back to the first supply station to collect another wire, and the crimped wires are stored within the holding and conveying device. In fact, the holding and conveying device is preferably configured to store all crimped wires. In this way, the crimping operation and the supply and conveying operations are performed substantially simultaneously, and the machine can process multiple wires faster than a standard system.

[0083] After the crimping operation is completed, all crimped wires stored in the holding and conveying devices are conveyed together to the IDC connection station. The holding and conveying devices are configured to accommodate multiple wires and are movable through all workstations of the machine.

[0084] Preferably, the first supply station includes a clamping portion for loading electrical wires onto a holding and conveying device. More preferably, the first supply station further includes a cutting device configured to cut each electrical wire disposed at the first supply station to a predetermined length.

[0085] Preferably, the crimping station includes three crimping tools. More preferably, each crimping tool is adapted to crimp a connector characterized by a predetermined shape. For example, the crimping tool may be of the type of crimping press.

[0086] Preferably, the IDC connection station is further provided with a trimming device for trimming the end of the wire to the same distance from the holding and transmitting device in which the wire is held before performing the step of terminating the wire through the IDC.

[0087] In a further preferred configuration, the machine includes twelve holding and conveying devices to handle several electrical wiring structures simultaneously.

[0088] According to another embodiment of the invention, a machine for producing electrical conductors further includes a second supply station for supplying additional electrical conductors located between a crimping station and an IDC connection station, wherein the machine is configured to move holding and conveying devices from a first supply station through the crimping station and the second supply station to the IDC connection station.

[0089] Corresponding to the second supply station, electrical wires with two ends that need to be terminated via IDC connection are supplied to the holding and conveying device, and they are further conveyed to the IDC connection station via the holding and conveying device.

[0090] This configuration is particularly advantageous because the holding and conveying device can accommodate crimped wires, including one end that needs to be terminated by the IDC connector, and additional wires, including two ends that need to be terminated by the IDC connector, and transport them all to the IDC connection station without the need for two separate conveying systems. This results in greater machine efficiency.

[0091] Preferably, the holding and conveying device is configured to move from a first supply station to a crimping station, then to a second supply station, and finally to an IDC connection station. For example, the holding and conveying device leaves the crimping station with the crimped wires, stops at the second supply station to collect additional wires that need to be terminated by the IDC connector, and conveys all wires to the IDC connection station, where they are housed in different sockets.

[0092] In another preferred embodiment, the first and second supply stations are configured to operate simultaneously, such that while the first supply station supplies the wire to be crimped to the holding and conveying device, the second supply station supplies additional wire to different holding and conveying devices that have already moved from the first supply station to the crimping station. The advantage of this configuration is that different supply operations can be performed simultaneously, thus further increasing productivity.

[0093] According to another embodiment of the invention, a machine for producing electrical wiring is provided, wherein the holding and conveying device includes a retainer comb comprising a frame and a plurality of seats designed to accommodate electrical wires.

[0094] This configuration is particularly advantageous because one or more ends of the electrical wires can be housed in the holder comb, and they can be readily used in a controlled and predetermined manner for further processing. For example, the electrical wires can be loaded into the holding and conveying device according to a programmed sequence of preferred positions, which may correspond to the number of mating sockets in a pre-defined connector.

[0095] According to another embodiment of the present invention, a machine for producing electrical wiring is provided, wherein the retainer comb is an asymmetric retainer comb including a temporary storage area and a permanent storage area, wherein the temporary storage area includes two seats placed at a first distance, and the permanent storage area includes at least two seats placed at a second distance, wherein the first distance is greater than the second distance.

[0096] This configuration is particularly advantageous because one or more ends of the electrical conductors can be housed in the seat of the asymmetric retainer comb, and they can be readily used in a controlled and predetermined manner for further processing.

[0097] In another preferred embodiment, a temporary storage area is designed to hold the wire supplied by the first supply station and convey it to the crimping device. For example, the first distance can be designed such that two seats accommodate the two ends of a wire bent into a U-shape. The advantage of this configuration is that both ends of the wire are held in the seats and it is readily available for use with the crimping device.

[0098] In another preferred embodiment, the permanent storage area includes multiple seats and is designed to accommodate multiple electrical wires in a U-shaped or linear configuration. For example, the permanent storage area can store crimped electrical wires when they return to the holding and conveying device. Alternatively, the permanent storage area can store additional electrical wires supplied by a second supply station.

[0099] Preferably, the crimped wire is loaded into a permanent storage area such that the uncrimped end is located within the empty seat of the asymmetric retainer comb, and the crimped end hangs down from the asymmetric retainer comb. This configuration is particularly advantageous because the uncrimped end requiring further processing is held by the asymmetric retainer comb, thus facilitating its use with processing devices at different workstations.

[0100] According to another embodiment of the invention, a machine for producing electrical wiring is provided, wherein the seats of the temporary storage area have a variable width for accommodating electrical wires with different cross-sections, and wherein at least two seats of the permanent storage area have predetermined different widths for accommodating electrical wires with different cross-sections.

[0101] The advantage of this solution is that it can be used with different cross-sections (e.g., 0.35mm). 2 and / or 1.5mm 2 The conductor (with a cross-section) can be housed in the holder of the retainer comb and can be held during feeding and conveying operations without the risk of deformation and / or breakage of the holder of the retainer comb.

[0102] In this disclosure, it must be understood that each seat is defined by a pair of teeth, and the width of each seat corresponds to the distance between these teeth.

[0103] In a preferred configuration, the seat of the temporary storage area can have a variable width that can dynamically change during use to accommodate wires with different cross-sections, for example, when they are received at the supply station and / or crimping station, and it is necessary to adapt the width of the seat to the cross-section of the received wires.

[0104] In a preferred configuration, the holders for the permanent storage area can have predetermined different widths. For example, one or more first holders can have a predetermined first width for accommodating electrical wires with a first cross-section, and one or more second holders can have a predetermined second width for accommodating electrical wires with a second cross-section. It must be understood that the holders for the permanent storage area can have as many predetermined different widths as the number of different cross-sections of the electrical wires that must be accommodated in the permanent storage area.

[0105] Preferably, the seats in the permanent storage area can be fixed by screws, and they can be added or removed from the permanent storage area as needed by the user, depending on the number of wires having a predetermined cross-section corresponding to the predetermined widths s, s' of the seats that must be held in the retainer comb.

[0106] According to a preferred embodiment, the variable width of the temporary storage area seat can be varied to correspond to one or more predetermined different widths of the permanent storage area seat. Preferably, if a first wire having a first cross-section must be held in the retainer comb, the variable width of the temporary storage area seat is dynamically changed to correspond to the first cross-section, for example, when the wire is received at the supply station. Thus, at least one seat of the permanent storage area having a predetermined width corresponding to the first cross-section is formed in the retainer comb, for example, for receiving the wire at the crimping station. Preferably, if a second wire having a second cross-section different from the first cross-section must be held in the retainer comb, the variable width of the temporary storage area seat is dynamically changed to correspond to the second cross-section, for example, when the wire is received at the supply station. Thus, at least one seat of the permanent storage area having a predetermined width corresponding to the second cross-section is formed in the retainer comb, for example, for receiving the wire at the crimping station. This process is repeated for all wires with different cross-sections that must be held in the retainer comb.

[0107] According to another embodiment of the invention, a machine for producing electrical wiring is provided, wherein the variable width of the seat for temporary storage area dynamically changes by an elastic device when an electrical wire is introduced into the seat.

[0108] The advantage of this solution is that it can be used with different cross-sections (e.g., 0.35mm). 2 and / or 1.5mm 2 The conductor (with a cross-section) can be housed in the holder of the retainer comb and can be held during feeding and conveying operations without the risk of deformation and / or breakage of the holder of the retainer comb.

[0109] In a preferred configuration, the seat of the temporary storage area can have a variable width that can dynamically change during use to accommodate wires with different cross-sections, for example, when they are received at the supply station and / or crimping station. Preferably, the variable width is dynamically changed by an elastic device, such as a helical traction spring.

[0110] According to another embodiment of the invention, a machine for producing electrical wiring is provided, wherein a first supply station includes a supply device combined with a stripping device for stripping the insulating shell of electrical wires, such that one end of each electrical wire supplied by the first supply station to a holding and conveying device is stripped by the stripping device upon supply.

[0111] The advantage of this configuration is that the stripping device is combined with the supply device at the first supply station, and when the wires arrive at the crimping station, they are already set up for crimping because the insulating shell has been stripped.

[0112] In a first illustrative embodiment, the stripping device may be positioned in front of the supply device and may include a stripping blade configured to receive the end of the electrical wire at the first supply station and remove the insulating shell when the wire is pulled back. In a second illustrative embodiment, the stripping device may be located near the supply device and may include a stripping blade configured to receive the end of the electrical wire at the first supply station and displaced relative to the wire to remove the insulating shell. In the configuration of the second illustrative embodiment, the electrical wire may preferably be bent into a U-shape before reaching the stripping blade.

[0113] According to a preferred embodiment, one end of the conductor can be stripped while the conductor is supplied by the supply device to the holding and conveying device of the first supply station, such that when the conductor is conveyed to the crimping station, it already includes the stripped end. Preferably, during the supply process, the supply device and the stripping device are further combined with a bending device to bend the conductor into a U-shape to simplify the handling of the conductor and make the supply station more compact.

[0114] Preferably, the first supply station includes three supply devices that can operate simultaneously.

[0115] According to another embodiment of the invention, a machine for producing electrical wiring is provided, wherein a first supply station and / or a second supply station includes a bending device configured to bend electrical wires supplied to the first supply station and / or the second supply station respectively, such that they present a U-shaped configuration.

[0116] The advantage of this design is that when the conductor is bent into a U-shape, both ends are readily available for processing devices at different workstations. In fact, conductors are typically long, and it is difficult to process them if one end hangs down from the holding and conveying device and is not held by it.

[0117] For example, the wire can be bent into a U-shape and its two ends are housed in two seats in the temporary storage area of ​​the retainer comb.

[0118] In another preferred embodiment, the first supply station includes a bending device to bend the supplied wire into a U-shape. In a more preferred embodiment, the U-shaped wire is placed on a holding and conveying device such that its two ends are received in different seats within the holding and conveying device. In an even more preferred embodiment, the U-shaped wire is placed in a temporary storage area of ​​the holding and conveying device.

[0119] In another preferred embodiment, the second supply station includes a bending device to bend the supplied wire into a U-shape. In a more preferred embodiment, the U-shaped wire is placed on a holding and conveying device such that its two ends are received in different seats of the holding and conveying device in a permanent storage area.

[0120] In another preferred embodiment, both the first and second supply stations include bending devices to bend the wires into a U-shaped configuration.

[0121] According to another embodiment of the invention, a machine for producing electrical wiring is provided, wherein the bending device includes a guide device rotatable about a pivot and mounted on a semi-circular clamp coaxial with the pivot and configured to bend electrical wires.

[0122] This design is particularly advantageous because it is simpler than machines typically used to produce electrical wiring, which are characterized by a pair of pliers to bend the wires.

[0123] In another preferred embodiment, the conductor is partially housed in the guide device, thus having a fixed end and a loose end. For example, the fixed end may be held by a specific clamp. The guide device rotates about a pivot and bends the conductor about a semi-circular clamp, which is coaxially mounted about the pivot, such that both ends of the conductor are ultimately held by the guide device. Preferably, they provide the U-shaped conductor directly to the retainer comb.

[0124] According to another embodiment of the present invention, an apparatus is provided for feeding electrical wires into a holding and conveying device in a machine for producing electrical wires, the apparatus comprising the following elements:

[0125] - A supply device for receiving the electrical conductor;

[0126] - A stripping device for stripping the insulating outer shell of the electrical conductor.

[0127] The device includes a supply device combined with a stripping device, such that the electrical wires are stripped when they are supplied to the supply device.

[0128] Therefore, the advantage of this device is that the insulating sheath at the end of the conductor is removed once it leaves the supply device, and the conductor is immediately ready for crimping. In this way, the device provides stripped conductors in a simple and quick manner.

[0129] According to a first illustrative embodiment, the device may include a stripping blade positioned in front of the supply device and configured to receive the end of an electrical wire from the supply device, and to remove the insulating shell when the wire is pulled back. According to a second illustrative embodiment, the device may include a stripping blade located near the supply device and configured to receive the end of an electrical wire from the supply device, and to be displaced relative to the electrical wire to remove the insulating shell. In the configuration of the second illustrative embodiment, the electrical wire may preferably be bent into a U-shape before reaching the stripping blade.

[0130] According to another embodiment of the present invention, an apparatus is provided for bending electrical wires for a machine producing electrical wiring, the apparatus comprising:

[0131] - A guide device that can rotate about a pivot;

[0132] - A semi-circular clamp coaxial with the pivot;

[0133] The guiding device is configured to accommodate electrical wires and bend them around a semi-circular clamp by rotating about a pivot.

[0134] This design is particularly advantageous because it is simpler than machines typically used to produce electrical wiring, which are characterized by a pair of pliers to bend the wires.

[0135] Preferably, the device is configured to accommodate an electrical conductor such that a portion of the conductor is held by a guiding device, while another portion is not held by the guiding device and rotates freely. More preferably, the guiding device includes a clamping portion. The device rotates the guiding device about a pivot and bends the electrical conductor about a semi-circular clamp coaxially mounted on the pivot, such that both ends of the electrical conductor are ultimately held by the guiding device. For example, the electrical conductor can be provided to a holding and conveying device for a machine used to produce electrical wiring.

[0136] According to another embodiment of the present invention, a retainer comb for a machine for producing electrical wiring is provided, wherein the retainer comb is an asymmetric retainer comb including a temporary storage area and a permanent storage area, wherein the temporary storage area includes two seats placed at a first distance, and the permanent storage area includes at least two seats placed at a second distance, wherein the first distance is greater than the second distance.

[0137] This configuration is particularly advantageous because one or more ends of the electrical conductors can be housed in the seat of the asymmetric retainer comb, and they can be readily used in a controlled and predetermined manner for further processing.

[0138] In another preferred embodiment, the temporary storage area is designed to hold the wire supplied by the machine's supply station and convey it to the machine's workstation. For example, the first distance can be designed such that two seats accommodate the two ends of a wire bent into a U-shape. The advantage of this configuration is that both ends of the wire are held in the seats and are readily available for further processing.

[0139] In another preferred embodiment, the permanent storage area is designed to accommodate multiple electrical wires and transmit them through different workstations of the machine. The electrical wires may have a U-shaped or linear configuration, with one end housed within a socket and the other end detached.

[0140] According to another embodiment of the invention, a retainer comb is provided, wherein the seat of the temporary storage area has a variable width for accommodating electrical wires with different cross-sections, and wherein at least two seats of the permanent storage area have predetermined different widths for accommodating electrical wires with different cross-sections.

[0141] The advantage of this solution is that it can be used with different cross-sections (e.g., 0.35mm). 2 and / or 1.5mm 2 The conductor (with a cross-section) can be housed in the holder of the retainer comb and can be held during feeding and conveying operations without the risk of deformation and / or breakage of the holder of the retainer comb.

[0142] In this disclosure, it must be understood that each seat is defined by a pair of teeth, and the width of each seat corresponds to the distance between these teeth.

[0143] In a preferred configuration, the seat of the temporary storage area can have a variable width that can dynamically change during use to accommodate wires with different cross-sections, for example, when they are received at the supply station and / or crimping station, and it is necessary to adapt the width of the seat to the cross-section of the received wires.

[0144] In a preferred configuration, the holders for the permanent storage area can have predetermined different widths. For example, one or more first holders can have a predetermined first width for accommodating electrical wires with a first cross-section, and one or more second holders can have a predetermined second width for accommodating electrical wires with a second cross-section. It must be understood that the holders for the permanent storage area can have as many predetermined different widths as the number of different cross-sections of the electrical wires that must be accommodated in the permanent storage area.

[0145] Preferably, the seats in the permanent storage area can be fixed by screws, and they can be added or removed from the permanent storage area as needed by the user, depending on the number of wires having a predetermined cross-section corresponding to the predetermined widths s, s' of the seats that must be held in the retainer comb.

[0146] According to a preferred embodiment, the variable width of the temporary storage area seat can be varied to correspond to one or more predetermined different widths of the permanent storage area seat. Preferably, if a first wire having a first cross-section must be held in the retainer comb, the variable width of the temporary storage area seat is dynamically changed to correspond to the first cross-section, for example, when the wire is received at the supply station. Thus, at least one seat of the permanent storage area having a predetermined width corresponding to the first cross-section is formed in the retainer comb, for example, for receiving the wire at the crimping station. Preferably, if a second wire having a second cross-section different from the first cross-section must be held in the retainer comb, the variable width of the temporary storage area seat is dynamically changed to correspond to the second cross-section, for example, when the wire is received at the supply station. Thus, at least one seat of the permanent storage area having a predetermined width corresponding to the second cross-section is formed in the retainer comb, for example, for receiving the wire at the crimping station. This process is repeated for all wires with different cross-sections that must be held in the retainer comb.

[0147] According to another embodiment of the invention, a retainer comb is provided, wherein the variable width of the seat for temporary storage area dynamically changes by an elastic device when an electrical wire is introduced into the seat.

[0148] The advantage of this solution is that it can be used with different cross-sections (e.g., 0.35mm). 2 and / or 1.5mm 2 The conductor (with a cross-section) can be housed in the holder of the retainer comb and can be held during feeding and conveying operations without the risk of deformation and / or breakage of the holder of the retainer comb.

[0149] In a preferred configuration, the seat of the temporary storage area can have a variable width that can dynamically change during use to accommodate wires with different cross-sections, for example, when they are received at the supply station and / or crimping station. Preferably, the variable width is dynamically changed by an elastic device, such as a helical traction spring. Attached Figure Description

[0150] The invention will be described with reference to the accompanying drawings, wherein like reference numerals and / or symbols denote like and / or similar and / or corresponding parts of the machine. In the drawings:

[0151] Figure 1 A two-dimensional view schematically illustrates an example of an electrical wiring structure of the type produced using the present invention;

[0152] Figure 2 A machine for producing electrical wiring according to an embodiment of the present invention is illustrated schematically;

[0153] Figures 3A to 3D The supply operation of electrical conductors at a first supply station 100 according to a first illustrative embodiment of the present invention is schematically shown.

[0154] Figures 4A to 4D The supply operation of the conductor at the first supply station 100 is illustrated schematically according to a second illustrative embodiment of the present invention.

[0155] Figure 5 A transfer comb for holding and transferring electrical wires according to a first embodiment of the present invention is schematically shown;

[0156] Figure 6 A transfer comb for holding and transferring electrical wires according to a second embodiment of the present invention is schematically shown;

[0157] Figure 7 A stripping device for stripping the insulating shell of an electrical conductor is schematically shown according to a first illustrative embodiment of the present invention;

[0158] Figure 8 A stripping device for stripping the insulating shell of an electrical conductor is schematically shown according to a second exemplary embodiment of the present invention;

[0159] Figures 9A to 9C The diagram schematically illustrates three steps of the process of bending an electrical conductor into a U-shaped structure using a bending device according to an embodiment of the present invention;

[0160] Figure 10 An IDC connection station for terminating electrical wires via an IDC connector is schematically illustrated according to an embodiment of the present invention.

[0161] Figures 11A to 11G The steps of a method for conveying electrical conductors from a first supply station to a crimping station according to an embodiment of the present invention are illustrated schematically. Detailed Implementation

[0162] The invention is described below with reference to specific embodiments shown in the accompanying drawings. However, the invention is not limited to the specific embodiments described in the following detailed description and shown in the drawings, but rather the described embodiments simply illustrate several aspects of the invention, the scope of which is defined by the appended claims.

[0163] Those skilled in the art will recognize further modifications and variations of the present invention. Therefore, this specification must be considered to include all modifications and / or variations of the invention, the scope of which is defined by the appended claims.

[0164] For simplicity, identical or corresponding parts are denoted by the same reference numerals in the accompanying drawings.

[0165] Figure 1 This illustrates an example of an electrical wiring structure 10 of this type produced using the present invention. The electrical wiring structure 10 is merely a non-limiting example of an electrical wiring structure produced by the present invention. The electrical wiring structure 10 includes electrical conductors 11, 12, 13, and 15, each conductor having two ends 11a, 11b and 12a, 12b and 13a, 13b and 15a, 15b respectively. Ends 11a and 12a of conductors 11 and 12 are terminated by crimp connectors 40. Ends 11b and 12b of conductors 11 and 12 are inserted into corresponding sockets 50 of connectors 30, which are provided with corresponding electrical terminals 20. The two ends of electrical conductors 13 and 15 are terminated by IDC connectors. Ends 13a and 13b of conductor 13 are inserted into corresponding sockets 50 of two connectors 30 and 30', which are provided with corresponding electrical terminals 20; one connector 30 and 30' is positioned in front of the other. The two ends 15a and 15b of the wire 15 are inserted into the corresponding sockets 50 placed on the same connector 30, so that the wire 15 is bent into a U-shaped structure.

[0166] Figure 2 A machine 1000 for producing electrical wiring comprising at least two conductors 11, 12 is schematically shown. Each conductor has two ends, one end of which is inserted into a corresponding socket 50 of a connector 30 provided with a corresponding electrical terminal 20, and the other end of each conductor is connected to a crimp terminal 40. Preferably, machine 1000 produces... Figure 1 The electrical wiring structure 10 of the type shown also includes electrical wires 13 and 15, both ends of which are terminated by IDC connectors.

[0167] Machine 1000 includes four workstations located on closed loop 800: a first supply station 100, a crimping station 200, a second supply station 300, and an IDC connection station 400. Machine 1000 uses linear motor tracks to move holding and conveying devices 500, which are configured to hold and convey electrical wires through different workstations 100, 200, 300, and 400 on closed loop 800. Holding and conveying devices 500 include independent movers that carry conveyor combs 500', 500", and the conveyor combs 500', 500" include seats and frames designed to accommodate one end of the electrical wire. Each mover can be independently controlled for maximum flexibility. For example, the linear motor tracks could be of the Beckhoff XTS or B&R Supertrack type.

[0168] The first supply station 100 includes a supply device 110 for loading electrical supply wires 11, 12 onto conveyor combs 500', 500" . For example, the supply device 110 may include clamping portions for loading the electrical wires 11, 12 onto the conveyor comb. The electrical wires 11, 12 supplied by the first supply station 100 include an end 11a, 12a, which is further terminated by a crimp connector at the crimping station 200.

[0169] The first supply station 100 includes three supply device 110 units that can operate simultaneously. For example, the first supply station 100 may include any number of supply device 110 units, such as one, two, four, five or more.

[0170] Crimping station 200 includes three crimping presses of different types to process different electrical wires simultaneously. For example, crimping is performed by inserting the stripped end of the wire into a portion of a terminal, which is then mechanically deformed by pressing it tightly around the wire, and each crimping press is configured to crimp a specific shape of connector. Preferably, crimping station 200 does not include a stripping device because the electrical wire has already been stripped at the first supply station 100. For example, crimping station 200 may include any number of crimping presses, such as one, two, four, five, or more. Preferably, crimping station 200 includes as many crimping presses as the number of supply units included in the first supply station 100.

[0171] The second supply station 300 is configured to supply electrical wires 13 and 15, the ends 13a, 13b, 15a, and 15b of which need to be terminated by IDC connectors. The second supply station 300 includes a bending device 310 to bend the electrical wires 13 and 15 into a U-shape, such that both ends of each electrical wire 13 and 15 are accommodated in the seats of the conveyor combs 500' and 500'". If the electrical wires remain in the U-shape, they are more easily conveyed through different workstations because both ends are directly available to the processing unit.

[0172] IDC connection station 400 includes multiple machines for terminating electrical wires via IDC connectors, the electrical wires being supplied by a first supply station 100 and a second supply station 300. IDC connection station 400 can achieve... Figure 1 Different hybrid electrical wiring structures 10 of the type shown. The IDC connection station 400 also includes a trimming device 410 for trimming the electrical wires 11, 12, 13, 15 before they are terminated by the IDC connectors, so that the electrical wires 11, 12, 13, 15 have a precisely matched predetermined length within the electrical connectors 30, 30'.

[0173] Figures 3A to 3D The supply operation of electrical conductors in a first supply station 100 according to a first illustrative embodiment of the present invention is schematically shown.

[0174] The first supply station 100 includes a supply device 110 for loading electrical supply wires 11, 12 onto conveyor combs 500', 500" .

[0175] According to the first illustrative embodiment, the supply device 110 is combined with the stripping device 120, which is positioned in front of the supply device 110 (see...). Figure 3A Thus, the ends of the wires 11 and 12 that must be crimped are first supplied to the supply device 110 and then to the stripping device 120, so that the insulating shell is immediately removed during the supply operation. Stripping of the wires 11 and 12 is performed by holding one end of the wires 11 and 12 in the stripping device 120 and pulling the wires 11 and 12 backward (see...). Figure 3A and Figure 6 ).

[0176] The first supply station 100 also includes a rotating clamping part 130', which bends the wires 11, 12 into a U-shape before supplying them to the retainer comb, such that the two ends of each wire 11a, 11b and 12a, 12b can be accommodated in the corresponding seats of the retainer combs 500', 500" (see...). Figure 3B For example, the rotating clamping part 130' may include a pneumatic clamp.

[0177] The first supply station 100 also includes a cutting device 140 for cutting the supplied wire to the required length L by means of a cutting blade (see...). Figure 3C For example, for an electrical conductor comprising one end to be crimped and one end to be connected to an IDC terminal, L can be between 100 mm and 1500 mm; more preferably, L can be between 150 mm and 1500 mm. For an electrical conductor comprising both ends to be connected to an IDC terminal, L can be between 100 mm and 3000 mm; more preferably, the length L can be between 150 mm and 3000 mm.

[0178] The supply device 110 supplies stripped and cut electrical wires 11, 12 to the conveyor combs 500', 500' located in front of them (see...). Figure 3D For example, the supply device 110 may include clamping parts for loading electrical wires 11, 12 onto the conveyor combs 500', 500").

[0179] Figures 4A to 4D The supply operation of electrical conductors in the first supply station 100 according to a second illustrative embodiment of the present invention is schematically shown.

[0180] The first supply station 100 according to the second illustrative embodiment differs from the first supply station 100 according to the first illustrative embodiment in the construction of the stripping device 120'. In the second illustrative embodiment, the stripping device 120' is adjacent to the supply device 110 and is movable. The electrical wires 11, 12 are first supplied to the supply device 110 and then bent into a U-shape by the rotating clamp 130' (see...). Figure 4A In the U-shaped configuration, one end of the conductors 11, 12 is held by the supply device 110, and the other end reaches the stripping device 120'. The stripping device 120' is then displaced to strip and remove the insulating outer shell from the end of the conductor (see...). Figure 4B and Figure 7 According to the second illustrative embodiment, the first supply station is also configured to use a cutting blade (see...). Figure 4C The supplied wire is cut to the required length L and fed to the conveyor combs 500', 500'", as in the first illustrative embodiment (see...). Figure 4D ).

[0181] Figure 5 An asymmetric retainer comb 500' according to a first embodiment of the present invention is shown. The asymmetric retainer comb 500' includes a frame 501 on which seats 511', 512', 521', 522' are formed according to a substantially horizontal orientation. Each seat 511', 512', 521', 522' is substantially V-shaped to receive corresponding wires 11, 12, 13, 15 from above.

[0182] The asymmetric retainer comb 500' features an asymmetric design and includes a temporary storage area 510 and a permanent storage area 520. The temporary storage area 510 includes two seats 511', 512' positioned at a first distance D. The permanent storage area 520 includes multiple seats 521', 522', such as twenty-one or more teeth, positioned at a second distance d. The first distance D is greater than the second distance D and is designed to correspond to the distance between the two ends of an electrical conductor bent into a U-shape. The temporary storage area 510 is designed to accommodate conductors 11, 12 including one end to be crimped, while the permanent storage area 520 is designed to accommodate already crimped conductors and additional conductors including the two ends to be terminated by an IDC connector.

[0183] Figure 6 An asymmetric retainer comb 500″ according to a second embodiment of the present invention is shown. The asymmetric retainer comb 500″ includes a frame 501 on which seats 511″, 512″, 521″, and 522″ are formed in a substantially horizontal orientation. Each seat 511″, 512″, 521″, and 522″ is generally V-shaped to receive corresponding wires 11, 12, 13, and 15 from above.

[0184] The asymmetric retainer comb 500” features an asymmetric design and includes a temporary storage area 510 and a permanent storage area 520. The temporary storage area 510 includes two seats 511”, 512” positioned at a first distance D, each seat 511”, 512” defined by a corresponding pair of teeth and having variable widths s, s'. The temporary storage area 510 is provided with an elastic device 530, such as a helical traction spring, configured to dynamically adjust the distance between each pair of teeth defining each seat 511”, 512”, thereby dynamically adjusting the width of each seat 511”, 512”. Thus, due to the elasticity of the helical traction spring, electrical wires with different cross-sections can be accommodated and retained in the seats 511”, 512” without the risk of deformation and / or damage to the teeth.

[0185] The permanent storage area 520 includes multiple seats 521”, 522”, for example, twenty-one or more teeth, which are positioned at a second distance d, wherein each seat 521”, 522” is defined by a pair of teeth. The seats 521”, 522” may have predetermined different widths s, s', i.e., each seat 521”, 522” may be defined by a pair of teeth positioned at predetermined different distances s, s', in order to accommodate and retain electrical wires with different cross-sections. Preferably, each seat 521”, 522” can be secured by screws and can be added to or removed from the permanent storage area 520 as needed by the user, i.e., according to the number of wires having a predetermined cross-section corresponding to the predetermined seat widths s, s' that must be held in the retainer comb 500”. In this way, electrical wires with different cross-sections can be accommodated and held in the seats 521”, 522” without the risk of deformation and / or damage to the teeth.

[0186] For example, an asymmetric retainer comb 500” with this configuration can be accommodated and retained in seats 511”, 512”, 521”, and 522” with a diameter of 0.35 mm. 2 and / or 1.5mm 2 The cross-section of the conductor. However, it is clear that a cross-section smaller than 0.35 mm is also possible. 2 or cross-section greater than 1.5mm 2 The conductor, or any other cross-section of the conductor, is contained and held in the retainer comb 500 according to the invention.

[0187] Each asymmetric retainer comb 500', 500" is placed on an independently controllable mover that conveys it through different workstations 100, 200, 300, and 400 of machine 1000. The mover is functionally controlled electronically. During the crimping operation, combs 500', 500" move continuously between the first feed station 100 and the crimping station 200. The asymmetric design of the conveying combs 500', 500" combined with the independent control provided by the linear motor conveying system offers significant advantages, as two operations can be performed at each translational moment: feeding uncrimped wires and collecting crimped wires.

[0188] Figure 7 A stripping device 120 according to a first illustrative embodiment of the present invention is shown. The stripping device 120 includes stripping blades located in front of the supply device 110, such that when one end 11a of the electrical wire 11 leaves the supply device 110, it reaches and passes through the stripping blades; when the electrical wire 11 is pulled back, the insulating shell 11a' on that end 11a is removed. In this way, the insulating shell 11a' of the electrical wire 11 is removed by the stripping blades 120 while the electrical wire 11 is supplied to the supply device 110 at the first supply station 100, and it is immediately ready for further crimping operations, thus reducing processing time.

[0189] Figure 8 A stripping device 120' according to a second illustrative embodiment of the present invention is shown. The stripping device 120' includes stripping blades located near the supply device 110. A conductor 11 exits the supply device 110 and is bent into a U-shape by a rotating clamp 130'. One end 11a of the U-shaped conductor 11 reaches the stripping blade; as the stripping blade moves, the insulating shell 11a' on the end 11a is removed. In this way, the insulating shell 11a' of the conductor 11 is removed by the stripping blade 120' at the first supply station 100, and it is immediately ready for further crimping operations, thus reducing processing time.

[0190] Preferably, the wire 11 has been pre-cut to the desired length by the cutting device 140.

[0191] Figures 9A to 9C A bending device 310, representing a preferred embodiment of the invention, includes a pivot 320, a semi-circular clamp 330, and guide devices 340. The guide devices 340 are rotatable about the pivot 320, and are pivotally mounted on the semi-circular clamp 330 coaxial with the pivot 320. The guide devices 340 are configured to initially receive (see...) Figure 9A ) and containment (see Figure 9B A portion of the electrical wire to be bent is then bent around the semi-circular clamp 330. The electrical wire thus exhibits a U-shaped structure around the semi-circular clamp 330 (see...). Figure 9C For example, the bending device 310 is configured to bend a wire with a bending length of 100 mm.

[0192] The bending device 310 is combined with the supply device 350 at the second supply station 300, so that the wire 13 is first bent into a U-shape by the bending device 310, and then the two ends are positioned in the corresponding seats in the asymmetric retainer combs 500', 500" .

[0193] Figure 10This illustrates an IDC connection station 400 according to a preferred embodiment of the present invention. The IDC connection station 400 may be similar to existing IDC connection stations, and it includes a mass termination unit 420 for simultaneously connecting all electrical wires 11, 12, 13, 15 held by asymmetric retainer combs 500', 500" to the corresponding electrical terminals 20 of the connector 30. The IDC connection machine also includes an inspection unit and a cover closing unit. The IDC connection station 400 further includes a trimming station 410 for trimming the electrical wires 11, 12, 13, 15 so that they have identical lengths before being inserted into the sockets of the connector 30 having corresponding terminals 20. In fact, the asymmetric retainer combs 500', 500" arriving at the IDC connection station 400 typically comprise different electrical wires, which do not necessarily have identical lengths.

[0194] Below, refer to Figures 11A to 11G The operation according to a preferred embodiment of the present invention is described.

[0195] The holding and conveying device 500 includes asymmetrical retainer combs 500', 500'". Initially, the asymmetrical retainer combs 500', 500' are positioned at the first supply station 100 in front of the supply device 110 (see...). Figure 11A The first supply station can be of a known type, for example, it is of the Flexible Harness Maker (FHM) type. The first conductor 11 is automatically inserted into the supply device 110 at the first supply station 100, and when it is withdrawn, it is forced through the stripping blades 120, 120', thereby removing the insulating shell of the end 11a.

[0196] Based on the above description and Figures 11A to 11G In the first illustrative embodiment shown, the stripping blade 120 can be positioned in front of the supply device 110. In the first illustrative embodiment, after being stripped by the stripping blade 120, the first electrical wire 11 is bent into a U-shape by the bending device 130, while one end of the wire is still held by the supply device 110, and the first electrical wire 11 is finally loaded onto the temporary storage area 510 of the asymmetric retainer combs 500', 500" . In fact, the distance D between the two seats 511', 512', 511" , 512" of the temporary storage area 510 is designed to match the distance between the two ends 11a, 11b of the electrical wire 11 bent into the U-shape.

[0197] According to the second illustrative embodiment described above, but not in Figures 11A to 11GAs shown, the stripping blade 120' may be adjacent to the supply device 110, and the wire 11 may need to be bent by the bending device 130 before being supplied to the stripping blade 120'. In the second illustrative embodiment, the wire 11 is first bent into a U-shape, then stripped by moving the stripping blade 120', and finally loaded onto a temporary storage area 510 of the asymmetric retainer combs 500', 500"".

[0198] Preferably, the seats 511', 512', 511”, and 512” of the temporary storage area 510 may have a variable width, which can be adjusted according to the cross-section of the electrical conductor 11 received at the first supply station 100. Preferably, the variable width is adjusted by an elastic device, such as a helical traction spring.

[0199] According to the first or second illustrative embodiment, the first electrical conductor 11 can be further cut to a predetermined length by a cutting device at the first supply station 100.

[0200] The asymmetric retainer combs 500' and 500" carrying the first conductor 11 are moved to the crimping station 200 (see...). Figure 11B The first electrical wire 11 is clamped by the clamping part and conveyed to the crimping press 210 for crimping the end portion 11a of the connector 40.

[0201] During the crimping process of the first conductor 11, the asymmetric retainer combs 500' and 500" are moved back to the first supply station 100 to receive the second conductor 12 (see...). Figure 11C Then move again to crimping station 200 (see...) Figure 11D During the movement from crimping station 200 to the first supply station 100, the temporary storage area 510 is empty. The permanent storage area 520 is empty only during the first cycle of movement from the first supply station 100 to the crimping station 200 and back, while in subsequent cycles it is supplied with crimped wires. In this way, the crimping cycle is optimized because the operations of crimping the first wire 11 and supplying and transferring the second wire 12 to the crimping station 200 are performed simultaneously.

[0202] At crimping station 200, the first crimped conductor 11 is released from the crimping clamp and positioned in the permanent storage area 520 of the asymmetric retainer combs 500', 500" . Preferably, the seats 521', 522', 521" , 522" of the permanent storage area 520 may have predetermined different widths s, s' for accommodating corresponding conductors with predetermined different cross-sections. For example, the conductor 11 may be accommodated in the seats 521', 522', 521" , 522" of the permanent storage area 520, the seats having a width corresponding to its cross-section.

[0203] Subsequently, the crimping clamp collects the second electrical wire 12 from the asymmetric retainer combs 500', 500" . The first crimped electrical wire 11 is loaded into the permanent storage area 520 such that the uncrimped end 11b is located in the empty seats 521', 521" , and the crimped end 11a, including the crimp connector 50, hangs down from the asymmetric retainer combs 500', 500" . During the crimping of the second electrical wire 12, the asymmetric retainer combs 500', 500" carrying the first crimped wire 11 are moved back to the first supply station 100 to receive the third electrical wire 14 (see Figure 11E It is then moved again to crimping station 200, where it carries the first crimping wire 11 in permanent storage area 520 and the third electrical wire 14 in temporary storage area 510 (see...). Figure 11F ).

[0204] At crimping station 200, the second crimped wire 12 is released from the crimping clamp and positioned together with the first crimped wire 11 in the permanent storage area 520 of the asymmetric retainer comb 500', 500" . Preferably, the wire 12 can be accommodated in seats 521', 522', 521" , 522" of the permanent storage area 520, the seats having a width corresponding to their cross-section.

[0205] Subsequently, the crimping clamp collects the third electrical conductor 14 from the asymmetric retainer combs 500' and 500" (see...) Figure 11G ).

[0206] These operations can be repeated multiple times to load multiple electrical wires into the temporary storage area 510 of the asymmetric retainer comb 500' at the first supply station 100 and transfer them to the crimping station 200.

[0207] These operations are performed such that while a previous wire is being crimped at crimping station 200, a new wire is loaded into temporary storage area 510 and conveyed to crimping station 200. Then, before the new wire is collected by the crimping clamp, the previous wire is released and loaded into permanent storage area 520 along with other crimped wires. During these conveying movements, all crimped wires are stored in permanent storage area 520.

[0208] Then, the asymmetric retainer combs 500', 500" storing multiple crimped electrical wires in permanent storage area 520 are moved to the second supply station 300. At the second supply station 300, the asymmetric retainer combs 500', 500" stop and receive at least one additional electrical wire 13, which includes two ends to be terminated by an IDC connector. For example, at the second supply station 300, multiple additional electrical wires 13, 15 are loaded into the permanent storage area 520 of the asymmetric retainer combs 500', 500" which also stores crimped electrical wires 11, 12, 14.

[0209] At the second supply station 300, additional electrical wires 13 and 15 are bent into a U-shape by a bending device 310. The additional electrical wires 13 and 15 are initially housed in a guiding device 340 and bent around a semi-circular clamp 330. Thus, the additional electrical wires 13 and 15 present a U-shape around the semi-circular clamp 330 and are directly loaded into the permanent storage area 520, such that both ends are housed in different seats within the permanent storage area 520. In this way, both ends of the electrical wires are readily available to the processing equipment of the IDC connection station 400.

[0210] Finally, the asymmetric pass combs 500', 500" are passed to the IDC connection station 400. The IDC connection machine 420 can be of a known type and is configured to insert electrical wires 11, 12, 13, 14, 15 into corresponding sockets 50 of connector 30 or different connectors 30, 30', each connector 30 or different connectors 30, 30' having at least one corresponding electrical terminal 20. The IDC connection station 400 also includes a trimming station 410 in which the ends of the wires are trimmed to the same distance from the asymmetric retainer combs 500', 500" to have the same insertion length in the connectors. Once the wires 11, 12, 13, 15 have been trimmed, the asymmetric retainer combs 500', 500" move toward the insertion area, where one or more connectors may be located, and the wires are inserted into the corresponding electrical terminals.

[0211] The machine according to the invention allows for the production of hybrid electrical wiring structures in a fully automated manner. For example, both ends of the electrical conductor can be inserted into corresponding sockets 50 of one or more connectors 30, 30', which are provided with corresponding electrical terminals 20, or one end of the electrical conductor can be terminated by a crimp connector 40 and the other end by an IDC connector.

[0212] Although the invention has been described with reference to preferred physical embodiments constructed thereunder, it will be apparent to those skilled in the art that various modifications, variations, and improvements may be made to the invention in accordance with the foregoing teachings and within the scope of the appended claims without departing from the spirit and intended scope of the invention.

[0213] For example, even though it is described that two or more wires are collected at the first supply station 100 and one or more wires are collected at the second supply station 300, it is clear that the machine can also operate in such a way that a single wire is collected at the first supply station, one end of which is crimped at the crimping station 200, without the asymmetrical retainer combs 500', 500" moving back to the first supply station 100 to collect the second wire, and then the other end of the first wire is connected to the IDC terminal at the IDC connection station 400. Furthermore, the machine can also operate in such a way that no wires are collected at the first supply station 100, and one or more wires are collected at the second supply station 300 for IDC connection.

[0214] For example, even though the structure and function of the bending device 310 have been described with reference to the second supply station 300, it is clear that the same principle can also be applied to the bending device 130 at the first supply station 100.

[0215] Furthermore, even though bending devices 130, 310 and stripping device 120 have been shown and described separately, it is clear that they can be combined at the first supply station 100. For example, according to an illustrative embodiment, the electrical wires 11, 12 supplied at the first supply station 100 can first be inserted into the supply device 110, then pass through the stripping blade 120 to be stripped, and finally bend into a U-shape by the bending device 130. For example, according to another illustrative embodiment, the electrical wires 11, 12 supplied at the first supply station 100 can first be bent into a U-shape by the bending device 130, and then one end of the electrical wires 11, 12 in the U-shape can pass through the stripping blade 120' to be stripped.

[0216] Furthermore, even though the stripping device 120, bending devices 130, 310 and asymmetric retainer combs 500', 500" have been described with reference to machine 1000, it is clear that they can also be used in different machines for producing hybrid electrical wiring.

[0217] Furthermore, the number of machines located at each workstation may differ from that shown in the figure. For example, even though it is shown that there are three supply machines at the first supply station 100 and the second supply station 300 respectively, it is clear that they could be, for example, one, two, four, five or more.

[0218] For example, even if three crimping machines are shown at crimping station 200, they could obviously be, for example, one, two, four, five or more.

[0219] For example, even though four holding and conveying devices 500 are shown on the closed loop 800, they can obviously be, for example, one, two, three, five or more. Preferably, there are nine holding and conveying devices 500 in the machine 1000.

[0220] Furthermore, to avoid unnecessarily obscuring the described invention, areas considered familiar to those skilled in the art have not been described herein. Therefore, it must be understood that the invention is not limited to the specific illustrative embodiments, but only to the scope of the appended claims.

[0221] List of reference numerals

[0222] 10 Electrical wiring structure

[0223] Wires 11, 12, 13, 14, and 15

[0224] The ends of conductors 11a, 11b, 12a, 12b, 13a, 13b, 14a, 14b, 15a, and 15b

[0225] 11A” Insulating shell peel end

[0226] 20 Insulated Displacement Connection (IDC) Terminals

[0227] 30' IDC connector

[0228] 40 crimp connector

[0229] Socket for 50 IDC connectors

[0230] 100 First Supply Station

[0231] 110 supply unit

[0232] 120, 120' stripping device

[0233] 130 bending device

[0234] 130' Rotary Clamping Section

[0235] 140 cutting device

[0236] 200 crimping station

[0237] 210 crimping press

[0238] 300 Second Supply Station

[0239] 310 Bending Device

[0240] 320 pivot

[0241] 330 semi-circular clamp

[0242] 340 guiding device

[0243] 350 supply unit

[0244] 400IDC Connection Station

[0245] 410 Dressing Device

[0246] 420IDC Quality Termination Unit

[0247] 500 Holding and Conveying Device

[0248] 500', 500" asymmetric retainer comb

[0249] 501 retainer comb frame

[0250] 502 retainer comb seat

[0251] 510 Temporary storage area

[0252] The temporary storage areas 511', 512', 511", and 512" are located in the same area.

[0253] 520 Permanent Storage Area

[0254] The 521', 522', 521", and 522" permanent storage areas

[0255] 530 helical traction spring

[0256] 600 Device for supplying and stripping electrical wires

[0257] 700 Device for bending electrical wires

[0258] 1000 machines used for producing electrical wiring

[0259] Distance between seats in the permanent storage area

[0260] Distance between seats in temporary storage area D

[0261] s, s' seat width

Claims

1. A method for producing electrical wiring comprising at least two conductors, each conductor having two ends, wherein one end of each conductor is connected to a crimp terminal, and the other end of each conductor is inserted into a corresponding socket of a connector provided with a corresponding electrical terminal, the method comprising the steps of: a) At a first supply station, a first conductor is supplied to a retainer comb, wherein the retainer comb includes a frame and a plurality of seats designed to accommodate conductors and is an asymmetrical retainer comb including a temporary storage area and a permanent storage area, wherein the temporary storage area includes two seats placed at a first distance, and the permanent storage area includes at least two seats placed at a second distance, wherein the first distance is greater than the second distance, and the seats in the temporary storage area have variable widths for accommodating conductors with different cross-sections, and wherein the at least two seats in the permanent storage area have predetermined different widths for accommodating conductors with different cross-sections; b) The first wire held in the retainer comb is fed to the crimping station, and the first wire is released into the crimping station; c) Crimping one end of the first conductor in the crimping station; d) At the first supply station, the second wire is supplied to the retainer comb; e) The second wire held in the retainer comb is fed to the crimping station; f) Supply the first crimped lead to the retainer comb and release the second lead from the retainer comb to the crimping station; g) Crimping one end of the second conductor in the crimping station; h) The crimped second wire is supplied to the retainer comb such that the retainer comb together accommodates both the crimped first wire and the crimped second wire; i) The crimped first wire and the crimped second wire are fed to the IDC connection station via the retainer comb; j) IDC connection: the free end of the first crimped conductor and the free end of the second crimped conductor.

2. The method according to claim 1, further comprising the following step: k) Corresponding to the second supply station, the third wire is supplied to the retainer comb; l) Corresponding to the IDC connection station, the IDC connects to the two ends of the third conductor; Step k) is performed during step I) such that the retainer comb together accommodates the crimped first wire, the crimped second wire, and the third wire.

3. The method according to claim 2, wherein, Step k) is repeated multiple times in order to supply multiple wires corresponding to the second supply station.

4. The method according to claim 2 or 3, further comprising the following step: m) Bend one or more wires supplied at the second supply station such that they form a U-shape, and such that both ends of the one or more wires are accommodated within the retainer comb. Step m) is executed during step k).

5. The method according to any one of claims 1 to 3, further comprising the following steps: n) Corresponding to the first supply station supplying another wire to the retainer comb and conveying the other wire held in the retainer comb to the crimping station; o) Release the other conductor to the crimping station; p) Crimping one end of the other conductor in the crimping station; q) The other crimped wire is then fed to the IDC connection station; r) The free end of the other wire crimped to the IDC connection; Step n) is performed during step g), and steps q) and r) are performed simultaneously with steps i) and j), such that steps q) and i) are performed by means of a retainer comb to feed all the crimped wires together.

6. The method according to claim 5, further comprising the following step: s) Repeat steps n) to p) multiple times to supply multiple wires at the first supply station, thereby performing steps n) and o) on the new wire supplied at the first supply station, while performing step p) on the previous wire supplied to the first supply station just before the new wire. t) The multiple crimped wires are fed together to the IDC connection station via the retainer comb; u) IDC connects the free ends of the multiple crimped wires.

7. The method according to any one of claims 1 to 3 further comprises the following step: v) Strip one end of one or more wires supplied at the first supply station while the one or more wires are supplied to the retainer comb.

8. The method according to any one of claims 1 to 3 further comprises the following steps: w) Bend one or more wires supplied at the first supply station such that they are U-shaped and that the two ends of the one or more wires are accommodated in the retainer comb. Step w) is performed during any of steps a), d), and n).

9. A machine for producing electrical wiring comprising at least two conductors, each conductor having two ends, wherein one end of each conductor is connected to a crimp terminal, and the other end of each conductor is inserted into a corresponding socket of a connector provided with a corresponding electrical terminal, said machine comprising: The first supply station is used to supply the conductor; A crimping station, used to crimp one end of each of the conductors; IDC connection station, used to terminate the other end of each of the wires via an IDC connector; A retainer comb, configured to receive the wires at the first supply station and convey them to the crimping station and the IDC connection station, the retainer comb including a frame and multiple seats designed to accommodate the wires. The machine is configured as a movable retainer comb such that when the first wire is crimped at the crimping station, the retainer comb is moved to the first supply station to receive the second wire, and then moved back to the crimping station to crimp the second wire. The machine is also configured to release a crimped first wire to the retainer comb, and subsequently release a crimped second wire to the retainer comb, so as to provide the crimped first wire and the crimped second wire together to the IDC connection station via the retainer comb. The machine is characterized by: The retainer comb is an asymmetrical retainer comb comprising a temporary storage region and a permanent storage region, wherein the temporary storage region comprises two seats placed at a first distance, and the permanent storage region comprises at least two seats placed at a second distance, wherein the first distance is greater than the second distance, and The seats in the temporary storage area have variable widths for accommodating wires with different cross-sections, and the at least two seats in the permanent storage area have predetermined different widths for accommodating wires with different cross-sections.

10. The machine according to claim 9, further comprising: The second supply station, used to supply additional conductors, is located between the crimping station and the IDC connection station. The machine is configured to move the retainer comb from the first supply station through the crimping station and the second supply station to the IDC connection station.

11. The machine according to claim 9 or 10, wherein, When the wire is introduced into the seat, the variable width of the seat in the temporary storage area changes dynamically through an elastic device.

12. The machine according to claim 9 or 10, wherein, The first supply station includes a supply device combined with a stripping device, such that one end of each wire supplied by the first supply station to the retainer comb is stripped by the stripping device while being supplied.

13. The machine according to claim 10, wherein, The first supply station and / or the second supply station include a bending device configured to bend the wires supplied to the first supply station and / or the second supply station respectively, so that they present a U-shaped structure.

14. The machine according to claim 13, wherein, The bending device includes a guide that is rotatable about a pivot and mounted on a semi-circular clamp, the semi-circular clamp being coaxial with the pivot and configured to bend the wire.

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