Wire termination system

Abstract

A wire processing system (200) includes a terminal cutter (230) having an opening (371) that receives a terminal strip (150) including a plurality of terminals (152) and defines a terminal strip supply path. A crimping tool or die (242) of the system is disposed on a first side of the terminal strip feed path. A terminal clamping device (260) is provided on a second side of the terminal strip supply path opposite the first side and is adapted to clamp a terminal (152) of the terminal strip (150).

Description

Technical Field

[0001] The present invention relates to the processing of wires or cables and associated terminals and, more particularly, to an improved system for applying terminals to wires, including multi-conductor cables, such as twisted pair cables. Background Art

[0002] A crimping or termination system for securing a terminal to an element such as an electrical conductor typically includes an applicator configured to feed a strip of terminals from a reel to a position for crimping onto a conductor, and more specifically to a position above a lower crimping tool or die. Once the terminal is in place, the end of the wire or cable to be terminated is fed to a position above or within the terminal. The terminal can be separated from the terminal strip using a shear press attached to a movable end of an applicator ram that drives an upper crimping die. As the applicator ram moves, the press engages a passive terminal shear or shear tool that shears the terminal from the strip just after the terminal is captured in the crimping tool.

[0003] Although effective for single conductors, the above arrangement is less suitable for use in multi-conductor cables, such as twisted pair cables. Specifically, in multi-conductor cable applications, due to the requirements of the final termination assembly, the wire ends may only extend a relatively short distance beyond the cable (e.g., its jacket). This makes it difficult to place the individual ends in the applicator during the crimping operation. In addition to the difficulty in accurate placement during termination, further problems arise due to the requirement that the pairs of discrete wires must be kept in close proximity to each other to prevent signal noise. Specifically, during the above-mentioned crimping process, the wire pairs can be pre-formed into a shape that creates enough space for the crimping tool. However, this spacing is larger than the final spacing in the connector and is larger than the allowable spacing between the wires for signal integrity. Therefore, the wires need to be reshaped after crimping to position them closer to each other. This reshaping process may result in length differences between the wire pairs or internal stresses that cause the wires to bend too far apart. In addition, the formed wires are not individually supported or controlled during crimping. Depending on the stiffness of the wires, sagging may occur, which may affect the repeatability of accurate wire placement within the terminal. While wire positioning devices may be implemented in an effort to accurately position the wire prior to crimping, these devices are often not compatible with existing applicators and terminal shearing devices or cannot be practically implemented.

[0004] Improved systems and methods that address these deficiencies are desired. Summary of the invention

[0005] In one embodiment of the present disclosure, a wire processing system includes a terminal shear having an opening that receives a terminal strip including a plurality of terminals and defines a terminal strip feed path. A crimping tool or die of the system is disposed on a first side of the terminal strip feed path. A terminal clamping device is disposed on a second side of the terminal strip feed path opposite to the first side and is adapted to clamp the terminals of the terminal strip. BRIEF DESCRIPTION OF THE DRAWINGS

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

[0007] Figure 1A is a front perspective view of a terminal applicator that may be used to describe an embodiment of the present disclosure;

[0008] Figure 1B yes Figure 1A A partial front perspective view of a terminal applicator with an exemplary wire or cable inserted therein;

[0009] Figure 2 yes Figure 1B A side perspective view of a terminal applicator;

[0010] Figure 3A is a front perspective view of a terminal applicator system according to an embodiment of the present disclosure;

[0011] Figure 3B yes Figure 3A A partial front perspective view of a terminal applicator system;

[0012] Figure 4 yes Figure 3A A side perspective view of a terminal applicator system of FIG. 1 with an exemplary wire or cable inserted therein;

[0013] Figure 5 is a side perspective view of a terminal cutter and a terminal cut drive assembly according to an embodiment of the present disclosure;

[0014] Figure 6 is a top view of a terminal clamping mechanism according to an embodiment of the present disclosure in a closed or clamped position;

[0015] Figure 7 is in the open position Figure 6 A top view of a terminal clamping mechanism;

[0016] Figure 8 is in the lowered and closed position Figure 6 and Figure 7 a side view of a terminal clamping mechanism; and

[0017] Fig. 9 is in the raised and open position Figure 8Side view of the terminal clamping mechanism. DETAILED DESCRIPTION

[0018] Overall reference Figure 1A and 1B , an exemplary crimping system 100 that can be used to describe an embodiment of the present disclosure is shown. The crimping system 100 generally includes an applicator or applicator assembly 110, a ram assembly 120, a terminal shear 130, and relative crimping tools or dies 141, 142. The system 100 is suitable for crimping a terminal 152 sheared from a terminal strip or carrier 150 including a plurality of interconnected terminals to (multiple) ends of a wire or cable. Specifically, the terminal applicator 110 is suitable for supplying the terminal 152 of the terminal strip 150 to a crimping position between a movable upper crimping die 141 and a relatively fixed lower die 142. The upper crimping die 141 is fixedly connected to the movable end of the applicator ram or crimping actuator 122. As shown, the applicator ram 122 may include, for example, one or more pneumatic or hydraulic cylinders or motor drive mechanisms for selectively moving the crimping die 141 in (multiple) vertical directions. During the termination process, the crimping head assembly 120 is lowered to separate the terminal 152 from the strip 150 via the terminal cutter 130, and the terminal 152 is crimped onto the free end of the wire or cable inserted therein via the crimping dies 141, 142. Figure 1B As shown, when used to crimp a terminal to a conductor 12 of a twisted pair cable 10 including two conductors 12, 14, the applicator 110 feeds the terminal 152 along a feed path to a termination point above a lower crimping tool 142. In a typical application, the prepared twisted pair cable 10 is manually placed in the termination area through an opening in the guard. This makes it difficult to accurately position the individual conductors 12, 14 relative to the terminal. The size of the cable 10 relative to the individual conductors also interferes with the terminal shear 130 located between the terminal 152 and the machine operator. The unterminated individual conductors 14 may also interfere with the crimping tools 141, 142 and may be damaged if not properly handled and positioned.

[0019] like Figure 2 As specifically shown in the figure, in order to compensate for these shortcomings, a wire handling or positioning device or assembly 190 can be used to orient the wires 12, 14 of the cable 10 to the crimping position between the upper crimping die 141 and the lower crimping die 142 described above. As shown in the figure, the positioning device 190 biases or shifts the other wire 14 out of the crimping area via relative rotation between the wires. The device 190 includes: a first clamp 191 suitable for clamping the first wire 12 of the cable 10, and a second clamp 192 that can move relative to the first clamp and can operate independently of the first clamp to clamp the second wire of the cable.

[0020] Still reference Figure 1A-2In some terminal applications, a terminal carrier strip 150 that positions and orients the terminal 152 prior to crimping is located between the wire crimp barrel of the terminal 152 and the front of the machine. This is referred to as a front carrier strip. The use of a front carrier strip necessitates that the terminal shear 130 be located on the side of the applicator 110 where the cable 10 is presented or inserted for termination. This is also referred to as a front shear. The use of a front shear applicator 110 is problematic, for example, Figure 2 The wire positioning device 190 interferes with the terminal shear 130, as shown. Therefore, it is impossible to properly position (ie, close enough) the wire positioning device 190 relative to the applicator 110.

[0021] Embodiments of the present disclosure enable the use of a wire positioning device such as Figure 2 The wire positioning device 190 shown in the figure prevents damage to the wire, cable or termination connector. More specifically, an embodiment of the present disclosure removes the existing terminal shear 130 from the front of the lower crimping tool 142 to allow the positioning device 190 to be correctly positioned for accurately placing the wires 12, 14 for termination. In use, the front carrier mounted terminal is fed to the back of the lower tool or ram. In an embodiment, a clamping mechanism is provided that is lowered to the terminal height and then closed to clamp the terminal. Once clamped, the rear mounted terminal shear is actuated via a cylinder, cam, pivot arm and shaft to separate the terminal from the terminal carrier strip. The conveying mechanism then moves the clamp forward to position the terminal above the lower crimping tool for termination.

[0022] More specifically, and with reference now to Figure 3A and 3B , an applicator system or assembly 200 according to an embodiment of the present disclosure includes a rear shear for a front carrier strip, which is designed to separate the terminal from the carrier strip behind a lower crimping tool. Assembly 200 includes an applicator 210, which includes a press head 220, a shearing tool 230, an upper crimping tool 241 and a lower crimping tool 242, and a terminal shear / clamping and conveying mechanism 250 for operating the system of the terminal shear 230 and a clamping mechanism 260. All or part of the above components are mounted on a base plate 262. As shown in the figure, the operating portion of the terminal shear 230 has been repositioned behind the lower crimping tool or die 242 (i.e., the rear shear), which is different from the front shear arrangement of the prior art assembly, and as described with respect to Figure 1A-2 Shown and described.

[0023] Figure 42 is a side view of the applicator system 200 showing the cable 10 inserted therein. As a result of the repositioning of the terminal shear 230 behind the crimping die 242, the base 262 can be shortened. This allows for improved placement of the wire positioning assembly 190 for holding and positioning the wires 12, 14 of the cable 10. Specifically, the assembly 190 can be positioned directly adjacent to the lower crimping die 242. This arrangement increases the accuracy and efficiency of wire placement, reducing the above-mentioned crimping errors and other related disadvantages of manual or unassisted wire placement.

[0024] If you can Figure 4 As further visualized in FIG. 1 , the gripper mechanism 260 is used to feed the terminal 152 from behind and toward the lower crimping die 242 in the indicated direction D. Specifically, the gripper mechanism 260 is lowered onto the terminal 152 and grips or holds the terminal as the terminal is sheared from the strip 150. After shearing, the conveyor mechanism 250 moves the gripper mechanism 260 and the terminal 152 forward to a termination position above the lower tool 242. It should be understood that the gripped and separated terminal 152 can be moved to a termination position above the lower crimping tool 242 by another actuator, such as a linear actuator 251 incorporated into the mechanism 250 and attached to the gripper mechanism 260.

[0025] Figure 5 An actuator or drive assembly or mechanism 300 of the system 200 for driving the rear shearing tool 230 is shown. The exemplary mechanism 300 includes a linear actuator 302 for selectively driving a shearing cam 304 in the indicated direction S. The cam 304 includes an opening 305 defining a cam surface. A cam arm 360 includes a cam follower 362 (e.g., a roller cam follower) engaged within the opening 305 and the associated cam surface. A rotatable pivot 364 is fixedly connected to the end of the cam arm 360. A shearing arm 366 is fixedly connected to the end of the pivot shaft 364. The movable shearing tool 230 is attached to the shearing arm 366 and is operable to shear a carrier strip from a terminal together with the fixed tool 231. Specifically, the shearing tools 230, 231 define an opening 371 formed therethrough for receiving the terminal strip 150 prior to shearing. When the actuator 302 is extended or retracted to rotate the pivot shaft 364 via the cam follower 362 and the cam arm 360, the shear tool 230 is lowered. The rotation of the pivot shaft 364 causes the movement of the shear arm 366, which lowers the shears 230 to separate the terminal from the strip. This process is different from the above-mentioned prior art, which drives the shears downwardly by the movement of the applicator ram during the termination process. It should be understood that the opening 371 generally defines a feed path for the terminal strip (i.e., the terminal strip 150) therethrough. The feed path is oriented transverse to the insertion direction of the cable 10, as shown in FIG. Figure 4As shown, and correspondingly transverse to the translation directions D, S of the clamp mechanism 260 and the shear cam 304.

[0026] Reference now Figure 6-9 , the clamping and / or conveying mechanism 250 will be described in further detail. Figure 6 and Figure 7 As shown, the clamp mechanism 260 includes an inner clamp 261 and an outer clamp 263 opposed to each other for clamping the terminal 152 therebetween, as described above. In an exemplary embodiment, the clamps 261, 263 can be moved or pivoted relative to each other in a scissor-like manner about an intermediate pivot point 264. Each of the clamps 261, 263 can be biased to a position via a corresponding (multiple) return spring 266, 268 (e.g., a plurality of compression springs) acting laterally on each arm of the corresponding clamp. Figure 6 Shown in closed position.

[0027] like Figure 7 As shown, the clamps 261, 263 are biased to the open position via a cam or camshaft 270 attached to the movable end of the linear actuator 269 against the elastic restoring force applied by the springs 266, 268. Specifically, the cam 270 can be selectively moved in the indicated direction G via the actuator 269. The cam 270 defines cam surfaces 271, 273, which engage adjustment screws 275, 277 or cam followers fixed to each arm of the clamps 261, 263, respectively, as the actuator 269 and the cam 270 extend. When the cam 270 is retracted, the springs 266, 268 return the clamps 261, 263 to the closed position. Figure 6 As shown, changing the length of each adjustment screw 275, 277 is operable to change the degree to which each clamp is biased (ie, how much the clamp is opened and / or closed).

[0028] Reference now Figure 8 and Fig. 9 During an exemplary termination or crimping operation according to an embodiment of the present disclosure, the clamp mechanism 260 can be moved from a lowered position ( Figure 8 ) vertically to the raised position ( Fig. 9 ), so as to allow the terminal 152 and / or the strip 150 to be fed under the clamp mechanism 260 via the applicator 110 and into a position to be clamped by the clamps 261, 263. In an exemplary embodiment, the clamp mechanism 260 is raised and lowered as the cam 270 extends and retracts accordingly. In this way, as Figure 8 As shown, when the clamping mechanism 260 descends and the terminal 152 is in the to-be-clamped position, the clamping mechanism is automatically closed under the action of the restoring force of the springs 266 and 268.

[0029] As shown, a spring 280 (ie, a compression spring) is disposed between a body 282 of the mechanism 250 and, for example, a base 262 or a transfer block 284 attached to the base. The spring 280 biases the gripper mechanism 260 to Figure 8 270 is in the retracted position. As the gripper cam 270 extends to open the gripper mechanism 260, the protrusion 279 on the gripper cam engages a stop screw 288 mounted on the transfer block 284. The force applied to the stop screw 288 creates a torque about the pivot screw or joint 290 that rotates the gripper mechanism 260 about the pivot screw, raising it until the adjustment screw 292 contacts the transfer block 284. When used in conjunction with the actuator 251 described above, the gripper mechanism 260 is operable to grip the terminal as it is sheared from the strip and to transfer the sheared terminal over the shears to a termination position above the lower crimping tool 242 for subsequent crimping.

Claims

1. A terminal applicator system (200), comprising: An applicator (210) having a crimping actuator (220) and a pair of opposing crimping dies (241, 242), the pair of opposing crimping dies comprising a movable upper die (241) mounted to a movable end of the crimping actuator (220) and a fixed lower die (242), the applicator (210) supplying a strip (150) of terminals (152) along a supply path extending in a first direction; a terminal clamping mechanism (260) adapted to clamp the terminal (152) supplied by the applicator (210) to a clamping position adjacent to the lower mold (242), the clamping mechanism (260) being arranged on a side of the supply path opposite to the lower mold (241) along a second direction transverse to the first direction; and A terminal cutter (230) is arranged between the lower die (242) and the clamping mechanism (260) along the second direction, and receives the strip (150) of the terminal (152) supplied by the applicator (210).

2. The system (200) according to claim 1 further comprises a wire clamping device (190), wherein the wire clamping device (190) is installed adjacent to the lower mold (242) on the side opposite to the terminal cutter (230) along the second direction, and the clamping device (190) comprises a first clamp (191) suitable for clamping a first wire (12) of the cable (10) and a second clamp (192) suitable for clamping a second wire (14) of the cable (10).

3. The system (200) according to claim 1, wherein: The terminal cutter (230) defines a slot opening (371) in the direction of the terminal clamping mechanism (260).

4. The system (200) according to claim 1, wherein: The terminal clamping mechanism (260) clamps the terminal (152) at the clamping position and causes the terminal to extend along the second direction to a termination position above the lower mold (242).

5. The system (200) of claim 4, further comprising an actuator (251) for translating the terminal clamping mechanism (260) along the second direction.

6. The system (200) of claim 4, further comprising a clamp actuator (269) for opening and closing the opposite ends (261, 263) of the clamp mechanism (260).

7. The system (200) according to claim 6, wherein: The terminal clamping mechanism (260) is raised to allow the terminal strip (150) to be fed to the clamping position by the applicator (210).

8. The system (200) according to claim 7, wherein: As the clamping mechanism moves to the raised position, the opposite ends (261, 263) of the clamping mechanism (260) are automatically biased to the open position, and as the clamping mechanism moves to the lowered position, the opposite ends (261, 263) are automatically biased to the closed position.

9. The system (200) of claim 6, further comprising a clamp cam (270) operably connected to the clamp actuator (269) to bias the opposing ends (261, 263) of the clamp mechanism (260) between an open position and a closed position.

10. The system (200) according to claim 9, wherein: Movement of the clamp cam (270) causes the clamp mechanism (260) to rise.

11. The system (200) of claim 1, wherein: The terminal shear (230) is driven by a shear actuator (302) that is independent of the crimping actuator (220).

12. A wire processing system (200), comprising: A terminal cutter (230) having an opening (371) sized to receive a terminal strip (150) including a plurality of terminals (152) and to define a terminal strip supply path; A crimping die (242) arranged on a first side of the terminal strip supply path; and A terminal clamping device (260) is arranged on a second side of the terminal strip supply path opposite to the first side and is suitable for clamping the terminals (152) of the terminal strip (150).

13. The system (200) of claim 12, further comprising a wire clamping device (190) mounted adjacent to the crimping die (242) on a side opposite to the terminal shear (230) and adapted to hold and position at least one wire (12, 14) to be terminated.

14. The system (200) of claim 12, wherein: The terminal clamping device (260) clamps the terminal (152) arranged at a clamping position, and allows the terminal to extend in a direction transverse to the strip supply path and reach a termination position above the crimping die (242).

15. The system (200) according to claim 14, further comprising: A first actuator (251) extends the terminal held by the clamping device (260) to the termination position; a second actuator (269) biasing opposing clamping elements (261, 263) of the clamping device (260) between a closed position and an open position and raising and lowering the clamping elements of the clamping device; and A third actuator (302) of the terminal cutter (230) is operated.

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