US 3758935 A
Apparatus for connecting each of a plurality of conductors to each of a plurality of terminals in an electrical device, such as an electrical connector, comprises a first jig for holding the electrical device in a predetermined position and a second jig for locating the conductors in predetermined positions. The conductors in the conductor holding jig are spaced apart by the same distances as the spacing between the terminals. A conductor inserting tool is moved past the second holding jig and towards the first jig to transfer the conductors from the first jig to the terminals in the electrical device. A shearing means, comprising one edge of the inserting tool and a stationary edge, is provided to trim the ends of the conductors while they are being transferred from the first jig to a connector.
Description (OCR text may contain errors)
( 1 Sept. 18, 1973 APPARATUS FOR SECURING WIRES TO TERMINALS IN CONNECTORS 29/203 HT 10/1970 Gurley 29/203 R 3,456,325 7/1969 Langlois et 3,531,846
Primary Examiner-Thomas H. Eager  Inventors: Robert Alvin Long; Roderick g l z grf g g r i gig Anomey-William J. Keating, Ronald D. Grefe, Gerald K.l('t,FdkW.R' dJ L.S'th'k Winston-Salem; John Robert I a re enc armg an ay c l Shoemaker, Walkertown, both of  ABSTRACT Apparatus for connecting each of a plurality of conductors to each of a plurality of terminals in an electrical 1 7 9 l 8 7 n. 7 m4 1 0 N .ml p m0. FA nu 22 [l the conductor holding jig are spaced apart by the same distances as the spacing between the terminals. A conductor inserting tool is moved past the second holding jig and towards the first jig to transfer the conductors P4 mww R 9- 0 1 Umm N T 555 [[l.
29/203 J, 203 P, 203 HT, 203 H from the first jig to the terminals in the electrical de- 5 References Cited vice. A shearing means, comprising one edge of the inserting tool and a stationary edge, is provided to trim UNITED STATES PATENTS the ends of the conductors while they are being transe 8 mm 0 W e n a D m u g t m m P l 8 C m n m o .H d e r r k WW H mmm 002 22 //9 992 22 l "a m m h mhfl ou MDG 0 9 776 999 111 III 973 50 502 84 293 333 PATENTED SEP I 81973 SHEET 01 0F 10 PATENTEU SEP'! 8 I975 SHEET 05 0F 10 PATENTEB SEP 1 8 I975 SHEET 07 0F 10 PATENTED sen 8191a SHEET 08 0F 10 PATENTEDSEP I 8I973 SHEET 09 0f 10 EMI PArEmEnsEm n 3.758.935
sum iour 10 Fi g \J 3 HUUHUHUUHUWHWUWJ PURPLE YELLOW JLBLACK REQ J APPARATUS FOR SECURING WIRES TO TERMINALS IN CONNECTORS BACKGROUND OF THE INVENTION Application Ser. No. 147,569 filed May 27, I971 by Lincoln Edwin Roberts for Pre-Loaded Electrical Connector discloses and claims an electrical connector having terminals therein to which individual conductors are adapted to be connected. The terminals have conductor receiving portions in the form of plate-like extensions at their rearward ends, the plate-like extensions having conductor receiving slots so that the conductors can be connected to the terminals by move ment of the conductors laterally of their axes into the slots. The embodiment of the invention disclosed in the above identified application Ser. No. 147,569 is described below to provide the necessary background information for the disclosure of the instant invention.
When a connector in accordance with application Ser. No. is applied to the ends of a plurality of conductors, the conductors can be individually inserted into the slots of the connecting portions of the terminals, however, it is preferable to carry out the connecting operation by simultaneously connecting all, or at least some, of the conductors to the terminals in a single operation.
The instant invention is directed to the achievement of an improved apparatus for connecting or joining each of a plurality of conductors to each of a plurality of terminals contained in an electrical device such as an electrical connector. The invention is further directed to the achievement of an apparatus which has means for trimming the ends of the conductors during the operation of connecting conductors to the terminals in an electrical device.
It is accordingly an object of the invention to provide an improved apparatus for connecting conductors to the terminals in an electrical device such as an electrical connector. It is a further object to provide an apparatus as a means for trimming the ends of each of a plurality of conductors and connecting trimmed ends to the terminals in an electrical device. A further object is to provide a conductor trimming and connecting apparatus having means for precisely locating the individual conductors and connecting specific conductors to specific predetermined terminals in an electrical connector.
These and other objects of the invention are achieved in a preferred embodiment thereof which is briefly described in the foregoing abstract, which is described in detail below, and which is shown in the accompanying drawing in which:
FIG. 1 is a perspective view of a connector assembly in accordance with a preferred embodiment of the invention comprising two connector parts, the parts being shown as coupled to each other in this Figure.
FIG. 2 is a perspective view showing the two connector parts separated from each other and showing the connector housing as exploded from its shroud or cover.
FIG. 3 is a sectional view taken along the lines 3-3 of FIG. 2.
FIG. 4 is an axial sectional view showing the forward ends of the two parts of the connector assembly of FIG. I in alignment with each other preparatory to their being coupled to each other.
FIG. 5 is a view similar to FIG. 4 but showing the parts coupled to each other.
FIG. 6 is a fragmentary sectional view showing a rearward portion of the connector housing and the rearward portion ofa contact terminal and illustrating a position of a wire which is about to be connected to the contact terminal.
FIGS. 7 and 8 are views similar to FIG. 6 but illustrating the successive stages of the insertion of the wire into the wire receiving slots of the terminal.
FIG. 9 is a sectional perspective view showing the lefthand end portion of a connector receptacle part in accordance with the invention and illustrating details of the contact receiving cavities of the receptacle.
FIG. 10 is a top plan view of a portion of the receptacle part of the connector assembly.
FIG. 11 is a sectional view taken along the lines 11-11 of FIG. 10.
FIG. 12 is a perspective view of one form of wire trimming and inserting tool for inserting a plurality of wires into the connecting portions of terminals contained in a connector in accordance with the embodi ments of FIG. 1-11, this view showing the positions of the parts while the wires are being located in positioning or holding jigs of the tool.
FIG. 13 is a frontal view, partially in section, of the tool of FIG. 12, the righthand portion of this drawing showing the positions of the parts at the time the wires are being positioned in the holding jigs and the lefthand portion of the drawing showing the positions of the parts immediately prior to trimming of the wires and insertion of the wires into the terminals.
FIG. 14 is a fragmentary sideview looking in the direction of the lines 14-l4 of FIG. 13.
FIG. 15 is a fragmentary plan view showing one of the wire holding jigs and showing a wire locating plate mounted adjacent to the jig.
FIG. 16 is a view taken along the lines l6l6 of FIG. 15.
FIG. 17 is a fragmentary perspective view showing one of the barrier pins of the positioning jigs.
FIG. 18 is a view taken along the lines 18-18 of FIG. 13, it should be noted, however, that the parts on both sides of the center line of the tool are in the positions they assume immediately prior to trimming of the wires and insertion of the wires into the connecting portions of the terminals.
FIG. 19 is a view similar to FIG. 18 but showing the position of the parts after trimming of the wires has taken place and immediately prior to insertion of the wires into the connecting portions of the terminal.
FIG. 20 is a plan view of a wire locating guide, shown in FIG. 15.
FIG. 21 is a perspective view of a modified form of wire trimming and inserting apparatus in accordance with the invention.
Referring first to FIGS. 1 and 2, an electrical connector assembly 2 in accordance with the invention comprises a connector receptacle part 4 and a connector plug part 6. As will be explained below, both of these connector parts contain a plurality of contact terminals which are electrically and mechanically connected to individual conductors or wires contained in cables 8, 10. When the connector parts 4, 6 are coupled to each other as shown in FIG. 1, the conductors in the cables will then be connected to each other.
The plug and receptacle connectors are in some respects identical to each other and in other respects substantially similar to each other so that a description of one connector will, in a large measure, suffice for both. Accordingly, only the receptacle part of the connector assembly is described in detail below and the same reference numerals, differentiated by prime marks, will be used to denote corresponding structural elements of the two parts. The same reference numerals, differentiated by prime marks, will be used to denote corresponding structural elements of the two parts. The structural differences between the plug and receptacle will also be specifically pointed out.
Referring now to FIGS. 2, 4, 9 and 10, the receptacle part of the connector assembly comprises a housing 16 of suitable plastic material and a cover or shroud 18 which is removably secured to the rearward side of the housing. The housing has a mating side or face 22 and a flange 24 which extends radially outwardly adjacent to the rearward side or face 20. This flange is enlarged at the ends of the housing as shown at 26 and openings 28 are provided which are adapted to receive fastener means as indicated at 30, 32 to lock the two parts of the connector assembly to each other.
A trough-like recess 34 extends transversely across the mating face 22 of the housing and has an inner wall 36, sidewalls 37, and end walls 41. A transversely extending rib 38 projects rearwardly from their rearward side and is enlarged adjacent to the rearward side to form a stepped structure defining laterally facing surfaces 66.
A plurality of contact receiving cavities, which are generally indicated at 44, extend through the housing from the upper and lower surfaces 40, 42 (as viewed in FIG. 4) of the rib 38 and open into inner wall 36 of the trough-like recess 34. These cavities are arranged in two parallel rows and are identical to each other although the cavities of the lower row as viewed in FIG. 4 are inverted relative to the cavities of the upper row in FIG. 4.
Each cavity contains a pre-loaded electrical contact terminal 46 comprising a rearward wire connecting section 48, a shank portion 52, and a contact portion 56. The wire connecting section 48 is generally U shaped and has an opening 50 extending into the bight of the U. This opening communicates with slots 51 in each leg of the U which have a width somewhat less than the diameter of the conducting core of a wire to which the terminal is to be connected. Electrical and mechanical connection of the wire to the terminal is effected by forcing the wire downwardly through the opening 50 and into the slots 51. Electrical connections of this general type are more fully disclosed and claimed in application Ser. No. 805,160, now US. Pat. No. 3,617,983, and need not be described in detail here.
The flat rectangular shank portion 52 extends forwardly from the lefthand leg of the wire connecting portion as viewed in FIG. 9 and merges with the relatively narrow transition section 54 which is inclined upwardly as shown in FIG. 4 relative to the plane of shank portion 52. The transition section 54 in turn merges with the contact portion 56, the width of which is the same as that of the transition section 54, this contact portion being adapted to engage a contact portion of a complementary terminal in the connector plug part 6. The end portion of the terminal is inclined upwardly as shown at 58 and a laterally inwardly bent ear 60 is provided on one side of the tip 58 of the terminal. Terminals of the type shown can be manufactured by stamping and forming methods from any suitable conductive material such as brass, phosphor-bronze, aluminumbronze, or berillum copper, suitable plating such as gold or silver being provided if desired.
The individual cavities which extend from the upper and lower surfaces 40, 42 through the housing are separated by a thin walled barriers 62 which are integral with these upper and lower surfaces and which merge with the enlarged inner section 39 of the projecting rib 38. The barriers extend laterally beyond the surfaces 40, 42 by a distance which is greater than the height of the wire connecting portions 48 of the terminals so that these wire connecting portions are electrically segrated from each other. The portions of the barrier ribs which are adjacent to the rib section 39 are of reduced height as shown at 64. The end barriers 68 are of relatively thicker than the other barriers as will be apparent from FIGS. 2 and 9 and are slightly higher.
Referring now to FIG. 9, an individual cavity which extends through the housing from the upper surface 40 of the rib 38 will be described in specific detail. As noted above, the lower row of cavities are inverted relative to the upper row and the terms used to describe the cavity of the upper row shown in FIG. 9 such as roof" and floor must be interpreted in this light.
The floor 70 of the cavity merges with the surface 40 of the rib 38 and extends uninterruptedly through the housing to the inner wall 36 of the trough-like recess. The opposed sidewalls 72 of the cavity are spaced apart somewhat less than the width of the floor 70 so that the cavity is in the form of an inverted T. The roof or top wall 78 of each cavity of the upper row slopes upwardly so that it can perform a camming function described below and the height of each cavity therefore increases from the front of the cavity, at the inner wall 36, to the rearward end of the cavity. The downwardly facing ledge 75, on the upper surface of the wide lower portion of the cavity extends rearwardly adjacent to the rearward side of the housing and then slopes upwardly as shown at 76, the slope of this ledge being substantially equal to the slope angle of the roof 78. The narrow portions of the sidewalls extend externally of the cavity as shown at 74 and form ears on the sides of the barrier 62. The opposite sides of the cavities are mirror images of each other and the cavities are symmetrical about the axes of their T shaped cross sections.
When an individual terminal is to be inserted into a cavity, it is positioned as shown in FIG. 9 in alignment with the cavity and moved leftwardly until the leading end 58 of the terminal engages the top wall 78. The leading end will then be cammed downwardly as insertion proceeds so that when the contact portion 56 has been inserted for a substantial distance and the shoulders 53 on the leading end of shank 52 approach the sidewall extensions 74, these shoulders will be between the extensions 74 and the surface 40. The wider shank portion 52 of the terminal will thus be guided into the wider lower section of the cavity. After the terminal has been fully inserted, the wide shank portion 52 is captured in the wide portion of the cavity as best shown in FIG. 11 and the contact portion extends into the trough-like recess 34.
The sidewalls 37 of recess 34 are provided with low barrier ribs 80 between adjacent cavities and relatively deeper recesses 82 extend inwardly from the mating face. The inner ends of the recesses 82 slope obliquely rearwardly and the recesses are adapted to receive the ears 60 of the terminals to lock them in place as illustrated best in FIG. 9.
As shown in FlG. 4, the plug part 6 of the connector differs from the receptacle in that it has projecting plug rib 34' rather than a recess 34, this rib being dimensioned to be received in the recess. Also, a recess or cavity is provided in surrounding relationship to the plug rib 34' to receive the sidewalls and endwalls of the receptacle housing. The contact terminals which are used in the plug part differ from the contact terminals used in the receptacle in that the tip portions 58' of the plug terminals are bent in the opposite direction from the tip portions 58 of the receptacle terminals. The contact surfaces 56 of the plug terminals are thus spaced slightly from the surfaces of the rib 34' and are resiliently flexed when the two parts of the connector are coupled to each other to provide contact pressure at the electrical interface.
As will be explained below, all of the conductors in a multi-conductor cable can be connected to all of the contact terminals in a connector parts in a mass insertion operation by the use of a suitably designed tool. At this stage it should be explained generally that forming of the electrical and mechanical connections merely involves the forcing of an individual conductor downwardly through the relatively wide opening 50 at the rearward end of the terminal and into the slots 51 in the spaced apart sides of the wire connecting portion of the terminal, the width of these slots being such that the insulation of the wire will be penetrated and electrical contact will be established with a conducting core thereof. Preferably, the rearward slot is somewhat wider than the forward slot to provide mechanical strain relief for the electrical connection in the forward slot. The essence of the wire insertion operation is illustrated in FIGS. 6-8 from which it can be seen that the wire need merely be aligned with the opening 50 and forced downwardly by a suitable insertion tool having legs 88, 89 and a center pushing member 91 which engage the wire on each side of the portion 48 of the terminal. As the wire is forced downwardly, the projecting end portion 90 of the wire is severed by the cooperable action of the lefthand leg of the insertion tool 88 and the corner 86 on the rib portion 39 of the housing. If the trimming operation is carried out in the manner shown FIG. 6-8, the housing should be made of relatively firm material or a cutting edge of suitable metal may be mounted on the comer 86.
A variety of insulating materials may be used for the manufacture of the housing 16. The material should be a relatively firm insulator having suitable dielectric properties and having suitable resistance to the environment in which the connector will be used. A suitable thermo plastic such as a glass filled nylon can be used since no heat is required to connect the individual conductors 14 to the contact terminals mounted in the housing. In previously known and used pre-loaded connectors, in which the individual wires are soldered to the terminals, it is necessary to use an insulating material for the housing which is capable of withstanding the heat required for the soldering operation such as dyallyl phthalate. These materials are in general relatively more expensive than a glass filled nylon so that connectors in accordance with the invention can be produced at a lower cost than previously known pre-loaded electrical connectors.
The shield or cover 18 may also be ofa suitable plastic such as glass filled nylon or can be a formed metal part if a higher degree of strength is desired than that available in plastic materials. The disclosed form of shield 18 is generally U-shaped in cross section throughout most of its length and has sidewalls 92 adapted to abutt the rearward side of the connector housing. The marginal edge portions 94 of the sidewalls are relatively thicker or heavier than the adjacent portion and are provided with grooves 96 which conform to the end barriers 68 on the rearward side of the housing. The shield is thus applied to the housing by merely aligning the grooves 96 with the barriers and sliding the shield axially until the ear 100 on the lefthand end of the shield is in alignment with the leftwardly extending portion of the flange 26 of the housing. The shield is then clamped in place by means of the screw 30 which is threaded through the bushing 28 in the housing flange.
Shield 18 has a semi-circular wire support 102 extending from its righthand end as viewed in FIG. 2 which is used in cooperation with a semi-circular spacer 104. The end portion of the cable 8 is located against the surface of the support 102 and the spacer is placed against the opposite side of the cable. The spacer and support have laterally extending bosses 109 which extend through slots in a conventional cable clamp 106. The cable clamp has radially extending cars which are adapted to receive fastening means 110. When the cable clamp is tightened firmly on the spacer, the spacer and support are urged firmly against the sheath of the cable 8 to clamp the shield securely to the cable and to prevent the transmission of any tensil forces to the conductors extending to the terminals in the connector.
As previously noted, the disclosed embodiment of the invention particularly adapted for use in the communications industry and can be dimensioned to be mateable with a presently used multi-contact connector having solder type contact terminals therein. Other embodiments of the invention can be designed for other uses and varying numbers of contact terminals can be loaded in the connector.
in all embodiments of the invention, a distinct advantage which is achieved is that the terminals can be preloaded in the connector at a factory and the connector applies to a conductor or conductors at the site of a wiring operation. A particular advantage of a disclosed embodiment is that multi-conductor cables of the type shown at 8 and 10 can be cut from a substantially endless cable supply and applied to the ends of the connectors by an installer at the site of a telephone wiring operation. in accordance with prior practice in the telephone industry, It was common practice to manufacture multi-conductor cables in standard lengths and to solder the conductors of the cables to connectors in a factory.
THE TRIMMING AND lNSERTlON TOOL FIGS. 12-20 show a preferred form of apparatus for trimming the ends of a plurality of conductors and inserting the trimmed ends into terminals contained in one of the connector parts 4, 6 in a single operation. At the outset, it should be explained that in the communications industry, conductors are utilized as twisted pairs as shown at in FIG. 12. Every cable, as with the cable 8 shown, will contain a plurality of twisted pairs of conductors. When two cable ends are connected to each other, individual pairs in the one cable end are connected to the individual pairs in the other cable end. Furthermore, the individual pairs are identified by color coding schemes as will be described below so that they may be quickly located. It follows that when the conductors of the cable 8 are connected to the terminals of the connector part, they cannot be indiscriminately connected to the terminals but must be connected to predetermined connectors so that predetermined pairs of conductors in the conductors of one cable end will be electrically connected to predetermined pairs of conductors in the other cable end.
As shown in FIGS. 12 and 13, the disclosed form of tool comprises a frame block 122 having a recess 124 extending therethrough and an upwardly extending arm 126 having a forwardly facing surface 128. The block is also notched as shown at 130 in front of the arm 126 to define a horizontal surface 132 which functions as a locating surface for one side of the rearwardly extending rib of the connector housing The housing is positioned as shown in FIG. 12 with its mating face opposed to the surface 128 of the arm 126 and is held in position by steel spring plates 134, 134 which are secured by fasteners 136 to the sides of the arm 126 and which extend beyond the rearward face of the connector housing. The arms 126 and the plates 134, 134 thus constitute a jig which precisely positions the housing on the apparatus.
As will be apparent from FIG. 12, the apparatus is substantially symmetrical about its vertical center line so that a description of the structural parts on the righthand side of the center line will suffice for the corresponding structural parts of the lefthand side of the center line. Accordingly, the righthand side of the apparatus will be described in detail and the same reference numerals, differentiated by prime marks, will be used to denote corresponding structural elements on the lefthand side of the center line.
The following brief description of the principle of operation of the trimming and insertion tool will facilitate the understanding of the detailed structural elements thereof presented below. When the conductors of the cable 8 are to be connected to the terminals in a connector housing, the housing is positioned as shown in FIG. 12 and one pair 15 of conductors is selected from the pairs of the cable. The end portions of the wires of the selected pair are separated and one wire is positioned in each of two wire holding jigs 140, 140 at predetermined locations on the jigs. The operation is repeated for every pair 15 in the cable, the one wire of the pair always being positioned at a location in the jig 140 which corresponds to the location in the jig 140' in which the other wire is positioned. After the wires have all been positioned in the holding jigs 140, 140', the jigs are swung upwardly to locate the wires adjacent to the terminals in the connector housing. The handles 192, 192' are then swung through counter clockwise arcs respectively as viewed in FIG. 12 so that trimming and insertion tools 188, 188' which are mounted on these handles will trim the ends of the wires and insert the trimmed end wires into the terminals in the connector housing.
The wire holding jig 140 on the right hand side of the apparatus is mounted on a support arm 142 which has a central elongated slot 143 therein through which the inserting and trimming tool 188 may move, see FIG. 16. The inner end of the arm 142, that is, the end adjacent to the frame 122, has an integral plate-like section 144 from which a laterally extending car 146 projects. This ear is pivotally mounted on a pivot pin 148 which extends through the recess or opening 124 in frame 122. Pivotal movement of the arm 142 in a clockwise direction is limited by a pin 150 which extends inwardly from the front side of the recess 124, see FIG. 14. A similar pin 150' is located on the rearward side of the recess to limit the pivotal movement of the arm 142' in a counter clockwise direction. The arms are thus shown in their open or outward position in FIG. 12. In FIG. 13, the arm 142 is shown in its open'position while the arm 142 is shown in its closed position.
The wire holdingjig means comprises a pair of plastic strips 152, 153 mounted on the upper surface of arm 142 on each side of the slot 143. These strips 152, 153 have depending flanges 154 on their sides which are adjacent to the sides of the arm 142 and these lips project laterally over the edges of the arms as shown best in FIG. 18. The strips are held in place by means of thin clamping plates 156 disposed against the flanges or lips and fasteners 158 which extend through the clamping plates and into the side edges of the arm 142. An L- shaped clamping block 159 which is mounted on the outer end of the arm 142 by means ofa screw 161 also supports and assists in the location of the strips 152, 153 on the upper surface of the arm, see FIG. 13.
The strip 152 has a plurality of upwardly extending barriers 162 which are spaced apart by a distance slightly less than the diameter of the conductors 14. The spacing between the barriers, and the number of barriers, is such that when the arm is in the closed position, as shown on the left in FIG. 13, the barriers 162 will be in alignment with the barrier plates 62 on the rearward side of the connector housing, and the spaces between the barriers will be in alignment with the connecting portions of the terminals in the housing.
The base strip 153 is also provided with barrier members 164 having vertically extending ribs 166 on their opposed sides, see FIG. 17. The number of integral barriers 164 on the strip 153 is however, only one half of that of the number of cavities on each row of the connector. U-shaped separator pins 168 are provided between each adjacent pair of barriers 164 so that each adjacent pair of barriers and the separator pin contained therebetween defines two slots for reception of a wire or wires as shown in FIG. 15.
The individual wires are thus located in the wire holding jig means by moving them downwardly between the barriers extending from the plastic strips 152, 153 and the wires will be held during subsequent trimming and insertion operation as will be explained below.
It will be apparent that when the pairs 15 of conductors are connected to the terminals in the connector housing, it is necessary to secure the two conductors of each pair to predetermined terminals in the connector housing. Proper location of the conductors is facilitated by means of a locating block 180, described in detail below, which is supported on a steel tray 172 mounted beside the arm 142. This tray has an extension 174 on its side which extend past the underside of the arm and which is secured to the underside of the arm by screws 176. The wire locating block is contained between upstanding flanges 178 on the ends of the tray, the guide block being provided with a suitable trunnions 182 which are received in openings in the flanges 178.
After all of the conductors in the cable have been positioned in the wire holding jigs 140, 140' both of the arms are swung arcuately against the sides of the upstanding arm 126 of the frame member. In order to precisely position the mounting arms 142 with respect to a connector housing held between the clamping plates 134, 134' locating pins 184, 184' are provided in the blocks 159, 159 on the ends of the support arms 142, 142. These locating pins are adapted to enter notches 186, 186' on the upper edges of the plates 134, 134' as shown in FIG. 13.
The wire trimming and inserting block 188 which is mounted on the righthand side of the apparatus, comprises a plate-like member which is secured by suitable fasteners to a lever 190 having an integral offset handle 192. The inner end of the lever 190 has a laterally extending mounting portion 194 which is pivotally mounted on the previously identified pin 158. The block 188 has a groove extending along its upper edge which defines two spaced apart flanges 198, 200 see FIG. 16. The flange 200 extends-somewhat beyond the flange 198 and is located on the side of the plate 188 which will move past the plastic locating member 152. Inserting pins 202 are mounted in the groove 196 at spaced apart locations corresponding to the spacing between adjacent contact terminals in the connector. The plate 188 is so located on the lever 190 that it will pass through the previously identified slot 143 in the support arm 142 as illustrated in FIG. 16. As also shown 7 in this Figure, the sides of opening 143 diverge but the opening at its upper end as viewed in this Figure has a width which is substantially equal to the thickness of the plate 188. By virtue of this arrangement, the plate will be precisely located and guided during the very critical insertion operation.
The'conductors of the cable 8 are connected to the terminals in a connector housing as follows: The operator first positions the parts of the tools as shown in FIG. 12 and selects a' pair 15 from the plurality of pairs in the cable 8. He then locates one wire of the pair in the wire locating jig 140 and the other wire of the pair in the wire locating jig 140'. It is advantageous to locate the first wires in the first pair in the innermost positions on the locating jigs. He then selects a second pair and locates the wires of this second pair in the adjacent positions in the jigs, the final pairs of wires of the cable being located in the outermost positions in'the jigs. Ultimately then, the first pair selected will be connected to the terminals in the lower end of the housing 16 on the opposite sides of the central rib which projects from the rearward side of the housing.
After all of the wires have been positioned in the locating jigs, the jigs are swung inwardly until the pins 184 enter the notches 186, 186'. The handles I92, 192' are then swung arcuately upwardly in opposite directions to cause the plate members 188, 188, to pass through the openings in the support arms 142, 142'. Referring specifically to FIGS. 18 and 19, the flanges 200, 200' on these arms will engage the wires and push them towards the terminals contained in the connector. As the flanges I98, 198 move past the edges of the clamping plates 138, 138, the end portions of the wires will be sheared as illustrated in FIG. 19 and the wires will be pushed inwardly towards each other and inserted into the terminals by the inserting pins 202,
202. During insertion, the portions of the wires on each side of the inserting pins will be pushed toward the opposed surfaces of the rib of the connector housing so that the wires will be securely seated in the terminals at the conclusion of the inserting operation.
' The wire guide block, FIG. 20, may be provided with any desired indicia which will assist the technician locating the conductors in any predetermined locations in the connector. The embodiment shown is particularly intended for use with a twenty-five pair cable of the type used in communication industry and having a specificcolor coding scheme for identifying different pairs of wires. In accordance with coding conventional practice, each wire has a predominant background color, and a specifically identifying stripe superimposed on the background color. The two wires of a pair will have the same colors but their background and stripe colors will be reversed; thus a pair may be composed of one wire having a white background on which a blue stripe is superimposed and the other wire will have a blue background on which a white stripe is superimposed. The surface of the guide block 180 is provided on one side with colored'blocks and narrow color bands of different colors which correspond to the color coding scheme. The guide block 180 thus has a wide colorbands on its upper side and has five differently colored narrow bands immediately beneath each wide band. The guide blocks mounted on the two arms 142,
142' are oriented such that the same colors are located as corresponding or the same distances from the center line of the tool. Guide blocks of the type shown in FIG. 1 can be manufactured with the same markings on both sides, but reversed end-for-end and by virtue of the trunnion mountings of the guide blocks, they can bereversed so that the technician can adapt the blocks to any particular wiring sequence he wishes to follow.
FIG. 21 shows a modification in which the frame member has a base 204 from which a pair of spaced apart blocks 206, 208 extend. The pivot pin on which the arms and levers are mounted extends between these blocks as shown and the rearward block is provided with a recess 210 in which an arm 212 is pivoted. This arm can be swung rearwardly as shown from an upright position to a horizontal position so that the technician who is performing the task of positioning the wires in the wire holding jigs will have a less cluttered work space. After the wires have been located in the wire holding jigs, the arm 212 is swung to an upright position and the general organization of the tool and operation thereof will be as explained above.
It will be apparent from the foregoing description that connectors and tools as disclosed therein offer substantial advantages where multi-conductor cables are being used in wiring installations or installing new communcations wiring. A multi-conductor cable of the required length need merely be severed from an endless length of cable and the conductors thereof positioned in the wire holding jigs as described. The conductors can then be connected to the individual terminals in a pre-loaded connector to produce afinished cable of the precise length for the particular wiring requirement.
Alternative embodiments of tools of the type disclosed will be apparent to those skilled in the art. If desired, and where the connector has only one row of contact terminals therein, the tool need be provided with only one wire positioning jig and inserting memher. Tools in accordance with the invention can furthermore be designed to insert relatively large numbers of wires with relative ease, particularly where the wires are small size. The disclosed type of tool is adapted to simultaneously insert all of the conductors of a 25 pair cable (50 individual conductors) into the terminals of a fifty position pre-loaded connector.
Changes in construction will occur to those skilled in the art and various apparently different modifications and embodiments may be made without departing from the scope of the invention. The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only.
What is claimed is:
1. Apparatus for connecting conductors to terminals, said terminals being mounted in the housing of an electrical device such as a multi-contact electrical connector, said terminals each having a conductor-receiving portion which is adapted to receive a conductor upon movement of said conductor laterally of its axis into said conductor-receiving portion, said conductorreceiving portions of said terminals being arranged in a row, said apparatus comprising:
first jig means for holding said electrical device'in a predetermined position, second jig means for releasably holding said conductors in parallel side-by-side relationship, said conductors being spaced-apart in said second jig means by distances corresponding to the spacing between said conductor-receiving portions of said terminals, said second jig-means being operatively positioned adjacent to said first jig means with said conductors in alignment with said conductorreceiving portions of said terminals, and
conductor transferring means for transferring conductors in said second jig means into the said conductor-receiving portions of terminals in an electrical device in said first jig means, said conductor transferring means being movable along a predetermined path extending past said second jig means and towards said first jig means, said conductor transferring means including means for pushing said conductors laterally of their axes from said second jig means into said conductor-receiving portions of said terminals whereby said conductors are connected to said conductor-receiving portions of said terminals.
2. Apparatus as set forth in claim. 1 including conductor trimming means for trimming the ends of said conductors during transfer of said conductors from said second jig means to said conductor-receiving portions of said terminals, said trimming means comprising shearing means on said second jig means and said conductor transferring means.
3. Apparatus as set forth in claim 1 including conductor trimming means for trimming the ends of said conductors during transfer of said conductors from said 1 second jig means to said conductor-receiving portions of said terminals, said trimming means comprising one shearing edge on said first jig means and one shearing edge on said conductor transferring means, said shearing edges being movable relative past each other during movement of said conductor-transferring means towards said first jig means.
4. An apparatus as set forth in claim 3 which is adapted for use with an electrical device having a second row of terminals, the conductor-receiving positions of the terminals of the previously recited row being oppositely directed from the conductor-receiving portion of the second row, said apparatus having an additional second jig means, an additional conductor transferring means and an'additional conductor trimming means, said additional means being arranged to releasably hold additional conductors, to trim the end 5 of said additional conductors, and to transfer said additional conductors to the conductor-receiving portions of the terminals of said additional row.
5. Apparatus for'trimming the ends of a plurality of electrical conductors and substantially simultaneously inserting said conductors into the conductor-receiving portions of terminals in an electrical device such as a multi-contact electrical connector, said conductorreceiving portions of said terminals being arranged in a row in said electrical device, said apparatus comprisfirst jig means for holding said electrical device in a predetermined position,
second jig means normally located beside said first jig means, said second jig means including holding means for releasably holding conductors in spacedapart relationship with each-conductor in alignment with a conductor-receiving portion of one of said terminals, said second jig means having a first severing edge extending parallel to, and beside, said row ofconductor-receiving portions of said terminals,
conductor transferring and inserting means movable along apredetermined path extending past said second jig means and towards said row, said conductor transferring and inserting means having means for engaging said conductors and moving said conductors laterally of their axes into said conductor-receiving portions of saidterminals, said conductor inserting means having a second severing edge which is movable past saidfirst severing edge during movement of said inserting means to trim said conductors prior to insertion into said terminals.
6. Apparatus as set forth in claim 5 includinga frame, said first jig means being on said frame, said conductor transferring and inserting means being pivotally connected to said frame, said predetermined path being an arcuate path. Y
7. Apparatus as set forthin claim 6 wherein. said holding means for said conductors comprises a plurality of parallel slots, each of said slots being adapted to hold one of said conductors. I
8. Apparatus as set forth in claim 7 wherein said second jig means comprises a plate having an elongated opening therein intermediate its ends, said inserting means being movable through said opening, said holding means comprising aligned slot means on each'side of said opening, each pair of aligned slots being adapted to hold one of said conductors, said first severing edge being defined by one edge of said. opening, said second severing edge being defined by one side of said transferring and inserting means.
9. Apparatus asset forth in claim 8, said apparatus being adapted for use with an electrical device having a second row of terminals, the wire receiving portions of the two rows of terminals being oppositely directed, said apparatus having an additional second jig means, an additional transferring and. inserting means, and additional first and second severingedges, said additional means and edges being on the opposite side of said first jig means from said first named means and edges, and being arranged to releasably hold additional conductors, to trim the ends of said additional conductors, and to transfer said additional conductors into the conductor-receiving portions of said additional row of terminals.
10. Apparatus as set forth in claim 9 wherein said second jig means and said additional second jig means are movably mounted on said frame, said second jig means and said additional second jig means being movable from their normal locations beside said first jig means to locations remote from said first jig means to facilitate placement of said conductors in said second and additional second jig means.
11. Apparatus as set forth in claim 10 wherein said first jig means is pivotally mounted on said frame and is movable from its normal position beside said second and said additional second jig means, when in their normal positions, to a remote position to facilitate placement of said conductors in said second and additional second jig means.
12. Apparatus as set forth in claim 10 wherein said second jig means and said additional second jig means each have conductor indicating means fixed thereto, said conductor indicating means having indicia thereon to indicate predetermined locations in said second and said additional second jig means for coded conductors whereby predetermined conductors are connected to predetermined terminals.