Abstract:
A die set assembly for crimp connecting an electrical lead to terminals or the like. The device includes apparatus for cooperatively feeding the length of electrical lead, a length of terminal, and a crimp connector strip, carrying series of crimp connectors. The device further includes apparatus for adjustably positioning a cutter relative to the die set assembly, whereby when the length of electrical lead and crimp connector strip have been positioned in the machine, and the terminal length determined, the machine will crimp a crimp connector, a lead and predetermined length of terminal and sever the crimp connector from the strip and cut a predetermined length of terminal.

Description:
FIELD OF THE INVENTION 
     This invention relates to an apparatus for joining conductors and more particularly to the joining together of an insulated wire and a gold plated wire by means of a gold crimping clip. 
     BACKGROUND OF THE INVENTION 
     In the past, various devices have been developed for cutting a predetermined length of gold wire and simultaneously crimping the gold wire to an insulated wire by means of a metallic crimping clip. A typical such device includes a press unit and a die set having various crimping and cutting tools. These previously employed devices have the disadvantages that the length of the gold wire extending from the crimp was dependent on the tools which were set into the press unit. Each time a new length was desired, it was necessary to change the tools in the press. This required removing the die set from the press unit, changing inserts in the die sets, and reinstalling the die set into the press unit. This operation--going from one wire length to another, was very time consuming. 
     OBJECTS 
     It is an object of this invention to provide a means for rapidly connecting a lead wire to a terminal wire by use of a crimp connector. 
     Another object of this invention is to provide a device for connecting a lead wire to a terminal wherein the length of terminal wire to be cut may be changed quickly and easily. 
     Still another object of the invention is to provide a system to cut gold terminal wire off at a specified length, to cut a partially-formed length of gold splice crimp off of its carrier strip and terminate them to a lead wire which is being fed into the system. 
     Yet a further object of the invention is to provide a system for connecting a terminal wire to a lead wire, which has the capability to change lengths of terminal wire to be cut without changing tool inserts in the device. 
     Still another object of this invention is to provide a die set assembly having punch means, crimp means, a movable cut-off punch and die holder assembly and means for adjusting the position of the cut-off punch and die holder assembly relative to the die set. 
     Still another object of the invention is to provide a die set assembly wherein the means for adjusting the position of the cut-off punch and die holder assembly includes a support member fixed to the die set and a movable member, extending between the support member and the cut-off punch and die holder assembly, positionable with respect to the support member and secured to the cut-off punch die holder assembly. 
     Another object of the invention is to provide a cutter adjustment means and driving mechanism so positioned as to not interfere with other feed means. 
     A further object of the invention is to provide accessibility to the mechanism for making the adjustments to the cutter so the cutter can be changed readily by use of a simple tool. 
     Still another object of the invention is to provide a device for connecting a lead wire to a terminal wire which does not require a complete change of equipment and can be adapted to presently used standard equipment. 
     SUMMARY OF THE INVENTION 
     In summary, this invention is designed to provide a machine for crimp connecting an electrical lead wire to a terminal wire or the like including means for cooperatively feeding a length of electrical lead, a length of terminal and a crimp connector strip carrying a series of crimp connectors. Further, the device includes: a die set assembly having a longitudinal axis; a cutter movable on the longitudinal axis with respect to said die set assembly; a crimper; means for adjustably positioning the cutter relative to the crimper; terminal wire length positioning means; and means for locking said means for adjustably positioning said cutter in a position with respect to the die set once the desired terminal length has been set and the terminal length determined. 
    
    
     DESCRIPTION OF THE DRAWINGS 
     These and other objects of this invention will be apparent from a study of the drawings in which the following figures are noted: 
     FIG. 1 is a perspective view of an embodiment of the invention; 
     FIG. 2 is a top plan view of the bottom die set showing the movable cut-off punch die holder assembly; 
     FIG. 3 is an exploded view of the embodiment of the invention illustrated in FIGS. 1 and 2; 
     FIG. 4 is an exploded view of the invention showing an alternative rod guide and rod stop which can be substituted for the rod guide shown in FIG. 3 for automatic operation; 
     FIG. 5 is a top plan view showing the alternative rod guide and stop of FIG. 4 in a position to produce a long terminal wire; 
     FIG. 6 is a top plan view showing the rod guide and stop device of FIG. 4 in the position to produce a short terminal wire. 
    
    
     DESCRIPTION OF THE INVENTION 
     FIGS. 1-3 Embodiment 
     In FIGS. 1-3, the die set generally designated D is made up of upper die set generally designated U which is springingly seated in lower die set generally designated L by means of upper die set posts 2 which mate with lower die set L by way of spring pocket 4. 
     As is best shown in FIG. 3, upper die set U holds cut-off punch driver 6, pressure pad driver 8, first upper crimp tool 10 and second upper crimp tool 12. Cut-off punch driver 6 has a recessed portion 14 for receiving the pressure pad driver 8. First upper crimp tool 10 has a recessed portion 16 and a lip portion 18 for receiving the second upper crimp tool 12 and second upper crimp tool flange 20. Bolt holes are provided in first upper crimp tool 10 and cut-off punch driver 6 for bolting first upper crimp tool 10, second upper crimp tool 12, pressure driver 8 and cut-off punch driver 6 to the upper die set U. Lower die set L holds filler block 22, lower pressure pad 24, first lower crimp tool 26 and second lower crimp tool 28. Filler block 22 is bolted to lower crimp tool 26 which in turn is bolted to lower die set L. First lower crimp tool 26 is held stationary with respect to second lower crimp tool 28 by means of second lower crimp tool slot 30 and first lower crimp tool flanges 32. Pressure pad 24 is slidingly positioned in filler block 22 and has a flange 34 which is received in slot 36 of first lower crimp tool 28. A slot 38 defined by pressure pad 24 is adapted to receive carrier strip C carrying gold splice crimp S. Attached to the rear portion of lower die set L is a wire holder 40 for positioning the terminal for gold plated wire T. It is apparent that other types of metal or conductive material terminals can be connected by this development. 
     Adjustment means A is made up of the movable cutoff punch and die holder assembly 42, rod guide 44, and adjustment rod 46. As best shown in FIGS. 2 and 3, the movable punch and die holder assembly 42 is slidingly seated on the base 49 of the lower die set L and positioned between side walls 50. The movable punch and die holder assembly 42 is therefore free to slide in a longitudinal direction up to filler block 22 in the forward portion of lower die set L and the wire holder 40 in the rearward portion of lower die set L. The movable cut-off punch die holder assembly 42 includes die holder 51 which defines cut-off die bore 52, spring pocket bore 54 and adjustment rod bore 56. The adjustment rod 46 is slidingly received by rod guide bore 58 and is fixed in adjustment rod bore 56 by cone point set screw 60. A cut-off die 62 is positioned in cut-off die bore 52 and a cutoff punch 63 is springingly seated in spring pocket bore 54. This structure allows the movable cut-off punch and die holder assembly to be moved along base 49 of the lower die set L, then held fixed by tightening clamp screw 64 which holds adjustment rod 46 in the position desired. 
     FIGS. 4, 5 and 6 Embodiment 
     FIGS. 4, 5 and 6 show an alternative rod guide structure having a generally U-shaped cross-section when viewed from top. Rod guide 68 includes rod guide bore 70 for receiving the adjustment rod. The adjustment rod passes through rod guide 68, stop 74, bore 76 and then is fixed to die holder 51, the same as shown in FIGS. 2-3 with reference to the previously described embodiment, by means of adjustment rod bore 56 and cone point set screw 60. With this configuration, stop 74 may be adjusted and different wire lengths may be obtained by presetting stop 74 so that in a first position, stop 74 comes in contact with the side wall of wire holder 40, thereby producing a shorter length wire, and in a second position, stop 74 comes in contact with rod guide 68, thereby producing a longer length wire. 
     OPERATION 
     In the operation shown in FIG. 1, carrier strip C carrying gold splice crimp S is fed into the die set assembly and positioned so that gold splice crimp S is directly above lower crimp tools 26 and 28 and directly beneath upper crimp tools 10 and 12. Carrier strip C is fed off carrier strip spool 78 by means of carrier strip feed 80. Insulated wire W is fed off insulated wire spool 82 by means of insulated wire feed 84 and is then positioned above gold splice crimp C. Gold plate terminal wire T is fed off gold plated terminal wire spool 86 through wire holder guide 88, through cut-off die 62, until the gold plated terminal wire&#39;s first end lies above the gold splice crimp C. 
     When the insulated wire W, the gold plated terminal wire T are each positioned above different ends of the gold splice crimp C, the desired wire length may be selected by moving the adjustment rod 46, thereby positioning the movable cut-off punch 63 and die holder assembly 51, so the cut-off punch 63 will cut the desired length of gold plated terminal wire. The clamp screw 64 is then tightened, holding adjustment rod 46 in a fixed position. Alternatively, in the die set shown in FIGS. 4, 5 and 6, stop 74 is set so that two wire lengths may be obtained automatically, as described hereinabove. The stroke of rod 46 may be varied so as to produce more than two wire lengths. In the embodiments shown, the stroke of rod 46 in FIG. 5 is with the piston rod of cylinder 48 fully retracted. In FIG. 6, the piston rod of cylinder 48 is fully extended. This is an easily programmed system for the automatic production of two wire lengths. More sophisticated driving devices with more complex controls and locating units than the stops 74 may be utilized for a completely automated set of preprogrammed wire lengths. 
     A conventional ram (not shown) descends on the cut-off punch driver 6. The gold plated terminal wire T is cut off and the cut-off punch driver strikes the cut-off punch 63, driving it past the cut-off die 62. The gold plated terminal wire T is then trapped between the pressure pad driver 8 and the pressure pad 24. The gold splice crimp S is cut free from the carrier strip C as the pressure pad driver 8 drives the pressure pad 24 past the lower crimp tools 26 and 28. At the lower end of the ram stroke, the gold plated terminal wire T, the gold splice crimp C and the insulated wire W are all crimped together into an assembled unit. 
     While this invention has been described as having preferred design, it is understood that it is capable of further modification, uses and/or adaptations of the invention following in general the principle of the invention and including such departures from the present disclosure as come within known or customary practice in the art to which the invention pertains, and as may be applied to the essential features set forth, and fall within the scope of the invention of the limits of the appended claims.