Cable harness assembly apparatus

Cable harness manufacturing apparatus comprises a pair of rails defining a linear path through a workstation where a press terminates ribbon cable to connectors in connector receiving fixtures independently journaled to the rails. A first stop on the path positions connectors sequentially at the workstation while a series of second stops along the path downstream of the workstation act on the lead fixture to define the length of cable between pairs of connectors as well as triggering the press for sequential terminations of connectors in remaining fixtures. A cutter carriage journaled to the rails upstream of the workstation is spring loaded to urge remaining fixtures to the workstation. A third stop along the path downstream stops the lead fixture when it is desired to cut the cable, the cut end subsequently being drawn flushly into the last connector terminated.

BACKGROUND OF THE INVENTION 
The present invention relates to apparatus and method for applying 
insulation displacing electrical connectors to a ribbon cable. 
Electrical connectors having insulation displacing terminals for 
application to ribbon cable are well known. U.S. Pat. No. 4,359,257, which 
is incorporated herein by reference, discloses such a connector, which is 
sold by AMP Incorporated under its AMP-LATCH trademark. Such connectors 
are conveniently handled in pre-assembled form, that is, the cover is 
latched to the connector allowing space to receive the cable so that 
termination is readily accomplished by pressing the connector and cover 
together. End terminations are readily achieved by bench apparatus such as 
that disclosed in U.S. Pat. No. 4,332,083. Apparatus for applying multiple 
connectors to a ribbon cable to manufacture a harness is disclosed in U.S. 
Pat. No. 4,148,130, but it is not automated and cannot handle 
pre-assembled connectors. 
U.S. Pat. No. 4,570,326 discloses cable harness assembly apparatus for 
applying connectors having insulation displacing connectors to a ribbon 
cable. The apparatus is of the type comprising a workstation with a press 
having a termination ram and a plurality of connector receiving fixtures 
including a lead fixture which receives the connector to which the cable 
is first terminated. The fixtures are mounted to a frame at predetermined 
intervals, pre-assembled connectors are placed in the fixtures, and the 
cable is threaded through the connectors before advancing the frame 
through the workstation, stopping the fixtures sequentially thereat to 
terminate the cable to the connectors. 
The prior art apparatus suffers the disadvantage of a long and cumbersome 
frame which is not readily adapted to automation, and further the 
requirement of fixtures having integral severing apparatus. 
SUMMARY OF THE INVENTION 
The present invention is characterized by rail means through the 
workstation and fixed relative thereto, the fixtures being independently 
journaled to the rail means for movement through the workstation from an 
upstream to a downstream side thereof. First stop means at the workstation 
is effective to stop the fixtures at the workstation sequentially as the 
fixtures are moved therethrough. Second stop means comprise a plurality of 
second stops along the rail means which cooperate with the lead fixture to 
stop it at predetermined intervals as it is moved downstream on the rail 
means. Upon aligning a ribbon cable with the connectors in the fixtures, 
terminating said cable to a connector in the lead fixture, temporarily 
releasing said first stop means, and moving said lead fixture downstream, 
said lead fixture will draw said cable through the workstation until the 
lead fixture hits a second stop. 
The apparatus does not require a long and cumbersome frame and is readily 
adapted for automation, the second stop means being interlocked with the 
termination ram, which on the upstroke triggers the release of the first 
and second stop means to permit advance of the lead fixture. Additional or 
third stop means along the rail means are interlocked with cable cutting 
apparatus upstream of the workstation. 
The automated embodiment of the invention disclosed herein requires only 
the following steps by the operator to manufacture a cable: 
(1) Load connectors in fixtures downstream of workstation; 
(2) Hit return button to move fixtures upstream of workstation; 
(3) Turn crank on cable feed to thread cable through fixtures; 
(4) Hit start button, which initiates harness manufacture (apparatus stops 
automatically when harness is complete); 
(5) Remove completed harness.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
Referring to FIG. 1, the cable making apparatus comprises a base 10 having 
mounted thereon a pair of cylindrical rails 16 supported by stanchions 18 
and defining a linear path for cutter carriage 22 and connector receiving 
fixtures 40 journaled to the rails 16. The rails pass through a 
workstation beneath a press 12, where a vertically reciprocable 
termination ram 14 acts on a connector 4 nested in a fixture 40. Each 
connector receiving fixture 40 comprises a base 41 and a module 42, the 
lead fixture 40' comprising a base 41' and module 42' with minor 
differences as will be discussed. Ribbon cable 2 is supplied from a reel 
20 mounted to the base 10 upstream of the workstation. A crank 27 on the 
cutter carriage 22 is used to initially feed the cable 2 through the 
carriage 22 and fixtures 40, which move downstream of the workstation 
sequentially as the terminations are completed. 
Referring to FIGS. 2, 3, and 4, the cable feed and cutter carriage 22 is 
journaled to rails 16 and urged resiliently downstream by cable 23 and a 
tension spring (not shown). The carriage 22 has first, second, and third 
fluted guide slots 25, 29, 38 therethrough which receive the cable 2, the 
fluting serving to laterally align the cable by cooperating with the 
ribbed cable surface. Feed rollers 26, 28 act on the cable 2 between first 
slot 25 and second slot 29, while cutting blade 30 acts on the cable 
between second slot 29 and third slot 38. The bottom roller 28 is an idler 
while the top roller 26 is driven by hand crank 27 to initially feed the 
ribbon cable 2 through guides 29, 38, fixtures 40, and connectors 4 
therein when the fixtures 40 abut the carriage 22. The blade 30 is mounted 
in a vertical guide 32 having a cable slot 30 which provides an opposed 
shear edge. The blade 30 is driven vertically by pneumatically actuated 
rod 36 which pivots link 34 about pivot pin 35 fixed in guide 32. A 
pneumatic cylinder on the carriage is interlocked with a third stop 84 as 
will be described. 
Referring to FIGS. 2 and 5, a first stop 54 serves to hold the connecting 
receiving fixtures 40 upstream of the workstation by interfering with 
extension 413', thus positioning the connector 4 in the lead fixture 40' 
at the workstation, which is aligned with the descent of the termination 
ram 14 adjacent press support 13 (the fixtures 40 are shown downstream in 
FIG. 2 for clarity). The stop 54 is released by actuating pneumatic 
cylinder 60, which drives rod 61 having pin 63 fixed vertically in the end 
thereof. This in turn pivots link 64 about fixed pin 65 to drive rack 66, 
thus rotating pin 68 which is keyed on the same shaft 56 as stop 54. 
Extensions 413, 413' are hinged to pass over stop 54 when the fixtures 
return. 
Referring again to FIG. 2, salient features of the connector receiving 
fixtures 40 are the modules 42 having nests 50 therein which receive 
connectors 4 (references to fixtures 40 herein should be taken as 
referring to lead fixture 40' as well). The lead module 40' is moved 
upstream and downstream by pneumatic cable feed cylinder 70, which is 
pressurized on the right side of a piston thereon and bled on the left 
side to move fixture 40' downstream, and pressured on the left and bled on 
the right to return the fixture 40' upstream. This is accomplished by a 
cable 72 emerging from opposite ends of cylinders 70 through appropriate 
seals, the cable 72 traveling over pulleys 74 and being attached to lead 
fixture 40'. Second stops 76 are fixed to a shaft 78 by set screws at 
intervals determined by spacing between connectors in the finished cable. 
Third stops 84 are situated on shaft 86 outboard of and parallel to rails 
16, however, only one stop 84 is set in the "up" position, to stop the 
lead fixture 40' when it is desired to cut cable 2 upstream of the 
fixtures remaining between carriage 22 and the workstation. 
FIGS. 6, 7, 8, 9 and 10 depict the sequence of operations in the 
manufacture of a four connector flat cable harness. Referring first to 
FIG. 6, the fixtures 40, 40' are drawn upstream by action of cylinder 70 
after the operator loads connectors 4 therein and hits the return button 
on control box 100 (FIG. 1). The connector receiving fixtures 40, 40' are 
loaded against first stop 54 by the action of cable 23 and pulley 24 (FIG. 
3), which urges carriage 22 in a downstream direction. The cable 23 is 
drawn upstream by a tension spring (not shown) fixed upstream of carriage 
22. The cable 2 is then fed through individual connectors 4 in nests 50 by 
turning crank 27. The start button on control box 100 (FIG. 1) is 
depressed to commence automatic cycling, which begins with descent of the 
terminating ram 14 (FIGS. 1, 13-17). As the ram 14 returns upward after 
terminating the cable, first stop 54 is rotated very briefly through 
ninety degrees, permitting the lead fixture 40' to pass. The stop 54 
begins its return before the fixture 40' is clear, thus assuring it will 
intercept the next fixture 40. While the stop 54 is down, the cable feed 
cylinder 70 is actuated to begin pulling the lead fixture 40' downstream. 
FIG. 7 shows the lead fixture 40' with hinged extension 414 butted against 
stop 84, which moves shaft 86 an axial increment to actuate a switch 88 
(FIG. 11), which triggers the pneumatic cylinder controlling the severing 
blade 30. The position of stop 84 is determined by the location of the 
last secondary stop 76 (FIG. 10), so that the cut cable 2 will be drawn 
flushly into the last connector 4 in the harness. Once the cable 2 is cut, 
the stop 84 is roated through ninety degrees and the lead fixture 40' is 
drawn further downstream by leftward movement of the piston in pneumatic 
cylinder 70. Note well that the stop 54 is not released during the release 
of stop 84. The release of stop 84 is mechanically synchronized with 
secondary stops 76, and thus is released only briefly so that the next 
stop 76 will be in position to stop fixture 40 as shown in FIG. 8. 
Referring to FIG. 8, the shaft 78, like shaft 86, is provided with limited 
end float and acts on a switch 80 (FIG. 11) which triggers the press. As 
the ram returns, stops 54, 76 are released simultaneously by actuating 
cylinders 60, 90 (FIGS. 2, 5, 11, 12) simultaneously. The fixture 40' is 
then drawn by cable 72 until it hits the next stop 76, as shown in FIG. 9, 
drawing the pre-cut cable 2 through the connectors 4 in the third and 
fourth fixtures 40. The stops 54, 76 are again simultaneously but briefly 
released so that the last fixture 40 moves to the workstation and the lead 
fixture 40' hits the last secondary stop 76, as shown in FIG. 10. This 
triggers the press for the final termination. 
FIG. 11 shows the downstream end of the apparatus when the harness is in 
the position of FIG. 10. After stops 54, 76 are released a final time, the 
cable cylinder 70 pulls the lead fixture downstream until it hits end 
stops 82, actuating a switch 83 which ends automatic operation. The 
operator then removes the completed harness, reloads fixtures 40, 40' with 
connectors, and hits the return switch to return the fixtures to the 
position of FIG. 6. The extensions 413, 413', 414 (FIGS. 5, 13, 15) are 
hinged to swing over stops 54, 76, 84 as the fixtures move upstream. Note 
that stops 76 are not as high as stops 54, while the stop 413' on the lead 
fixture 40' (FIG. 3) extends lower than succeeding stops 413. This permits 
the fixtures 40 following the lead fixture 40' to pass freely over second 
stops 76. 
Referring to FIGS. 11 and 12, the second stop shaft 78 and third stop shaft 
86 are rotated simultaneously to release the stops 76, 84 thereon by a 
single action of pneumatic cylinder 90. This pushes rod 92, which is 
adjustably fixed to inboard rack 94, which in turn rotates second pinion 
95 which is keyed on second shaft 78, as are stops 76. Clockwise rotation 
of second pinion 95 effects rightward movement of transverse rack 96, 
which in turn causes counter clockwise rotation of third pinion 98, which 
is keyed on shaft 86, as are stops 84. Note that this drive arrangement 
permits the axial float of shafts 78, 86 which is necessary to activate 
respective sensors 80, 88. 
Often, cable harnesses having multiple connectors as herein concerned 
require that the connectors have different orientations, i.e., that the 
mating faces face oppositely from the plane of the cable. This problem is 
addressed by providing two types of connector receiving modules for the 
fixtures 40. 
FIGS. 13 and 14 show the module 42 for a "mating face up" orientation. The 
module 42 comprises a bottom portion 44 having a key 45 received in bore 
411 of a base 41 or 41', a spring loaded detent 412 providing retention. 
The base 41' is identical to succeeding bases 41, except for extension 
413' being longer so as to intercept the second stops 76, and further 
having side extension 414. The module 42 further comprises a top portion 
48 fixed to bottom portion 44, the ribbon cable 2 being received 
therebetween against fluted surface 46 on bottom portion 44. The module 
has a nest 50 which receives the connector 4 with the mating side up and 
the exposed slotted plate portions of terminals 6 facing down. A cover 8 
pre-assembled to the connector 4 is received in the bottom of the nest 50. 
A spring loaded detent 51 holds the connector 4 in position, and the cable 
2 is threaded through the fixture between the connector 4 and the cover 8. 
The lead fixture 40' differs from other fixtures 40 only by having means 
in the module 42 for stopping the end of cable 2 flush with the side of 
the connector. The cable is terminated by descent of ram 14, which acts 
directly on connector 4 to push it down onto the cable 2. Note that nest 
50 is considerably longer than the connector 4 shown therein. The fluted 
surface 46 is likewise capable of receiving a wider cable 2. Thus longer 
connectors may be terminated to wider cable, having up to sixty-four 
conductors. Shorter connectors and narrower cable may also be terminated. 
Regardless of the size of connector and cable being terminated, the 
connectors will have a common datum point, which is the end of the nest 
(shown on the left in FIG. 13). 
FIGS. 15 and 16 show the module 110 for the "mating face down" orientation, 
where the cable 2 and cover 8 must be forced down onto terminals 6 of 
connector 4. The module 110 comprises a bottom portion 112 having a key 
113 for fixing it to a base 41 (FIG. 1), an intermediate portion 118 
mounted for lost motion by shafts 116 fixed in bottom portion 112, and 
springs 117 serving to return the portion 118. A top portion 120 is fixed 
to intermediate portion 118, the ribbon cable 2 being received 
therebetween on fluted surface 119. All fluted surfaces 46, 119 are in the 
same plane when the cable 2 is fed through the modules 42, 110. The ram 14 
partially enters nest 112 and bears on both the top portion 120 and cover 
8 to force the cable 2 down onto terminals 6, the connector 4 sitting in 
nest on anvil 114, which does not move down. After termination, the cable 
2 returns upward to the position shown in FIG. 15, drawing the connector 4 
with it and off of anvil 114. 
The foregoing is exemplary and not intended to limit the scope of the 
claims which follow.