Terminal locator for a terminal crimping device

A terminal locator for holding a terminal in a crimping zone of a terminal crimping device includes a housing configured to be positioned forward of crimp tooling defining the crimping zone. The housing has a terminal cavity extending along a terminal axis configured to receive the terminal such that a crimp barrel of the terminal extends rearward of the housing along the terminal axis into the crimping zone for crimping to a wire. A spacer is held by the housing. The spacer has a spacer blocking surface configured to locate the terminal and block axial rearward movement of the terminal. A latch is held by the housing. The latch is deflectable to allow insertion and removal of the terminal from the terminal cavity, the latch having a latch blocking surface configured to locate the terminal and block axial forward movement of the terminal.

BACKGROUND OF THE INVENTION

The subject matter herein relates generally to terminal crimping devices for crimping terminals to wires.

Terminal crimping machines have long been used in the connector industry to terminate terminals to ends of wires. Various terminal crimping machines are hand-tools; however to automate the termination process and thereby speed up the termination process and provide a more repeatable and reliable termination, some terminal crimping machines are electrically, hydraulically or pneumatically actuated. Such terminal crimping machines are typically referred to as a terminator or press. The terminal crimping machines include a movable ram that is moved towards an anvil during a crimping stroke to crimp a terminal to an end of a wire received in a crimping zone between the ram and the anvil.

Some terminal crimping machines, such as machines used for termination of large wires to large wire terminals, have an operator hold the terminal to position the terminal in place in the machine until the crimp tooling has closed enough to grip the terminal. Along with the inefficiency in a manual process, there is a risk of injury to the operator, such as to the operators hand or fingers, when holding the terminal near the crimping zone.

A need remains for a terminal crimping machine that allows hands-free operation and positioning of the terminal during the crimping operation.

BRIEF DESCRIPTION OF THE INVENTION

In one embodiment, a terminal locator is provided for holding a terminal in a crimping zone of a terminal crimping device that includes a housing configured to be positioned forward of crimp tooling defining the crimping zone. The housing has a terminal cavity extending along a terminal axis configured to receive the terminal such that a crimp barrel of the terminal extends rearward of the housing along the terminal axis into the crimping zone for crimping to a wire. A spacer is held by the housing. The spacer has a spacer blocking surface configured to locate the terminal and block axial rearward movement of the terminal. A latch is held by the housing. The latch is deflectable to allow insertion and removal of the terminal from the terminal cavity, the latch having a latch blocking surface configured to locate the terminal and block axial forward movement of the terminal.

In another embodiment, a terminal crimping device is provided that crimps a terminal to a wire that includes crimp tooling including a movable ram and an anvil defining a crimping zone. The movable ram is movable along a crimp stroke towards and away from the anvil, The crimp tooling crimps the terminal to the wire during the crimp stroke. The terminal crimping device includes a terminal locator configured to hold the terminal in the crimping zone during the crimp stroke. The terminal locator includes a housing configured to be positioned forward of crimp tooling defining the crimping zone. The housing has a terminal cavity extending along a terminal axis configured to receive the terminal such that a crimp barrel of the terminal extends rearward of the housing along the terminal axis into the crimping zone for crimping to a wire. A spacer is held by the housing. The spacer has a spacer blocking surface configured to locate the terminal and block axial rearward movement of the terminal. A latch is held by the housing. The latch is deflectable to allow insertion and removal of the terminal from the terminal cavity, the latch having a latch blocking surface configured to locate the terminal and block axial forward movement of the terminal.

In a further embodiment, a crimping system is provided including a driving mechanism, crimp tooling and a terminal locator. The driving mechanism is driven in an axial driving direction during a crimping operation. The crimp tooling includes a movable ram and an anvil defining a crimping zone. The movable ram is coupled to the driving mechanism and is movable along a crimp stroke towards and away from the anvil by the driving mechanism during the crimping operation. The crimp tooling crimps the terminal to the wire during the crimp stroke. The terminal locator is configured to hold the terminal in the crimping zone during the crimp stroke. The terminal locator includes a housing configured to be positioned forward of crimp tooling defining the crimping zone. The housing has a terminal cavity extending along a terminal axis configured to receive the terminal such that a crimp barrel of the terminal extends rearward of the housing along the terminal axis into the crimping zone for crimping to a wire. A spacer is held by the housing. The spacer has a spacer blocking surface configured to locate the terminal and block axial rearward movement of the terminal. A latch is held by the housing. The latch is deflectable to allow insertion and removal of the terminal from the terminal cavity, the latch having a latch blocking surface configured to locate the terminal and block axial forward movement of the terminal.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1is a front perspective view of a crimping system100in accordance with an exemplary embodiment. The crimping system100includes a terminal crimping device102and a crimping machine104that holds the terminal crimping device102and operates the terminal crimping device102. The terminal crimping device102is used for crimping a terminal106onto a wire108, such as to produce an electrical lead. Optionally, the terminal106may be a power terminal and the wire may be a power cable; however the terminal106may be a signal contact in other embodiments. The crimping machine104may be a terminator that presses the terminal crimping device102during a crimping operation. The crimping machine104provides the motive force for the crimping process or operation. The terminal crimping device102mechanically forms the terminal106around the wire108during each crimping operation.

The crimping machine104includes a frame110that supports a driving mechanism112used to move the terminal crimping device102during the crimping operation. The frame110may support other components, such as a terminal feeder device that supplies the terminals106, a wire feeder device that supplies the wires108, or other components.

The terminal crimping device102includes crimp tooling114defining a crimping zone115. The terminal106and wire108are received in the crimping zone115and crimped by the crimp tooling114in the crimping zone115. The crimp tooling114includes a movable ram116and an anvil118. In an exemplary embodiment, the anvil118is stationary; however, the anvil118may be movable in alternative embodiments. The terminal crimping device102includes a terminal locator120for holding the terminal in the crimping zone115during the crimping operation. The terminal locator120supports the terminal106such that the operator does not need to hold the terminal106by hand. The terminal locator120provides a hands-free crimping operation. Optionally, the terminal crimping device102, or various components thereof, may be removed and replaced within the crimping machine104, such as when a different size/type of terminal106is to be terminated, when a different size/type of wire108is to be terminated, when the components are worn or damaged, or when a machine having a different configuration is desired.

When assembled, the ram116is coupled to the driving mechanism112. The driving mechanism112is driven in an axial driving direction (e.g., vertically up-and-down) during a crimping operation. The movable ram116is actuated by the driving mechanism112and movable along a crimp stroke towards and away from the anvil118by the driving mechanism112during the crimping operation. The driving mechanism112may be a motor having a crank shaft that moves the ram116. Alternatively, the driving mechanism112may be a linear actuator, a piezoelectric actuator, a pneumatic actuator, or the like. The ram116is moved along the driving axis in an advancing direction and a retracting direction relative to the anvil118during the crimp stroke. The anvil118receives the terminal106and the wire108in the crimping zone115and supports the terminal106against the pressing operation of the ram116during the crimp stroke. For example, the ram116and the anvil118both engage the terminal106and form or crimp the terminal106around the wire108such that the terminal106locks onto the wire108. The terminal106and/or the wire108may at least partially extrude during the crimping operation to form a mechanical and electrical connection therebetween. In an exemplary embodiment, the terminal106is sealed to the wire108once crimped thereto. Optionally, the terminal106may be a closed-end terminal to provide a sealed barrel around the wire108.

FIG. 2is a front perspective view of the terminal locator120in accordance with an exemplary embodiment.FIG. 3is a rear perspective view of the terminal locator120in accordance with an exemplary embodiment.FIG. 4is a sectional view of the terminal locator120in accordance with an exemplary embodiment. The terminal locator120includes a housing122, which may be coupled to the anvil118(shown inFIG. 1), a spacer124held by the housing122, and latches126held by the housing122. The terminal locator120is used for holding the terminal106(shown inFIG. 1) in the crimping zone115(shown inFIG. 1). In an exemplary embodiment, the terminal locator120is used to block axial movement of the terminal106and/or block rotational movement of the terminal106.

The housing122defines a terminal cavity130configured to receive the terminal106. In the illustrated embodiment, the housing122is U-shaped around the terminal cavity130having an open top132through which the terminal106is received and removed. The housing122includes a bottom134opposite the top132and sides136,138extending between the top132and the bottom134. The housing122may have other shapes in alternative embodiments. The terminal cavity130extends along a terminal axis140between a front142and a rear144of the housing122. The terminal cavity130receives the terminal106generally along the terminal axis140.

In an exemplary embodiment, the housing122includes a spacer channel146that receives the spacer124. The spacer channel146may be open at the rear144to receive the spacer124. Optionally, the spacer124may be moveable relative to the housing122within the spacer channel146. For example, the spacer124may be moveable perpendicular to the terminal axis140in the spacer channel146. The spacer124may be spring biased to a resting or normal position, which may be at the top of the spacer channel146. Optionally, the spacer124may be moveable vertically (e.g., up and down) within the spacer channel146. The walls of the housing122may guide movement of the spacer124within the terminal cavity130. Having the spacer124moveable relative to the housing122allows the terminal106to be positioned within the terminal cavity130and accommodates movement of the terminal106during the crimping operation. For example, during the crimping operation, the terminal106may be moved downward. The terminal106may move during the crimping operation as the terminal106is being extruded.

In the illustrated embodiment, the housing122includes guide channels148at the sides136,138. The guide channels148receive guide pins150coupled to the spacer124. The guide channels148are elongated to allow the guide pins150to move within the guide channels148. Optionally, springs may be provided in the guide channels148that are biased against the guide pins150to return the spacer124to the resting or normal position, which may be at the top of the spacer channel146.

In an exemplary embodiment, the housing122includes fasteners152used to secure the housing122to the anvil118. Other securing means may be provided in alternative embodiments. Optionally, the housing122may include datum or blocking surfaces that engage the terminal106to locate and/or hold the terminal106in the terminal cavity130. For example, such blocking surfaces may block axial movement and/or rotational movement of the terminal106within the terminal cavity130.

The spacer124includes a pocket160configured to receive a portion of the terminal106. The spacer124extends between a top162, a bottom164and opposite sides166,168extending between the top162and the bottom164. Optionally, the pocket160may be open at the top162to receive a portion of the terminal106. The pocket160may be open at a front170of the spacer124to receive the terminal106. Additionally or alternatively, the pocket160may be open at a rear172of the spacer124. In the illustrated embodiment, the pocket160may be generally U-shaped to receive a portion of the terminal106. The pocket160may have other shapes in alternative embodiments. The pocket160may have different sections for receiving different portions of the terminal106, such as a forward section and a rearward section.

In an exemplary embodiment, the spacer124includes a spacer blocking surface174configured to locate the terminal106relative to the spacer124. The spacer blocking surface174may directly engage a portion of the terminal106to locate the terminal106relative to the spacer124. In an exemplary embodiment, the spacer blocking surface174blocks axial rearward movement of the terminal106. For example, the spacer blocking surface174may be positioned rearward of a portion of the terminal106to block rearward movement of the terminal106.

In an exemplary embodiment, the spacer124includes a ledge180defining a portion of the pocket160. The ledge180defines an anti-rotation surface182configured to engage the terminal106and block rotation of the terminal106about the terminal axis140. In the illustrated embodiment, the anti-rotation surface182is oriented generally vertically; however, the anti-rotation surface182may have other orientations in other embodiments. The spacer124may include multiple anti-rotation surfaces182, such as at opposite sides of the pocket160. The terminal106may fit snuggly between the anti-rotation surfaces182to prevent rotation of the terminal106relative to the spacer124.

In the illustrated embodiment, the terminal locator120includes a pair of the latches126on opposite sides of the terminal cavity130. For example, a first of the latches126is provided at the first side136and a second of the latches126is provided at the second side138. However, the terminal locator120may include any number of latches126in alternative embodiments, including a single latch126. The latches126are received in latch openings190in the housing122. Alternatively, the latch openings190may be provided in the spacer124such that the latches126are directly held by the spacer124, which itself is held by the housing122. However, in the illustrated embodiment, the latches126are moveably coupled to the housing122.

The latches126are deflectable to allow insertion and removal of the terminal106from the terminal cavity130. For example, the latches126may be moved between open positions and closed positions. In the closed positions, the latches126secure the terminal106in the terminal cavity130. In the open positions, the terminal106may be movable relative to the housing122, such as loaded into the terminal cavity130or removed from the terminal cavity130. In the illustrated embodiment, the latches126are moveable axially within the latch openings190. For example, the latches126may slide between the open and closed positions along latch pins192in the latch openings190. The latches126may include elongated slots194to allow the latches126to move laterally within the latch openings190. Optionally, springs may be provided in the latch openings190to bias the latches126toward the closed positions. In alternative embodiments, rather than being slidable within the latch openings190, the latches126may be pivotably coupled to the housing122to rotate between the opened and closed positions.

The latches126include latching ends196positionable in the terminal cavity130to engage the terminal106. The latching ends196have latch blocking surfaces198configured to locate the terminal106in the terminal cavity130. For example, the latch blocking surfaces198may engage the terminal106and block axial movement of the terminal106in the terminal cavity130. For example, the latches126may block axial forward movement of the terminal106within the terminal cavity130. As such, the terminal106may be captured between the spacer blocking surface174and the latch blocking surfaces198to hold the axial position of the terminal106within the terminal cavity130. In the illustrated embodiment, the latch blocking surface198is axially offset with respect to the spacer blocking surface174.

The latching ends196may be shaped to interface with the terminal106. For example, the latching ends196may have complementary shapes to the terminal106. In the illustrated embodiment, each latch126includes an angled undercut200along a rear edge202of the latch126. The rear edge202at the angled undercut200defines the latch blocking surface198configured to engage the terminal106. For example, the latch blocking surface198may engage an angled forehead of the terminal106.

The latch126may have angled ramps204along a top206and/or a bottom208of the latch126. The ramps204may engage the terminal106during insertion or removal of the terminal106from the terminal cavity130. As the terminal106is pressed against the ramps204, the terminal106may force the latches126to deflect to the open positions automatically. For example, downward pressure on ramps204along the tops206of the latches126may force the latches126from closed positions to open positions to allow the terminal106to be loaded into the terminal cavity130. Similarly, upward pressure from the terminal106onto ramps204at the bottom208of the latches126may force the latches126to move from the closed positions to the open positions to allow removal of the terminal106from the terminal cavity130. The terminal106is driven into the ramp206during insertion or removal to force the latch126to deflect outward to an open position relative to the terminal cavity130to allow insertion or removal of the terminal106.

FIG. 5is a perspective view of the terminal crimping device102in accordance with an exemplary embodiment showing the terminal106poised for loading into the terminal crimping device102.FIG. 6is a perspective view of the terminal crimping device102showing the terminal106partially loaded into the terminal crimping device102.FIG. 7is a perspective view of the terminal crimping device102showing the terminal106fully loaded into the terminal crimping device102. In the fully loaded position, the terminal locator120holds the axial position and/or rotational position of the terminal106relative to the anvil118of the crimp tooling114.

The terminal106includes a terminating end220at a rear222of the terminal106. Optionally, the terminal106is closed at a front224of the terminal106. For example, the terminal106includes a closed crimp barrel226at the terminating end220having a closed end228that faces the front224. Optionally, the terminal106includes a tab230at the front224, such as a weld tab. The terminal106may be another type of terminal having a different type of end at the front224. Optionally, the terminal106is a machined terminal having a closed crimp barrel226that is seamless, which is in contrast to a stamped and formed terminal having an open barrel closed during the crimping process. The closed crimp barrel226may be more robust and provide a better environmental seal at the interface with the wire108(show inFIG. 1) as compared to open barrel crimp terminals.

In an exemplary embodiment, the terminal106includes a plurality of bearing surfaces configured to be engaged by the terminal locator120to locate and hold the terminal106during the crimping process. The bearing surfaces may be used to hold an axial position of the terminal106and/or a rotational position of the terminal106. In the illustrated embodiment, the terminal106includes a rear-bearing surface232, a front-bearing surface234and side-bearing surfaces236. When the terminal106is loaded into the terminal crimping device102, the spacer blocking surface174engages the rear-bearing surface232to block axial rearward movement of the terminal106. The latch blocking surface198engages the front-bearing surface234to block axial forward movement of the terminal106. The anti-rotation surfaces182engage the side-bearing surfaces236to block rotation of the terminal106about the terminal axis140.

When the terminal106is held in the terminal locator120, the crimp barrel226of the terminal106extends rearward of the housing122along the terminal axis140into the crimping zone115for crimping to the wire108. The crimp barrel226is received in the anvil118and aligned with the ram116. During the crimping operation, the ram116is moveable along the crimp stroke towards and away from the anvil118to crimp the terminal106to the wire108during the crimp stroke.

In an exemplary embodiment, the anvil118includes a channel240that receives the crimp barrel226. In the illustrated embodiment, the channel240is U-shaped having side walls242,244and a base246between the side walls242,244. In an exemplary embodiment, the terminal locator120holds the terminal106such that the crimp barrel226is received in the channel240and is spaced apart from the side walls242,244and/or the base246. For example, gaps248are defined between the crimp barrel226and the anvil118. The terminal locator120locates the terminal106with a high degree of repeatability without the operator needing to physically hold the terminal106in place and thus provides hands-free support of the terminal106during the crimping operation. During the crimp stroke, the ram116may be received in the gaps248to engage the crimp barrel226. The terminal locator120holds the side-to-side position of the terminal106spaced apart from the anvil118such that the ram116may be received in the gaps248between the crimp barrel226and the side walls242,244.

During use, the terminal106is loaded into the terminal cavity130through the open top132(FIG. 5). For example, the terminal106may be pressed downward into the terminal cavity130. As the terminal106is loaded into the terminal cavity130, the terminal106may press against the latches126to deflect the latches to the open position allowing the terminal106to pass under the latches126. The wire108may be positioned in the crimp barrel226prior to loading the terminal106into the terminal crimping device102.

Optionally, the terminal106may be loaded into the terminal crimping device102in a slightly forward position (FIG. 6). After the terminal106is pressed downward into the terminal cavity130the terminal106may be moved rearward to position the terminal106in the terminal locator120. As the terminal106is moved rearward, the terminal106is pushed against the spacer blocking surface174of the spacer124. Once the terminal106is pushed rearward far enough (FIG. 7), the latches126may return to the closed position thus latching the terminal106in the terminal cavity130. The latch blocking surfaces198may engage the front-bearing surface234of the terminal106at the forehead238of the terminal106. The forehead238closes the crimp barrel226. In the fully loaded position (FIG. 7), the side-bearing surfaces236are aligned with and engage the anti-rotation surfaces182of the spacer124. The spacer124resists rotation of the terminal106within the terminal cavity130about the terminal axis140.

Optionally, during the crimping operation, the terminal106may be pressed downward against the anvil118. The spacer124is moveable relative to the housing122to accommodate the downward movement of the terminal106during the crimping process. After the crimping operation is complete, the terminal106and the crimped wire108may be removed from the terminal crimping device102. For example, the terminal106may be lifted upward to release the latches126and remove the terminal106from the terminal cavity130.

FIG. 8is a front perspective view of a terminal locator320in accordance with an exemplary embodiment for use with the crimp tooling114in the crimping system100.FIG. 9is a perspective view of the terminal locator320showing the terminal106poised for loading into the terminal locator320.FIG. 10is front perspective view of the terminal locator320showing the terminal106loaded into the terminal locator320. The terminal locator320is similar to the terminal locator120(shown inFIG. 1) and like components are identified with like terminology. The terminal locator320may replace the terminal locator120in the crimping system100.

The terminal locator320includes a housing322, which may be coupled to the anvil118, a spacer324held by the housing322, and latches326held by the housing322. The terminal locator320is used for holding the terminal106in the crimping zone115. In an exemplary embodiment, the terminal locator320is used to block axial movement of the terminal106and/or block rotational movement of the terminal106.

The housing322defines a terminal cavity330configured to receive the terminal106along a terminal axis. In an exemplary embodiment, the housing322includes a spacer channel that receives the spacer324. Optionally, the spacer324may be moveable relative to the housing322within the spacer channel. In an exemplary embodiment, the housing322includes datum or blocking surfaces328that engage the terminal106to locate and/or hold the terminal106in the terminal cavity330. For example, such blocking surfaces328may block axial movement and/or rotational movement of the terminal106within the terminal cavity330. The blocking surface328may directly engage a portion of the terminal106to locate the terminal106relative to the housing322. In an exemplary embodiment, the blocking surface328blocks axial rearward movement of the terminal106. For example, the blocking surface328may be positioned rearward of a portion of the terminal106to block rearward movement of the terminal106. Optionally, the spacer324includes a spacer blocking surface374configured to locate the terminal106relative to the spacer324.

The blocking surface328may block axial movement of the terminal106within the terminal cavity330. For example, the housing322may include a ledge380defining a portion of the terminal cavity330. The ledge380defines an anti-rotation surface382configured to engage the terminal106and block rotation of the terminal106. In the illustrated embodiment, the anti-rotation surface382is oriented generally vertically; however, the anti-rotation surface382may have other orientations in other embodiments. The housing322may include multiple anti-rotation surfaces382, such as at opposite sides of the terminal cavity330. The terminal106may fit snuggly between the anti-rotation surfaces382to prevent rotation of the terminal106relative to the housing322.

In the illustrated embodiment, the terminal locator320includes a pair of the latches326on opposite sides of the terminal cavity330. For example, a first of the latches326is provided at the first side and a second of the latches326is provided at the second side. However, the terminal locator320may include any number of latches326in alternative embodiments, including a single latch326. The latches326are received in latch openings390in the housing322. The latches326are deflectable to allow insertion and removal of the terminal106from the terminal cavity330. For example, the latches326may be moved between open positions and closed positions. The latches326may be pivotably coupled to the housing322. Optionally, springs may be provided in the latch openings390to bias the latches326toward the closed positions.

The latching ends396may be shaped to interface with the terminal106. For example, the latching ends396may have complementary shapes to the terminal106. In the illustrated embodiment, each latch326includes an angled undercut along a rear edge of the latch326. The rear edge at the angled undercut defines the latch blocking surface398configured to engage the terminal106. For example, the latch blocking surface398may engage an angled forehead of the terminal106.

The latches326include latching ends396positionable in the terminal cavity330to engage the terminal106. The latching ends396have latch blocking surfaces398configured to locate the terminal106in the terminal cavity330. For example, the latch blocking surfaces398may engage the terminal106and block axial movement of the terminal106in the terminal cavity330. For example, the latches326may block axial forward movement of the terminal106within the terminal cavity330. As such, the terminal106may be captured between the blocking surfaces328(or blocking surfaces of the spacer324) and the latch blocking surfaces398to hold the axial position of the terminal106within the terminal cavity330.

The latch326may have ramps along a top and/or a bottom of the latch326. The ramps may engage the terminal106during insertion or removal of the terminal106from the terminal cavity330. As the terminal106is pressed against the ramps, the terminal106may force the latches326to deflect to the open positions automatically. For example, downward pressure on ramps along the tops of the latches326may force the latches326from closed positions to open positions to allow the terminal to be loaded into the terminal cavity330. Similarly, upward pressure from the terminal106onto ramps at the bottom of the latches326may force the latches326to move from the closed positions to the open positions to allow removal of the terminal106from the terminal cavity330.

FIG. 11is a front perspective view of a terminal locator420in accordance with an exemplary embodiment for use with the crimp tooling114in the crimping system100.FIG. 12is a front perspective view of the terminal locator420showing the terminal106poised for loading into the terminal locator420.FIG. 13is front perspective view of the terminal locator420showing the terminal106loaded into the terminal locator420.FIG. 14is front perspective view of the terminal locator420showing the terminal106at the bottom of the crimp stroke. The terminal locator420is similar to the terminal locator120(shown inFIG. 1) and like components are identified with like terminology. The terminal locator420may replace the terminal locator120in the crimping system100.

The terminal locator420includes a housing422, which may be coupled to the anvil118, a spacer424held by the housing422, latches426held by the housing422and a spring plate428held by the housing422. The spacer424is similar to the spacer124(shown inFIG. 2); however the spacer424includes latch openings490similar to the latch openings190that are located in the housing122(both shown inFIG. 2). As such, the latches426are held by the spacer424, which is in turn held by the housing422. The spring plate428is used to hold the spacer424relative to the housing422at a plurality of predetermined positions, such as for loading the terminal106in the terminal locator420, for holding the terminal106in the terminal locator420during the crimping process and for allowing the terminal106to be released from the terminal locator420. In an exemplary embodiment, the terminal locator420is used to block axial movement of the terminal106and/or block rotational movement of the terminal106during the crimping process.

The housing422defines a terminal cavity430configured to receive the terminal106along a terminal axis. In an exemplary embodiment, the housing422includes a spacer channel432that receives the spacer424. Optionally, the spacer424may be moveable relative to the housing422within the spacer channel432. Optionally, the housing422may include datum or blocking surfaces that engage the terminal106to locate and/or hold the terminal106in the terminal cavity430, such as to block axial movement and/or rotational movement of the terminal106within the terminal cavity430.

In an exemplary embodiment, the spacer424includes spacer blocking surfaces474, which may be similar to the spacer blocking surfaces174(shown inFIG. 2), to locate the terminal106relative to the spacer424. The spacer blocking surfaces474block axial movement of the terminal106within the terminal cavity430. The spacer424includes ledges480that define anti-rotation surfaces482, which may be similar to the anti-rotation surfaces182(shown inFIG. 2), configured to engage the terminal106and block rotation of the terminal106.

In the illustrated embodiment, the terminal locator420includes a pair of the latches426on opposite sides of the terminal cavity430. For example, a first of the latches426is provided at the first side and a second of the latches426is provided at the second side. However, the terminal locator420may include any number of latches426in alternative embodiments, including a single latch426. The latches426are received in the latch openings490in the spacer424. The latches426are deflectable to allow insertion and removal of the terminal106from the terminal cavity430. For example, the latches426may be moved between open positions and closed positions. The latches426may be pivotably coupled to the spacer424in various embodiments. Optionally, springs may be provided in the latch openings490to bias the latches426toward the closed positions in various embodiments. However, in an exemplary embodiment, the latches426are spring biased to the open positions and are forced to the closed positions by the housing422. When the spacer424is moved downward into the housing422, a portion of the housing422engages the latches426and pushes the latches426to the closed positions. For example, the spacer channel432may be profiled and include protrusions that engage the latches426to move the latches426inward as the spacer424is moved downward into the spacer channel432.

The latches426include outer ends492, which may be positioned outside of the spacer424in the open positions (FIG. 12). The outer ends492are configured to engage the housing422when the spacer424is moved to the loaded position in the housing422. The housing422may force the outer ends492and the latches426inward to the closed positions (FIG. 13). The latches426include latching ends496positionable in the terminal cavity430to engage the terminal106in the closed positions. The latching ends496have latch blocking surfaces498configured to locate the terminal106in the terminal cavity430. For example, the latch blocking surfaces498may engage the terminal106and block axial movement of the terminal106in the terminal cavity430. For example, the latches426may block axial forward movement of the terminal106within the terminal cavity430. As such, the terminal106may be captured between the spacer blocking surfaces474and the latch blocking surfaces498to hold the axial position of the terminal106within the terminal cavity430.

The latching ends496may be shaped to interface with the terminal106. For example, the latching ends496may have complementary shapes to the terminal106. In the illustrated embodiment, each latch426includes an angled undercut along a rear edge of the latch426. The rear edge at the angled undercut defines the latch blocking surface498configured to engage the terminal106. For example, the latch blocking surface498may engage an angled forehead of the terminal106.

The latch426may have ramps along a top and/or a bottom of the latch426. The ramps may engage the terminal106during insertion or removal of the terminal106from the terminal cavity430. As the terminal106is pressed against the ramps, the terminal106may force the latches426to deflect to the open positions automatically. For example, downward pressure on ramps along the tops of the latches426may force the latches426from closed positions to open positions to allow the terminal to be loaded into the terminal cavity430. Similarly, upward pressure from the terminal106onto ramps at the bottom of the latches426may force the latches426to move from the closed positions to the open positions to allow removal of the terminal106from the terminal cavity430.

In an exemplary embodiment, the spacer424has locating pins440extending forward therefrom. The locating pins440pass through slots442in the housing422and interact with the spring plate428to position the spacer424relative to the housing422. The spring plate428includes arms444each having a profiled surface defining a ratchet446that interacts with the locating pins440. The ratchet446is defined by notches448in the arm444. The locating pin440may be retained in the notches448to hold the relative position of the spacer424. The arm444is deflectable to allow the locating pin440to move between the notches448when sufficient pressure is applied to the spacer424to move the spacer424(e.g., downward or upward) to the next notch448.

In an exemplary embodiment, the spacer424is movable between an unlocked position (FIG. 12) and a locked position (FIG. 13). In the unlocked position, the latches426are configured to be positioned in the open positions allowing the terminal106to be loaded into the terminal cavity430and/or removed from the terminal cavity430. In the illustrated embodiment, the unlocked position corresponds to an upper or top-most position. The spacer424may be moved downward to the locked position, such as by pushing the spacer424downward with the terminal106is loaded into the terminal cavity430. In the locked position, the latches426are closed (e.g., pushed inward) to hold the terminal106in the terminal cavity430. The latches426may be moved to the closed positions by the housing422. For example, as the spacer424is moved downward, the outer ends492of the latches426engage the housing422and the housing422forces the latches426inward. The spacer424may be movable to other positions, such as a release position (FIG. 14) where the terminal106may be released from the terminal cavity430. Optionally, the release position may be below the locked position. For example, during the crimping process, the ram116may press the terminal106and the spacer424downward relative to the housing to the release position. In the release position, the latches426may be allowed to move outward to the open position to allow the terminal106to be removed from the terminal cavity430.

FIG. 15is a cross-sectional view of the terminal locator420showing the spacer424in the locked position.FIG. 16is a cross-sectional view of the terminal locator420showing the spacer424in the release position. The spacer channel432is shown inFIGS. 15 and 16showing a profiled edge434including pockets436and protrusions438along the profiled edge434. When the latches426are aligned with the protrusions438, the protrusions438force the latches426inward to the closed positions (FIG. 15). When the latches426are aligned with the pockets436, the latches426are allowed to be spring biased outward to the open positions (FIG. 16) to allow the terminal106to be removed from the spacer424.

FIG. 17is a front perspective view of the terminal locator420without the terminal106to illustrate the various features of the spacer424, the housing422and the spring plate428.FIG. 17shows the spacer424in the release position. The locating pins440are held in notches448in the ratchets446along the arms444of the spring plate428. The spacer424may be moved upward from the release position, such as back to the unlocked position, by lifting up on the spacer424. Optionally, a handle may be coupled to the spacer424that allows the operator to manually lift the spacer424upward to reset the terminal locator420for receiving the next terminal106. In other various embodiments, the spacer424may be reset automatically, such as by the crimping machine104as part of the return stroke of the crimping machine.

FIG. 18is a front perspective view of a terminal locator520in accordance with an exemplary embodiment for use with the crimp tooling114in the crimping system100. The terminal locator520is similar to the terminal locator120(shown inFIG. 1) and like components are identified with like terminology. The terminal locator520may replace the terminal locator120in the crimping system100.

The terminal locator520includes a housing522, which may be coupled to the anvil118, a spacer524held by the housing522, and latches526held by the housing522. In the illustrated embodiment, the spacer524is an integral part of the latches526. For example, each latch526may include a spacer524in the form of a protrusion extending therefrom configured to engage the terminal106. The terminal locator520is used for holding the terminal106in the crimping zone115. In an exemplary embodiment, the terminal locator520is used to block axial movement of the terminal106and/or block rotational movement of the terminal106.

The housing522defines a terminal cavity530configured to receive the terminal106along a terminal axis. Optionally, the housing522may include datum or blocking surfaces that engage the terminal106to locate and/or hold the terminal106in the terminal cavity530. For example, such blocking surfaces may block axial movement and/or rotational movement of the terminal106within the terminal cavity530.

The spacers524include spacer blocking surfaces574configured to locate the terminal106relative to the spacer524. The spacer blocking surfaces574, which may be similar to the spacer blocking surfaces174(shown inFIG. 2), locate the terminal106within the terminal locator520. The spacer blocking surfaces474block axial rearward movement of the terminal106within the terminal cavity430.

In an exemplary embodiment, the latches526include ledges580. The ledges580define anti-rotation surfaces582configured to engage the terminal106and block rotation of the terminal106. In the illustrated embodiment, the anti-rotation surfaces582are oriented generally vertically; however, the anti-rotation surfaces582may have other orientations in other embodiments. The terminal106may fit snuggly between the anti-rotation surfaces582to prevent rotation of the terminal106relative to the housing522. In various embodiments, the housing522and/or the spacers524may include anti-rotation surfaces.

In the illustrated embodiment, the terminal locator520includes a pair of the latches526on opposite sides of the terminal cavity530. For example, a first of the latches526is provided at the first side and a second of the latches526is provided at the second side. However, the terminal locator520may include any number of latches526in alternative embodiments, including a single latch526. The latches526are received in latch openings590in the housing522. The latches526are deflectable to allow insertion and removal of the terminal106from the terminal cavity530. For example, the latches526may be moved between open positions and closed positions. In the illustrated embodiment, the latches526are pivotably coupled to the housing522. Optionally, springs may be provided in the latch openings590to bias the latches526toward the closed positions.

The latching ends596may be shaped to interface with the terminal106. For example, the latching ends596may have complementary shapes to the terminal106. In the illustrated embodiment, each latch526includes an angled undercut along a rear edge of the latch526. The rear edge at the angled undercut defines a latch blocking surface598configured to engage the terminal106. For example, the latch blocking surface598may engage an angled forehead of the terminal106. The latch blocking surfaces598may engage the terminal106and block axial movement of the terminal106in the terminal cavity530. For example, the latches526may block axial forward movement of the terminal106within the terminal cavity530.

The latch526may have ramps along a top and/or a bottom of the latch526. The ramps may engage the terminal106during insertion or removal of the terminal106from the terminal cavity530. As the terminal106is pressed against the ramps, the terminal106may force the latches526to deflect to the open positions automatically. For example, downward pressure on ramps along the tops of the latches526may force the latches526from closed positions to open positions to allow the terminal to be loaded into the terminal cavity530. Similarly, upward pressure from the terminal106onto ramps at the bottom of the latches526may force the latches526to move from the closed positions to the open positions to allow removal of the terminal106from the terminal cavity530.