Methods of and apparatus for assembling articles with a support

A plurality of pins (24) held at opposite ends by carrier strip (48 and 50) is positioned within a pin applicator (54) where the pins are moved into nests (66) of a stationary jaw (56). As the pins (24) are moved by a movable jaw (58) into the nests (66), the carrier strip (48) engages a stripper bar (70) to separate the strip from the pins. A flared surface (88) of the movable jaw (58) engages portions of the pins (24) to position the pins axially with respect to planar aligned surfaces (68) of the stationary jaw (56). The movable jaw (58) then clamps the pins (24) within the nests (66). The strip (50) is separated from the pins (24) and the stationary and movable jaws (56 and 58) are moved to insert portions of the clamped pins into apertures (26) of a board (22).

TECHNICAL FIELD 
This invention relates to methods of and apparatus for assembling articles 
with a support, and particularly relates to methods of and apparatus for 
assembling a plurality of strip-held shoulder-containing pins within 
apertures of a supporting substrate. 
BACKGROUND OF THE INVENTION 
In the manufacture of some types of rigid pin-populated printed wiring 
boards, terminal pins are inserted into apertures of the boards and 
electrically engage portions of printed wiring on the boards to provide 
for connections to external circuits. Typically, the spacing between 
adjacent apertures on each board is extremely small. For example, the 
spacing between apertures on one board is 0.125 inch. Further, each 
terminal pin typically has a square cross section of, for example, 0.025 
inch except in those areas where the pin is formed with lateral ears 
having a push shoulder and an aperture-engaging portion intermediate the 
ends thereof. The pin is relatively slender and typically measures one and 
one-half inches in length. 
In assembling the pin within an aperture of a board, the end of the pin 
which is closest to the aperture-engaging portion is inserted into the 
aperture. A pushing force is then applied to the push shoulder of the pin 
to urge the aperture-engaging portion into the aperture whereby the pin is 
frictionally retained with the board. 
Due to close spacing between apertures and the small size of the pin, it is 
most difficult and tedious to assemble the pins on an individual basis. 
Additionally, the relatively small size and slenderness of the pins 
necessitates delicate handling during insertion of the pins into the 
apertures. However, where each board may contain thousands of 
closely-spaced apertures, efficiency and economy dictate that the pins be 
prealigned and gang-inserted into the board apertures. 
In the past, many techniques have been developed for assembling pins or 
terminals with a supporting structure. For example, in one technique, a 
supporting structure containing apertures is placed in a generally 
horizontal plane within a vibratory device. A plurality of individual 
slender pins are deposited on top of the supporting structure which is 
then vibrated. The pins are then vibratorily directed into the apertures. 
The vibratory technique requires that the pins be separated from each 
other before being deposited onto the supporting structure and that they 
be generally slender without any unbalancing structure such as lateral 
ears. Examples of the vibratory technique are illustrated in U.S. Pat. 
Nos. 3,667,103 and 3,812,569. 
In another technique, the pins are stamped in a linked configuration having 
an edge-strip carrier. The pins are then fed into an insertion machine in 
the linked configuration and are separated individually from the carrier. 
Each of the separated pins are fed individually and independently of the 
other separated pins through feed chutes and assembled with a supporting 
structure. Examples of this technique are illustrated in U.S. Pat. Nos. 
2,814,802; 2,970,370; 3,067,902; 3,566,464; and 3,867,760. 
In a similar technique, strip-carried pins or terminals are separated one 
at a time from the linked assembly and assembled with a supporting 
structure. Examples of this technique are illustrated in U.S. Pat. Nos. 
3,711,922 and 3,867,760. 
Another technique provides for the simultaneous assembly of pins with a 
supporting structure as the pins are held in a linked comb-like 
arrangement by a carrier strip. After assembly of the pins with the 
structure, the strip is separated from the pins. Examples of this 
technique are illustrated in U.S. Pat. Nos. 
3,676,926; 3,769,679; 3,875,636; and 3,946,477. 
In a variation of the strip-held insertion technique, just noted above, a 
plurality of rows of pins are linked in an end-to-end configuration with 
laterally aligned pins of the rows forming sets of pins. Lateral linking 
strips define each set of pins. The leading set of pins with the lateral 
linking strip is separated from the trailing sets and assembled with a 
bobbin. After the bobbin and assembled pins are processed through several 
pin-staking steps, the lateral linking strip is separated. This technique 
is illustrated in U.S. Pat. No. 3,562,903. 
In still another technique illustrated in U.S. Pat. No. 3,545,606, 
individual pins are assembled in a precise arrangement with a carrier pad. 
The pins are inserted into apertures of a supporting structure and the 
carrier pad is removed. 
U.S. Pat. Nos. 2,871,551 and 2,947,965 illustrate an assembly of pins 
linked by carrier strips. Although not illustrated, it is generally noted 
that strip carried pins of this type can be fed into automatic machines 
for assembly of the pins with supporting structures. However, neither of 
these patents suggest specific techniques for such assembly of the pins 
with the supporting structures. 
In another technique disclosed in U.S. Pat. No. 3,550,250, a plurality of 
pins are formed in a parallel spaced arrangement with a carrier strip and 
an anti-distortion strip extending along opposite ends of the pins to form 
a linked assembly. The pins are formed in sets of three each with the 
outer pins of each set being identical and the center pin being 
dissimilar. The set of pins of the linked assembly are advanced into an 
apparatus whereat the anti-distortion strip is removed from the leading 
set of three pins. Thereafter, an intermediate portion of the center pin 
of the leading set is clamped and the center pin is then separated from 
the carrier strip while the two outer pins of the set are retained with 
the carrier strip. A prepositioned bobbin is then moved to insert 
relatively the three pins into apertures of the bobbin. The carrier strip, 
which remains linked to the two outer pins of the leading set and all 
other pins of the trailing sets, is then utilized to advance the bobbin 
through a series of stations whereat various operations are performed. 
Therefore, this technique teaches initially clamping a single pin of a set 
of strip-held pins, then separating only the single clamped pin from the 
strip, inserting the clamped pin and the strip-held pins into a bobbin and 
utilizing the strip to transport the pin-bobbin assembly. Further, use of 
the strip to transport the pin-bobbin assembly tends to place stresses on 
the inserted pins which are still retained with the strip. This is 
particularly critical when the pins are slender. 
In still another technique illustrated in U.S. Pat. No. 
3,641,646, three independent rows of end-to-end linked pins are fed into a 
machine and the leading pin of each row is initially clamped while the 
pins are separated from the trailing pins. The clamped pins are then 
inserted into a bobbin. It is noted that the three pins are not initially 
linked together in any way and thereby do not contain a carrier strip. 
Thus any alignment necessary for insertion must depend on the manner of 
feeding the individual rows of pins into the machine. 
SUMMARY OF THE INVENTION 
A plurality of individual articles such as pins, which are initially 
integrally held in a precise spaced alignment by a carrier strip extending 
between adjacent portions of the pins, are to be simultaneously inserted 
into apertures of a support structure. 
In a method for assembling the pins with the support structure, in 
accordance with certain principles of the invention, the carrier-strip 
held pins are moved into a plurality of nests of a pin applicator. As the 
pins are being moved into the nests, the carrier strip is separated from 
the pins. Intermediate portions of the pins are then clamped within nests 
of the pin applicator whereby the pins are held individually with the pin 
applicator in the precise spaced alignment. The pin applicator is then 
moved toward the support structure to insert the individually held pins 
into apertures of the support structure. 
An apparatus for inserting the pins into apertures of a support structure, 
in accordance with certain principles of the invention, includes means for 
receiving intermediate portions of the carrier-strip held pins. Means are 
provided for separating the carrier strip from the pins as the pins are 
being moved into the receiving means. Means are provided for then clamping 
the intermediate portions of the pins within the receiving means. Means 
for moving the receiving and clamping means with the individually held 
pins then provide for the insertion of the pins into the apertures of the 
support structure.

DETAILED DESCRIPTION 
Referring now to FIG. 1, there is illustrated a substrate support such as a 
printed wiring board 22. A plurality of terminal pins, designated 
generally by the numeral 24, are assembled in apertures 26 of the board 22 
to form a pin-populated board assembly designated generally by the numeral 
28. The assembly 28 can be used in a variety of ways to provide 
interconnection for electronic circuits such as those used, for example, 
in communication networks. 
Referring to FIG. 2, the terminal pin 24 is formed from blank stock (not 
shown) to include axially aligned shank portions 30 and 32 at opposite 
ends thereof. The end of the shank portion 32 is to be inserted into the 
aperture 26 of the board 22 while the end of the shank portion 30 is a 
non-inserting end. Lateral ears 34 and 36 are formed intermediate the ends 
of the pin 24 adjacent the shank portion 30 and include shoulder or push 
surfaces 38 and 40, respectively, closest the the shank portion 30 and 
undersurfaces 42 and 44, respectively, closest to the shank portion 32. 
The pin 24 is also formed with a board-engaging, pin-retaining portion 46 
which is eventually located within one of the apertures 26 (FIG. 1) of the 
board 22 and is designated to facilitate removable retention of the pin 
with the board. The design of the pin-retaining portion 46 of the pin 24 
could be an enlarged section as illustrated in FIG. 2 which could be urged 
into the aperture 26 of a smaller dimension so that the pin is 
frictionally held with the board 22. Also, the design of the pin-retaining 
portion 46 of the pin 24 could be a compliant section of sufficient 
dimension to fit compliantly within the aperture 26 and thereby removably 
retain the pin with the board 22. An example of a compliant section which 
could be utilized is illustrated in U.S. Pat. No. 4,076,356. 
Referring to FIG. 3, there is illustrated a plurality of terminal pins 24 
which have been formed in a predetermined uniform spacing from blank stock 
(not shown) during a punching and stamping operation. The pins 24 are held 
in the uniform spacing by integrally attached end-carrier strips 48 and 50 
also formed from the blank stock in the same punching and stamping 
operation. The pins 24 and end-carrier strips 48 and 50 form a multiple 
pin assembly designated generally by the numeral 52. The ends of the shank 
portions 30 and 32 of the pins 24 which are linked integrally with the 
end-carrier strips 48 and 50, respectively, are scored at points 49 and 
51, respectively, to facilitate subsequent easy removal of the strips from 
integral attachment with the pins. 
A technique and facility are needed for simultaneously and efficiently 
inserting a plurality of the pins 24 into apertures 26 of the board 22 
while insuring and maintaining the structural integrity and straightness 
of the pins. 
A pin applicator, designated generally by the numeral 54, is designed to 
receive and clamp, within the applicator and in the predetermined spacing, 
a major portion of the shank portions 30 of each of the pins 24 of the pin 
assembly 52 while removing the strip 48 at the scored points 49 as the 
pins are being received. The strip 50 can then be removed at the scored 
points 51 and the pins 24 inserted into the apertures 26 (FIG. 1) of the 
board 22 by pushing on the shoulders 38 and 40 (FIG. 2). The use of the 
pin applicator 54 provides for the simultaneous and efficient assembly of 
the plurality of pins 24 with the board 22 without disturbing the 
integrity of the structure of the pins. 
Referring to FIGS. 3 and 5, the applicator 54 includes a stationary jaw, 
designated generally by the numeral 56, and a movable jaw, designated 
generally by the numeral 58, which is movable relative to the stationary 
jaw. The stationary jaw 56 is secured to a top plate 57 which is attached 
to an overhead ram 60 (partially shown) and which forms an operable 
portion of a press (not shown). The press is operable to move the ram 60 
vertically, as viewed in FIGS. 3 and 5, and to thereby move the stationary 
and movable jaws 56 and 58 therewith. The lower surface of the movable jaw 
58 extends below the lower surface of the stationary jaw 56. Three 
stop-travel pads 59 are secured at spaced locations to the lower surface 
of the stationary jaw 56 and extend beyond the lower surface of the 
movable jaw 58. Each of the pads 59 is formed with a board-engaging 
undersurface 61. 
Referring to FIGS. 3 and 4, the stationary jaw 56 is formed in one face 62 
thereof with a plurality of spaced rectangular protrusions 64. The 
protrusions 64 extend from the face 62 by a distance slightly less than 
the thickness of the pin 24. Each adjacent pair of the protrusions 64 
forms therebetween one of a plurality of nests 66. Each of the nests 66 is 
dimensioned in width to receive the shank portion 30 of the pin 24 and has 
a depth dimension slightly less than the thickness of the pin. Each 
protrusion 64 also includes a pin-shoulder engaging surface 68 which is 
located a precise distance from the undersurfaces 61 of the pads 59 with 
the engaging surfaces being in planar alignment within the pin applicator 
54. A stripper bar 70 is also formed on the face 62 of the stationary jaw 
56 and includes a flat face 72 to facilitate subsequent separation of the 
end-carrier strip 48 from the plurality of pins 24. 
Referring to FIG. 3, the movable jaw 58 is formed with a cutout 74 which 
fits about a forward extension plate 76 which is secured to the stationary 
jaw 56. This facilitates the securing of the movable jaw 58 to the 
stationary jaw 56 by pivot pins 78 and 80 to permit pivotal movement of 
the movable jaw relative to the stationary jaw. The movable jaw 58 is 
formed with an elongated opening 82 which is generally aligned with the 
stripper bar 70 to provide for visual sighting of the multiple pin 
assembly 52 with the nests 66 and to facilitate ready removal of the 
separated end-carrier strip 48 of the multiple pin assembly. 
As illustrated in FIG. 7, the movable jaw 58 is formed with an inner face 
84 which is positioned adjacent to the protrusions 64 of the stationary 
jaw 56. The cutout 86 is formed in the face 84 generally from side to side 
thereof with a flared surface 88 extending downwardly and outwardly to a 
foot surface 90. A plurality of spaced notches 92 are formed in the foot 
surface 90 and extend beyond the flared surface 88. The foot surface 90 is 
located in a plane which is forward of the plane of the inner face 84 as 
viewed in FIGS. 5 and 6. The notches 92 are aligned with the nests 66 of 
the stationary jaw 56 (FIG. 3) with each notch ultimately receiving a 
portion of one of the pins 24 as illustrated in phantom in FIG. 7. 
Referring to FIG. 4, a pair of spring-biasing elements, designated 
generally by the numeral 94 (one shown), are mounted at spaced locations 
in the stationary jaw 56 (FIG. 3) and facilitate normal separation of the 
movable jaw 58 from the stationary jaw as illustrated in FIGS. 8 and 9. 
Each of the spring-biasing elements 94 includes an externally threaded 
sleeve 96 formed with a head 98 on one end thereof which is mounted within 
a threaded aperture in the stationary jaw 56. A plunger tip 100, which is 
captured for movement within the sleeve 96, protrudes movably from the 
other end of the element 94 and is urged to this position by a spring (not 
shown) within the sleeve. The spring normally urges the plunger tip 100 of 
each element 94 to an extended position, as illustrated in FIGS. 8 and 9, 
whereby the tip engages and moves the movable jaw 58 to a pivoted or open 
position relative to the stationary jaw 56. The location of the elements 
94 are also illustrated in FIG. 3. 
As illustrated in FIG. 5, a pair of air cylinders 102 (one shown) are 
secured to the stationary jaw 56. Each of the air cylinders 102 has a 
piston rod 104 which extends through a bushing 106 mounted in the 
stationary jaw 56 and further through an aperture 108 formed in the 
movable jaw 58. A spherical washer 110 and a pair of nuts 112 are mounted 
threadedly on the free end of the piston rod 104 to capture the stationary 
jaw 56 and the movable jaw 58 between the washer and the air cylinder 102. 
The physical location of the air cylinders 102 are also illustrated in 
FIG. 3. 
When each of the air cylinders 102 is operated to draw the piston rod 104 
further within the air cylinder, the washer 110 moves the movable jaw 58 
against the biasing action of the spring-biasing elements 94 to a position 
adjacent to the stationary jaw 56 as illustrated in FIGS. 5, 6 and 10. 
When each of the air cylinders 102 is operated to move the piston rod 104 
outwardly from within the air cylinder, the washer 110 is moved away from 
the movable jaw 58. The springs of the spring-biasing elements 94 then 
facilitate outward movement of the plunger tips 100 and thereby moves the 
movable jaw 58 to the open position as illustrated in FIGS. 8 and 9. 
Referring to FIG. 5, when the pin applicator 54 is to be used to insert the 
pins 24 into the board 22, the board is placed on a support table 114 so 
that the apertures 26 of the board are located over apertures 116 formed 
in the support and which are larger than the board apertures. The 
apertures 116 of the table 114 are sufficiently large to permit free entry 
and passage of any portion of the pins 24 which will normally extend below 
the board 22 such as the shank portions 32. This provides for ready 
removal of the pin-populated board assembly 28 upon completion of the 
insertion of all pins 24 in the apertures 26 of the board 22. 
Referring to FIG. 8, the air cylinders 102 (FIGS. 3 and 5) are operated to 
facilitate movement of the movable jaw 58 to the open position. The lower 
portion of the multiple pin assembly 52 is then positioned into a top 
opening of a carrier, designated generally by the numeral 118, which is 
also illustrated in FIG. 3. The carrier 118 includes a base 120, two end 
members 122 and 124 and two spaced side walls 126 and 128. The base 120, 
end members 122 and 124, and the side walls 126 and 128 are fastened 
together to form an open-top enclosure for receiving the lower portion of 
the pin assembly 52 and supporting the assembly for manual transport. The 
side walls 126 and 128 are each formed with an upper planar surface 129 
which are in alignment with each other. The carrier 118 can be composed of 
any suitable material such as, for example, a lightweight plastic. 
Referring further to FIG. 8, the carrier 118 is then manipulated to 
position the pin assembly 52 into the opening between the stationary jaw 
56 and the movable jaw 58 so that the strip 48 is located adjacent to the 
stripper bar 70. In addition, the shank portion 30 of the pins 24 are 
aligned with the nests 66. The opening 82 of the movable jaw 28 
facilitates visual locating of the strip 48 relative to the stripper bar 
70 and the shank portions 30 relative to the nests 66. 
Referring to FIG. 9, the carrier 118 is moved to the right to position the 
shoulder surfaces 38 and 40 of each pin 24 into engagement with the front 
edge of the engaging surfaces 68 of the protrusions 64 with the strip 48 
remaining essentially aligned with the flat face 72 of the stripper bar 
70. The air cylinders 102 are then operated to pivot the movable jaw 58 
toward the stationary jaw 56 as illustrated in FIG. 10. 
As the movable jaw 58 approaches the stationary jaw 56, the inner face 84 
of the movable jaw engages a major portion of an adjacent face of the 
shank portion 30 of each of the pins 24 of the multiple pin assembly 52 
and urges the shank portions into the aligned nests 66 of the stationary 
jaw. Simultaneously, the end-carrier strip 48 is urged into engagement 
with the flat face 72 of the stripper bar 70 whereby a torque action 
occurs to bend the strip 48 at each of the scored points 49 whereat the 
strip is integrally joined with each pin 24. This results in the 
separation or severance of the strip 48 from the pins 24 as illustrated in 
FIG. 10. As noted above, the stripper bar 70 is aligned with the elongated 
opening 82 of the movable jaw 58 and facilitates ready removal of the 
separated end-carrier strip 48 from the area of the pin applicator 54 
prior to insertion of the pins 24 into the apertures 26 of the board 22. 
As the inner face 84 of the movable jaw 58 is urging the shank portions 30 
of the pins 24 into the nests 66, the multiple pin assembly 52 is being 
oriented into a vertical position which causes the carrier 118 to move to 
the left as viewed in FIG. 10. 
Thus, the strip 48 is separated from the pins 24 while the pins are being 
pressed into the nests 66. Therefore, the structural integrity and 
straightness of the pins 24 is maintained by the pin applicator 54. 
As the movable jaw 58 is being pivoted to the right as illustrated in FIG. 
10, the flared surface 88 of the movable jaw engages the undersurfaces 42 
and 44 of each of the pins 24 and urges the pins upwardly axially thereof 
to insure that the shoulder surfaces 38 and 40 are pressed snugly into 
engagement with the engaging surfaces 68 of the stationary jaw 56. In this 
manner, the ears 34 and 36 of each of the pins 24 are captured between the 
flared surface 88 and the engaging surfaces 68 to thereby accurately 
locate each of the pins along its axis within and with respect to the pin 
applicator 54 for subsequent insertion into the apertures 26 (FIGS. 1 and 
5) of the board 22. Additionally, this insures that the shoulder surfaces 
38 and 40 of each pin 24 are in planar alignment with the shoulder 
surfaces of all other pins in the multiple pin assembly 52. Also, as noted 
above, each of the notches 92 (FIG. 7) formed in the movable jaw 58 
receives a portion of one of the pins 24 as the pins are being located 
within the pin applicator 54. 
As noted above, and as illustrated in FIGS. 4 and 6, the depth of the nests 
66 as defined by the protrusion 64 is slightly less than the thickness of 
the pins 24 so that, when the shank portions 30 are fully positioned 
within the nests, a forward portion of each of the shank portions extends 
outside the nests. In this manner, the inner face 84 of the movable jaw 58 
is continuously pressing the shank portions 30 of the pins 24 against the 
back wall of the nests 66 whereby the shank portions 30, and the pins, are 
clamped with the pin applicator 54 as viewed in FIGS. 6 and 10. 
Thereafter, as viewed in FIG. 11, the carrier 118 is lowered until the 
planar surfaces 129 are parallel to the scored points 51. The strip 50 is 
then separated from the pins 24 by rocking the carrier 118 along the 
scored points 51 to flex and separate the strip whereby the pins are now 
individually supported in the predetermined uniform spacing by the pin 
applicator 54 for insertion into the apertures 26 of the board 22 as 
illustrated in FIG. 5. The separated strip 50 deposits into the carrier 
118 which is then removed from the area of the pin applicator 54. 
The ram 60 (FIG. 5) is then lowered to facilitate insertion of the 
plurality of pins 24, held by the pin applicator 54, into the apertures 26 
of the board 22. The shank portions 32 of the pins 24 move freely through 
the apertures 26 and through the apertures 116 of the table 114 until the 
pin-retaining portions 46 begin to enter the apertures 26. Then a pushing 
force is required and is applied to the shoulder surfaces 38 and 40 
through the engaging surfaces 68 of the stationary jaw 56. Some pushing 
force is also transmitted through the clamped portions of the shank 
portions 30 of the pins 24. 
During this period when the portions 46 are being urged into the apertures 
26, the shank portions 30 of the pins 24 are firmly clamped so that the 
structural integrity of the pins is not disturbed. In addition, no pushing 
force is applied to the tip ends of the shank portions 30 the structural 
integrity of which is important in later utilization of the pin-populated 
board assembly 28. The pins 24 are thereby guided into the apertures 26 
and the pin-retaining portions 46 are positioned in the apertures to 
facilitate retention of the pins with the board 22. 
Eventually the undersurfaces 61 of the feet 59 engage and rest on the upper 
surface of the board 22 to thereby limit and stop the downward movement of 
the ram 60. As noted above, the undersurfaces 61 of the feet 59 are 
located a precise distance from the pin-shoulder engaging surfaces 68 of 
the stationary jaw 56 thereby providing that the shoulder surfaces 38 and 
40 are located, by the precise distance, above the upper surface of the 
board 22. This satisfies a requirement that the ears 34 and 36 of all of 
the pins 24 in the board 22 be located a uniform distance above the 
adjacent surface of the board. 
After the pins 24 have been assembled with the board 22, the air cylinders 
102 are operated to move the piston rods 104 outwardly from the air 
cylinders. The movable jaw 58 is then moved to the open position under the 
urging of the spring-biasing elements 94 to unclamp the shank portions 30. 
The ram 60 is then moved upwardly to reveal the pins 24 fully assembled 
with the board 22. 
While the foregoing description relates to a single multiple pin assembly 
52 of a given number of pins 24, the carrier 118 can be modified 
internally to receive several spaced strip-supported multiple pin 
assemblies each of a lesser number of pins 24 than the given number of the 
illustrated pin assembly. The carrier 118 is manipulated in the same 
manner as described above and the pins 24 are inserted in the same manner 
without departing from the spirit and scope of the invention. 
Further, the multiple pin assembly 52 could include initially only one 
carrier strip. For example, the pin assembly 52 could include either the 
strip 48 or the strip 50 to retain the pins 24 in the spaced alignment. If 
the strip 48 is used, the strip would be removed in the same manner as 
described above by the stripper bar 70. If the strip 50 is used, the strip 
would be removed by rocking the prepositioned carrier 118, as illustrated 
in FIG. 11, after the pin assembly 52 has been positioned in the nests 66 
and clamped with the pin applicator 54.