Selective wire feed for a plurality of wires

A selective wire feed for feeding any one of a plurality of wires which are arranged in pairs, each pair having a first wire and a second wire. Each wire pair has a feeding unit associated therewith which comprises a driven belt and two idler belts. The idler belts are movable between a feeding position and a non-feeding position. A specific wire is fed by moving its associated feeding belt to its feeding position and actuating the driven belt so that the wire is fed by the two belts. A wire guide is provided and has convergent passageways which extend to a wire outlet. A cutter is provided adjacent to the outlet so that a wire which has been fed can be cut. Thereafter, the wire which has been fed can be retracted by reversing the direction of the driven belt.

FIELD OF THE INVENTION 
This invention relates to wire feeding devices of the type which are 
capable of selectively feeding any one of a plurality of wires in an 
array. 
BACKGROUND OF THE INVENTION 
A commonly known type of lead making machine, as shown for example in U.S. 
Pat. Nos. 3,019,697, and 4,489,476 comprises a wire feeder for feeding 
wire from an endless source, such as a barrel or reel, through and beyond 
a cutting and stripping zone. After the wire has been fed, it is cut to 
produce a cut lead with the leading end of the wire extending from the 
endless source to a location adjacent to the cutter. Machines of the type 
shown in the above-identified U.S. patents thereafter present the cut ends 
of both the lead and the wire extending from the source to crimping 
machines so that terminals can be crimped onto the wire ends. 
Most, if not all of the machines of the type described above are capable of 
feeding only a single wire (or perhaps two wires in tandem) and are not 
capable of feeding any one of a plurality of wires which would be drawn 
from a plurality of endless sources. It would be desirable to add to 
machines of the type described above the capability of selectively feeding 
any one of a plurality of wires for the reason that it would then be 
possible to produce, during continuous operation of the machine, a series 
of leads having wires of different colors or different gauges which would 
be used to produce a specific harness. Recent advances in the harness 
making arts require that all of the leads for a given harness be produced 
immediately prior to the assembly of these leads to each other and if all 
of the leads required for a specific harness are to be produced by the 
same machine and within a short time cycle, it is obvious that the machine 
must be capable of selectively feeding any one of the types of wires 
required in the harness. 
There are several difficulties which must be overcome in order to provide a 
multiple wire feeding system to lead making machines of the type described 
or harness making machines employing the same features as the machines 
described above. For example, machines of the type described in the 
above-identified U.S. Pat. Nos. 3,019,697, and 4,489,476 require that 
after the wire extending from the source has been cut, it must be in a 
predetermined position so that it can then be presented by the machine to 
the crimping press which requires precise location of the wire between the 
crimping die and the crimping anvil. Most, if not all, of the known types 
of selective wire feeds which are known to the art require that the array 
of wires be in side-by-side, parallel, co-planar relationship and the 
known types of wire feeds are capable of only feeding these wires in the 
direction of their axes along straight line paths. At the end of a given 
feeding cycle for a specific wire then, the wire end will be at a location 
which is spaced from the location at which any of the other wires in the 
array would be located, see for example U.S. Pat. Nos. 4,043,494 and 
4,192,207. 
The present invention is directed to the achievement of an improved 
selective wire feed for feeding any one of a plurality of wires and which 
locates the end of a fed wire in a precisely predetermined position 
regardless of which wire in the array is fed. The invention is further 
directed to the achievement of an improved feeding apparatus and improved 
control systems for feeding devices. 
THE INVENTION 
One embodiment of the invention comprises a wire feeding unit for 
selectively feeding either one of a first wire and a second wire, the 
wires being in parallel relationship. The feeding unit is characterized in 
that first, second, and third endless feeding surfaces are provided which 
are in side-by-side relationship with the third feeding surface between 
the first and second feeding surfaces. The first and third feeding 
surfaces have first opposed portions which function as first wire feeding 
portions. The first wire is between the opposed portions of the first wire 
feeding portions. The second and third surfaces have opposed portions 
which function as second wire feeding portions and the second wire is 
between these opposed portions. Each of the feeding surfaces is movable 
along its length in both directions of its length, the opposed portions of 
each of the first and second wire feeding portions being relatively 
laterally displaceable towards and away from each other between a feeding 
position and a non-feeding position. The opposed portions of each of the 
wire feeding portions are against each other when in the feeding position 
and are spaced apart when in the non-feeding position. Actuating means are 
provided for displacing either of the first and second feeding portions to 
their feeding positions and for moving one of the endless surfaces which 
is in its feeding position whereby either one of the wires can be 
selectively fed in a common direction by displacing the wire feeding 
portions which are associated with the one wire to their feeding position 
and thereafter moving one of the associated surfaces along its length. 
Advantageously, each of the feeding surfaces comprises an endless belt. In 
accordance with a preferred embodiment, the third endless feeding surface 
is a driven surface and the first and second endless surfaces are idler 
surfaces. The actuating means is effective, in this embodiment, to move 
only the third feeding surface. 
In accordance with a further embodiment, wire guide means are provided for 
guiding the wires during feeding. The wire guide means is in alignment 
with the first and second wires and has convergent portions and a single 
wire passageway which extends to a wire outlet. The convergent portions 
extend to, and converge at, the single wire passageway whereby the wires 
are fed from the single wire outlet. 
In accordance with a further embodiment, a wire cutter is provided 
proximate to the wire outlet and the actuating means is effective to 
actuate the cutter after a selected wire has been fed past the wire 
cutter. Advantageously, the actuating means further comprises feed control 
means for moving the driven surface in the one direction which will result 
in the feeding of a selected wire during a feeding interval and is also 
effective to move the driven surface in the opposite direction after a 
feeding interval whereby after a wire has been fed and cut, the selected 
wire can be retracted through the wire outlet and through the single wire 
passageway. 
A further embodiment comprises wire feeding apparatus for selectively 
feeding one wire selected from either one of a first wire pair and a 
second wire pair, the first wire pair comprising a first pair first wire 
and a first pair second wire. The second wire pair comprises a second pair 
first wire and a second pair second wire. The feeding apparatus comprises 
first and second feeding units for the first pair and the second pair 
respectively. The feeding units and the actuating means are as described 
above. The first and second feeding units are in stacked and aligned 
relationship with the driven surface and the first and second idler 
surfaces for the first and second pairs of the first unit being beside the 
endless driven surface and the idler surfaces of the second unit 
respectively. Wire guide means as described above are preferably provided 
adjacent to the feeding units, the guide means having four convergent 
passageways for the four wires. The convergent passageways extend to a 
single wire passageway as described above which in turn extends to a wire 
outlet.

THE DISCLOSED EMBODIMENT 
FIGS. 10 and 11 illustrate the manner in which any one of six wires 2, 4, 
6, 8, 10, 12 are fed during a feeding cycle of the apparatus. The wires 
are arranged in pairs, the wires 2, 4 being the first pair, the wires 6, 8 
the second pair, and the wires 10, 12 the third pair. The wire 2 is 
identified as the first wire of the first pair and the wire 4 is the 
second wire of the first pair. Similarly, the wires 6 and 10 are the first 
wires of the second and third pairs and the wires 8 and 12 are the second 
wires of the second and third pair. At the beginning of the operating 
cycle, the ends of the wires will be aligned as shown. If it is desired to 
feed the wire 10 selectively, the apparatus feeds this wire from its 
normal position along a path which extends to one end of a wire passageway 
148. During this feeding operation, the wire must be fed not only axially 
but laterally towards the passageway as indicated in FIG. 11. The wire is 
fed into the passageway 148 through the outlet 150 of the passageway and 
past a pair of normally open severing blades 14, 16. At the conclusion of 
the feeding cycle, the blades 14, 16 are closed to cut the wire so that a 
cut lead is produced which extends leftwardly from the cutter. The cut end 
of the wire 10 can then be withdrawn or retracted to its starting position 
and during the next feeding cycle, a different wire can be fed along a 
convergent path towards the single wire passageway 148. 
The feeding apparatus 18, FIGS. 1-3, is supported on a base plate 20 which 
is in turn supported above a support platform 22. The support platform may 
be part of the harness making or lead making machine of which the wire 
feeding apparatus is a part. The apparatus 18 comprises generally a wire 
feeding section 24, an upstream wire clamping section 26, a wire guide 
section 28, and a downstream wire clamp 30. The terms "upstream" and 
"downstream" refer to the direction of wire feed which is from right to 
left as viewed in FIG. 3. The wire is supplied from endless sources such 
as barrels or reels. 
A frame structure is mounted on the base plate 20 and comprises two pairs 
of spaced-apart opposed plates 38, 40 and 38', 40'. A cover plate 42 is 
secured to the upper edges of these plates and is over the feeding belts 
which are described below. The machine is substantially symmetrical about 
a center line extending therethrough in the direction of wire feed and the 
same reference numerals, with some exceptions, will be used to indicate 
corresponding structural elements on each side of the center line. 
The wires are guided into the feeding section by an entry guide assembly 
44, FIGS. 4 and 6, which has openings 46 extending therethrough, one 
opening being provided for each of the wires. Each of the openings 46 has 
a clamping block 48 associated therewith in order to clamp the wire in the 
opening when it is not being fed. The clamping blocks extend through side 
openings 50 in the entry guide assembly which communicate with the 
passageways 46. The clamping blocks 48 are secured to the ends of piston 
rods 52 which extend in turn from piston cylinders 54. These cylinders are 
mounted on ears 56 which are integral with the side plates 38, as shown 
best in FIG. 4. All of the clamping blocks are normally in clamping 
relationship with their associated wires, excepting during a feeding 
interval when one of the clamping blocks will be in its retraced position 
in order to permit feeding of the wire. 
The feeding section comprises three feeding units, one feeding unit being 
provided for each of the pairs of wires. The feeding units are 
substantially identical to each other so that a description of one will 
suffice for all. 
Each feeding unit comprises first and second belts 58, 60 which are idler 
belts and a third belt 62 which is a driven belt, the driven belt being 
between the two idler belts. As shown best in FIG. 7, the drive belts or 
third belts 62 of the feeding units extend around a common drive shaft 64 
and a common idler shaft 66. The drive shaft extends through the cover 
plate 42 and has a locknut 68 on its upper end. The lower end of the drive 
shaft extends through the plate 20 and has a bevel gear 70 on its end 
which meshes with a bevel gear 164 on a shaft 166. The shaft 166 in turn 
is rotated by a printed circuit motor (not specifically shown) which is 
under the control of the control system described below. Separate 
sprockets 72 are provided as shown which is keyed to the shaft by key 74. 
Guides 76 are provided between adjacent belts. 
The idler shaft 66 is rotatably supported by means of bearings 77 on a 
fixed pin 78 which has its ends fixed in an adjustable U-shaped support 
frame 80. This U-shaped support frame is between the opposed surfaces of 
the plates 20 and 42, a recess 88 being provided in the surface of the 
base plate 20 to permit movement of the support frame for purposes of 
adjusting the tension in the belt. The tension is adjusted by means of an 
eccentric shaft 82 which extends through an opening 83 in the web portion 
of the frame member so that rotation of the eccentric shaft will cause 
movement of the frame member one way or another to increase or decrease 
the tension in the belt. The eccentric shaft has a kerf 86 in its upper 
end which is above the cover plate 20 and has a locknut 84 threaded onto 
its end so that it can be locked in a given position after the required 
tension has been imparted to the shaft. The printed circuit motor which 
drives the power shaft 166 and the driven shaft can be rotated, under the 
influence of the control system, in either direction so that the belt can 
be driven in either direction. 
Each of the feeding units has two idler belt assemblies 90, FIG. 8, one 
assembly being provided for each of the first and second wires of the 
associated wire pair. Each wire assembly comprises an open rectangular 
frame 91 having side rails 92, a back rail 94, and a front rail 96 which 
is adjacent to the driven belt. Slots 98 are provided in the outwardly 
facing surfaces of the side rails 92 and slots 99 are provided in the 
opposed faces of the associated plates 38, 40. A guide bar 100 is mounted 
by suitable fasteners in the associated slot of one of the plates 38 or 
40. This guide bar is dimensioned to enter the opposed slot in the side 
rail of the associated frame. The other side rail of the frame has one of 
the guide bars 100 mounted therein so that it enters the slot of the 
associated frame plate. These guide bars are advantageously of a graphite 
filled polyester having a low friction coefficient. 
The idler belt assemblies are individually movable between a feeding 
position and a non-feeding position, the idler belt being substantially 
against the associated driven belt when in its feeding position and being 
spaced from the associated driven belt when it is in its non-feeding 
position. Movement of the individual idler belt assemblies between their 
two positions is achieved by means of air cylinders 104, a separate air 
cylinder being provided for each of the belt assemblies. The air cylinders 
are supported on a column 106 which are secured to the base plate 20 by a 
fastener 108 as shown in FIG. 5. The air cylinder associated with a 
particular frame member has a coupling block 110 on the end of its piston 
rod which in turn is pivoted at 112 to the rail 96 of the frame 91. The 
air cylinders 104 are under the control of the control system and can be 
individually pressurized to move a particular belt assembly from its 
non-feeding position to its feeding position. The idler belt on each of 
the frame members 91 extends around idler sprockets 118 which are mounted 
for free rotation on a fixed shaft 114 and an adjustable shaft 116. The 
fixed shaft is supported between an ear 120 and a ledge 122 on the front 
rail 96 of the associated frame 91. The adjustable shaft 116 is mounted in 
a U-shaped bracket 124 having spaced-apart arms 126 between which the 
shaft is mounted and a laterally extending arm 128 which is adjustably 
secured to the front rail 96 by a fastener 130. The tension of the idler 
belt can thus be adjusted by simply loosening the fastener and moving the 
bracket 124 until the desired amount of belt tension is achieved. A 
support block 132 is also secured to the ledge 122 to provide a support 
for the portion of the belt which is against the driven belt during a 
feeding operation. 
The wire guiding section 28 (FIGS. 4 and 9), by means of which any one of 
the six wires are guided to the single wire passageway 148 and the wire 
cutter 14, 16, comprises a generally wedge shaped center block 134 and two 
outside blocks 136 which are mirror images of each other. The blocks are 
secured to each other by suitable fasteners 138 and are secured to the 
plate 20 by fasteners 140. The outside blocks 136 have converging opposed 
surfaces 142 which merge with flat surfaces 144 that are against each 
other when the blocks are in assembled relationship. Channels 146 are 
provided in each of the surfaces 142 and extend from a location adjacent 
to the ends of wires in the feeding section to a single wire passageway 
148. The passageway 148 in turn is formed by channels in the opposed flat 
surfaces 144. All of the channels 146 converge towards the single wire 
passageway 148 and merge with the single wire passageway so that a wire 
fed through any one of the channels enters the passageway and is guided to 
the wire outlet 150. The outlet is on the face 152 of the wire guiding 
assembly and the downstream wire clamp 30 is secured to the guiding 
assembly adjacent to this face. The blocks 134 and 136 are advantageously 
of a graphite filled polyester material in order to facilitate movement of 
the wires therethrough during a feeding cycle. 
The downstream wire clamp 30 comprises a pair of spaced-apart, L-shaped 
fingers 154 which are mounted on arms 156 of a pneumatically controlled 
parallel motion gripper 158. The arrangement is such that when the arms 
156 move towards each other, the arms 154 will move against each other and 
grip a wire located therebetween. The parallel motion gripper 158 may be 
of any suitable type, for example, a model RP 10 manufactured by Robohand 
Incorporated of 171 Spring Hill Road, Trumbull, CT. The gripper 158 is 
secured by fasteners 162 to an adapter block 160 which in turn is secured 
to the top surface of the guide block assembly. 
To briefly review the operation during a single feeding cycle, the upstream 
wire clamps will normally be closed onto the wires, the downstream wire 
clamp will be open, and all of the idler belt assemblies will be retracted 
so that the idler belts will be in their non-feeding positions. When a 
command is received by the apparatus to feed a specific one of the six 
wires, the appropriate idler belt assembly is moved from its non-feeding 
position to its feeding position and the associated upstream wire clamp is 
open so that the wire is free to be fed. The driven belt is thereafter 
moved in the appropriate direction to cause feeding of the wire, from 
right to left as viewed in FIG. 3, through the guide assembly 28, from the 
wire outlet and through the downstream wire clamp 30. After feeding, the 
cutter is actuated to cut the wire and the direction of movement of the 
driven belt is reversed to withdraw the wire to its starting position so 
that a different wire may be fed during the next operating cycle. 
The operating cycle as described above refers only to the wire feeding 
apparatus itself. When the apparatus is part of a harness making or lead 
making machine, the downstream wire clamp 30 will be closed prior to 
retraction of the wire and the entire feeding apparatus will be rotated on 
a vertical axis to present the cut end of the wire to a crimping press. 
Thereafter, the same wire, which now has a terminal on its end, is fed 
again to produce a lead. Only when a different wire is to be fed in the 
subsequent feeding operation is the wire which has been fed retracted to 
its initial position. 
A typical control system for the apparatus is shown in FIG. 12. This 
control system is of the type which permits the production of a wide 
variety of different leads during several wire feeding cycles. The system 
shown comprises an input unit 168 such as a touch screen or a keyboard, a 
computer 170, and a data bank 172. The data bank will usually be part of 
the computer but is shown as a separate unit for purposes of explanation. 
When an operator 174 wishes to produce a particular harness requiring 
several different wires selected from the array of wires in the machine, 
he provides the necessary intelligence by line 176 to the input unit 168. 
The input unit 168 in turn transmits the information by line 178 to the 
computer 170 which in turn calls upon the data bank, as indicated by line 
180, for the necessary information. The information is transmitted by line 
182 back to the computer which in turn displays it on the screen 168 as 
indicated by line 183. When the operator 174 receives this information via 
line 185, he makes any necessary adjustments or changes to the machine as 
indicated by line 186. Changes for example, might require that a different 
or other wire be provided to the machine for a particular harness. After 
the changes have been made, the operator sets the computer in motion as 
indicated by the lines 188 and 189 which in turn controls the operation of 
the machine as indicated by line 190. 
It will be apparent from the foregoing description that a machine in 
accordance with the invention is capable of feeding any one of a plurality 
of wires and locating the end of a wire which has been fed in one 
predetermined position. The feeding section, including the belts and the 
actuating means, can be used under circumstances other than those shown 
and described; for example, where it is not required to have the end of 
the fed wire in the one position at the outlet of the passageway. Also, 
the guiding system can be used with feeding systems other than the system 
shown.