Inspection device for connectors and connector

An inspection device for connectors comprises a connector support (6) and an inspection main body (3) movable relative to each other. The main body has therein a plurality of inspection pins (11) connected to an inspecting electric circuit, which inspection pins are each urged forwardly by a spring (2). A connector to be inspected has a plurality of terminal-accommodating chambers, each containing a resilient cantilever support piece (14) and a space (16) adjacent the support piece. Each inspection pin (11) includes a continuity-test surface (11a) and an incomplete-insertion detector portion (11b) protruding forwardly of the continuity-test surface, which detector portion (11b) is at the front end formed with an abutment means (11c) engageable with a corresponding abutment means (14b) of the related support piece (14). During inspection, the detector portion (11b) enters the space (16) adjacent the support piece (14) so that the continuity-test surface contacts a terminal lug (C) in fully-inserted position in the accommodating chamber. Terminal lugs are individually inspected whether in fully-inserted or incompletely-inserted position without making errors.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
This invention relates to an inspection device for connectors for use in 
connection of automotive wiring harnesses and the like, which enables 
checking whether a terminal lug is incorporated in proper position in a 
connector, and checking for continuity of a wire connected to the terminal 
lug, and also to a connector having a structure adapted for such 
inspection. 
2. Description of the Related Art 
FIGS. 12A to 12C are longitudinal sectional views of a conventional 
connector, shown with a terminal in the process of being inserted 
thereinto. 
A plurality of terminal-accommodating chambers b are formed in the 
connector housing q, each of which contains a resilient cantilever locking 
piece c whereby a terminal lug is locked in position in its accommodating 
chamber and prevented from rearwardly slipping off. During insertion of 
the terminal lug d, its front end portion contacts a locking projection c1 
of locking piece c to resiliently displace locking piece c inside a 
resilient-displacement allowing space e (FIG. 12B), and then locking piece 
restores its original position when terminal lug d rides thereover and the 
locking projection c1 is in alignment with an engagement hole d1. The 
terminal lug d is at this time locked in position (FIG. 12C). 
Referring to FIG. 13, designated at f is an inspection device which 
incorporates therein tube-like inspection terminals g in correspondence 
with respective terminal-accommodating chambers b in the housing a. Each 
inspection terminal g has a slidable continuity pin h normally urged and 
protruding forwardly by a coil spring i. Inspection device f includes an 
incomplete-insertion detector arm j for detecting when a terminal lug d is 
in incompletely-inserted position in the housing a. 
If the connector to be inspected is set on inspection device (FIG. 13), 
incomplete-insertion detector arm j advances into resilient-displacement 
allowing space, and terminal lug d locked in fully-inserted position, the 
lower one, abuts against the continuity pin h and pushes the same 
rearwardly, so that the result of the continuity test will be indicated as 
satisfactory by a checker k. The terminal lug d which is not locked by the 
locking piece c does not contact the continuity pin h, so that the test 
result will be indicated as unsatisfactory by the checker k. Referring 
Referring to FIG. 14, the upper terminal lug d is in incompletely-inserted 
position and resiliently displaces locking piece c to close the 
resilient-displacement allowing space e therebelow. If in this condition 
the connector is set on inspection device f, since the 
incomplete-insertion detector arm j abuts against the end surface of the 
upper locking piece c that is closing the space e, the setting cannot be 
completed, thereby letting it be known that the terminal lug d is in 
incompletely-inserted position. 
The prior art as mentioned above is disadvantageous in that, if one 
terminal lug d is in such incompletely-inserted postion as resiliently 
displaces locking piece c, since the detector arm j cannot enter the space 
e, all the terminal lugs d in the housing a cannot be subjected to 
inspection, in other words, each terminal lug d cannot be individually 
inspected. 
SUMMARY OF THE INVENTION 
This invention has been accomplished to overcome the above drawbacks and an 
object of this invention is to provide an inspection device for connectors 
which enables terminal lugs to be individually detected when in 
incompletely-inserted position, and which gives reliable, error-free test 
results. This invention also seeks to provide a connector having a 
structure adapted for such inspection. 
In order to attain the object, according to an aspect of this invention, 
there is provided an inspection device for connectors, which comprises: a 
connector support and an inspection main body movable relative to each 
other; a plurality of inspection pins provided in the inspection main 
body, each connected to an inspecting electric circuit, each normally 
urged towards the connector support by a spring, and each having a 
continuity-test surface and an incomplete-insertion detector portion 
protruding closer to the connector support than the continuity-test 
surface; a connector to be inspected which comprises a housing and a 
plurality of terminal-accommodating chambers formed in the housing, and 
terminal lugs inserted in the terminal-accommodating chambers to be locked 
therein, each of the terminal-accommodating chambers containing a 
resilient cantilever support piece and a space adjacent the support piece 
inside which the support piece is resiliently displaced while being 
contacted and pressed by the related terminal lug; and a first abutment 
means at a front end of each of the incomplete-insertion detector 
portions, which is engageable, when the related terminal lug is in 
incompletely-inserted position, with a second abutment means on the 
related support piece so that the incomplete-insertion detector portion is 
prevented from entering the space, and which is not engageable, when the 
related terminal lug is in fully-inserted position, with the second 
abutment means so that the incomplete-insertion detector portion is 
allowed to enter the space, and that the continuity-test surface is 
brought into contact with the related terminal lug in locked position, 
wherein the first abutment means comprises a tapered driving surface and 
the second abutment means comprises a corresponding tapered driven 
surface, the tapered driving surface being tapered such that, on contact 
with the tapered driven surface, it causes the driven surface and thus the 
support piece to be resiliently displaced inside the space. 
In the invention as recited above, if a terminal lug is in 
incompletely-inserted position in the connector since the 
incomplete-insertion detector portion of the inspection pin abuts against 
the resiliently-displaced end of the support piece and is prevented from 
entering the resilient-displacement allowing space adjacent the support 
piece, the continuity-test surface of the inspection pin does not come 
into contact with the terminal lug, resulting in the inspection electric 
circuit maintained unconnected. 
Preferably, the first abutment means comprises a tapered driving surface 
and the second abutment means comprises a corresponding tapered driven 
surface, the tapered driving surface being tapered such that, on contact 
with the tapered driven surface, it causes the driven surface and thus the 
support piece to be resiliently displaced inside the space. 
In this way, on abutment of the first abutment means against the second 
abutment means, the latter always receives a force whereby it is 
resiliently displaced inside the space to close the same, thereby to 
securely prevent the advancement of the inspection pin into the space. 
Consequently, it is prevented that the inspection pin is forcibly pushed 
into the space to possibly give damages to the support piece and/or 
terminal lug. 
According to another aspect of this invention, there is provided a 
connector which comprises: a housing; a plurality of 
terminal-accommodating chambers formed in the housing, with terminal lugs 
inserted in the terminal-accommodating chambers to be locked therein, each 
of the terminal-accommodating chambers containing a resilient cantilever 
support piece and a space adjacent the support piece inside which the 
support piece is resiliently displaced while being contacted and pressed 
by the related terminal lug; and an abutment means on each of the support 
pieces engageable, when the related terminal lug is in 
incompletely-inserted position, with a corresponding abutment means at a 
front end of an incomplete-insertion detector portion of a related 
inspection pin of an inspection device for connectors, so that the 
detector portion is prevented from entering the space. 
In the invention as recited above, since the resilient support piece is at 
the front end provided with abutment means engageable, when the terminal 
lug is in incompletely-inserted position, with the incomplete-insertion 
detector portion of the inspection device for connectors, the advancement 
of the detector portion into the space adjacent the support piece is 
securely prevented when the terminal is in incompletely-inserted position, 
thereby excluding errors in inspection of connectors. 
The above and other objects, features and advantages of this invention will 
become apparent from the following description and the appended claims, 
taken in conjunction with the accompanying drawings in which like parts or 
elements are denoted by like reference characters.

DESCRIPTION OF THE PREFERRED EMBODIMENT 
Embodiments of this invention will now be described with reference to the 
attached drawings. 
Referring to FIGS. 1 to 6, an inspection device A includes a mount plate 1, 
a stationary wall 2 with a wire outlet 2a which is upright at one side of 
mount plate 1, and an inspection main body 3 movably provided at the side 
of mount plate 1 opposite stationary wall 2. Inspection main body 3 is 
synchronized to move towards and away from stationary wall 2 when an 
operation lever 5 is rotated about a shaft 4 thereof. 
A connector support 6 is provided between stationary wall 2 and inspection 
main body 3. Connector support 6 includes a connector-accommodating 
chamber 6a which is opened upwardly and at the side towards inspection 
main body 3. Connector support 6 has a wire outlet 6b at the side towards 
stationary wall 2. Guide rods 7 extend from stationary wall 2 to inside 
connector support 6, and connector support 6 is normally urged towards 
inspection main body 3 by coil springs 8 around respective guide rods 7. 
Connector support 6 is against coil springs 8 moved in the opposite 
direction when pressed by inspection main body 3 (FIG. 4). 
A connector B is received from above into connector support 6, with wires 
W1 at the rear end of connector B passed through wire outlets 6b and 2a 
(FIGS. 2, 3 and 4). 
Inspection main body 3 has a plurality of inspection terminals 10 provided 
therein in correspondence with a plurality of terminal-accommodating 
chambers 9 formed in the housing 20 of connector B, each of the inspection 
terminals 10 containing a slidable pin 11 normally urged into a front 
inspection chamber 13 by a coil spring 12. 
As shown enlarged in FIGS. 5 and 6, inspection pin 11 is at the front end 
provided with an inspection member 11' having a continuity-testing surface 
11a and an incomplete-insertion detector portion 11b extending forwardly 
at one side of the continuity-testing surface 11a. Detector portion 11b 
has a tapered driving surface 11c formed at the outside of its front end. 
A resilient support piece 14, which is contained in each of the 
terminal-accommodating chambers 9, is provided at the front end with a 
corresponding tapered driven surface 14c (FIG. 6) parallel to driving 
surface 11c. Each of the inspection terminals 10 is connected via a lead 
wire W2 to a checker (not-shown). 
The inspection of a connector with the inspection device A will now be 
described. 
To perform the inspection, after mounting connector B into connector 
support 6, operation lever 5 is rotated to advance inspection main body 3 
until inspection chamber 13 receives a front portion of connector B 
therein and inspection member 11' contacts a female terminal lug C (FIG. 
7). 
Referring to FIG. 7, the terminal lug C in the lower terminal-accommodating 
chamber 9 of connector B is fully inserted, so that a resilient cantilever 
support piece 14 has restored its original position, with its locking 
projection 14a located in an engagement hole 15 in the terminal lug C, 
while the terminal lug C in the upper chamber 9 is incompletely inserted, 
so that support piece 14 is in contact with and resiliently displaced or 
deflected by the terminal lug C. 
In the case in FIG. 7, in the lower terminal-accommodating chamber 9, since 
the incomplete-insertion detector portion 11b of inspection pin 11 
advances into a resilient-displacement allowing space 16 adjacent the 
support piece 14, the continuity-testing surface 11a contacts the terminal 
lug C to close the inspection electric circuit. 
On the other hand, in the upper terminal-accommodating chamber 9, the 
incomplete-insertion detector portion 11b of inspection pin 11 abuts 
against the end of the resiliently displaced support piece 14 and is 
prevented from entering the space 16, so that the continuity-testing 
surface 11a is kept apart from the terminal lug C'. Consequently, 
continuity is not made in the inspection electric circuit, and the 
terminal lug C' is found by the checker as incompletely inserted. 
In abutment of detector portion lib and support piece 14 at their opposing 
ends, tapered driving surface 11c contacts the correspondingly tapered 
driven surface 4c in such manner as resiliently displaces the support 
piece 14 towards the space 16 to close same and to securely prevent the 
detector portion 11b from entering the space 16. Thus, it is most unlikely 
that an unsatisfactory product is erroneously found as a good one. 
FIG. 8 shows another embodiment of this invention in which a step 17 is 
formed inside a terminal-accommodating chambers 9' in the connector 
housing 20' for locking a terminal lug in place, and a resilient 
cantilever support piece 18 is provided on the side opposite step 17, the 
support piece 18 having at the front end a tapered driven surface 18a. 
In this embodiment, terminal lug C is engaged with step 17 to be locked in 
fully-inserted position in the upper chamber 9', and maintained in this 
position by its contact with support piece 18 through which terminal lug C 
is pressed downwardly against a bottom wall of the upper chamber 9'. In 
the lower chamber 9', terminal lug C' is in incompletely-inserted 
position, with its shoulder portion 19 riding on step 17, and the support 
piece 18 has not yet returned to its original position. Thus, 
incomplete-insertion detector portion 11b of inspection pin 11 can enter 
the resilient-displacement allowing space 16 in the upper chamber 9' where 
terminal lug C is in fully-inserted position, but cannot enter the space 
16 in the lower chamber 9' where terminal lug C' is in 
incompletely-inserted position, because in the latter case the driving 
surface 11c of detector portion 11b abuts against driven surface 18a at 
the end of the support piece 18, so that no continuity will be detected. 
Referring to FIG. 9, an incomplete-insertion detector portion 11b is at 
opposite sides of its end surface (abutment surface) 11b1 provided with 
driving pieces 11d, each having a tapered driving surface 11c' protruding 
from the plane in which end surface 11b1 lies. The locking projection 14a 
of the resilient support piece 14' to be provided in 
terminal-accommodating chambers 9" in a connector housing 20"(FIG. 10) is 
at opposite sides of its front end provided with driven pieces 14d, each 
having a driven surface 14c' 
Referring to FIG. 10, a male terminal lug D is in fully-inserted position 
in the upper terminal-accommodating chamber 9" of connector B", with 
locking projection 14a of support piece 14' being located inside an 
engagement hole 15' in terminal lug D to allow support piece 14' to 
restore its original position. The male terminal lug D' is in 
incompletely-inserted position in the lower terminal-accommodating chamber 
9" and presses against locking projection 14a to resiliently displace 
support piece 14' to close space 16. 
If connector B" is inspected in the same manner as described in connection 
with FIG. 7, in the upper chamber 9", incomplete-insertion detector 
portion 11b of inspection pin 11 advances into the resilient-displacement 
allowing space 16 adjacent support piece 14', thereby allowing the 
continuity-test surface 11a to contact terminal lug D to make continuity 
in the inspection electric circuit. 
On the other hand, in the lower chamber 9", with terminal lug D' being in 
incompletely-inserted position, the advancement of inspection pin 11 is 
prevented, and the continuity-test surface 11a is maintained apart from 
terminal lug D', so that insufficient insertion will be indicated by the 
checker. In other words, incomplete-insertion detector portion 11b and 
support piece 14' abut against each other, with their end surfaces 11b1 
and 14b1 as well as their driving and driven surfaces 11c' and 14c' 
brought into contact with each other. In this instance, suppose the force 
with which inspection pin 11 presses support piece 14' is F, components F1 
and F2 will act on the driven surface 14c', the former being parallel to 
the driven surface 14c' and the latter perpendicular thereto. Of these, 
component F1 is negligible because the driven surface 14c' is of small 
coefficient of friction, and thus, support piece 14' receives as a whole 
the component F2 whereby it is resiliently displaced inside the 
resilient-displacement allowing space 16, so that the entrance of 
incomplete-insertion detector portion 11b into the space 16 is securely 
prevented. Therefore, an error in inspection will be precluded. 
The component F2 as mentioned above may be construed as a composition of a 
component F1' acting in an axial direction of the front portion 14a of 
support piece 14' and a component F2' acting perpendicular thereto. 
Accordingly, when inspection pin 11 is pressed against the resilient 
support piece 14', to the front end portion 14a is applied a force acting 
in a direction along an axis of the front end portion 14a so as to least 
damage the same, while support piece 14' is as a whole pressed inside the 
resilient-displacement allowing space 16 by the perpendicular component 
F2'. 
Further, in the lower terminal-accommodating chamber 9" in FIG. 10, suppose 
that the male terminal lug D' is at a slightly retreated position as 
indicated by a two-dotted line, causing support piece 14' to be halfway 
deflected, and that inspection pin 11 is coming in this condition. In this 
case, too, since the driving surfaces 11c' at opposite sides of the front 
end of inspection pin 11 abut against the driven surfaces 14c' at the end 
of support pieces 14' to pick up and displace support piece 14' inside 
space 16, the entrance of inspection pin 11 will be securely prevented. 
Thus, while a terminal lug is being in incompletely-inserted position, 
incomplete-insertion detector portion 11b of inspection pin 11 is 
prevented from being unintentionally forcibly pushed into the 
resilient-displacement allowing space, thereby to prevent damages or 
distortions to the resilient support piece 14. 
Having now fully described the invention, it will be apparent to one of 
ordinary skill in the art that many changes and modifications can be made 
thereto without departing from the spirit and scope of the invention as 
set forth herein.