Abstract:
A contact insertion device comprises an arrangement of elements the like of independent linear multi axis actuator providing positioning and fixation for electrical connection element and cylindrical elongated electrical conductor article having a wire electrically attached to one end with opposite end being positioned in collinear fashion adjacent to an insulator cavity preselected by computer controlled enunciation and installed manually or by another linear actuator into pre selected cavity of electrical connection element. A further independent linear actuator provides a test element connected to an enunciation element for verification of error free installation of conductor article into electrical connection element. Aforesaid independent actuators are being initiated by a controller having a computer assigned that is driven by an algorithm and feed back system capable of programmed selection for positioning and verification of non error completion for installation of electrical conductor article.

Description:
RELATED APPLICATIONS  
       [0001]     This application claims the priority date of prior filed applications having Ser. No. 60/750,021 and filing date of Dec. 13, 2005 and entitled: Device for Insertion of Contacts into Connector Insulator Cavities. 
     
    
     INCORPORATION BY REFERENCE  
       [0002]     Applicant(s) herein incorporate by reference, any and all U.S. patents and U.S. patent applications cited or referred to in this application.  
       BACKGROUND OF THE INVENTION  
       [0003]     1. Field of Invention  
         [0004]     This invention relates generally to contact assembly into connector in particular to an automated contact insertion device including the arrangement of elements to provide independent linear actuators in multi axis to automatically position a contact crimped to a wire including visual enunciation of contact location and insert contact into an insulator cavity of a connector. A test pin will automatically verify that the contact has been inserted into the correct and for this contact designated insulator cavity.  
         [0005]     2. Background  
         [0006]     Connectors are usually the termination elements of a cable and harness. Harnesses are a combination of cables bundled together with their end points or connectors interconnecting with other connectors for the purpose to transmit electric current or signals to respective elements such as power supplies, computers, control instrumentation and the like. Harnesses are used in many different applications ranging from airplanes, automobiles, televisions, machinery and the like. Harnesses can be very small but also very extensive in size and number of connectors. A common connector comprises a shell encircling an insulator thereof equipped with numerous contacts inserted and locked into. Aforesaid contacts are permanently connected with a wire that is conducting electric current. The connection with the contact can be a crimped connection or a soldered connection depending on the application the harness is being used for. Each connector can carry a small number of contacts but usually carries an extensive number of contacts confined within a single insulator. Consequential aforesaid necessitates a very small distance of each individual contact from each other within the periphery of a single insulator. Aforesaid is expressed in common terms as of high density. High density in connecting devices has become the norm as it is very desirable to achieve a compact or smallest in size design of applicable devices for the purpose to reduce cost and promote efficiency in terms of optimum performance. The common method for inserting contacts permanently attached to a wire is by manual method. This comprises an elaborate and very skillful process involving a trained assembler carefully comparing cavity location with contact identification in a connector for inserting carefully the contact into a designated location. Foresaid process is cumbersome and of low reliability meaning that each individual contact has been inserted in its designated cavity of insulator without error. Error recovery comprises a costly repair process. There can be up to 60 cavities over the area equivalent to one square inch with each cavity designated to a specific contact in a high-density connector. Said high density necessitates an elaborate and time-consuming verification process after the final insertion of contact into the cavity of insulator. It is well known that the cost to manufacture harnesses comprises a major portion of the total cost to manufacture specific equipment. Aforesaid especially is of significance for avionics such as airplanes and the like. An automated contact insertion device with an automated post verification process will greatly reduce the time element for completion of contact assembly and additionally will negate the need for highly skilled assembly technicians and guarantee zero defects hence a very costly repair process.  
         [0007]     3. Description of Related Art  
         [0008]     The following art describes the present state of this field:  
         [0009]     There are numerous US patents describing the making and assembly of electrical harnesses including automated feeding of contacts to the insertion process into cavities of connector insulator and automated routing of wires and automated stripping of wire insulation prior to the automated crimping of bare wire termination with contact. U.S. Pat. No. 5,590,576 describes the feed mechanism for connectors to be assembled with contacts whereas the wire terminations are crimped with contact crimp barrel either prior contact insertion or after contact insertion. Connectors are of many different sizes and carry contacts of much different size, numbers in many different array or layout arrangement of insulator. It is common to find in especially high density connectors that each individual cavity within one layout has each contact assigned to a particular cavity which commonly is identified by a number silk screened onto surface of insulator immediately adjacent to the specific cavity location. A color code on wire is assigned to a specific cavity location hence number, which has to be verified, searched for prior to the contact insertion process. Referenced patent above fails to teach a method which includes aforesaid in its specifications. U.S. Pat. No. 5,933,932 describes an apparatus for making electrical harness including a wire harness transport assembly. Said patent does not teach the automated location of cavity in insulator with matching contact color code and subsequent automated insertion process including an automated test for verification of correct contact to cavity match. U.S. Pat. No. 515,9749 discloses a harness making machine to process the wires to a desirable array of fixed and spaced wires, such as the wires can be further processed into harnesses the like of wires are placed into crimping machines to electrically connect the wires with the electrical connector. Aforesaid process does not teach selective assignment of electrical wire connection to electrical connector and insulator cavity respectively which is essential to many multi purpose and high density connectors to enable to transmit many various current, voltage and signals within a single connector. Within the periphery of said connector there may be terminating a large number of wires with each wire assigned to a discrete termination element thereof required to perform a specific function.  
       SUMMARY OF INVENTION  
       [0010]     The present invention teaches certain benefits in construction and use, which give rise to the objectives described below.  
         [0011]     In the preferred embodiment of the invention, then the contact insertion device comprises an arrangement of elements the like of independent linear multi axis actuator providing positioning and fixation for electrical connection element and cylindrical elongated electrical conductor article having a wire electrically attached to one end with opposite end being positioned in collinear fashion adjacent to an insulator cavity preselected by computer controlled enunciation and mated manually or by another linear actuator to pre selected cavity of electrical connection element. A further independent linear actuator provides a test element connected to an enunciation element for verification of error free mating of conductor article to electrical connection element. Aforesaid independent actuators are being initiated by a controller having a computer assigned that is driven by an algorithm and feed back system capable of selective positioning thereof and verification of non error completion of mating process.  
         [0012]     A primary objective of one embodiment of the present invention is to provide an apparatus and method of use of such apparatus that yields advantages not taught by the prior art.  
         [0013]     It is an objective of the invention then to design a contact insertion apparatus, which will selectively and automatically match contacts with the appropriate cavity within the insulator of an electrical connector.  
         [0014]     A still further objective is to assure that an embodiment of the invention is to provide an adapter for universal and quick location of electric connection elements having various layouts for electric conducting articles to be mated.  
         [0015]     A still further objective is to assure that an embodiment of the invention is to provide an adapter for universal and quick location of electric connection elements having various clocking positions in relation to layout for electric conducting articles to be mated.  
         [0016]     A still further objective is to assure that an embodiment of the invention is to provide an automated enunciation and diagnostics capability for error recovery immediately at post insertion.  
         [0017]     A still further objective is to assure that an embodiment of the invention is to provide the testing of electric conducting article with a test probe automatically.  
         [0018]     A still further objective is to assure that an embodiment of the invention is capable to adjust the test probe automatically to provide proper electric conductance with electric conducting article to the various height in horizontal plane of electric connection element for referencing and verification.  
         [0019]     A still further objective is to assure that an embodiment of the invention is capable to process certain input information into processor with the objective to quickly and automatically match electric connection element with proper electric conducting article.  
         [0020]     A still further objective is to assure that an embodiment of the invention Is conceived to present advantages over other inventions for a contact insertion apparatus with one advantage providing the ability to readily change a preferred configuration to another preferred configuration done and completed by the end user of this invention.  
         [0021]     Other features and advantages of the embodiments of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by the way of example, the principles of at least one of the possible embodiments of the invention.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0022]     The accompanying drawings illustrate at least one of the best mode embodiments of the present invention. In such drawings:  
         [0023]      FIG. 1  is a perspective view of a preferred embodiment of present invention of a contact insertion and testing device;  
         [0024]      FIG. 2  is another perspective and exploded view of a preferred embodiment of present invention of a contact insertion and testing device;  
         [0025]      FIG. 3  is a perspective and exploded view of a preferred embodiment of present invention of a contact insertion and testing device with a sectional cutout view;  
         [0026]      FIG. 4  is a partial perspective and exploded view of a preferred embodiment of present invention;  
         [0027]      FIG. 5  is another partial and perspective and exploded view of a preferred embodiment of present invention;  
         [0028]      FIG. 6  is another partial and perspective and exploded view of a preferred embodiment of present invention;  
         [0029]      FIG. 7  is a cross sectional view of a preferred embodiment of present invention taken along lines  7 - 7  respectively in  FIG. 1   
         [0030]      FIG. 8  is a perspective view of a preferred embodiment of present invention of a contact insertion and testing device showing peripheral control devices;  
         [0031]      FIG. 9  is a process flow diagram of a preferred embodiment of present invention of a contact insertion and testing device;  
         [0032]      FIG. 10  is a signal communication hierarchy of a preferred embodiment of present invention of a contact insertion and testing device;  
         [0033]      FIG. 11  is a perspective view of a preferred embodiment of present invention of a contact insertion and testing device showing peripheral control devices;  
         [0034]      FIG. 12  is a front elevation view of a contact having a color marking and wire electrical attached having a color marking;  
         [0035]      FIG. 13  is a front elevation view of a contact having a numeric marking and wire electrical attached having a color marking;  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0036]     The above-described drawing figures illustrate the present invention in at least one of its preferred, best mode embodiments, which are further, defined in detail in the following description. Those having ordinary skill in the art may be able to make alterations and modifications in the present invention without departing from its spirit and scope. Therefore it must be understood that the illustrated embodiments have been set forth only for the purposes of example and that they should not be taken as limiting the invention as defined in the following.  
         [0037]      FIG. 1  shows female connector  46  with assembled insulator  57  mounted into clocking insert  38  and mounting bracket  32 , which is fastened onto upright  34 . Locator pin  36  warrants proper clocking of insert  38 . Underneath mounting bracket  32  is 2 axes horizontal positioning table  19  thereof easily to be obtained in commerce. Stepper or servomotor  16  moves the mounting table  25  in the x-axis linear direction and stepper or servomotor  73  moves the mounting table  25  in a y-axis linear direction. Motor  73  and  16  respectively is connected to controller  58  with plurality of line  68  enabling motor  73  and  16  respectively to position mounting table  25  in various positions within the boundary or work envelope maximized due to travel length for x and y axis respectively. The pre selected or preprogrammed positions as a function of x-axis value and y-axis value or coordinates are limited in number by the resolution or minimum increments per each individual coordinate. Dwell time per position is programmable or event driven. Upper extremity of mounting table  25  is having base plate  27  and platform  20 . Base plate  27  supports vertically mounted plurality of bar  21 . Platform  20  straddles plurality of bar  21  and slides along the vertical plane in reciprocating fashion. Servo or stepper motor  22  is mounted on platform  20  and connected to controller  58  with plurality of line  68  enabling motor  22  to position mounting plate  23  in various position along z axis. Plurality of linear bearing  26  straddling plurality of bar  21  is providing precision movement of mounting plate  23 . Limit switch  28  is fixated on mounting plate  23  as such that wiper arm  30 A of micro switch  28  is below of and collinear with test pin  30 . Limit switch  28  is connected with controller  58  via plurality of line  68 . Test pin  30  is held in vertical plane by fixture  31 . Base plate  71  supports upright column  17  having adjustment clamp  52 . Laser beam generator  50  is held in a permanent position coaxial with test pin  30  by swivel bracket  54 , placed atop of clamp  52 . Setscrew  64  holds swivel bracket  54  in position setting against stop pin  56 . If necessary a laser beam generated by generator  50  thereof controlled by controller  65  is able to illuminate cavity positions of insulator  57 . Aforesaid is the enunciation required for an operator to insert contact  57  into the cavity illuminated.  
         [0038]      FIG. 2  is another embodiment of this invention. Respectively it shows a three-dimensional and exploded view of the complete contact insertion device. All elements as labeled otherwise are referenced in  FIG. 1 .  
         [0039]      FIG. 3  is another perspective and exploded of this invention including a cut away view of mounting bracket  32 . This shows the relative position of test pin  30  in consideration to mounting bracket  32  and limit switch  28  and wiper blade  30 A respectively. It also shows connector  46  and clocking insert  38  in an exploded view above mounting bracket  32 . All elements as labeled otherwise are referenced in  FIG. 1 .  
         [0040]      FIG. 4  is a perspective and exploded view of a portion of my contact insertion device. It shows more explicatively z-axis linear actuator  22  with lead screw  22 A and thrust bearing  24 . It also shows height adjustment pins  18  in relation to platform  20 . The height adjustment pins  18  are interfacing with holes provided in plurality of bar  21  as such locking platform  20  in vertical plane. The purpose of aforesaid is to increase the work envelope of z-axis actuator  22 . A hole provided in platform  20  provides clearance for lead screw extension of z-axis actuator  22  when in retracted position.  
         [0041]      FIG. 5  is a perspective expanded and zoomed view of a portion of the invention. It shows female connector  46  having insulator  57  with clocking insert  40  located and locked over locator pin  32  to assure that connector  46  is positioned properly meshing with clocking pin  38 ,  44 ,  42  with the connector  46  plurality of keyway—not shown—thereof located on inside diameter of outer shell  46 A.  
         [0042]      FIG. 6  is a perspective expanded and zoomed view of a portion of the invention. It shows male connector  45  having insulator  61  with clocking insert  41  located and locked over locator pin  32  to assure that connector  45  is positioned properly meshing with clocking key way  80 ,  81 ,  82 ,  83 ,  84  with connector  45  having keyway  80 A,  81 A,  82 A,  83 A,  84 A located on outside diameter of outer shell  45 A.  
         [0043]      FIG. 7  is a cross section view of connector  46  with inserted plurality of contact  51  into plurality of cavity of insulator  57 . Connector  46  rests atop of clocking insert  38 . Locator pin  44  and  42  respectively is meshing with plurality of key way on inside diameter of connector shell  46 A. Test pin  30  held by bushing  37  and setscrew  35  is in coaxial alignment with inserted contact  51 . Tip thereof is pushing the tip  30 A of test pin  30  downwardly causing the opposite end tip  30 B thereof pushing wiper blade  30 A of limit switch  28  to trigger an electrical signal. At that point contact  51  insertion process is complete.  
         [0044]      FIG. 8  is a perspective view of this invention. In retrospect it shows the final location of female connector  45  with clocking insert  41  in ready position for insertion process of plurality of contact  61 . All elements as labeled otherwise are referenced in  FIG. 1 .  
         [0045]      FIG. 9  shows the process flow diagram of the contact insertion of this invention. Description of this process begins with Step A, locate connector. Referencing to  FIG. 1  connector  46  is selected for insertion of contact  51  referencing to  FIG. 7 . Referencing to  FIG. 7  insulator  57  with plurality of cavity arranged in number and position per an array called the layout. There are a great number of connector types each with insulator having differing layout from each other. Also there are a great number of types of contacts. A code or color band identifies each type of contact. The code is numeric and stamped onto contact  57  referencing to  FIG. 7  or in retrospect the color band is painted onto the contact. In many cases a wire is connected to the contact. The connected wire has also a color marking. Each type of connector  46  referencing to  FIG. 1  has an identification number printed on the outer diameter of connector shell  46 A. This identification number determines also the type of layout for insulator  57  referencing to  FIG. 7 . Step B, Select Layout is the identification process for type of contact  51  referencing to  FIG. 7  to match cavity location of insulator  57  referencing to  FIG. 1 . Step B means the display of a menu on touch screen display  67  of computer  65  referencing to  FIG. 1 . The menu is a touch screen type depicting code  74  embossed on contact  51  referencing  FIG. 15  or color banding  76  painted on contact  51  referencing  FIG. 14  or color marking  72  of wire  70  of contact  51  referencing on  FIG. 14 . Step C in retrospect is the selection of a contact subject to be inserted into insulator  51  referencing to  FIG. 7 . Step D is the identification of the marking such as stamped code  74  referenced on  FIG. 15  or color band  76  of contact  51  referencing to  FIG. 14 . This can be done manually by reading the code or color band of contact  51  referencing to  FIG. 14  and touching the comparable code or color code displayed on touch screen display  67  of computer  65  referencing to  FIG. 1 . In retrospect this will initiate the z-axis mounting plate  23  referencing to  FIG. 1  with limit switch  28  referencing to  FIG. 1  and test pin  30  referencing to  FIG. 7  to adjust to correct height and position x-y positioner table  25  referencing to  FIG. 1  into the appropriate assigned x-y coordinate. In retrospect of laser illuminated cavity of insulator  57  referencing to  FIG. 1  is visual. Step E is the insertion with the in step D identified contacts  57  referencing to  FIG. 1 . Sub routines occurring in retrospect to completion of step D are for verification and corrective action. Specifically a timer activates for timing of the insertion process within an allotted time period. This is to assure that the previously identified contact  57  referencing to  FIG. 1  is being inserted within allotted time delay thus guaranteeing that the proper contact will be in the proper cavity. In retrospect the plunger of test pin  57  referencing to  FIG. 7  will be pushed down by the inserted contact  51  referencing to  FIG. 7  thus causing the test pin  30  referencing to  FIG. 7  opposing end to trigger wiper blade of limit switch  28  referencing to  FIG. 7  to close the timer circuit once contact  51  referencing to  FIG. 7  is properly inserted and thus canceling the timer. Once timing cycle has been cancelled within the specific time increment allowed it is verified that the correct contact  57  referencing to  FIG. 7  has been inserted correctly into the correct cavity of insulator  51  referencing to  FIG. 7 . For corrective action misreading of code or color band will be flagged and corrected at the input level. In retrospect at step E the assigned x-y coordinate to x-y positioner table  25  referencing to  FIG. 1  will match with a specific assigned contact code or color band of contact  51  referencing to  FIG. 7  or color of wire attached to contact  51  referencing to  FIG. 7 . The now positioned x-y positioner table  25  referencing to  FIG. 1  has been encoded to its coordinate accepting only the to this coordinate assigned contact  57  referencing to  FIG. 1 .  
         [0046]      FIG. 10  is a matrix showing the protocol how the layout for cavity locations of insulator  57  referencing to  FIG. 1  is communicated via controller  58  referencing to  FIG. 1  to x-y positioning table  25  referencing to  FIG. 1  and z axis actuator  22  referencing to  FIG. 1 . for matching cavity location of insulator  57  referencing to  FIG. 1  for contact  51  referencing to  FIG. 7 . Step G is the input of part number for connector to be ready for contact insertion. Input device  65  referencing to  FIG. 1  is a computer connected with controller  58  referencing to  FIG. 1 . The input part number will initiate the computer  65  referencing to  FIG. 1  to down load via code the layout information to controller  58  referencing to  FIG. 1  which in turn will initiate the z-axis actuator  22  referencing to  FIG. 1  to position mounting plate  23  referencing to  FIG. 1  into proper height or z-position. Step H is being implemented simultaneously to step G, the input part number will initiate the computer  65  referencing to  FIG. 1  to down load via code the layout information to controller  58  referencing to  FIG. 1  which in turn will initiate the x-y axis table positioner  25  referencing to  FIG. 1  to recognize proper cavity locations in x-y coordinate according to layout for insulator  57  referencing to  FIG. 1 . Step  1  is the complete association for all cavity locations for insulator  57  referencing to  FIG. 1  to contact  51  referencing to  FIG. 7  for positioning of positioner table  25  referencing to  FIG. 1  upon command for contact insertion.  
         [0047]      FIG. 11  shows female connector  46  with assembled insulator  57  mounted into clocking insert  38  and mounting bracket  32 , which is fastened onto upright  34 . Locator pin  36  warrants proper clocking of insert  38 . Underneath mounting bracket  32  is 2 axes horizontal positioning table  19  thereof easily to be obtained in commerce. Stepper or servomotor  16  moves the mounting table  25  in the x-axis linear direction and stepper or servomotor  73  moves the mounting table  25  in a y-axis linear direction. Motor  73  and  16  respectively is connected to controller  58  with plurality of line  68  enabling motor  73  and  16  respectively to position mounting table  25  in various positions within the boundary or work envelope maximized—due to travel length for x and y axis respectively. The pre selected or preprogrammed positions as a function of x-axis value and y-axis value or coordinates are limited in number by the resolution or minimum increments per each individual coordinate. Dwell time per position is programmable or event driven. Upper extremity of mounting table  25  is having base plate  27  and platform  20 . Base plate  27  supports vertically mounted plurality of bar  21 . Platform  20  straddles plurality of bar  21  and slides along the vertical plane in reciprocating fashion. Servo or stepper motor  22  is mounted on platform  20  and connected to controller  58  with plurality of line  68  enabling motor  22  to position mounting plate  23  in various position along z axis. Plurality of linear bearing  26  straddling plurality of bar  21  is providing precision movement of mounting plate  23 . Limit switch  28  is fixated on mounting plate  23  as such that wiper arm  30 A of micro switch  28  is below of and colinear with test pin  30 . Limit switch  28  is connected with controller  58  via plurality of line  68 . Test pin  30  is held in vertical plane by fixture  31 . Base plate  71  supports upright column  17  having adjustment clamp  52 . Z-axis servo actuator  63  is held in an adjustably permanent position by swivel bracket  54 , which sits atop of clamp  52 . Setscrew  64  holds swivel bracket  54  in position setting against stop pin  56 . The output shaft of servo actuator  63  positions a gripper  62  with contact  51  coaxial with cavity of insulator  57 . A signal from controller  58  via lines  68  will initiate z-axis movement of output shaft of servo actuator  63  and insert contact  51  into appropriate cavity of insulator  57 . Aforesaid embodiment of this invention enables automated insertion for contact  51  into plurality of cavity of insulator  57 .  
         [0048]      FIG. 12  is depicting contact  51  having  3 -color band  76  and crimp area  74  for wire  70 . On insulation of wire  70  color marking  72  is shown.  
         [0049]     Certain applications are using contacts wherewith the color marking may be substituted with a numeric code as is shown on  FIG. 13  depicting contact  51  having embossed code  75  and crimp area  74  for wire  70 . On insulation of wire  70  color marking  72  is shown.  
         [0050]     The enablements described in detail above are considered novel over the prior art of record and are considered critical to the operation of at least one aspect of one best mode embodiment of the instant invention and to the achievement of the above described objectives. The words used in this specification to describe the instant embodiments are to be understood not only in the sense of their commonly defined meanings, but to include by special definition in this specification: structure, material or acts beyond the scope of the commonly defined meanings. Thus if an element can be understood in the context of this specifications as including more than one meaning, then its use must be understood as being generic to all possible meanings supported by the specifications and by the word or words describing the element.  
         [0051]     The definitions of the words or elements of the embodiments of the herein described invention and its related embodiments not described are, therefore, in this specifications to include not only the combination of elements which are literally set forth, but all equivalent structure, material or acts for performing substantially the same function in substantially the same way to obtain substantially the same result. In this sense it is therefore contemplated that an equivalent substitution of two or more elements may be made for any one of the elements in the invention and its various embodiments or that a single element may be substituted for two or more elements in a claim. Changes from the claimed subject matter as viewed by a person with ordinary skill in the art, not known or later devised, are expressly contemplated as being equivalents within the scope of the invention and its various embodiments. Therefore, obvious substitutions now or later known to one with ordinary skill in the art defined to be within the scope of the defined elements. The invention and its various embodiments are thus to be understood to include what is specifically illustrated and described above, what is conceptually equivalent, what can obviously substituted, and also what essentially incorporates the essential idea of the invention.  
         [0052]     While the invention has been described with reference to at least one preferred embodiment, it is to be clearly understood by those skilled in the art that the invention is not limited thereto. Rather, the scope of the invention is to be interpreted only in conjunction with the appended claims and it is made clear, here, that the inventor believes that the claimed subject matter is the invention.