Abstract:
The electrical pin installation apparatus provides a user with a real time video display of the process of pinning an electrical connector body. Such real time video display substantially improves the user&#39;s ability to accurately and effectively install electrical pins into electrical connectors without the attendant electrical test equipment and fixturing of prior art devices. The apparatus assists in the pinning process by providing various prompts and guides to guide the user in error-proof pin installation. The apparatus further includes built-in electrical pin insertion and retention load assessment to assure proper insertion and retention loads are applied during the pin installation process. Additionally, the apparatus may include storage of manufacturing data as it is inputted into the apparatus.

Description:
CROSS-REFERENCED RELATED APPLICATIONS 
     This patent application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/027,460 that was filed on Feb. 9, 2008, for an invention titled APPARATUS FOR ELECTRICAL PIN INSTALLATION AND RETENTION CONFIRMATION. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to guided insertion of electrical pins into electrical connectors and to retention confirmation of such electrical pins. In particular, the invention relates to an improved apparatus for guided pin insertion that assists in assuring a correctly “pinned” electrical connector. 
     2. Description of the Related Art 
     The proper insertion of electrical pins into electrical connector bodies is often a tedious and time consuming process requiring significant manual dexterity and long-term concentration, both being highly error prone. A single “mis-wire” can have catastrophic consequences for the down-stream user of the resultant wiring harness. 
     Accordingly, it is known in the art to provide pin insertion assistance devices for use in properly “pinning” or inserting pins in corresponding electrical connectors. Specifically, the following list of U.S. patents and applications disclose inventions related to pinning devices and each is incorporated herein by this reference: U.S. Pat. Nos. 4,658,212, 4,658,503, 4,757,606, 4,787,138, 4,803,778, 4,864,718, 4,947,546, 4,949,451, 5,083,370, 5,689,191, 6,116,935, 6,447,346, 6,489,780, 6,799,370, 6,989,895, 7,243,415, 7,270,565, 20060185158, and 20070277372. However, such devices do not provide the advantages of the embodiments of the present invention. Such embodiments significantly reduce or eliminate mis-wiring errors and visually aide pin placement with proper insertion and retention force. 
     SUMMARY OF THE INVENTION 
     The present invention is an apparatus for the guided or assisted insertion of electrical connector pins into a proper corresponding electrical connector body cavity, and for the confirmation of retention of such electrical connector pins. The apparatus comprises a pinning station with a mounting device having clamping jaws for holding an electrical connector body and a two-way load-detecting device having a load cell, a video camera, one or more input devices, a computer, and one or more output devices such as a video display screen. 
     The load cell is in electrical communication with the computer such that detected loads are transmitted to the computer. This electrical communication, and any other electrical communication decribed herein, can be of any suitable type known in the art whether hard wired or wireless. 
     The camera is adjustably mounted to the holding device such that the camera may be manipulated to have a line of sight to the mounting device, whether the line of sight is direct or indirect. The camera is further in electrical communication with the computer such that a signal is provided to the computer. The camera may be of any suitable type, however, a video camera that provides a real time video signal is preferred. 
     Each input device is also in electrical communication with the computer such that input signal(s) can be provided to the computer. Any of a number of known input devices can be used either alone or in combination with one or more of the input devices. Examples of input devices that can be used include, but are not limited to, a keyboard, a camera, a number key pad, any type of code reader such as a bar code reader, a color reader, an optical scanner, a microphone, a voice recognition device, any type of pointing device such as a mouse, a track ball, or a joy stick, and a cable tester. 
     The computer is in electrical communication with each output device. Any of a number of known output devices can be used either alone or in combination with one or more of the output devices. Although it is preferred that at least a monitor with a video display screen for displaying real time video be included among the output devices used, examples of other output devices include, but are not limited to, audio speakers, a colored light, a laser, a vibrating device, a voice synthesizer and a buzzer. 
     In a preferred embodiment, the computer is programmed such that an overlay of a historical image of the electrical connector body is shown overlaid on an actual real time video of the electrical connector body in a manner to be more fully described hereinafter. This overlay is adjustable to determine the degree of the overlay so that the user is able to ignore or not be distracted by obstructions. For example, a portion of the actual real time video may be adjusted so that obstructions such as the user&#39;s hand or other already placed pins fade into shadow or are removed so that the user can see the proper cavity for insertion without these obstructions. 
     In practice, an electrical connector body is mounted in the clamping jaws, centered, and oriented in preparation for pin placement. This centering and orientation can be aided by a visual depiction of at least two pin cavities on the video display screen for the user to align with the electrical connector body. The computer determines the alignment pin cavities after receiving input information from an input device regarding the type of electrical connector body for which pin placement is to be performed. The computer may have preprogrammed information about multiple types of electrical connector bodies in its memory or in an accessible database. 
     Each electrical connector body has cavities designed to receive insertable members and retain them for use as an electrical connector in an electric system. These insertable members may be any of a number of types of electrical wires with pin ends, optical fiber ends, or seal plugs. The seal plugs are used to close/cover unused cavities to prevent moisture or debris from entering the unused cavity and compromise the electrical connection. 
     To assist in the pin placement process, real time video of the electrical connector body is displayed on the video display screen. The real time video magnifies the image of the connector body so that user can better see what is transpiring during pin installation. Information displayed on the video display screen can also provide other instructions or aides to assist the user in the pin placement process. 
     Once the electrical connector body is properly positioned within the clamping jaws, the electrical connector body is ready for the insertion of an insertable member. The user may select an insertable member for insertion. Each insertable member typically has an identifying indicia that identifies the insertable member. This identifying indicia may take one or more forms such as wire insulation color, a bar code, an alpha-numeric code, and/or a scanable code. This identifying indicia is inputted to the computer to enable the computer to recognize the insertable member the user desires to insert. 
     The computer is programmed to receive input of the identifying indicia from the insertable member via the input device. A program within the computer identifies the cavity corresponding to correct pin placement for that insertable member and highlights the proper cavity on the video display screen. Additionally, the display may also provide a substantially enlarged view of the electrical connector body. As compared to the actual size of the electrical connector body, this enlarged view provides a magnification of the video in the immediate area for the insertion. Thus, an operator is readily able to see in real time an enlarged view of the pin insertion process which significantly aids in the proper pin insertion. 
     In embodiments where a video display screen is not used, the computer signals some other type of output device to identify the proper cavity, for example, the cavity may be highlighted by a light or laser beam. 
     In the event that an insertable member does not have identifying indicia, a cable tester can be used to identify the insertable member and transmit that identification to the computer. 
     In one embodiment, the computer may be preprogrammed to determine the order in which the insertable members are inserted. This pre-ordering of the installation of the insertable members dictates to the user the order for placement so that installation is orderly and avoids problems where already inserted insertable members may surround and obscure the proper cavity, making it difficult for the user to accomplish proper insertion. 
     The computer may be programmed to detect proper and improper electrical pin insertion through comparing the pixel display of a pin insertion to a predetermined proper pin insertion pixel display. This process is called AOI (i.e., automated optical inspection) and is performed automatically to determine proper or improper pin placement. Further, the computer is programmed to provide an error indicator if the pin is inserted into the incorrect cavity. The error indicator can be any suitable indicator such as, for example, a sound associated with the error that is emitted from the computer and/or a visual error indicator such as the color red displayed over the wrongly selected cavity or any other visual signal. 
     The computer is also programmed to detect the proper and improper application of force during pin installation. An affirmative indicator is provided if the pin is inserted into the correct cavity with the proper amount of force. The affirmative indicator can be any suitable indicator that can be differentiated from the error indicator such as, for example, a sound associated with the correct pin placement that is emitted from the computer and/or a highlight over the correctly pinned cavity in a color such as green or some other visual signal. 
     Upon detecting an insertion load in excess of the proper insertion range, an alarm may be provided. This alarm can be any suitable alarm such as, for example, a visual and/or audible indication that the insertion load is outside the proper range. 
     Similarly, a proper retention load may be detected. Upon detecting a retention load in a proper retention load range, a success acknowledgement signal of any suitable type may be provided to indicate that the pin has been successfully placed and that the next pin can be inserted. This success acknowledgement signal may be, for example, any suitable visual, audible, and/or kinetic acknowledgement. Similar to when excessive insertion force is used, upon detecting a retention load in excess of the proper retention range, an alarm may be provided. This alarm can be the same as the alarm used for excessive insertion force or any suitable alarm such as, for example, a visual and/or audible indication that the retention load is outside the proper range. 
     It is contemplated that proper pin placement can be accomplished using an apparatus that comprises a camera, a device for holding the electrical connector body in the camera&#39;s line of sight, a computer, one or more input devices, and a monitor to visually display output data, without using the load-sensing feature of the present invention. Similarly, it is also contemplated that proper pin placement can be accomplished without using the real time video feature of the present invention. Such an apparatus would use a device for holding the electrical connector body connected to a load sensor, a computer, any of a number of known devices for targeting the proper cavity for pin placement (i.e., an insertion indicator), and an output device to give the user output data relating to the load sensed. 
     Reference throughout this specification to features, advantages, or similar language does not imply that all of the features and advantages that may necessarily be realized with the present invention should be or are in any single embodiment of the invention. Rather, language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an embodiment is included in at least one embodiment of the present invention. Thus, discussion of the features and advantages, and similar language, throughout this specification may, but do not necessarily, refer to the same embodiment. 
     Furthermore, the described features, advantages, and characteristics of the invention may be combined in any suitable manner in one or more embodiments. One skilled in the relevant art will recognize that the invention may be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments of the invention. 
     These features and advantages of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter. 
    
    
     
       DESCRIPTION OF DRAWINGS 
       In order that the advantages of the invention will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which: 
         FIG. 1  is a perspective view of an embodiment of the pin installation apparatus showing a keyboard as an example of an input device; 
         FIG. 2  is a perspective view of the pinning station portion of the pin installation apparatus; 
         FIG. 3  is an exploded perspective view of the pinning station; 
         FIG. 4  is a partially cut-away elevational view of the centering vise assembly portion of the pinning station with the vise shown in a closed position holding an electrical connector; 
         FIG. 5  is a cross-sectional view of the pinning station taken at the location indicated by the section arrows in  FIG. 2 , with some portions of the device not shown and only the load cell shown cross-hatched for clarity; and 
         FIG. 6  is an enlarged view of an exemplary screen display. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment. 
     Furthermore, the described features, structures, or characteristics of the invention may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are included to provide a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention can be practiced without one or more of the specific details, or with other methods, components, or materials. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention. 
     The invention is an apparatus for the guided or assisted insertion of insertable members such as electrical connector pins into a proper corresponding electrical connector body cavity, and for the confirmation of retention of such electrical connector pins. The apparatus comprises a mounting device having clamping jaws for holding an electrical connector body and a two-way load detecting device with a load cell, a camera such as a video camera, one or more input devices, a computer, and one or more output devices such as a video display screen. 
     The load cell electrically communicates with the computer such that detected loads are transmitted to the computer. 
     The video camera is adjustably mounted to a holding device so that the camera can be positioned to have a line of sight to the clamping jaws and an electrical connector body held therein. The video camera also electrically communicates with the computer to provide a video signal to the computer. 
     Each input device electrically communicates with the computer to provide input signal(s) to the computer. 
     The computer electrically communicates with each output device. When the video display screen is used as an output device, real time video can be displayed on the video display screen. In one embodiment, the computer is programmed such that an overlay of an historical image of the electrical connector body is shown overlaid on an actual real time video displayed of the electrical connector body. 
     In order to facilitate an understanding of the present invention in reviewing the drawings accompanying the specification, like features are like numbered throughout all of the figures. 
     Referring generally to  FIG. 1  of the drawings, an embodiment of the invention is a pin installation apparatus  20  comprising a pinning station  30 , a computer  200 , an input device  210  such as the keyboard shown, and an electronic display monitor  220  having a video display screen  230 . 
     As best shown in  FIG. 2 , pinning station  30 , comprises a base assembly  40 , a chassis assembly  60 , a load-sensing assembly  90 , a centering vise assembly  120 , a hand rest assembly  160 , and a camera arm assembly  180 .  FIGS. 1 and 2  each shows an electrical connector body  270 , properly centered and oriented, secured within the centering vise assembly  120  so that the pin cavities  272  are properly oriented. 
     Base assembly  40  (best shown in  FIG. 3 ) further comprises a base plate  42 , a plurality of feet  44 , a lower attach plate  46 , a post  48 , a cap  50 , a thumbscrew  52 , and an upper attach plate  54  having an upper plate arm  56 . Each of the components of base assembly  40  may be fabricated from suitable materials. Feet  44  are preferably fabricated from rubber or like high friction material. Base assembly  40  is assembled such that feet  44  are fastened to base plate  42 , lower attach plate  46  is fastened to base plate  42 , post  48  is attached to lower attached plate  46 , cap  50  is mounted to post  48 , and upper attach plate arm  56  of upper attach plate  54  is swivably mounted to cap  50 . Further, thumbscrew  52  is adjustably connected to cap  50  such that upper attach plate  54  may be positioned and repositioned and then fixed in place by loosening and subsequently tightening thumbscrew  52 . 
     As best viewed in  FIG. 3 , chassis assembly  60  comprises a base plate  62 , a back plate  64 , a first side plate  66 , a second side plate  68 , a top plate  70  having a notch  72 , and a handle  74 . Each of the components of chassis assembly  60  may be fabricated from suitable materials. Chassis assembly  60  is assembled such that base plate  62 , back plate  64 , first side plate  66 , second side plate  68 , and top plate  70  are connected together to form an open box-like structure. Further, the handle  74  is attached to back plate  64  and enables the user to manipulate the position of the chassis assembly  60 . 
     Load-sensing assembly  90 , best shown in  FIGS. 3 and 5 , comprises a standard commercially available load sensor such as a load cell  92 , a threaded spacer  94 , a lever combining washer  96 , a set screw  98 , a load cell support arm  100 , a load-sensing plate  102 , a lower support plate  104 , an upper support plate  106 , and a plurality of load-sensing levers  108 . Each of the components of load-sensing assembly  90  except for load cell  92  may be fabricated from suitable materials. The load cell  92  is constructed in a manner and of materials known in the art. A cross-sectional view of the load-sensing assembly  90  as fully assembled is shown in  FIG. 5 , wherein the load cell  92  is shown cross-hatched. 
     The load-sensing lever  108  is of a generally known configuration that conveys a load applied to the load cell  92  by being flexible in a first direction and yet substantially stiff or inflexible in other directions. Accordingly, load-sensing lever  108  has a predetermined stiffness that facilitates the operation of the load-sensing assembly  90  in a manner known to skilled artisans. 
     The load-sensing assembly  90  is assembled such that threaded spacer  94 , lever combining washer  96 , set screw  98 , and load cell summing tabs  110  of the load-sensing levers  108  are operatively connected to the load cell  92 . The load cell support arm  100  positions and supports the load cell  92 . The load-sensing plate  102  is attached to the load-sensing levers  108 . The lower support plate  104  and upper support plate  106  are also attached to the load-sensing plate  102 . It is noted that threaded spacer  94 , lever combining washer  96 , and set screw  98  are adjustable to adjust the load-sensing assembly  90 . The load-sensing assembly  90  is preferably adjusted such that any resulting gap between the summing tabs  110 , load cell  92 , and lever combining washer  96  is minimized and yet not such that summing tabs  110  bind between load cell  92  and lever combining washer  96 , resulting in a substantially accurate sensing and indication of loading applied to load cell  92  from insertion or retention loads. 
     Referring again to  FIG. 3 , the centering vise assembly  120  comprises a hand crank  122 , a first movable support  126 , a second movable support  136 , a drive mechanism  138 , a first jaw  144 , a second jaw  146 , an upper vise retention bracket  148 , and a lower vise retention bracket  150 . The load sensor (load cell  92 ) functionally communicates with the centering vise assembly  120 , whether mechanically or otherwise, such that a load applied to the centering vise assembly  120  is detected by the load sensor. Each of the components of the centering vise assembly  120  may be fabricated from suitable materials. 
     The centering vise assembly  120  is assembled such that hand crank  122  is connected to the drive mechanism  138  that is supported rotatingly by the first movable support  126  and the second movable support  136 . The first jaw  144  is connected to the first movable support  126 , and second jaw  146  is connected to the movable support  136 . Upper vise retention bracket  148  and lower vise retention bracket  150  are slidingly positioned to retain jaws  144  and  146  in a proper orientation. As the hand crank  122  is operated, the first movable support  126  and the second movable support  136  move towards or away each other at the same rate. This, in turn, moves the second jaw  146  towards or away from the first jaw  144  to center and enable clamping engagement and release from clamping engagement of the electrical connector body  270  within the centering vise assembly  120 . 
     Although the embodiment described and shown utilizes a centering vise assembly  120  having first and second movable support s  126 ,  136 , it is contemplated and a skilled artisan would understand how a different centering vise system could be used. For example, one support could be movable and one fixed or a different configuration could be used. 
     Hand rest assembly  160 , as best shown in  FIGS. 3-5 , comprises a first support arm  162 , a second support arm  164 , a rest plate  166 , and a rest pad  168 . Each of the components of the hand rest assembly  160  may be fabricated from suitable materials. Rest pad  168  is preferably fabricated from a resiliently compressible material. The hand rest assembly  160  is assembled such that first support arm  162  and the second support arm  164  support and suspend the rest plate  166 . The rest pad  168  is secured to rest plate  166 . The hand rest assembly  160  is connected to and supported by chassis assembly  60  and positioned such that an operator of the pin installation apparatus  20  can rest his/her hands on the rest pad  168  without compromising readings being made by the load-sensing assembly  90 . 
     Referring to  FIGS. 1-3 , the camera arm assembly  180  comprises a camera support arm  182  having a first end  184  and a second end  186 , a plurality of camera attachment brackets  188 , and a camera  190 . Although any suitable camera  190  may be used, it is preferred that camera  190  is a standard preferably color universal serial bus (USB) connectable video camera  190 . Each of the components of camera arm assembly  180  may be fabricated from suitable materials. Camera arm assembly  180  is assembled such that brackets  188  are connected to second end  186  of camera support arm  182 , and camera  190  is mounted via the brackets  188 . 
     The pinning station  30  is assembled such that upper attach plate  54  of base assembly  40  is connected to base plate  62  of chassis assembly  60 , with load cell support  100  positioned in top plate notch  72 . The load-sensing levers  108 , stationary support  126 , movable support  136 , upper vise retention bracket  148 , and lower vise retention bracket  150  of centering vise assembly  120  are connected to the load-sensing plate  102  of load-sensing assembly  90 . The first support arm  162  and second support arm  164  of hand rest assembly  160  are connected to first side plate  66  and second plate  68  of chassis assembly  60 . The camera support arm first end  184  of camera arm assembly  180  is connected to load cell support arm  100  of load-sensing assembly  90 . With the pinning station  30  thus assembled, pinning station  30  is adapted such that chassis assembly  60  is rotatably adjustable with respect to base assembly  40 , and hand rest assembly  160  is rotatably adjustable with respect to the chassis assembly  60 . 
     Pinning station  30  is further adapted such that a rotation of hand crank  122  in a first direction causes first and second jaws  144 ,  146  to close, and rotation of hand crank  122  in a second direction causes first and second jaws  144 ,  146  to open. 
     Further, the pinning station  30  is adapted such that when an insertion type load is applied to the centering vise assembly  120 , the centering vise assembly  120 , load-sensing assembly  90 , and camera arm assembly  180  move somewhat in a first direction with respect to chassis assembly  60  and an insertion load is sensed by load cell  92 . Similarly, when a retention type load is applied to centering vise assembly  120 , the centering vise assembly  120 , load-sensing assembly  90 , and camera arm assembly  180  move somewhat in a second direction with respect to chassis assembly  60  and a retention load is sensed by load cell  92 . It is noted that pinning station  30  is adapted to be calibrated as needed such that an actual load detected by load cell  92  is properly and accurately displayed on display screen  230 . 
     Computer  200  may be a standard commercially available personal computer or any suitable computing device that is preferably capable of running standard commercially available software and capable of emitting predetermined sounds. Of course, any suitable computing device configured to receive the inputs contemplated herein, interpret such inputs, and provide the desired outputs, whether audible, visual, or kinetic can be used and is within the knowledge of the skilled artisan. 
     Any of a number of input devices may be used to communicate with computer  200 . The keyboard  210  shown in  FIG. 1  is just one example of an input device and is a standard commercially available keyboard that functions as a data input device to allow the input of data such as a wire identification number  212  (an example of a wire identification indicia appears on wires  276  shown in  FIG. 6  as a wire band with printed indicia thereon) into computer  200 . Alternate input devices are contemplated and may be used alone or in combination with each other and with keyboard  210 . For instance, rather than a keyboard, the input device may take the form of a scanner, a voice input device (e.g., a microphone), or any combination of a keyboard, a scanner, and a microphone. In such optional instance, the user may optionally speak a wire identification number  212  for input into computer  200  via voice recognition software or a voice recognition device or the data may be scanned for input into computer  200 . Additionally, a cable tester may be used to identify a wire that has no identification indicia. In such a case, the cable tester provides the identification indicia  212  by probing the insertion end of the wire with a probe from the cable tester. Once identified, the cable tester provides the wire identification indicia  212  to the computer  200 . Cable testers that can perform this function are well known. 
     The electronic display monitor  220  communicates with the computer  200  and may be a standard commercially available display monitor. Monitor  220  may be, for instance, a CRT (Cathode Ray Tube) type display monitor, an LCD (Liquid Crystal Display) type monitor, or a plasma type display monitor or any other type of monitor. Electronic display monitor  220  is preferably adapted to show visually a display  230 . 
     Although the display  230  may have any suitable configuration, display  230 , as best shown in  FIG. 6 , preferably includes a screen main viewing area  232 , an enlarged viewing area  234 , a pin cavity indication circle  236 , a pin position identification display  238 , a pin wire color display  240 , a wire label display  242 , a user prompt display  244 , a status indication display  246 , a selectable functions area  248 , a load indication display  250 , and a STOP display  260 . 
     Load indication display  250  preferably further includes a load indication needle  252 , an intermediate load range  254 , a sufficient insertion load range  256 , and a sufficient retention load range  258 . 
     Apparatus  20  is assembled such that load cell  92  of load-sensing assembly  90 , keyboard  92 , and electronic display monitor  220  electrically communicate with computer  200 , and electrical power is supplied to apparatus  20 . 
     In practice, for a user to perform an assisted installation of electrical wires into an electrical connector body  270 , the following steps are performed on an electrically powered pin installation apparatus  20  as described herein. A select electrical connector  270  is placed between first and second jaws  144 ,  146 , centered, oriented, and clamped into position. The proper position and orientation of the electrical connector  270  can be assisted and confirmed as described more fully below. Data corresponding to electrical connector  270  is entered into computer  200  via manually typing the data corresponding to electrical connector  270  on keyboard  210 , or by any other suitable manual or automated means such as by scanning data corresponding to electrical connector  270  or by voice recognition of data corresponding to electrical connector  270 . By inputting such data into computer  200 , a program within the computer  200  loads electrical wire  276  and seal plug  280  position data and displays a preprogrammed historical image of the electrical connector  270  on display screen  230 . 
     The user positions the electrical connector body  270  within first and second jaws  144 ,  146  and manually rotates and centers the electrical connector body  270 . When properly centered and oriented, the user tightens first and second jaws  144 ,  146  about the electrical body  270  by turning hand crank  122  in a first direction. The user may be assisted in this process by the computer  200  providing alignment instructions or aides, whether audible or visual or a combination of both. Such aides may, for example, be a visual depiction of at least two pin locations for the user to manipulate the electrical connector  270  so that the pin locations depicted align with corresponding pin cavities in the electrical connector  270 . A view of electrical connector  270  is displayed on display screen  230  as shown in  FIG. 6 . 
     With respect to one embodiment, the real time video display of electrical connector  270  and a preprogrammed historical image of electrical connector  270  are substantially overlaid or positioned coincident to each other. A selected area around the cavity to receive the pin placement (e.g., the pin cavity indication circle  236 ) does not display the overlay, but displays only the real time video in that area. Outside that area, the overlay is present and the user can select the degree to which each image is visible. With the real time video being totally visible, the user&#39;s hand and the wire (and previously pinned wires) are visible to the user. As the user selects a lesser degree of visibility of the real time video, the user&#39;s hand and other obstructions fade to shadow revealing more and more of the historical image until the real time video is replaced by the historical image everywhere except in the selected area around the desired cavity. In this manner, the user can determine how much of the real time video image is visible and can choose to ignore obstructions. 
     The user is prompted to input an electrical wire  276  (or other insertable member) identification number into computer  200  by prompt  244 . An identification number of a first electrical wire  276  is inputted into computer  200  and is subsequently displayed at wire label display  242  by typing the identification number on keyboard  210  or alternately by inputting the identification number by using another type of input device. 
     In response to the input of an electrical wire identification number, computer  200  displays pin position identification  238  and pin wire color  240 , and the pin cavity indication circle  236  is overlaid over the proper pin cavity  274  in both screen main viewing area  232  and in enlarged viewing area  234 , and prompt  244  prompts the user to insert an electrical wire  276  (the actual electrical wire  276  to be inserted is not shown in  FIG. 6  so not to obscure the insert viewing area  234 ) into the proper indicated pin cavity  274  (as distinguished from the other pin cavities  272 ). While viewing the movement and the installation of electrical wire  276  in real time on display screen  230 , the user inserts the electrical wire  276  into the indicated pin cavity  274 . 
     To assure proper installation by means of a proper installation load range, the user applies an installation load to electrical wire  276 , causing load cell  92  to detect the installation load and transmit the detected load to load indication display  250  of display screen  230  by means of the computer  200 . The applied installation load is increased until load indication needle  252  moves from intermediate load indication range  254  to sufficient or “good” load installation range  256 . 
     Upon load indication needle  252  moving into sufficient load installation range, an affirmative indicator such as an audible tone or sound associated with use of a proper amount of insertion force and prompt  244  changes to an “apply retention load” type prompt. The user stops applying an insertion load and begins to apply a retention load (a load opposite to an installation load). It is noted that if a detected installation load exceeds sufficient load installation range  256 , prompt  244  may change to a “load exceeded” type prompt and an alarm such as an audible “load exceeded” verbal prompt or a buzzer or other distinguishable sound may be emitted by computer  200  or a suitable output device. 
     The applied retention load is increased until load indication needle  252  moves from intermediate load indication range  254  to sufficient or “good” load retention range  258 . Upon load indication needle  252  moving into the sufficient load retention range, a success acknowledgement signal such as an audible tone is sounded by computer  200  or a visual acknowledgment is provided. Upon success acknowledgement, prompt  244  may change to an “input next electrical wire identification” type prompt. The user stops applying a retention load. It is noted that if a detected retention load exceeds sufficient load retention range  258 , prompt  244  may change to a “load exceeded” type prompt and/or an alarm such as an audible “load exceeded” verbal prompt or buzzer may be emitted by computer  200  or a suitable output device. 
     It should be noted that as more and more pins are inserted, the weight of the wires applies a load to the load cell  92 . Consequently, with the insertion of each successive wire, the computer  200  determines a base load level so that the load measured for insertion and retention is the net load wherein the weight of already pinned wires is excluded from the total load applied to the load cell  92 . 
     Upon completion of the installation of a first electrical wire  276 , the user then repeats the wire installation steps for all required electrical wires  276 . The user also performs a process similar to the wire installation process to install any and all required seal plugs  280  (shown in  FIG. 6 ). Upon completion of the insertion of all required electrical wires  276  and seal plugs  280 , stop indication  260  is displayed and the user is prompted by prompt  244  to remove electrical connector  270  from the apparatus  20 . 
     When there are numerous insertable members to be placed in the electrical connector body  270 , it may be particularly helpful to insert the insertable members in a predetermined order. In this instance, the computer  200  may be preprogrammed to determine the order in which the insertable members are inserted. This pre-ordering of the installation of the insertable members dictates to the user the order for placement so that installation is orderly and avoids problems where already inserted insertable members may surround and obscure the proper cavity, making it difficult for the user to accomplish proper insertion. 
     It is noted that all prompts and emitted tones may be replaced with or augmented by audible voice synthesized prompts or prerecorded audible verbal prompts and by various color changes on the display screen  230 . It is also noted that the various inputted data such as wire identification numbers, applied loads, etc. may be stored by computer  200  in association with the respective assembled electrical and wire bundle assembly. 
     The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.