Abstract:
A machine for terminating wire assemblies comprising: a means for holding a wire assembly; a linear movement means for moving said means for holding between a first area and a second area; an insertion head; and, a means for dislodging; wherein, after a wire assembly is loaded into the means for holding a wire assembly, the means for holding a wire assembly is moved by the linear moving means from the first area to the second area for assembly termination by the insertion head; and, following termination, the assembly is at least partially unseated from the means for holding a wire assembly by the means for dislodging.

Description:
FIELD OF THE INVENTION 
   The present invention generally relates to apparatus, methods and articles of manufacture for automatically terminating magnet-wire. More particularly, this invention relates to apparatus, methods and articles of manufacture for automatically terminating magnet-wire in magnet-wire assemblies. 
   BACKGROUND OF THE INVENTION 
   Magnet-wire assemblies, used in various electrical applications, such as motors, solenoids and transformers, are comprised of one or more wire assemblies and one or more terminals. The wire assemblies, which may be coil, bobbin or field assemblies, are usually created through winding wire in some desired fashion about a core. The terminals, which may be any of a number of configurations, provide means for connecting the ends of the wire assembly to other components in the electrical application. 
   Terminals may be attached to the wire assembly using a number of methods, in a process generally known as a “termination process.” The termination process might be manual or automated (with the latter category including semiautomated processes.) Whether manual or automated, a termination process typically begins with a wire assembly comprised of a core and wire winding. On the core, and/or other areas on the wire assembly, a terminal attachment area or areas is provided, for affixing the terminal or terminals. For example, a terminal attachment area is often a cavity disposed on a side of the core with the ends of the wire winding extending through the bottom of the core. 
   If a terminal or terminals is installed within a terminal attachment area and so through the wire end extending through the cavity, an electrical connection is made between the terminal and wire winding. Thus, when the wire assembly is installed in an application, appropriate connections are made to the terminals and the assembly may be energized as desired. 
   Both wire assemblies and terminals may come in a number of specialized configurations, and so terminal installation may become quite complex. One type of machine that is commonly used in the automated termination process provides a mounting platform, known as a “fixture,” for holding wire assemblies while a terminal is installed on the assembly. Each fixture is customized for holding a desired wire assembly configuration, and differently customized fixtures may be used in the same machine. 
   In these machines, an operator inserts a wire assembly into a fixture in the machine to begin the termination process. The operator then maneuvers the fixture into position for the termination operation. The machine inserts the desired terminal or terminals into the appropriate area or areas on the wire assembly, which, as noted above, is usually a cavity area or areas. The operator then withdraws the fixture from its position, removes the now-terminated wire assembly from the fixture, and inserts a new to-be-terminated wire assembly in the fixture, beginning a new termination process cycle. 
   The termination process in these machines is slowed by the operator&#39;s need to insert each assembly into the fixture, maneuver the fixture with assembly into an appropriate position for the termination operation, withdraw the terminated assembly and fixture from the termination operation position and then withdraw the terminated assembly. Of course, if a fixture needs changing, such as when a different assembly configuration is to be terminated, the operator needs to change the fixture as well, thus adding to downtime. 
   Some attempts have been made to improve assembly rates of prior art automated termination machines. For example, prior art machines may allow an operator to unload a fixture with a terminated assembly and load a new to-be-terminated assembly while yet another assembly is processing on the machine. Even with such a machine, each assembly still needs to be loaded individually, and so the overall process is still limited by the need for operator intervention for each assembly. 
   Therefore, it is an object of the present invention to provide apparatus, methods and articles of manufacture for automatically terminating wire assemblies. 
   It is a further object of the present invention to provide apparatus, methods and articles of manufacture for automatically terminating wire assemblies through use of fixtures that provide for multiple assembly loading and unloading. 
   It is a further object of the present invention to provide apparatus, methods and articles of manufacture for automatically terminating wire assemblies through use of fixtures that provide for multiple assembly loading and unloading, including automatic fixture ejection. 
   SUMMARY OF THE INVENTION 
   The summary, as well as the following detailed description of the invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there are shown in the drawings, certain embodiment(s) which are presently preferred. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. 
   The present invention comprises apparatus, methods and articles of manufacture for automatically terminating magnet-wire in magnet-wire assemblies. In the preferred embodiments, a termination machine is provided. A pallet is provided for use in the machine. The pallet has multiple chambers for holding assemblies to be terminated. The pallet is removably mounted to a fixture in the machine. The fixture, in turn, is mounted to a rotary actuator, which in turn is mounted upon a linear actuator for movement to and from an insertion head, where the terminals are inserted in the assemblies and so the assemblies are terminated. 
   A termination process according to the preferred embodiments begins with the pallet, with to-be-terminated assemblies, being loaded upon the fixture by an operator. The fixture is positioned in a loading/unloading area in the termination machine. The fixture with pallet is then moved along the linear actuator to the termination area. In the termination area the terminals are inserted into the assemblies by the insertion head. The rotary actuator may spin or otherwise rotate the pallet as well in order to accommodate terminal insertion across a number of assemblies. 
   After the assemblies have been terminated, a two stage dislodging process begins. In the first stage, the now-terminated assemblies are loosened from the pallet. In the second stage the pallet is unseated from the fixture. The fixture with pallet is moved back along the linear actuator to the loading/unloading area, and the pallet is removed from the fixture by the operator. A new pallet with to-be-terminated assemblies may then be loaded upon the fixture and a new termination process can then begin. 
   Additional objects, advantages and novel features of the invention will be set forth, in part, in the description and figures which follow, and other additional objects will become apparent to those skilled in the art on examination of the following, or may be learned by practice of the invention. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a view of a preferred embodiment. 
       FIG. 2  is another view of the embodiment of  FIG. 1 . 
       FIG. 3  is another view of the embodiment of  FIG. 1 . 
       FIG. 4  is a view of a preferred embodiment. 
       FIG. 5  is another view of the embodiment of  FIG. 4 . 
       FIG. 6  is a partial schematic view of the embodiment of  FIG. 4 . 
       FIG. 7  is another partial schematic view of the embodiment of  FIG. 4 . 
       FIG. 8  is another partial schematic view of the embodiment of  FIG. 4 . 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   Reference is now made to the accompanying Figures for the purpose of describing, in detail, the preferred embodiments of the present invention. The Figures and accompanying detailed description are provided as examples and are not intended to limit the scope of the claims appended hereto. 
     FIG. 1  shows a preferred embodiment. Termination machine  40  has transparent panels on the two sides for operator viewing, and a light curtain in the front of the machine. Fixture  21 , mounted on rotary actuator  25 , is shown in loading/unloading area a, that is, where the operator has loaded the fixture with pallet  20 . Pallet  20  holds four assemblies for termination, which are friction fit in the pallet. The assemblies should be fit tightly within the pallet so they do not shift as they are terminated. In other embodiments, other methods besides friction fit may be used to accommodate the assemblies within the pallet, such as a pneumatically operated clamping device, as long as the assemblies are sufficiently retained so as to withstand forces imposed by the termination operation. 
   The fixture and pallet will then be moved to termination area b along linear actuator  35  (see  FIG. 2 ) where terminals are inserted into the assemblies on pallet  20  by insertion head  26  (a process also known as termination of the assemblies.) The assemblies are then dislodged from the pallet and the pallet is dislodged from the fixture. The pallet and fixture then return to loading/unloading area a, where the pallet with the terminated assemblies is unloaded. A new pallet with assemblies to be terminated may then be loaded on the fixture for the start of another termination cycle. 
   It should be noted that in this embodiment and all preferred embodiments, a pallet comprises a variable number of chambers for receiving assemblies to be processed. For example, in this embodiment, as will be further described below, four chambers are available on the pallet to receive assemblies. Other embodiments may have less than four or more than four. For example, a pallet may only hold one very large assembly. Moreover, in operation, not all available chambers need to be filled with assemblies during any particular termination process. 
   It should also be noted that the chambers of any particular pallet may be customized for the assemblies to be terminated. So for example, customized pallet embodiments may be configured for retaining various types of assemblies as desired. 
   Returning now to  FIG. 1 , feed reels  41  and  43  hold terminals, in the form of strips t′ and t″, to be installed upon the assemblies. The strips unreel from the feed reels  41  and  43  and into the machine by way of recesses against the back wall. Recess  42  provides entry for the terminals on strip t′, and a similar recess (not shown) provides entry for the terminals on strip t″. The terminals on strips t′ and t″ are then installed on the assemblies through insertion head  26  in termination area b. 
   The fixture moves from loading/unloading area a to termination area b and back on linear screw actuator  35 . In the especially preferred embodiment, a linear screw actuator from Tol-O-Matic, Inc. is used, Part No. TBD-M3S-SNO 1 SPL. A stepper motor (not shown) and driver drives the screw, with a control system in place to control the stepper motor, which in the especially preferred embodiment is a motor and driver from Pacific Scientific appropriate to drive the actuator. The control system is as known in the art. In other embodiments, other methods may be used to control the screw, such as for example, a servomotor, which may be desired for greater speed and/or precision. Additionally, other linear movement means as known in the art may be used in yet other embodiments. 
     FIG. 2  shows the preferred embodiment of  FIG. 1  with fixture  21  moved, via linear screw actuator  35  to termination area b. 
     FIG. 3  shows the preferred embodiment of  FIG. 2  with pallet  20  on fixture  21  brought to a rotation area slightly beyond termination area b, by actuator  35 , in order to rotate the fixture via rotary actuator  25 . A rotary movement means such as rotary actuator  25  helps provide flexibility in installing terminals on the assemblies (such as assemblies x shown in the drawing) as insertion head  26  can then more easily access various areas throughout the assembly for terminal installation. Flexible carrier  22  holds pneumatic hoses and cables for rotary actuator  25  operation. Scrap removal chute  48  is used to collect any excess wire and other components removed as a result of the termination process. 
   The especially preferred embodiments use a rotary actuator from Robohand, Inc., Model RR-36M-180-M, although other means to provide rotary motion to the fixture may be used in other embodiments. Of course, only partial rotary motion, or no rotary motion, may be desired. Additionally, the rotary actuator and fixture may be provided as one unit in various other embodiments. Additionally, the especially preferred embodiments use an MPT-5 insertion module from Tyco Electronics Corporation as an insertion head. By use of the MPT-5, assemblies to be terminated can have cavities in either a linear pattern, axial pattern or a combination of both. Of course, other embodiments may use other termination heads as known in the art. 
   It should be noted that in other embodiments, a first area may comprise separate loading and unloading areas as desired. Additionally, a second area may comprise a termination area, rotation area and/or dislodging area, or any combination thereof as desired. 
   Before turning to a further description of the terminal installation process of the preferred embodiments, it might be helpful to review the pallet, fixture, and rotary actuator of the preferred embodiment. 
     FIG. 4  shows a view of the pallet, fixture, and rotary actuator of the preferred embodiment. Assemblies x of types as known in the art, e.g. coil, bobbin or field assemblies, are shown above the pallet (shown generally at 20) with termination cavities c′ through c″″ shown on an assembly as well. In these assemblies, terminals will be inserted into the desired cavity or cavities. Of course, other assemblies may have terminal attachment areas or cavities in other areas, and be terminated by various embodiments of the present invention accordingly. 
   Generally, assemblies are loaded into the pallet from the top of the pallet, and pushed downward, as there is some frictional resistance from the pallet rails, until the bottom edge or edges of the assembly (depending upon assembly shape) encounters the top edge of assembly ejector plate  42 , as is described in further detail below. 
   Pallet  20  comprises first and second pallet rails  40  and  41 , assembly ejector plate  42 , and pallet base assembly  43 . The pallet rails are fixed by pallet screws, as for example, screw  44  in ridges of pallet base assembly  43 . Pallet retaining plate  47  is fixed by screws  49  to the pallet rails. Torsion springs  50  and  51  are fixed to pallet retaining plate  47  by screws  52 . Dowel pin stops  53  are also fixed to pallet retaining plate  47 . 
   Moving briefly to  FIG. 5 , the upper legs  50   a  and  51   a  respectively of torsion springs  50  and  51  are retained within a recess on pallet retaining plate  47 . The lower legs  50   b  and  51   b  respectively of torsion springs  50  and  51  contact the inner edges of assembly ejector plate  42 . Thus the springs provide resistance against the upward movement of the assembly ejector plate  42 , which is moved via pneumatic cylinder  45 , so that when assemblies are loaded into the pallet from the top of the pallet, the assemblies do not have to force assembly ejector plate  42  downward. A similar arrangement of pallet retaining plate, torsion springs, screws and dowels is present on the opposite ends of the pallet rails as shown by the partially seen assembly  55 . The entire pallet assembly is constructed of steel, although other materials as known in the art may be used. 
   Returning to  FIG. 4 , pallet  20  is retained upon fixture  21  through ball detents, such as shown by ball detent  46 , which are inserted within respective recesses in fixture  21  and so protrude slightly from the inner walls of fixture  21 . Thus the ball detents permit the edges of a pallet to be pushed into place over the detents and onto fixture  21 . It should be noted that in alternative embodiments, alternative means, such as springs or mechanical fingers may be used for loading and/or retaining a pallet upon a fixture. It also should be noted that, in other embodiments, it may be desired to eliminate the fixture and load a pallet directly upon an appropriately configured flange on a rotary actuator or other retention platform. 
   Fixture  21  also provides a recess r for pneumatic cylinder  45 . Pneumatic cylinder  45 , as will be described in further detail below, assists in dislodging the assemblies and pallet. Pins c and d on fixture  21  insert into recesses on pallet base assembly  43  and so locate the pallet when loaded upon fixture  21 . 
   It should be noted that, in certain embodiments, it may be desired to utilize locating pins that are directional as well, that is, utilize locational pins that are uniquely shaped so as to provide appropriate guidance into uniquely shaped corresponding recesses on the pallet base assembly. Thus, in these embodiments, if the base assembly is attempted to be fitted in reverse, the studs would not engage with the opposite recess. 
   Fixture  21  is itself mounted on flange  28  of rotary actuator  25 , through the use of screws not shown here. Flange  28  may rotate as a termination process proceeds (see, e.g.,  FIG. 3 ) and so any installed fixture, such as fixture  21 , and, in turn pallet  20 , may rotate as well. 
   Ports  26  provide the connections for pneumatic cylinder  45 . Additionally flow controls  27  and  29  are shown, for the rotary drivers within the actuator and for the pneumatic cylinder  45 . Legs  30  retain actuator  25  on base  31  on linear actuator  35 . Not shown are various feed lines for the pneumatics. 
   A rotary actuator, such as is used in the preferred embodiments, provides sufficient speed, accuracy and strength (to resist the downward force supplied by the termination head.) Other embodiments may use other mechanisms as known in the art to provide any desired rotation. Additionally, yet other embodiments may not use a rotary movement means at all, and have a pallet, and/or pallet-fixture combination, or other means as known in the art for holding a wire assembly installed upon a retention platform on a linear movement means. 
   As described above, with regard to this embodiment, once the assemblies are terminated, or otherwise as desired, the assemblies and pallet  20  are dislodged from the fixture  21  in a two stage process. (It should be noted that other embodiments may use a one stage process in dislodging a pallet and assembl(ies) from a fixture or other retention platform.) The first stage at least partially loosens the assemblies within the pallet, which eases subsequent removal of the assemblies from the pallet and subsequent reuse of the pallet. The second stage unseats the pallet from the ball detents of the fixture, where it may be removed as desired. In the especially preferred embodiments, this dislodging occurs in a dislodging area, away from the termination area but before the rotary actuator, fixture and pallet reach the loading/unloading area. The rotary actuator, fixture and pallet stop along the linear actuator, the dislodging process occurs, and then the rotary actuator, fixture and pallet proceed to the loading/unloading area where the unseated pallet with loosened assemblies is removed. In the especially preferred embodiments, the light curtain shuts down when the rotary actuator, fixture and pallet reach the loading/unloading area and so the operator can reach into the machine for pallet and assembly removal. (Otherwise of course, any breach of the light curtain by the operator would shut the machine down.) As was described above, in yet other embodiments, a second area may be expansive enough to include a dislodging area. 
   Turning to  FIG. 6 , a partial schematic view of the preferred embodiment is seen. Pallet  20  is loaded on fixture  21  and held by ball detents, such as for example ball detent  46 . Fixture  21  is mounted in turn on flange  28  of rotary actuator  26 . Only two assemblies x are shown loaded into the pallet for ease of review of the figure. 
   Torsion springs  50  and  51  and  60  and  61  are shown on either side of pallet  20 , behind pallet retaining plates  47  and  67  respectively. Dowel stop pins  53  and  63  are also shown. Pneumatic cylinder  45  is at rest. 
     FIG. 7  shows the first dislodging stage of the preferred embodiments, where the assemblies are loosened. The stage begins when piston  45   a  of pneumatic cylinder  45  pushes assembly ejector plate  42  a sufficient distance upwardly, through pallet rails  40  and  41 , until assembly ejector plate  42  contacts dowel pin stops  53  and  63  and so stops moving. The embodiment then proceeds to the second dislodging stage shown in  FIG. 8 . The second dislodging stage unseats the pallet from the fixture. 
   Turning now to  FIG. 8 , the piston  45   a  of pneumatic cylinder  45  continues to extend upwardly. Since piston  45   a  can no longer move assembly ejector plate  42  independently of the pallet rails—assembly ejector plate  42  has struck the dowel stop pins of the pallet rails—piston  45   a  now proceeds to drive assembly ejector plate  42 , as well as the remainder of the pallet, including pallet base assembly  43 , out of the ball detents, thereby unseating the pallet from the fixture. 
   The pallet is still sufficiently retained within the fixture so as to be able to travel back along the linear actuator to the loading/unloading area. Once it arrives, the light curtain shuts down and the operator can then reach inside the machine, remove the pallet and remove the assemblies from the pallet. 
   Once the pallet with terminated assemblies has been removed, the operator may load a new pallet with assemblies to be terminated. These are usually loaded into a new pallet while a pallet is being terminated. The operator places the pallet with the assemblies to be terminated on the fixture and pins c and d (shown in  FIG. 4 ) engage their mating recesses. The operator presses the pallet down onto the fixture so as to engage the pallet base assembly edges over the ball detents. Once the fixture snaps in place, the operator starts the machine up, the light curtain is again turned on, and the termination process begins again. 
   The above description and the views and material depicted by the figures are for purposes of illustration only and are not intended to be, and should not be construed as, limitations on the invention. 
   Moreover, certain modifications or alternatives may suggest themselves to those skilled in the art upon reading of this specification, all of which are intended to be within the spirit and scope of the present invention as defined in the attached claims.