Patent GB-1021367-A (GB)
Title: Method and apparatus for fabrication and in situ testing of wire harness structures
IPC: H01R31/00
Filed: 1962-08-07
Abstract: 1,021,367. Electric fault testing. R. M. DYKSTERHOUSE. Aug. 7, 1962 [Aug. 4, 1961], No. 30239/62. Heading G1U. [Also in Division H2] An assembly line for fabricating electric cable harnesses comprises a horizontal rectangular track circuit 11 (Figs. 2, 3) having parallel rails 12, 13 on which plural assembly boards 14 run on rollers 15 through plural work stations at each of which a single operation is performed. Each assembly board carries guide pins 19, 25 (Fig. 4) establishing the configuration of each conductor of the harness, split terminal moulds 17 for receiving and encapsulating in resin plastic the connecting terminal ends 21 of the prepared conductors 26 to 29 &c. which are assembled one per work station around the locating pins, and branch take out moulds 18 for similarly encapsulating and reinforcing the points of departure of side branches of the harness. In assembly, the terminal ends of each wire are inserted in cooperating test receptacles 23 (which may be pivotally mounted) contained in the moulds each connection being isolated by a dielectric sleeve and the moulds spacing out the terminal ends of the several conductors of the harness by means of guide pins 25. The mould halves are provided with quick release lock devices for use during moulding, and are also closed with resilient cushion dams. Test leads 24 from the test receptacles 23 are connected to appropriate contacts A A<SP>1</SP> to D D<SP>1</SP> of block 20 carried by each of the assembly boards, and a test circuit 36 in (Fig. 5) is provided at station 8 and another at station 11 of the assembly line. At each station a contact block 30 is provided carrying spring loaded contacts registering with AA<SP>1</SP> to DD<SP>1</SP>. A selector switch 5 successively connects AA<SP>1</SP> BB<SP>1</SP> CC<SP>1</SP> and DD<SP>1</SP> in series with batteries 34 and indicator lamps 31 to indicate continuity and shortcircuiting, while test meters 35 may be included to measure voltage drops along the conductors. Test circuit 36 checks continuity and freedom from shortcircuit, after which the terminal and reinforcing moulds are filled by injection machines carried by supports 38 overhanging the individual moulds at stations 9, 10, 11. Faulty harnesses on their assembly boards are removed to a repair bay for rectification, after which they are re-introduced into the line prior to test station 36. After final testing for continuity, shortcircuit and voltage drop at station 37 each assembly board is inched through station 13 where its harness is wrapped by machine 22 and stripped from the board, faulty harnesses being routed to a repair bay without wrapping, as before. The empty loads are recycled along the track to the beginning of the line. Fig. 6 shows a complete harness having two female and two male contacts 41, 42 moulded into jacket 40, a moulded reinforcing ring 41, a reinforcement 45 for branch 46 terminating in spade terminal 48 and jacketed slidable connector 47, a moulded reinforcing ring 52, and a two contactor moulded socket and prong connector 51, the whole being wrapped with an insulating tape.