Patent Description:
A connector is generally mounted upon the end portions of a plurality of conductors, such as optical fibers, electrically conductive wires or the like. In some implementations, the connector is mated with another connector to connect respective bundles of the conductors. In alternative implementations, the connector is connected to a receptacle of an instrument or the like.

It is conventional for each connector to comprise a mating shell which is mechanically connected to the shell of the other connector when the two connectors are brought into operative relationship. Each connector also includes a contact-receiving insert. The insert is typically made of dielectric material and is in the form of a plate having an inner surface which confronts the corresponding insert of the other connector, and an opposite, outer surface which is parallel to the inner surface. Numerous holes penetrate this member, opening at their opposite ends at the inner and outer surfaces respectively of the insert.

In instances in which the conductor is a wire, the wire is prepared for attachment to the connector by stripping the electrically insulative jacket from the end of the wire so as to expose the conductive core, and crimping a contact onto the conductor. This contact is in the form of a pin or a receptacle (referred to hereinafter as a "socket"). The contact is introduced into a hole in the aforementioned insert by way of the outer surface thereof and, in the case of a pin, projects beyond the inner surface of the insert. When all the wires have been attached to respective connectors and the connectors are brought into mating relationship, the contacts that are received in the holes of one insert are physically engaged by the contacts that are received in the holes of the other insert. Thus, the connectors typically do not have pins or receptacles other than those that are physically attached to the wires before introduction into the holes of the insulating insert.

When attaching a bundle or breakout of conductors from a wiring harness or the like to a connector, it is necessary to ensure that the conductors are located in the proper holes of the insert, since otherwise the proper circuits will not be completed when the connector is coupled to its mating connector.

A further problem is that a contact may be incompletely inserted or otherwise improperly seated in a hole of the insert. If a contact is improperly seated, it is possible that the retention force exerted by the retention clips inside the connector may be insufficient to retain the pin or socket in contact with a corresponding socket or pin if the wire to which the pin or socket is attached is pulled with sufficient force or if the connectors are shaken, for example, by vibrations.

Despite the existence of several testing methods and mechanisms to limit the occurrence of unseated or improperly seated contacts, it is still difficult to identify cases when contacts are barely touching but still able to pass an electrical continuity test, yet would easily disconnect when the connection has been shaken, for example. Current wire connection installation mechanisms are mainly manual, relying on the force exerted by the operator to insert wires properly into the connector. As such, consistency is unattainable and often either too much force is exerted to a point that causes damage to the connector or too little force to a point that a tenuous connection is disconnected.

Similarly, testing for unseated or improperly seated contacts is usually manual. During a manual operation performed by a technician or inspector, the person can either pull on a wire or push on a contact to test retention. Similar issues regarding inconsistent results arise during manual retention testing. Since there is no way for an operator to gage the pulling or pushing force being applied, too little force may result in a faulty test and too much force may again cause damage to the wire or the connector.

Inserting wires properly while reducing unseated contact occurrences is needed for the electrical industry across multiple sectors. In the particular scenario where bundles of wires are to be handled, a solution is needed for both ends of the bundles. A solution that would enable predefined consistent quality testing is needed to address the problem of unseated contacts in wire bundle assemblies.

<CIT>, in accordance with its abstract, states a tool has a scissor grip mechanism through which the wire to be connected passes. The gripper slides along a bar actuated by an actuating mechanism, coupled by a coupling mechanism to the gripping mechanism. The wire end has a plug which is inserted into a connector on the connector box. The wire is then pulled back to a predefined tension level to check that correct connection has been made.

<CIT>, in accordance with its abstract, states a terminal insertion device for insertion of the terminal of a terminal-equipped wire into a cavity formed in a terminal insertion housing, comprising: a housing retention unit for retaining the terminal insertion housing; a holding unit capable of holding and releasing the terminal of the terminal-equipped wire; and an advancing/retracting drive unit for insertion purposes capable of advancing/retracting drive of the holding unit with respect to the cavity. The holding unit is advanced towards the cavity so as to insert the terminal of the wire provided with the terminal held by the holding unit into the cavity. In a state in which the terminal of the terminal-equipped wire held by the holding unit is inserted into the cavity, the holding unit is retracted from the cavity with an upper-limit driving force corresponding to the required extraction force. An evaluation is then made as to whether a terminal extraction test has been passed or not, on the basis of the duration of the action of the upper-limit driving force corresponding to the required extraction force.

<CIT>, in accordance with its abstract, states a terminal-in-connector checking device consists of a mount, a connector holder fixed on the mount for holding a connector in position, a continuity checking member for terminals in the connector, provided on one side of the connector holder and movable to and from the connector holder, a terminal pressing member provided on the side of the connector holder opposite the first-mentioned side, movable to and from the connector holder and including a pressing portion for advancing into the connector and moving a terminal therein to fully-inserted position when the terminal pressing member is moved to the connector holder, and an operating member for moving the checking member and the terminal pressing member to and from the connector holder. A terminal, if in incompletely-inserted position, is automatically moved to fully-inserted position to be checked for continuity.

In a first aspect, there is provided a method as defined in claim <NUM> for inserting and retention testing an electrically conductive contact in an electrical connector. In another aspect, there is provided an apparatus as defined in claim <NUM> for inserting and retention testing an electrically conductive contact in an electrical connector. The subject matter disclosed herein is directed to an apparatus and methods for inserting and retention testing an electrically conductive contact in an electrical connector. The method includes the following steps: manually partially inserting the contact into a hole formed inside the electrical connector; inserting the contact further into the hole by pushing the contact along an axis using an insertion tip that is aligned with the axis and that displaces in a first direction along the axis during inserting; and after inserting the contact further into the hole, testing retention of the contact inside the electrical connector by pushing the contact along the axis using a test probe that is aligned with the axis and that displaces in a second direction opposite to the first direction during retention testing. The force exerted by the test probe on the contact is less than a specified contact retention force. The method further includes generating an alert signal if the test probe displaces along the axis in the second direction by more than a specified distance during retention testing.

Although various examples and embodiments of apparatus and methods for inserting and retention testing an electrically conductive contact in an electrical connector will be described in some detail below, one or more of those examples or embodiments is characterized by one or more of the following aspects. One aspect of the subject matter disclosed in detail below is a method for inserting and retention testing an electrically conductive contact in an electrical connector, comprising: (a) placing an electrical connector underneath an insertion tip and above a test probe; (b) coupling a contact to the insertion tip; (c) moving the test probe toward the electrical connector until an end of the test probe is at a starting position; (d) activating a first linear actuator to insert the contact further into a hole in the electrical connector by moving the contact in a first direction opposite to the second direction for a sufficient distance that an end of the contact would contact the end of the test probe at the starting position and then displace the test probe in the first direction away from the starting position provided that the insertion tip and test probe are in the same hole; (e) using a position sensor to detect whether the position of the end of the test probe at the end of step (d) is separated from the starting position by at least a first distance or not; and (f) if step (e) detects that the position of the end of the test probe at the end of step (d) is separated from the starting position by at least the first distance, activating a second actuator to move the test probe in the second direction and toward the starting position by applying a force that is equal to or greater than a minimum contact retention force. At least steps (d) and (f) may be performed under control by a computer.

Another aspect of the subject matter disclosed in detail below is a method for inserting and retention testing an electrically conductive contact in an electrical connector, comprising: manually partially inserting the contact into a hole formed inside the electrical connector; inserting the contact further into the hole by pushing the contact along an axis using an insertion tip that is aligned with the axis and that displaces in a first direction along the axis during inserting; and after inserting the contact further into the hole, testing retention of the contact inside the electrical connector by pushing the contact along the axis using a test probe that is aligned with the axis and that displaces in a second direction opposite to the first direction during testing. During inserting the contact further into the hole, the insertion tip may be in contact with one end of the contact, and during retention testing the test probe may be in contact with another end of the contact. The method may further comprise displacing the test probe along the axis in the second direction before inserting the contact further into the hole, the displacement of the test probe in the second direction before inserting the contact further into the hole being driven by applying a force manually.

In accordance with various examples, the method described in the preceding paragraph may further comprise one or more of the following steps: generating an electrical signal if the test probe does not displace along the axis in the first direction by at least a specified distance during inserting the contact further into the hole; causing the insertion tip to vibrate if the test probe does not displace along the axis in the first direction by at least a specified distance during inserting the contact further into the hole; and applying a force on the test probe that urges the test probe to displace along the axis in the second direction after inserting the contact further into the hole, wherein the force applied is less than a specified contact retention force.

A further aspect of the subject matter disclosed in detail below is an apparatus for inserting and retention testing an electrically conductive contact in an electrical connector, comprising: a connector holder configured to hold an electrical connector; an insertion tip configured to contact one end of a contact partially inserted in a hole in the electrical connector while providing clearance for a wire that is terminated by the contact; an insertion tip displacement assembly configured to displace the insertion tip in a first direction along a first linear path to further insert the insertion tip in the hole in the electrical connector; a test probe configured to contact another end of the contact after the contact has been inserted further into the hole; and a test probe displacement assembly configured to displace the test probe in a second direction along a second linear path, wherein the second direction is opposite to the first direction, and the first and second linear paths partially overlap. The apparatus may further comprise: a controller configured to cause the insertion tip displacement assembly to displace the insertion tip along the first linear path in the first direction during a first portion of a time cycle and later cause the test probe displacement assembly to displace the test probe along the second linear path in the second direction during a second portion of the time cycle; and a position sensor that senses a position of the test probe and outputs signals representing the position of the test probe to the controller.

In accordance with one example of the system described in the preceding paragraph, the controller may be further configured to generate an error signal if the test probe does not displace along the second linear path in the first direction by at least a specified distance during displacement of the insertion tip along the first linear path in the first direction. In accordance with the same example or a different example, the apparatus may further comprise a vibrator mounted to the insertion tip displacement assembly, in which case the controller is further configured to activate the vibrator if the test probe does not displace along the second linear path in the first direction by at least a specified distance during displacement of the insertion tip along the first linear path in the first direction. In accordance with the same example or a different example, the test probe displacement assembly may be configured to urge the test probe to displace along the second linear path in the second direction by applying a force that is less than a specified contact retention force, and the controller is further configured to generate an error signal if the test probe displaces along the second linear path in the second direction by more than a specified distance in response to application of the force by the test probe displacement assembly.

In accordance with some examples, the insertion tip displacement assembly may comprise: an insertion cylinder that causes the insertion tip to displace along the first linear path in the first direction in response to activation of the insertion cylinder; and a first return cylinder that causes the insertion tip to displace along the first linear path in the second direction in response to activation of the first return cylinder. In addition, the test probe displacement assembly may comprise a test cylinder that causes the test probe to displace along the second linear path in the second direction in response to activation of the test cylinder and a second return cylinder that causes the test probe to displace along the second linear path in the first direction in response to activation of the second return cylinder.

In accordance with one proposed implementation, the test probe displacement assembly may further comprise: a rotatable shaft; a manually operable activation lever fixedly mounted to one end of the shaft; a pinion gear fixedly mounted to the shaft and comprising a multiplicity of teeth; a test probe support shelf to which the test probe is fixedly mounted; and a rack affixed to the test probe support shelf and comprising a multiplicity of teeth, at least one tooth on the rack being interengaged with a pair of teeth on the pinion gear, wherein the test cylinder and the test probe support shelf are arranged so that the test probe support shelf is contacted by and displaced in a direction parallel to the second direction by one end of a piston rod of the test cylinder when the test cylinder is activated, but is not attached to the one end of the piston rod of the test cylinder. In one implementation, the test probe displacement assembly may further comprise a return block fixedly mounted to the shaft and disposed in a path of one end of a piston rod of the second return cylinder after the test probe support shelf has been displaced by the one end of the piston rod of the test cylinder. The test probe may be displaceable along the second linear path in the second direction by manual rotation of the activation lever while the test cylinder is inactive.

Yet another aspect of the subject matter disclosed in detail below is a method for inserting an electrically conductive contact in a hole in an electrical connector, comprising: (a) placing an electrical connector underneath an insertion tip and above a test probe; (b) coupling a contact to the insertion tip; (c) moving the test probe toward the electrical connector until an end of the test probe is at a starting position; (d) moving the insertion tip to insert the contact further into the hole in the electrical connector; (e) using a position sensor to detect whether the position of the end of the test probe at the end of step (c) is separated from the starting position by at least a specified distance or not; and (f) if step (e) detects that the position of the end of the test probe at the end of step (d) is not separated from the starting position by at least the specified, displaying symbology on a human-machine interface (or emitting/generating an audible or other perceptible signal) indicating that the contact and the test probe are not in the same hole.

Other aspects of apparatus and methods for inserting and retention testing an electrically conductive contact in an electrical connector are disclosed below.

The features, functions and advantages discussed in the preceding section may be achieved independently in various embodiments or may be combined in yet other embodiments. Various embodiments will be hereinafter described with reference to drawings for the purpose of illustrating the above-described and other aspects. None of the diagrams briefly described in this section are drawn to scale.

Reference will hereinafter be made to the drawings in which similar elements in different drawings bear the same reference numerals.

Illustrative embodiments of apparatus and methods for inserting and retention testing an electrically conductive contact in an electrical connector are described in some detail below. However, not all features of an actual implementation are described in this specification. A person skilled in the art will appreciate that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developer's specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.

The apparatus and method disclosed in some detail below provides a technical solution to the technical problem of contacts which are not properly seated in electrical connectors during contact insertion. In accordance with one embodiment, the position of a test probe is monitored during a contact insertion operation to detect instances wherein the inserted contact is not being retained with sufficient retention force to be considered as locked in place inside the electrical connector. The machine inserts one contact (which contact is already crimped on one end of a wire) downward into one hole of a multiplicity of holes inside the electrical connector during a downward stroke of an insertion arm that holds an insertion tip configured to push on one end of the contact. Prior to this automated contact insertion step, a test probe is moved to a vertical position calculated to intercept the downward-moving contact near the bottom face of the electrical connector located with its centerline axis parallel to the axis of the insertion tip. (The axis of the test probe is coaxial with the axis of the insertion tip. ) If the contact is inserted in the correct hole, then the downward-moving contact will impinge on the test probe (which either covers or is partially inserted in the correct hole) and force the test probe downward. That downward movement of the test probe is detected by a position sensor to confirm that the contact was inserted in the correct hole.

In an alternative scenario, it is possible that the contact will have been only partially inserted into the correct hole so that the contact is improperly seated and not retained with sufficient contact retention force. In other words, the contact in service may be pulled out of the hole or vibrations may cause the contact to move gradually out of the hole. If the contact is only partially inserted in the correct hole, then the downward-moving contact will impinge on the test probe (which either covers or is partially inserted in the correct hole) and force the test probe downward, but to an extent that is less than full insertion. That shortened downward movement of the test probe during automated contact insertion is again detected by the position sensor, which sends sensor data to a controller that causes the controller to activate a vibrator which is coupled to the insertion tip by way of a metal rod. The vibrator generates vibrations which propagate down the metal rod and cause the insertion tip to vibrate. If the partially inserted contact is hung up on a hard edge inside the electrical connector, the vibrations may induce the contact to move downward past the hard edge and further into the hole to a fully inserted position.

If the position sensor detects that the end of the test probe has moved downward to a vertical position below the lower bound of the "activate vibration" elevation range (indicating that the contact has been fully inserted), then the controller initiates an automated contact retention test, again involving the test probe. During conventional manual contact retention testing, the test technician tests the retention force being exerted on the contact by the electrical connector by manually either pulling on the wire or pushing on the contact using a tool. The automated contact retention test method disclosed herein replicates the latter, i.e., pushing on the contact.

In accordance with one embodiment of the testing apparatus, the testing method involves applying a force on the test probe that urges the test probe to displace in an upward direction along a linear path that is collinear with the axis of the insertion tip, i.e., in a direction opposite to the direction of movement of the insertion tip during an insertion stroke. It should be noted at this juncture that, although the apparatus embodiments disclosed herein are arranged so the insertion tip and the test probe both travel along a line that is generally vertical, the methodology disclosed herein can be adapted to an apparatus in which the insertion tip and the test probe both travel along a line that is generally horizontal or any angle between vertical and horizontal. In accordance with one proposed implementation, the retention test force is applied pneumatically. The force applied pneumatically is less than a specified contact retention force. Since at the start of the retention test, the test probe abuts the distal end of the contact at the time when a piston rod of a pneumatic cylinder is extended, urging the test probe to move upward, the contact and test probe will move upward in tandem unless the retention force is sufficient to hold the contact in place despite the applied force. The controller generates an electrical signal if the position sensor indicates that the test probe has displaced upward by more than a specified distance in response to the applied force. In response to the electrical signal, an error indicator or message may be displayed on a human-machine interface, alerting the operator to the fact that the contact insertion has failed. In other embodiments, the error indicator is "sounds", "beeps", or a control message send to another machine that is connected to it.

<FIG> is a diagram representing a view of an apparatus <NUM> for automated insertion and testing of electrical contacts. An electrical connector <NUM> is seen clamped in a position underneath an insertion tip <NUM>. The apparatus <NUM> includes the following components: a base <NUM>; a housing <NUM> attached to the base <NUM>; a pair of lift-restricting arms <NUM> attached at one end in the manner of a cantilever beam to the base <NUM>; and a connector holder assembly <NUM> which holds the electrical connector <NUM>. The connector holder assembly <NUM> is restrained from moving vertically upward by the lift-restricting arms <NUM>, but is able to slide horizontally during contact insertion, which allows a contact-receiving hole in the electrical connector <NUM> to move into final alignment with the contact being inserted. The connector holder assembly <NUM> (which will be described in more detail later with reference to <FIG> and <FIG>) includes: a main plate <NUM> that fits in a pair of slots underneath the lift-restricting arms <NUM> and is slidable in any direction for aligning a particular hole in the connector <NUM> with the insertion tip <NUM> (including incremental adjustments to align the hole with the contact being inserted); a sliding plate <NUM> that slides linearly in a linear groove formed in the main plate <NUM> and to which the electrical connector <NUM> is clamped; and a locking handle <NUM> that locks the sliding plate <NUM> in place relative to the main plate <NUM>.

<FIG> is a diagram representing a view of the connector holder assembly <NUM>. Sliding of the sliding plate <NUM> in the linear groove formed in main plate <NUM> is facilitated by a pair of slide arms <NUM> that are attached (e.g., fastened) to the main plate <NUM> and configured to partly overlie the linear groove along its parallel edges, thereby preventing the sliding plate <NUM> from being lifted upward and out of the groove. As seen in <FIG>, the locking handle <NUM> is rotatably mounted to a bolt that passes through a linear slot <NUM> formed in the sliding plate <NUM> and is threadably coupled to the main plate <NUM>. The linear slot <NUM> prevents interference with the bolt as the sliding plate <NUM> is slid in the linear groove. The connector holder assembly <NUM> further includes a clamp <NUM> consisting of a first jaw <NUM> which is fixedly coupled to the main plate <NUM> and a second jaw <NUM> which is fixedly coupled to the sliding plate <NUM>. As seen in <FIG>, the electrical connector <NUM> (with a wire <NUM> connected to a contact inserted in one hole) is clamped between the jaws <NUM> and <NUM>. The position of the second jaw <NUM> is adjustable by moving the sliding plate <NUM> toward the electrical connector <NUM> until the second jaw <NUM> abuts the shell of the electrical connector <NUM>. Then the sliding plate <NUM> is locked in place by turning the locking handle <NUM>, thereby firmly clamping the shell of the electrical connector <NUM> and holding the shell in a fixed position relative to the main plate <NUM>.

Referring again to <FIG>, the apparatus <NUM> further includes the following components: an insertion tip <NUM> having an axis and a distal end configured to contact one end of a contact partially inserted in a hole in the electrical connector <NUM> while providing clearance for a wire that is terminated by the contact; and associated mechanisms (referred to herein as the "insertion tip displacement assembly") for displacing the insertion tip <NUM> along a first linear path (in this example, a vertical linear path) that is collinear with the axis of the insertion tip <NUM>. The insertion tip displacement assembly includes an insertion arm <NUM> that is vertically displaceable relative to the housing <NUM> and projects through a vertical slot formed in the housing <NUM>. The insertion tip displacement assembly further includes a quick release pin <NUM> that passes through a vertical bore in the end of the insertion arm <NUM> and a quick release button <NUM> that is attached to the insertion arm <NUM> and holds the quick release pin <NUM> in a fixed vertical position relative to the insertion arm <NUM>. The insertion tip displacement assembly further includes an insertion tip holder <NUM> (e.g., in the form of a collar) that holds the insertion tip <NUM> so that the axis of the insertion tip <NUM> is parallel with a centerline of the shell of the electrical connector <NUM> during vertical displacement of the insertion arm <NUM>. The components for driving vertical displacement of the insertion arm <NUM> (which components are described in more detail below) are disposed inside the housing <NUM> and not visible in <FIG>. The apparatus <NUM> shown in <FIG> further includes a vibration module <NUM> that is vibrationally coupled to the quick release pin <NUM>. The vibration module <NUM> is configured to generate vibrations in the quick release pin <NUM>. When activated by the apparatus controller (not shown in <FIG>), the vibration module <NUM> generates vibrations which propagate down the quick release pin <NUM> and cause the insertion tip <NUM> to vibrate. This assembly depicted in <FIG> provides a method to quickly attach and detach the insertion tip <NUM>, provides the ability to apply vibratory forces to the insertion tip <NUM> to aid in insertion, and provides for the insertion tip <NUM> to be rotated slightly after being mounted to aid in manipulating the wire <NUM> into the insertion tip <NUM>.

<FIG> is a diagram representing a view of the apparatus <NUM> depicted in <FIG>, with the difference that an electrical contact at the end of a wire <NUM> has been manually partially inserted into a hole in the clamped electrical connector <NUM>. The vibration module <NUM> includes a clamp 44a that clamps onto the quick release pin <NUM> and a vibration motor 44b mounted to the clamp 44a. The insertion tip <NUM> is fixedly coupled to the end of the quick release pin <NUM> by the insertion tip holder <NUM>.

Electrical connectors come in many sizes and configurations. This disclosure is concerned with multi-hole electrical connectors which accept a multiplicity of contacts which respectively terminate a multiplicity of wires making up a wire bundle. Electrical connector assemblies generally include a plug and a receptacle, each of which contains a dielectric insert that has electrical contacts retained within bores in the inserts. The rear portion of the assembly contains a sealing grommet, through which the wires connected to the contacts pass, and which grommet seals the contacts contained in the insert from moisture. The sealing grommet is usable in various electrical connector assemblies wherein contacts are retained within dielectric inserts with the wires leading to said contacts passing through a grommet that seals the connectors from moisture. One-half of a connector assembly for use with pin-type (i.e., male) contacts has a contact retaining insert formed of dielectric material, a plurality of pin-type contacts secured within axial holes of the insert, an interfacial seal, a front retaining ring, a connector shell, a retaining nut and a rear retaining nut, with the sealing grommet provided to prevent access to the contacts by moisture from the environment. The dielectric insert has a face which contacts the sealing grommet and an opposite face which faces the interfacial seal for the front of the pin-type contacts. Wires lead from the contacts through the sealing grommet. The sealing grommet is typically formed of a rubber-type material, such as a silicone rubber or neoprene rubber, has a front face and a rear face, with a plurality of axial passageways therethrough which cooperate and align with the axial holes of the dielectric insert. Each contact occupies a single axial passageway formed in the sealing grommet.

<FIG> is a diagram representing a three-dimensional view of a typical insertion tip <NUM>. The insertion tip <NUM> has a circular cylindrical portion 41a that is held by the insertion tip holder <NUM> (not shown in <FIG>, but see <FIG>). The insertion tip <NUM> also has a grooved portion 41b having a C-shaped cross section. The radius of the grooved portion 41b is selected to fit inside the holes of the electrical connector <NUM> (not shown in <FIG>, but see <FIG>). The grooved portion 41b of the insertion tip <NUM> has a C-shaped or semi-circular end face <NUM> which abuts a portion of the electrical contact during insertion into the electrical connector <NUM>.

<FIG> is a diagram representing a side view of a portion of a wire <NUM> pressed into the groove <NUM> formed in the insertion tip <NUM> depicted in <FIG>. An unjacketed end portion of the wire <NUM> has a pin-type contact 4a (made of metal) crimped thereon. The pin-type contact 4a includes a contact pin <NUM>, a locking tab or shoulder <NUM> (which will be retained by a retainer mechanism inside a hole in the electrical connector <NUM>), and a crimp barrel <NUM> having indentations where the crimp barrel <NUM> has been crimped onto the unjacketed end portion of the wire <NUM>. In the example depicted in <FIG>, during downward motion of the insertion tip <NUM>, the end face <NUM> abuts the confronting end face of the crimp barrel <NUM> and pushes the pin-type contact 4a into a hole in the electrical connector <NUM>. In other situations, the end face <NUM> of the insertion tip <NUM> is configured to engage the locking tab or shoulder <NUM> of the pin-type contact 4a.

<FIG> is a diagram representing a cross-sectional view of a typical pin-type contact 4a inserted in a hole formed in a rigid front insulator <NUM> and in an axial passageway <NUM> formed in a sealing grommet <NUM> of an electrical connector <NUM>. The sealing grommet <NUM> and rigid front insulator <NUM> are both seated inside a shell <NUM> of the electrical connector <NUM>. As seen in <FIG>, the pin-type contact 4a protrudes out of the hole <NUM> in the rigid front insulator <NUM> when the pin-type contact 4a is in its final position. In some implementations, the pin contacts 4a is held in place by resilient fingers (not shown in <FIG> that latch behind the locking tab or shoulder <NUM> of the pin-type contact 4a.

<FIG> is a diagram representing a magnified view of the portion of the assembly inside the oval labeled 19A in <FIG>. The assembly includes a sealing grommet <NUM> and a rigid front insulator <NUM> with a resilient front insulator <NUM> sandwiched therebetween. The axial passageway <NUM> in the sealing grommet <NUM> is aligned with the hole <NUM> in the front insulators. The internal surface of each axial passageway <NUM> has resilient convolutions <NUM> which enable the use of the sealing grommet <NUM> with a range of wire gauges, so that the sealing grommet <NUM> is usable in various connector assemblies without the need for a special grommet for each different wire gauge, while assuring an efficient moisture seal for the contacts.

<FIG> is a diagram representing a cross-sectional view of a socket-type contact 4b inserted in an electrical connector <NUM>. In some implementations, the electrical connector for receiving socket-type contacts 4b has components similar to the components seen in <FIG>. However, as seen in <FIG>, the socket-type contacts 4b do not protrude outside the holes <NUM> formed in the rigid front insulator <NUM>.

<FIG> is a diagram representing a view of portions of the apparatus <NUM> depicted in <FIG> following removal of the connector holder assembly <NUM> to reveal a test probe <NUM> (separated from the insertion tip <NUM> above by a large gap) and associated mechanisms (referred to herein as the "test probe displacement assembly") for vertically displacing the test probe <NUM> along a second linear path that is collinear with the axis of the insertion tip <NUM> and aligned with the first linear path. The movements of the test probe <NUM> and insertion tip <NUM> are coordinated by a controller <NUM> which is programmable (see <FIG>). The distal end of the insertion tip <NUM> leads the insertion tip <NUM> when the insertion tip <NUM> is displaced in a first direction (e.g., downward), and the distal end of the test probe <NUM> leads the test probe <NUM> when the test probe <NUM> is displaced in a second direction (e.g., upward) opposite to the first direction. The test probe <NUM> has an axis and a distal end configured to contact another end of the contact 4a or 4b after the contact 4a or 4b has been inserted further into a hole in the electrical connector <NUM> by the insertion tip <NUM>.

The test probe displacement assembly includes the following components: a rotatable shaft <NUM>; a pair of manually operable activation levers <NUM> fixedly mounted to opposing ends of the shaft <NUM>; a pinion gear <NUM> fixedly mounted to the shaft <NUM> and comprising a multiplicity of teeth; a test probe support shelf <NUM> which is movable vertically along a linear bearing <NUM> and to which the test probe <NUM> is fixedly mounted; a rack <NUM> affixed to the test probe support shelf <NUM> and comprising a multiplicity of teeth, at least one tooth on the rack <NUM> being interengaged with a pair of teeth on the pinion gear <NUM>; and a return block <NUM> fixedly mounted to the shaft <NUM>. The rack <NUM> and pinion gear <NUM> convert rotation of shaft <NUM> into linear displacement of the test probe support shelf <NUM>. The shaft <NUM> is rotated during manual rotation of the activation levers <NUM>. Thus the test probe <NUM> is displaceable along the second linear path in the second direction by manual rotation of the activation levers <NUM>. As described below, the test probe <NUM> is also vertically displaceable up and down by a pair of pneumatic cylinders, which cause the shaft <NUM> to rotate. <FIG> is a diagram representing a view of portions of the apparatus depicted in <FIG> after the test probe <NUM> has been displaced upward. <FIG> shows the test probe <NUM> separated from the insertion tip <NUM> above by a small gap; in contrast to <FIG>, which shows the test probe <NUM> in a lower position with a larger gap separating the test probe <NUM> and the insertion tip <NUM>.

As best seen in <FIG>, the apparatus <NUM> further includes an angular position sensor <NUM> (e.g., a rotary potentiometer) which is configured and mounted to detect the angular position of the shaft <NUM>. Since the vertical displacement of the test probe <NUM> is directly proportional to the degree of rotation of the shaft <NUM>, the angular position sensor <NUM> outputs electrical signals that represent the vertical position of the test probe <NUM> relative to the frame of reference of the base <NUM>. The angular position sensor <NUM> senses the position of the test probe <NUM> and outputs signals representing the position of the test probe to a controller <NUM> (see <FIG>) for processing the sensor data.

The controller <NUM> is configured to cause the insertion tip displacement assembly to displace the insertion tip <NUM> along the first linear path in the first direction during a first portion of a time cycle and later cause the test probe displacement assembly to displace the test probe <NUM> along the second linear path in the second direction during a second portion of the time cycle. The apparatus is also configured to output display control signals to a human-machine interface <NUM> indicating error states or successful retention based on shaft angular position data received from the angular position sensor <NUM>. In response to receipt of such display control signals from the controller <NUM>, the human-machine interface <NUM> displays symbology indicating error states or successful retention to the operator. <FIG> is a diagram representing a view of the human-machine interface <NUM> of the apparatus <NUM> depicted in <FIG>. This implementation of the human-machine interface <NUM> is a touch-screen liquid-crystal display device.

In accordance with one proposed implementation depicted in <FIG>, both the insertion tip displacement assembly and the test probe displacement assembly include pneumatic cylinders <NUM>, <NUM>, <NUM> and <NUM> for driving the respective displacements in either direction. The pneumatic cylinders are connected to electrically controlled pneumatic valves <NUM> (e.g., solenoid valves) which are selectively activated by the controller <NUM>, which sends electrical valve control signals to control the states of the pneumatic valves <NUM>. When any one pneumatic valve is opened, compressed air from a main air supply is provided to the associated pneumatic cylinder, causing the piston rod of that pneumatic cylinder to be extended.

Still referring to <FIG>, the insertion tip displacement assembly includes the following additional components: an insertion cylinder <NUM> (having a piston <NUM> connected to a piston rod <NUM>) that causes the insertion arm <NUM> to displace in the first direction with the insertion tip <NUM> displacing along the first linear path (in the first direction) in response to activation of the insertion cylinder <NUM> and a first return cylinder <NUM> (having a piston <NUM> connected to a piston rod <NUM>) that causes the insertion arm <NUM> to displace in the second direction with the insertion tip <NUM> displacing along the first linear path (in the second direction) in response to activation of the first return cylinder <NUM>. Similarly, the test probe displacement assembly includes the following additional components: a test cylinder <NUM> (having a piston <NUM> connected to a piston rod <NUM>) that causes the test probe support shelf <NUM> to displace in the second direction with the test probe <NUM> displacing along the second linear path (in the second direction) in response to activation of the test cylinder <NUM> and a second return cylinder <NUM> (having a piston <NUM> connected to a piston rod <NUM>) that causes the test probe support shelf <NUM> to displace in the first direction with the test probe <NUM> displacing along the second linear path (in the first direction) in response to activation of the second return cylinder <NUM>. Thus the up and down movements of the insertion tip <NUM> are decoupled, as are the up and down movements of the test probe <NUM>. Furthermore, it should be noted that the test cylinder <NUM> and the test probe support shelf <NUM> are arranged so that the test probe support shelf <NUM> is contacted by and displaced in a direction parallel to the second direction by one end of the piston rod <NUM> of the test cylinder <NUM> when the test cylinder <NUM> is activated, but is not attached to the one end of the piston rod <NUM> of the test cylinder <NUM>. This upward vertical displacement of the test probe support shelf <NUM> in turn raises the test probe <NUM>, which is affixed to the test probe support shelf <NUM>. In addition, the return block <NUM> (seen in <FIG>, <FIG> and <FIG>), which is fixedly mounted to the shaft <NUM>, is disposed in the path of the one end of the piston rod <NUM> of the second return cylinder <NUM> after the test probe support shelf <NUM> has been displaced upward by the one end of the piston rod <NUM> of the test cylinder <NUM>.

<FIG> is a diagram representing a side view of the apparatus depicted in <FIG> with the left-side cover open to reveal the pressure regulators and gauges inside the housing <NUM>. Each pneumatic cylinder is operatively coupled to a pressure regulator <NUM> by way of a respective pneumatic valve and a respective flexible hose (not shown in the drawings). The pressure regulator <NUM> regulates (i.e., reduces) the pressure of the compressed air being supplied via tubing from a main air supply (not shown in the drawings).

The controller <NUM> also controls activation of the vibration module <NUM> (see <FIG> and <FIG>). The controller <NUM> activates the vibration module <NUM> in response to data from the angular position sensor <NUM> indicating that the contact being inserted was not fully inserted. More specifically, the controller <NUM> is configured to activate the vibration module <NUM> if the test probe <NUM> does not displace along the second linear path in the first direction by at least a specified distance during displacement of the insertion tip <NUM> along the first linear path in the first direction. For example, this occur if the contact was inserted in the correct hole but did not reach a position whereat the contact could be retained by the retention mechanism (e.g., spring fingers or a retention clip) inside the hole.

In other cases, the contact 4a or 4b is inserted in the wrong hole while the test probe <NUM> is inserted in the correct hole. In this case, the test probe <NUM> will not move in the first direction when the insertion tip <NUM> is moved in the first direction because the contact being pushed downward by the insertion tip <NUM> does not impinge upon the test probe <NUM>, which is in a neighboring hole. The controller <NUM> is further configured to generate an error signal if the test probe <NUM> does not displace along the second linear path in the first direction by at least a specified distance during displacement of the insertion tip <NUM> along the first linear path in the first direction.

As previously mentioned, the controller <NUM> is configured to cause the test probe displacement assembly to displace the test probe <NUM> along the second linear path in the second direction during a second portion of the time cycle for the purpose of testing the retention of an inserted contact. During the retention test, the test probe displacement assembly (namely, the test cylinder <NUM>) urges the test probe <NUM> to displace along the second linear path in the second direction by applying a force that is less than a specified contact retention force. The controller <NUM> is further configured to generate an error signal if the test probe <NUM> displaces along the second linear path in the second direction by more than a specified distance in response to application of force by the test cylinder <NUM>. Upward displacement by more than the specified distance indicates that the pin- or socket-type contact (which is abutting the distal end of the test probe <NUM>) is not being retained inside the hole <NUM> in the electrical connector <NUM>.

<FIG> are diagrams representing side and end views respectively of a pin-type test probe 46a (for use in inserting a pin-type contact 4a of the type depicted in <FIG>) in accordance with one embodiment. The pin-type test probe 46a has a shank <NUM> and a distal end <NUM> with a flat end face <NUM> that is designed to abut and push against the end of the pin-type contact 4a. As seen in <FIG>, the distal end <NUM> of pin-type test probe 46a has a diameter less than the diameter of the shank <NUM>.

<FIG> are diagrams representing side and end views respectively of a socket-type test probe 46b (for use in inserting a socket-type contact 4b of the type depicted in <FIG>) in accordance with one embodiment. The socket-type test probe 46b has a shank <NUM> and a round distal end <NUM> with a flat end face that is designed to be partially inserted into and push against the end of the socket-type contact 4a. Thus the flat end face is circular with a diameter less than the diameter of the opening in the socket-type contact 4a.

<FIG> is a diagram representing a side view of portions of the apparatus <NUM> depicted in <FIG> with the right-side cover open and the connector holder assembly <NUM> removed. This view shows a linear guide rail <NUM> disposed inside the housing. More specifically, the linear guide rail <NUM> is disposed vertically and guides vertical displacement of an insertion arm displacement plate <NUM> to which the insertion arm <NUM> is affixed. The apparatus further includes linear bearings that enable the insertion arm displacement plate <NUM> to travel smoothly along the guide rail <NUM> in response to activation of the one of the insertion cylinder <NUM> and first return cylinder <NUM>.

The smaller channel to the right of the linear guide rail <NUM> in <FIG> is a linear displacement transducer <NUM> that directly measures the vertical position (elevation) of the insert arm <NUM>. More specifically, the linear displacement transducer <NUM> senses a position of a component (e.g., insertion arm displacement plate <NUM>) of the insertion tip displacement assembly that has a fixed positional relationship relative to the insertion tip <NUM> and outputs signals representing the position of the insertion tip <NUM> to the controller <NUM>.

In accordance with one implementation, the linear displacement transducer <NUM> is used to unlock a "hold up" function of the insert arm <NUM> which happens at the end of a complete cycle. The insert arm <NUM> is raised at the end of a cycle and held there until it is manually lifted above a threshold position. This tells the controller <NUM> to cause the first return cylinder <NUM> to lower the piston rod <NUM>. This gives the operator the ability to freely load contacts and manipulate the electrical connector <NUM> without the insert tip <NUM> getting in the way.

The linear displacement transducer <NUM> is useful for other purposes. For example, by noting the position of the insertion arm <NUM> as the tool inserts the contact in relation to insert time, in one proposed implementation the controller <NUM> is configured to determine if the contact is sticking and use that information to trigger warnings and also turn on the vibratory system. Another potential use case is to create "insertion graphs" of movement versus time which is displayed on the screen of the human-machine interface <NUM> and used as both a troubleshooting and a feedback mechanism for illustrating problem insertion cycles. In addition, the position information provided by the linear displacement transducer <NUM> enables calculation of the movement speed for the purposes of calibrating the machine for consistent operation and helping to detect maintenance issues.

<FIG> is a diagram representing a view of portions of the apparatus <NUM> for automated insertion and testing of electrical contacts in a state wherein an insertion tip <NUM> and a test probe <NUM> are separated by a large gap. In this example, the test probe is a socket-type test probe 46b. <FIG> provides a more advantageous view of the components of the test probe displacement assembly which cause the test probe support shelf <NUM> to displace downward in response to activation of the second return cylinder <NUM>. When the second return cylinder <NUM> is activated, the piston rod <NUM> is extended. As the piston rod <NUM> extends, the end of the piston rod <NUM> pushes against the return block <NUM>, thereby causing the shaft <NUM> to rotate. Likewise the pinion gear <NUM>, which is fixedly mounted to the shaft <NUM>, rotates, thereby causing the rack <NUM> to displace vertically downward. This downward motion of the rack <NUM>-which is attached to the test probe support shelf <NUM>-lowers the socket-type test probe 46b.

<FIG> is a flowchart identifying steps of a method <NUM> for inserting a contact in an electrical connector and then testing for contact retention. The angular position sensor <NUM> monitors the position of the test probe <NUM> at any time during the contact insertion and retention testing operations. The controller <NUM> receives feedback from the angular position sensor <NUM> during these operations and then applies logic to the sensor data to trigger certain actions. For example, the controller <NUM> determines if an error has occurred or, in the alternative, if insertion was successful in the sense that the inserted contact is being retained with a retention force greater than the testing force being exerted on the contact by the test probe <NUM>.

Referring to <FIG>, the method <NUM> includes the following steps. The electrical connector <NUM> is loaded in the connector holder assembly <NUM> (step <NUM>). Then the connector holder assembly <NUM> is loaded into the slots underneath the lift-restricting arms <NUM> (step <NUM>). The position of the main plate <NUM> is coarsely adjustable so that the electrical connector <NUM> is underneath the insertion tip <NUM>. The contact is manually inserted in the insertion tip <NUM> by the operator (step <NUM>). Then the insert arm <NUM> is lowered until the contact is partially inserted in a selected hole <NUM> in the electrical connector <NUM> (step <NUM>). Again the position of the main plate <NUM> is finely adjustable so that the selected hole <NUM> in the electrical connector <NUM> is directly below the contact carried by the insertion tip <NUM>. The operator then rotates the activation levers <NUM> (step <NUM>), thereby moving the test probe <NUM> upward into the starting position. The mechanical components that make up the test probe mount and actuating mechanism provide adequate friction to hold the end face <NUM> of the test probe <NUM> at the starting position during tool activation. The primary sources of this friction is the angular position sensor <NUM> (e.g., rotary potentiometer), the solid bushings on opposing ends of the shaft <NUM>, and the linear bearing (not shown in the drawings) which enables the test probe support shelf <NUM> to displace vertically.

<FIG> is a diagram indicating various vertical positions A through F of the end face <NUM> of the test probe <NUM> during one test cycle. The lowermost horizontal line represents the zero position F of the end face <NUM> when the machine is reset (for example, by activation of the second return cylinder <NUM>). The uppermost horizontal line represents the starting position A after the test probe <NUM> has been displaced vertically upward by the test cylinder <NUM>. The next horizontal line represents a vertical position B corresponding to the alignment check point (explained in more detail below). The next horizontal line represents a vertical position C corresponding to the vibration check point (explained in more detail below). The next horizontal line represents a vertical position D corresponding to the insertion failure point (explained in more detail below). The dashed horizontal line represents a vertical position E corresponding to the position of the tip of the fully inserted contact and the position of the abutting end face <NUM> of the test probe <NUM>.

Referring again to <FIG>, subsequent to manual rotation of the activation levers <NUM>, the controller <NUM> then determines whether the end face <NUM> of the test probe <NUM> is in the starting position A (see <FIG>) based on the sensor feedback being received from the angular position sensor <NUM> or not (step <NUM>). On the one hand, if the controller <NUM> determines in step <NUM> that the end face <NUM> of the test probe <NUM> is not in the starting position A, then the automated cycle is not initiated and an error message is displayed by the human- machine interface <NUM>, indicating that the operator should troubleshoot the problem and then try again (step <NUM>). On the other hand, if the controller <NUM> determines in step <NUM> that the end face <NUM> of the test probe <NUM> is in the starting position A, then the controller <NUM> activates the insertion cylinder <NUM>, causing the insertion arm to move downward, thereby inserting the contact further into the selected hole <NUM> (step <NUM>).

The controller <NUM> then determines whether the end face <NUM> of the test probe <NUM> has moved below the alignment check point at vertical position B (see <FIG>) based on the sensor feedback being received from the angular position sensor <NUM> or not (step <NUM>). On the one hand, if the controller <NUM> determines in step <NUM> that the end face <NUM> of the test probe <NUM> has not moved below the alignment check point, then the machine is reset by activating the first return cylinder <NUM> and an error message is displayed by the human-machine interface <NUM>, indicating to the operator that the contact and the test probe <NUM> are not in the same hole (step <NUM>).

On the other hand, if the controller <NUM> determines in step <NUM> that the end face <NUM> of the test probe <NUM> has moved below the alignment check point, then the controller <NUM> determines whether the end face <NUM> of the test probe <NUM> has moved below the vibration check point at vertical position C (see <FIG>) based on the sensor feedback being received from the angular position sensor <NUM> or not (step <NUM>). On the one hand, if the controller <NUM> determines in step <NUM> that the end face <NUM> of the test probe <NUM> has not moved below the vibration check point, then the vibration motor 44b is activated (step <NUM>) and an error message is displayed by the human-machine interface <NUM>, warning the operator to check the insertion pin (step <NUM>) when the vibration cycle has ceased.

On the other hand, if the controller <NUM> determines in step <NUM> that the end face <NUM> of the test probe <NUM> has moved below the vibration check point, then the controller <NUM> deactivates the insertion cylinder <NUM> to release the downward force being exerted on the insertion tip <NUM> and then initiates the retention test by activating the test cylinder <NUM> to apply a force that pushes the test probe upward (steps <NUM>), which applied force is less than the specified minimum retention force for the contact.

The controller <NUM> then determines whether the end face <NUM> of the test probe <NUM> has moved from below to above the insertion failure point at vertical position D (see <FIG>) based on the sensor feedback being received from the angular position sensor <NUM> or not (step <NUM>). On the one hand, if the controller <NUM> determines in step <NUM> that the end of the test probe <NUM> has moved above the insertion failure point, then the machine is reset by activating the first return cylinder <NUM> and an error message is displayed by the human-machine interface <NUM> (step <NUM>), indicating to the operator that contact insertion has failed. On the other hand, if the controller <NUM> determines in step <NUM> that the end of the test probe <NUM> has not moved above the insertion failure point, then the controller <NUM> instructs the human-machine interface <NUM> to display a message indicating that contact insertion was successful, at which point the retention test cycle automatically ends.

<FIG> is a diagram representing a view of the same components seen in <FIG>, except that the connector holder assembly <NUM> has been removed. Elements in <FIG> which bear the same reference numerals as those appearing in <FIG> have the same functionality as the corresponding element in <FIG>, which functionality has been described above and will not be repeated here. <FIG> is a diagram representing a cut-away view showing some internal components of the apparatus depicted in <FIG>, including a test probe gear system <NUM> in the form of a rack <NUM> and a pinion gear <NUM>.

<FIG> is a diagram representing an orthographic view of a connector holder assembly <NUM> in accordance with an alternative embodiment. The connector holder assembly <NUM> includes a clamp <NUM> consisting of a first jaw <NUM> which is fixedly coupled to the main plate <NUM> and a second jaw <NUM> which is fixedly coupled to the sliding plate <NUM>. As seen in <FIG>, the electrical connector <NUM> is clamped between the jaws <NUM> and <NUM>. The position of the second jaw <NUM> is adjustable by moving the sliding plate <NUM> toward the electrical connector <NUM> until the second jaw <NUM> abuts the shell of the electrical connector <NUM>. A pair of slide arms <NUM> are attached to the main plate <NUM> to prevent the sliding plate <NUM> from lifting upward out of the groove in which the sliding plate <NUM> slides.

<FIG> are diagrams representing respective example screenshots displayed on the human-machine interface <NUM> of the apparatus <NUM> depicted in <FIG>. <FIG> shows a screenshot <NUM> wherein the operator starts the system by touching the virtual button named "SYSTEM START". <FIG> shows the main operating screen <NUM>. Not all of the fields shown in <FIG> are displayed at the same time. The symbol "?" is a warning to manually check the contact. The warnings only appear if the corresponding event has happened. The data on the side is displayed only in a data display mode. <FIG> shows a pins/socket selection screen <NUM>. By pressing the main virtual button, the operator can toggle between selecting a program for pin-type contacts and selecting a program for socket-type contacts. <FIG> shows a typical maintenance screen <NUM> for adjusting test and error values.

While apparatus and methods for inserting and retention testing an electrically conductive contact in an electrical connector have been described with reference to various embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the teachings herein. In addition, many modifications may be made to adapt the teachings herein to a particular situation without departing from the scope thereof. Therefore it is intended that the claims not be limited to the particular embodiments disclosed herein.

Computer numerical control (CNC) is the automation of machine tools by means of computers executing pre-programmed sequences of machine control commands. Some steps of the methods described herein are encoded as executable instructions embodied in a non-transitory tangible computer-readable storage medium, including, without limitation, a storage device and/or a memory device. Such instructions, when executed by a CNC controller, cause the apparatus to perform at least a portion of the methods described herein.

As used herein, the term "controller" means a computer or processor configured to execute pre-programmed sequences of machine control commands for controlling computer-controlled components of the contact insertion and retention testing apparatus disclosed herein.

The embodiments disclosed above use one or more processing or computing devices. Such devices typically include a processor, processing device, or controller, such as a general-purpose central processing unit, a microcontroller, a reduced instruction set computer processor, an ASIC, a programmable logic circuit, an.

instructions embodied in a non-transitory tangible computer-readable storage medium, including, without limitation, a storage device and/or a memory device. Such instructions, when executed by a CNC controller, cause the apparatus to perform at least a portion of the methods described herein.

Claim 1:
A method for inserting and retention testing an electrically conductive contact (4a, 4b) in an electrical connector (<NUM>), comprising:
manually partially inserting the contact (4a, 4b) into a hole (<NUM>) formed inside the electrical connector (<NUM>);
inserting the contact further into the hole by pushing the contact along an axis using an insertion tip (<NUM>) that is aligned with the axis and that displaces in a first direction along the axis during inserting; and
after inserting the contact further into the hole, testing retention of the contact inside the electrical connector by pushing the contact along the axis using a test probe (<NUM>) that is aligned with the axis and that displaces in a second direction opposite to the first direction during testing.