Patent Document

CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a divisional application of U.S. patent application Ser. No. 11/544,277 filed Oct. 5, 2006 and which claims the priority of U.S. Provisional Patent Application Ser. No. 60/724,430, filed Oct. 7, 2005 and U.S. Provisional Patent Application Ser. No. 60/758,084 filed Jan. 12, 2006; the disclosures of which are incorporated by reference in their entirety. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Technical Field 
         [0003]    The invention disclosed herein relates generally to electrical terminal applicators, and more particularly to providing terminal applicator methods and systems for automatically crimping terminals or connectors to wires wherein the terminals or connectors are provided in strip form and may be of varying sizes, shapes, and pitches. 
         [0004]    2. Background Art 
         [0005]    As is known in the art, a wide range of electronic and electrical products use crimp terminals to make electrical connections from wires to other wires, printed circuit boards or other components. Generally, a crimp terminal consists of three sections that function to create a proper electrical connection. The first section is the contact area, which is designed to physically connect with a mating terminal to establish an electrical connection. For example, a “pin” terminal would slide inside of a “socket” terminal to make the connection. The second section is the wire crimp area, which is designed to capture the end of a wire. The wire in this area of the terminal must be stripped; that is, the insulation around the conductor of the wire must be removed to expose the conductor portion. Metal tabs on the terminal are folded around the stripped wire very tightly. Generally, the tabs are folded so tightly that a “cold” weld occurs between the wire strands and the terminal. This crimping action provides a physical connection of the terminal to the wire as well as an electrical connection. The electrical connection is highly resistant to moisture, temperature changes, corrosion, and other negative environmental conditions that may be present. The third section is the strain relief area, which is designed to capture the wire where the insulation begins. Generally, in this section metal tabs are loosely folded around the wire insulation. The strain relief area prevents flexure of the wire from breaking wire strands in the wire crimp area. 
         [0006]    Generally, the process for attaching a crimp terminal to a wire involves several basic steps. First, the end of the wire must be stripped to expose the correct length of bare conducting wire. Second, the stripped wire must be positioned over the terminal to properly orient the wire with the terminal. Finally, the tabs on the wire crimp and strain relief areas of the terminal must be folded and compressed, or crimped, on to the wire in a defined manner in order to create and maintain a proper electrical connection. 
         [0007]    To accomplish the last step described above relating to crimping the terminal onto the wire, tooling specifically designed for the terminal must be used. In some cases, hand tools are used with terminals that are packaged as loose pieces. In this case, an operator secures the terminal in the hand tool by placing the base of the terminal on an anvil. While using one hand to maintain the prepared wire end in the correct position over the terminal, the operator uses the other hand to close the handles of the tool. A set of precisely designed blades then closes against the terminal. The action of the blades against the terminal as the terminal sets in the anvil provides the correct folding of the tabs in the wire crimp and strain relief sections. The use of hand tools and loose-piece terminals is a very common and popular method to crimp terminals to wires, especially amongst homeowners and electrical contractors. However, given the labor intensity and time consuming nature of this manual process, the use of hand tools is not suitable for medium to high speed/volume production. 
         [0008]    To support high volume production, terminal applicators have been used wherein applicator tooling is typically used in conjunction with a press. The applicator is installed in the press and generally a unique applicator is required for each terminal or family of terminals (i.e., terminals of similar size, shape, etc.). In these terminal applicators, terminals packaged in daisy-chain fashion on a carrier strip (as opposed to loose-piece) are fed from a reel into a guide integral to the applicator. The applicator contains a fixed anvil, shear block, and moveable blades, all suitable for crimping the wire crimp and strain relief portion of the terminal and cutting the terminal from its carrier strip. The press has means for holding the base of the applicator in a fixed position in the press and also has means for lowering/raising a ram in the applicator to which the blades are attached. If the press is mounted on a bench-top, an operator places a prepared wire in the proper position over the terminal and actuates a pedal. The pedal triggers the press to lower the ram and then raise it to its starting position, all in one rapid and complete motion. 
         [0009]    In these typical press terminal applicators, movement of the ram by the press results in the following actions, all occurring within the applicator. First, given that the blades are attached to the ram, as the ram is lowered, the blades are pressed against the terminal as it rests against the fixed anvil. This action crimps the terminal to the wire. Second, the shear block is activated to cut the terminal from the terminal carrier strip. Finally, through a cam mechanism in the applicator, movement of the ram also drives a feed pawl which advances terminals into position over the anvil. Depending upon the design of the applicator and specific requirements of the terminal, terminals may be advanced on either the upward or downward motion of the ram (known as post-feed or pre-feed). Additionally, in some applicators, the terminal is advanced using a pneumatic feed mechanism mounted on the applicator. 
         [0010]    In addition to being mounted on bench-tops as described hereinabove, terminal applicator presses can also be installed on fully automated wire processing equipment as shown in the prior art. In this configuration, the press is activated under control of the wire processing equipment as opposed to manual control. Once set-up and operational, this type of equipment cuts, strips, and terminates wires with no human involvement with production rates that can support high volume operations. In some fully automated wire processing equipment, the presses have a feature called crimp force analysis. In these presses, the force required to move the ram in the applicator is measured and analyzed to determine the quality of the crimp. 
         [0011]    Various configurations of terminal applicators of varying types are known in the prior art as described hereinbelow. 
         [0012]    U.S. Pat. No. 3,553,814 to Rider is directed to an applicator for crimping electrical terminals in the form of a continuous belt onto the ends of wires and substantially simultaneously removing the crimped terminations from the belt. The applicator has a crimping die and crimping anvil which are movable relatively towards and away from each other and the belt of terminals is fed along a feed path extending behind the dies to present the leading terminal on the belt to the dies. After crimping, the terminal feed means moves laterally off the feed path away from the dies while the terminal is held between the dies so that the crimped terminal is broken away from the belt. A pair of spaced-apart sprocket wheels are disclosed which engage spaced-apart perforations on the terminal belt and push/pull the belt through the crimping zone during operation. 
         [0013]    U.S. Pat. No. 4,043,032 to Spangler is directed to a terminal applicator apparatus wherein terminals provided on a continuous belt are indexed towards crimping dies and wherein the crimped wire end is moved away from the belt and the crimping dies so that the terminal is broken away from the belt. A sprocket wheel is provided which includes teeth that engage perforations on the belt and function to index the belt through the press, thereby presenting the lead terminal of the belt at the crimping station during each operating cycle. An ejection means spaced laterally from the feed path moves into engagement with the wire and away from the crimping dies, while the other end of the wire is held by a wire clamp, so that the crimp terminal is broken away from and removed from the belt. 
         [0014]    U.S. Pat. No. 4,667,397 to Day et al. discloses a machine for crimp connecting an electrical lead wire to a terminal wire or the like. The device includes means for cooperatively feeding a length of electrical lead, a length of terminal, and a crimp connector strip carrying a series of crimp connectors. The device further includes a die set assembly, a cutter movable with respect to the die set assembly, a crimper, means for positioning the cutter relative to the crimper, terminal wire length positioning means, and means for locking the means for positioning the cutter once the desired terminal length has been set. 
         [0015]    U.S. Pat. Nos. 4,718,160 and 4,805,278 to Bulanda et al. are each directed to a terminal strip applicator that purports to disclose a self-adjusting mechanism that can accept a wide variety of structurally disparate continuously molded terminal strips and accurately apply each terminal to a wire without the need for readjustment and/or exchange of the working parts of the strip feed mechanism. The apparatus includes a terminal strip applicator feed track that automatically adjusts to accept terminal strips of varying widths and varying terminal contours. The apparatus further includes a terminal feeding mechanism for resiliently biasing the terminal strip for sequentially advancing a lead terminal of the terminal strip. The terminal feeding mechanism of these patent documents includes a feed link and a feed finger on the applicator itself for feeding of the terminal strip. 
         [0016]    U.S. Pat. No. 5,131,124 to Skotek describes a strip feeding mechanism for terminal applicators for crimping terminals onto the ends of wires. The strip feeder is actuated by a rack on the applicator ram and a gear train which is between the applicator ram and the actual feeding mechanism. The strip feeding mechanism comprises a feed pawl or feed finger which is on the end of a pivotable arm and which moves the terminal strip. 
         [0017]    U.S. Pat. No. 5,491,887 to Quinn is directed to an electrical terminal applicator with an improved split cycle system for the crimping die means of the applicator. The apparatus includes moving means mounted directly on the applicator frame adjacent the applicator ram and connected to the crimping die for moving the crimping die through a first portion of movement into engagement with an uncrimped terminal to preposition the terminal for crimping thereof. Additionally, the applicator ram thereafter can move the crimping die through a second portion of movement to effect crimping of the terminal. 
         [0018]    U.S. Pat. Nos. 5,440,799 to Marshall et al. and 5,481,796 to Quinn are each directed to electrical terminal applicators with improved terminal tape moving means. Marshall et al. provides a terminal applicator having an applicator feeding system employing a very low-profile tooth mechanism wherein the mechanism is adjustable to vary the feed stroke thereof to accommodate terminal tapes with different pitches between the terminals. The applicator of Marshall et al. includes fixed stop teeth that engage the indexing apertures of a terminal tape to prevent the tape from moving back away from the crimping anvil on the return stroke of the shuttle member. Quinn discloses a typical feed mechanism with teeth that engage the slots on the carrier tape, but also discloses a guide plate which defines a pair of opposing clamping jaws for engaging and gripping outside surfaces of the tape for pulling the tape laterally off the path and away from the crimping die to break the terminal away from the tape. 
         [0019]    U.S. Pat. Nos. 5,483,739 to Smith et al. and 5,517,749 to Zuin are each directed to an electrical terminal applicator with improved crimp height adjustment plate means. Smith et al. discloses an adjustment plate means which adjusts the crimp heights of the two crimping dies in an electrical terminal applicator wherein the adjustment plate means includes two adjusting plates which are continuously or gradually adjustable by employing ramped adjusting surfaces versus the finite number of positions of adjustment afforded by the calibrated plates of the prior art. Zuin describes a calibrated disk which can be retrofitted on existing applicator rams and includes a flexible adjusting plate mounted for rotation about an axis to selectively interpose projection means between the press ram and a first adjustable plate means to provide further adjustment of the shunt height of the crimping die. 
         [0020]    U.S. Pat. No. 5,577,318 to Smith et al. describes an electrical terminal applicator with improved track adjustment means for a track which guides tapes with terminals secured thereto. An applicator ram is drivable in a first path through a working stroke towards, and a return stroke away from, a crimping anvil. A track guides the strip in a second path which intersects the first path of the ram and includes a track portion mounted for adjustable movement in a direction transverse to the second path. An adjusting screw is threaded into a transverse hole in the movable track portion for adjusting the position of the track portion in the direction transverse to the second path and a locking set screw is threaded into the transverse hole for jamming against an end of the adjusting screw to lock the adjusting screw and, thus, the track portion in any position of adjustment. 
         [0021]    U.S. Pat. No. 6,026,562 to McMillin et al. discloses a global terminal assembly die of a modular design comprising a base unit assembly having several assemblies attached thereto. The possible removable assemblies include a slide retainer assembly, a terminal feed assembly, a terminal guide and brake assembly, an upper tool pack assembly, and a lower tool pack assembly. A mechanical feed assembly is disclosed which includes a feed finger that is attached to a trolley by a feed adjuster. The feed finger of the feeding mechanism cooperates with a guide and brake assembly to advance a terminal strip through the guide and brake assembly to a crimping area between the upper and lower tool pack assemblies. 
         [0022]    Finally, U.S. Pat. No. 6,655,013 to Wilson et al. describes an applicator machine including a wire guide carried by the ram of the machine for guiding a wire into position for crimping a single-sided flag terminal thereto. The wire guide has a wire guiding surface that cooperates with lead-in angled surfaces of the crimping tool to guide the wire into alignment with the terminal. 
         [0023]    Many companies which produce wire and cable assemblies are required to handle a wide variety of crimp terminals of varying sizes, shapes, etc. in order to satisfy customer demands. As a result, these companies must own or lease a large number of applicators in order to be able to produce a wide array of terminal products. The costs associated with owning or leasing these applicators is a major contributor to the overhead costs for the business. 
         [0024]    Attempts have been made to reduce the cost to own or lease applicators. In one example, a product was offered that consisted of a base applicator body with interchangeable anvils, shear blocks, blades, guides, and other parts. It was intended that the end user of this type of applicator, such as personnel at wire and cable assembly companies, would purchase one (or a few) applicator bodies. Instead of ordering one complete applicator for each terminal type, only a set of parts (i.e., an anvil, shear block, blade, guide, and other items) would be needed for each terminal type and each set could be fitted onto the base applicator. Given the substantial reduction of complete applicators required, a substantial cost savings was expected. In practice, however, the cost savings was never fully realized. 
         [0025]    Shortcomings of these prior art interchangeable applicators were based in part because little to no improvements were made to the terminal feed mechanism. Because the terminal feed mechanism remained an integral part of the mechanical workings of the applicator, no provisions existed to adapt a single feed mechanism to accommodate a wide variety of terminals. A large number of base applicators were therefore required to solve this problem, thereby defeating the goal of using one (or a few) base applicators and eroding any cost savings that was otherwise achievable. 
         [0026]    Accordingly, there remains a need for terminal applicator apparatuses, systems, and methods for feeding, guiding and advancing a wide variety of terminals to enable terminal-specific parts (i.e., anvil, blade, and shear block) to be easily interchangeable. 
       BRIEF SUMMARY OF THE INVENTION 
       [0027]    The present invention provides an applicator installed in a bench-top press or in a press installed in automatic wire processing equipment to attach crimp terminals to wires. The applicator performs the crimping process and can cut the terminal from the terminal carrier strip. The applicator may or may not have any means for advancing terminals to the applicator anvil. In the latter case, the applicator can instead comprise a separate and independent advancing mechanism located on and controlled by the bench-top press or wire processing equipment. Interchangeable guide plates can be mounted on the applicator to guide terminals of varying sizes into the applicator. 
         [0028]    The applicator of the present invention provides several advantages, including: 
         [0029]    1. Providing an applicator which consists of a base plus parts that are uniquely designed to crimp a specific terminal or family of terminals. The applicator is further designed to allow those unique parts to be easily interchangeable. 
         [0030]    2. The reduction in costs to lease or own applicators as a result of the reduced functionality of the applicator and the opportunity to easily interchange unique parts. 
         [0031]    3. Reduction in the distance the ram travels to permit higher production rates. 
         [0032]    4. Improved accuracy and precision of crimp force analysis. 
         [0033]    5. More consistent and accurate positioning of terminals. 
         [0034]    6. Reduction in the likelihood of jams during the advancement and positioning of terminals. 
         [0035]    7. Sensing of the positions of terminals on the terminal carrier strip prior to termination for the purpose of properly positioning the next terminal to be crimped. 
         [0036]    According to one embodiment of the present invention, an apparatus for crimping electrical terminal connectors onto wires, the connectors being secured to a terminal strip in side-by-side relationship with their axes extending laterally from the strip, is provided wherein the apparatus comprises an applicator body and a ram movably mounted in relation to the body and drivable in a first path through a working stroke towards, and a return stroke away from, a crimping anvil. The apparatus further comprises a crimping die on the ram for cooperation with the anvil and adapted to crimp a terminal connector located therebetween onto a wire during each working stroke of the ram. The apparatus additionally comprises a drive mechanism adapted to contact the strip through pressure engagement and to feed the strip along a second path to locate a next leading connector on the strip between the anvil and the die. 
         [0037]    A method is also provided for crimping electrical terminal connectors onto wires. The method generally comprises providing a plurality of terminal connectors, the connectors being secured to a terminal strip in side-by-side relationship with their axes extending laterally from the strip, and moving a crimping die on a ram through a working stroke towards, and a return stroke away from, a crimping anvil to crimp an individual terminal connector located therebetween onto a wire during each working stroke of the ram. The method further comprises indexing the strip between successive crimping operations thereby to locate a next leading connector on the strip between the die and anvil, wherein the strip is indexed by a drive mechanism contacting the strip through pressure-engagement. 
         [0038]    A system for crimping electrical terminal connectors onto wires, the connectors being secured to a terminal strip in side-by-side relationship with their axes extending laterally from the strip, is also provided wherein the system comprises a crimp press and a universal crimp applicator adapted to be installed in the crimp press and comprising interchangeable guide plates adapted for guiding an electrical terminal connector into the applicator for crimping of the connector to a wire. The system further comprises a separate drive mechanism adapted to be located on and controlled by the crimp press to contact the strip through pressure engagement and to feed the strip along a path extending through the applicator, wherein advancement of the connector is independent from operation of the applicator. 
         [0039]    It is therefore an object to provide terminal applicator apparatuses, systems, and methods for automatically crimping terminals or connectors to wires wherein the terminals or connectors are provided in strip form and may be of varying sizes, shapes, and pitches. 
         [0040]    An object of the present invention having been stated hereinabove, and which is addressed in whole or in part by the present invention, other objects will become evident as the description proceeds when taken in connection with the accompanying drawings as best described hereinbelow. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0041]      FIG. 1  is a plan view of a packaged terminal assembly such as can be used with the applicator of the present invention; 
           [0042]      FIG. 2  is an elevation view of an applicator of the prior art which has an integrated terminal feed mechanism; 
           [0043]      FIG. 3  is an elevation view of an applicator of the prior art which has an integrated terminal feed mechanism installed in a press; 
           [0044]      FIG. 4  is a plan view of an automatic wire processor of the prior art; 
           [0045]      FIG. 5  is an elevation view of a terminal application assembly in accordance with one embodiment of the present invention; 
           [0046]      FIG. 6  is an elevation view of an applicator used in the terminal application assembly shown in  FIG. 5  in accordance with one embodiment of the present invention; 
           [0047]      FIG. 7  is an elevation view of a terminal feed mechanism used in the terminal application assembly shown in  FIG. 5  in accordance with one embodiment of the present invention; 
           [0048]      FIG. 8  is a perspective view of a terminal guide used in the terminal application assembly shown in  FIG. 5  in accordance with one embodiment of the present invention; 
           [0049]      FIG. 9  is a perspective view of an applicator in accordance with one embodiment of the present invention; 
           [0050]      FIG. 10  is a perspective view of a drive mechanism of the applicator shown in  FIG. 9  in accordance with one embodiment of the present invention; 
           [0051]      FIG. 11  is a block diagram illustrating a controller of the applicator shown in  FIG. 9  in accordance with one embodiment of the present invention; 
           [0052]      FIG. 12  is a plan view of a user interface of the applicator shown in  FIG. 9  in accordance with one embodiment of the present invention; 
           [0053]      FIG. 13  is an elevation schematic view of the processing of a terminal in accordance with one embodiment of the present invention; and 
           [0054]      FIG. 14  is a graphical representation of a signal that is provided by a terminal sensor in accordance with one embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Terminal Assembly 
       [0055]    Referring now to  FIG. 1 , a typical packaged terminal assembly shown generally as  10 , is of the type that can be used in the applicators of the present invention. Terminal assembly  10  is known in the art to support the feeding of individual terminals  12  into applicators. It is understood that terminals  12  can comprise open barrel terminals, closed barrel terminals, or any other terminal known to those of skill in the art. Many terminals  12  can be attached to a single, continuous terminal carrier strip  14  and in some cases, many thousands of terminals  12  can be produced on one terminal carrier strip  14 . Terminal carrier strip  14  can comprise a plurality of feed holes  16  wherein at least one feed hole  16  is provided for each terminal  12 . Each feed hole  16  can also be precisely positioned with respect to an individual terminal  12  and can be used to facilitate the manufacturing process of terminals  12 . As is known in the art, feed mechanisms in applicators can also use feed hole  16  to advance and position individual terminals  12 . Terminals  12  on terminal carrier strip  14  can typically be delivered in cardboard reels. Additionally, it is envisioned that other packaged terminal assemblies, including but not limited to terminals  12  attached to a tape carrier, can be used with the embodiments of the present invention as described further hereinbelow. 
       Applicator Operation Background 
       [0056]    Applicators currently available from a variety of manufacturers typically include a terminal feed mechanism in the applicator. A description of the basic elements and fundamental operation of these applicators is provided below. 
         [0057]    Referring now to  FIG. 2 , an applicator as known in the art is shown generally as  20 . Applicator  20  includes a body  22  (also referred to as a die) which provides a frame to which all other elements are attached or provides a means to capture and guide moving parts. Terminals  12  attached to a terminal carrier strip  14  in daisy chain fashion (see  FIG. 1 ) are fed from a reel and enter terminal strip guides  24  just above a drag plate  26 . During operation, terminals  12  are moved along terminal strip guides  24  toward an anvil  28 . A drag plate release  32  is moved to a position to release the drag of drag plate  26  when terminals  12  are loaded by an operator into applicator  20 . Once terminals  12  are loaded, drag plate release  32  is moved to a position to engage the drag. The drag must be engaged during operation of applicator  20 . 
         [0058]    When applicator  20  is loaded into a press, shown generally as  50  in  FIG. 3 , body  22  is held in a fixed position in press  50 . The top-most portion of a ram  34  slides into a fitting located in press  50  to enable the press to raise and lower ram  34  within body  22  of applicator  20 . Blades  36  (also referred to as crimping die or conductor punch and insulation punch) are attached to ram  34 . When ram  34  is lowered by press  50 , blades  36  move toward and come in close proximity to anvil  28 . If terminal  12  has been positioned properly over anvil  28  and a properly stripped wire (not shown) has been positioned properly over terminal  12 , blades  36  will squeeze terminal  12  and stripped wire against anvil  28 , resulting in the crimping of terminal  12  to the wire. A shear block  38  is depressed by blades  36  to cut terminal  12  from terminal carrier strip  14 . 
         [0059]    After crimping is complete and terminal  12  has been sheared from terminal carrier strip  14 , ram  34  is raised to its original starting position. As ram  34  is raised, terminal  12  may not release from blades  36 . If this occurs, a terminal stripper  42  removes terminal  12  from blades  36  as ram  34  rises. An operator (or wire processing equipment in automated machines) then removes the wire, with terminal  12  crimped on one end, from applicator  20 . 
         [0060]    The operation of typical feeding mechanisms will now be described. A cam mechanism (not shown) in body  22  of applicator  20  actuates a feed pawl  44  as ram  34  is raised and lowered. In many designs, the tip of feed pawl  44  fits into feed hole  16  in terminal carrier strip  14 . Feed pawl  44  is angled such that it engages (pushes) on feed hole  16  when moving forward (toward anvil  28 ), but slides over feed hole  16  when moving backward (away from anvil  28 ). Drag plate  26  must be in a position to induce drag to prevent feed pawl  44  from inadvertently moving terminal carrier strip  14  as feed pawl  44  moves backward. In some designs, feed pawl  44  will push directly on one terminal  12  instead of engaging in a feed hole  16  in terminal carrier strip  14 . The movement of feed pawl  44  can be adjusted by setting the position of a feed pivot  46  and adjusting a feed adjustment  48 . The position of feed pivot  46  controls the throw of feed pawl  44 , that is, it controls the distance feed pawl  44  travels. Feed adjustment  48  controls the position of feed pawl  44  when feed pawl  44  reaches its maximum forward position. It is understood that feed adjustment  48  and feed pivot  46  are highly interactive, thereby making feed adjustments in these prior art system very difficult. 
         [0061]    Referring now to  FIG. 3 , press  50  as known in the art is shown with applicator  20  installed. Applicator  20  is typically mounted on and secured to a base  52 . When applicator  20  is installed into press  50 , ram  34  on applicator  20  slides into a ram fitting  54  on press  50 . Ram fitting  54  is driven by a motor (not shown) in press  50  to raise and lower ram  34 . A user control interface  56  can be provided to enable a user to set-up press  50  and to monitor operation. 
         [0062]    Press  50  can be used on a bench top. In this case, a human operator presents a properly prepared wire over terminal  12  to be crimped and actuates press  50 , usually via a foot pedal. Press  50  can also be installed in fully automated wire processing equipment as described below with reference to  FIG. 4 . 
         [0063]      FIG. 4  illustrates a plan view of an automatic wire processor  60 . Wire from a drum or reel (not shown) is fed into a wire feed  62 . Wire feed  62  dispenses precisely measured lengths of wire to a side  1  transfer  64  and to blades  66 , which effectuate cutting of the wire. Blades  66  also strip (remove insulation) from neither, one, or both ends of the wire. Side  1  transfer  64  grabs one wire end and presents to a side  1  press  68 . A side  2  transfer  72  grabs one wire end and presents it to a side  2  press  74 . Applicators  20  are installed in each press if a terminal  12  must be crimped to that wire end. Completed wire leads are deposited in a wire deposit  76 . 
         [0064]    An electrical cabinet  82  can contain wiring, relays, computers, etc. (none shown) required to make automatic wire processor  60  functional. This functionality includes coordinating all elements of the machine to feed, measure, cut and strip wire; control transfers and presses; and deposit completed assemblies. A human operator can use a control panel  84  to set up, store and retrieve jobs and monitor production throughout the operation. 
       Embodiment with Separate Terminal Feed Mechanism 
       [0065]    Referring now to  FIGS. 5-8 , one embodiment of the present invention includes a terminal application system or assembly shown generally as  100 . Terminal application assembly  100  can include an applicator  110  loaded in a press  130  (similar to press  50  described hereinabove). A terminal feed mechanism  140  can be provided to pull packaged terminal assemblies  10  (see  FIG. 1 ) through a terminal guide  180 . 
         [0066]    Referring now to  FIG. 6 , applicator  110  includes a body  112  (also referred to as a die) which provides a frame to which all other elements are attached or provides a means to capture and guide moving parts. A ram  114 , blades  116 , terminal stripper  118 , and anvil  122  perform the same functions as described hereinabove for applicator  20 . A shear block  124  cuts terminal  12  from terminal carrier strip  14 , but otherwise leaves terminal carrier strip  14  intact. Applicator  110 , in this embodiment, does not include any mechanisms for advancing, guiding or positioning terminals  12 . 
         [0067]    Referring now to  FIG. 7 , terminal application assembly  100  can further include terminal feed mechanism  140  which can be located apart from applicator  110  (described further hereinabove) and terminal guide  180  (described further hereinbelow). Terminal carrier strip  14  (minus terminals  12 ) that is produced by applicator  110  after the crimping process is completed is channeled through a first guide  142 . Terminal carrier strip  14  is then fed between a first belt  144  and a second belt  146 . Motor roller  148 , first roller  152 , second roller  154 , and third roller  156  are configured to enable motor roller  148  to move first belt  144  and second belt  146  and thereby move terminal carrier strip  14  in a direction from first guide  142  to a second guide  158 . 
         [0068]    Terminal carrier strip  14  can be routed through second guide  158  to a sensor  162 . Sensor  162  detects the presence of feed holes  16  in terminal carrier strip  14  using optical, mechanical or other sensing means. A signal is generated by sensor  162  when it detects a feed hole  16 . A controller  164  provides a signal to motor roller  148  to turn when a terminal  12  must be advanced. A trigger signal from a foot pedal (not shown) or from another controller in an automatic wire processing machine (not shown) indicates when the next terminal  12  must be advanced. Controller  164  turns motor roller  148 , thereby advancing terminal carrier strip  14  (and all terminals  12  attached thereto). Motor roller  148  is turned by controller  164  until the signal from sensor  162  indicates detection of a feed hole  16 . 
         [0069]    In a separate feature of the current embodiment, terminal carrier strip  14  can also be fed through a third guide  166  and a chopper  168 . Chopper  168  cuts terminal carrier strip  14  into individual pieces. The cut pieces can then be ejected into a debris tray  172  for ultimate disposal. 
         [0070]    Referring now to  FIG. 8 , a terminal guide  180  consists of an upper plate  182  and lower plate  184 . Terminal guide  180  can be mounted on applicator  110 . Lower plate  184  contains a channel  186  which is dimensioned to accommodate terminals  12 . At least one outer edge of terminal carrier strip  14  rides against at least one edge  186 ′ of channel  186 . Upper Plate  182  contains a ridge  188 . Ridge  188 , by acting on a feature in terminal  12 , presses terminal carrier strip  14  against one edge  186 ′ of channel  186  in lower plate  184 , thereby guiding terminals  12  appropriately. Terminal guide  180  typically does not include drag plate  26  (as described hereinabove) or any mechanism to intentionally induce drag. 
         [0071]    Referring back to  FIG. 5 , terminal application assembly  100  can include press  130  incorporating applicator  110 , terminal feed mechanism  140 , and terminal guide  180  for the advancement and processing of packaged terminal assembly  10 . Preferably, terminal feed mechanism  140  pulls packaged terminal assembly  10  through terminal guide  180  to applicator  110 . By adjusting the position of sensor  162  in terminal feed mechanism  140 , an operator can precisely position terminals  12  over anvil  122  in applicator  110 . Because sensor  162  generates a signal from a feed hole  16  for each terminal  12 , and this signal is used to control motor roller  148 , positioning errors do not accumulate. An operator uses a foot pedal (not shown) to initiate actions by press  130  to crimp a terminal  12  to a wire (this process can also be initiated by another controller in an automatic wire processing machine (not shown)). Under control of press  130 , the terminal feed mechanism  140  is triggered to operate at the proper times to advance terminals  12  for processing. 
         [0072]    As described above with reference to  FIG. 5 , the position of sensor  162  in terminal feed mechanism  140  is adjusted to precisely position terminal  12  over anvil  122  in applicator  110 . If the sensor  162  position were controlled by a stepper motor, for example, and the stepper motor were controlled by press  130 , then terminal  12  positioning for each job could be saved in the memory of press  130 . As such, positioning for each terminal  12  could be set using a user interface  132  of press  130  and, once set, would not have to be set again. Alternatively, if a sensor capable of detecting a range of feed hole  16  positions was implemented (such as by using a linear arrangement of closely spaced optical sensors), advantages described above could be accomplished with no movement or physical re-positioning of sensor  162 . In yet another alternative, a single sensor (optical or otherwise) in a fixed position can be used as follows. A signal is generated after a precisely controlled time delay after a feed hole  16  is detected. The operator can control terminal  12  positions by setting the time delay. 
         [0073]    It is understood in this embodiment that press  130  has an option to reduce the stroke of ram  114 , that is, reduce the height to which ram  114  rises at the end of its cycle. The reduced height is possible since applicator  110  does not have to advance terminals  12 . The reduced height allows faster production rates. 
         [0074]    It is additionally understood in this embodiment that an operator can accommodate different terminals  12  by changing upper plate  182  of terminal guide  180  and the anvil  122 , blades  116 , and shear block  124  in applicator  110 . This aspect will permit easy and fast interchange of parts for specific terminal crimp job requirements. 
         [0075]    It is known in the art that some presses provide a capability called Crimp Force Analysis (“CFA”). CFA measures and analyzes the force imposed on the ram by the press motor to derive information about the quality of the crimp. For presses which perform CFA, the current embodiment presents opportunities to make the analysis simpler, more accurate and more precise. This is possible because applicator  110  is not used to advance terminals  12  and the CFA is therefore not required to determine what portion of the forces imposed on ram  114  must be allocated for terminal  12  advancement. 
         [0076]    The embodiment described hereinabove is described for implementation on a press  130 . It is understood that this embodiment can also be employed on an automatic wire processor  60 , such as that described hereinabove with reference to  FIG. 4 . In such applications, the automatic wire processor  60  can control terminal feed mechanism  140  and sensor  162  positioning, and store those settings with other data for a specific job. This allows for fast and easy set-up the next time that job is used. 
         [0077]    Implementation of this embodiment or variations of it do not preclude the use of standard applicators with integrated terminal feed mechanisms in bench-top presses or in presses mounted in automatic wire processing equipment. Additionally, it is understood that various modifications of this embodiment are encompassed herein, including: (1) usage of a terminal feed mechanism which pushes terminals to the applicator as opposed to pulling them through the applicator; (2) usage of a terminal feed mechanism which uses a paw engaged in the terminal carrier strip feed holes to advance terminals; (3) usage of a terminal feed mechanism which uses a paw to press directly against terminals to advance terminals; (4) usage of a pneumatic-based terminal feed mechanism; (5) usage of rollers instead of belts in a terminal feed mechanism; (6) usage of a terminal guide that is separate from the applicator; and (7) usage of a terminal guide which has adjustable features to accommodate a variety of terminals. 
       Embodiment with Integral Terminal Feed Mechanism 
       [0078]    With reference to  FIGS. 9-13 , another embodiment of the present invention contemplates a terminal applicator including an integrated terminal feed mechanism, preferably a feed mechanism adapted to feed a variety of terminal carrier strips through pressure engagement with the strip. 
         [0079]    Referring now to  FIG. 9 , an applicator is shown generally as  200  and employs a die  202  as a base or frame upon which other elements can be attached. A ram  204  within applicator  200  can be mated with a press (not shown, but similar to those described hereinabove) using a ram coupling  206 . An external press moves ram  204  through a working stroke towards, and a return stroke away from, an anvil  208  and a cutter  212 . Cutter  212  is activated by the downward stroke of ram  204 . Cutter  212  cuts terminal  12  from terminal carrier strip  14  and otherwise leaves terminal carrier strip  14  intact. Attached to ram  204  can be an insulation punch  214  and conductor punch  216 . 
         [0080]    Terminal  12  attached to terminal carrier strip  14  is fed through and guided by a guide plate  218  to insure proper front-to-back positioning of terminal  12  over anvil  208 . When a terminal  12  is properly positioned over anvil  208  and a properly stripped wire (not shown) is properly positioned over terminal  12 , the complete working stroke of ram  204  first towards and then away from anvil  208  will crimp terminal  12  to the wire and cut terminal  12  from terminal carrier strip  14 . The crimping of the exposed conductor of the wire to terminal  12  occurs as a result of forming elements of terminal  12  around the wire conductor as both are pressed between anvil  208  and conductor punch  216 . The crimping of an insulated portion of the wire to terminal  12  (for strain relief purposes, as described hereinabove) occurs as a result of forming elements of terminal  12  around an insulated portion of wire as both are pressed between anvil  208  and insulation punch  214 . 
         [0081]    A terminal sensor  222 , such as a through-beam optical sensor, can be provided and is used to sense the presence of a terminal  12  or some attribute of terminal carrier strip  14 , such as a hole. Terminal sensor  222  can include a light emitter and a light receiver. Terminal  12  or terminal carrier strip  14  is positioned between the light emitter and light receiver of terminal sensor  222 . An output of a first logic state occurs when the light beam from the emitter reaches the receiver unimpeded, which is the case when a terminal  12  or terminal carrier strip  14  is not in a position to block the light beam. An output of a second logic state occurs when a terminal  12  or terminal carrier strip  14  is in a position to block the light beam. The output state of terminal sensor  222  toggles as terminals  12  and terminal carrier strip  14  are moved past terminal sensor  222  because the light beam is alternately blocked/unblocked. 
         [0082]    A ram sensor  224 , such as a magnetic sensor, can be provided and is used to sense the position of ram  204 . An output of a first logic state occurs when ram  204  is down. An output of a second logic state occurs when ram  204  is up. Another feature that can be located in the vicinity of ram  204  is a crimp height adjustment dial  226  that is used to set the proper crimp height. 
         [0083]    Terminal progression, that is, the advancement and proper positioning of terminal  12  to anvil  208 , preferably occurs post-termination or post-separation. In one such arrangement, an intact terminal carrier strip  14  (with terminals  12  removed after application) is pressed between a drive wheel (or roller)  232  and an idler wheel (or roller)  234 . It is understood that idler wheel  234  could also be an additional drive wheel. The support structure for idler wheel  234  (not shown) can include a spring to bias idler wheel  234  toward drive wheel  232 . The resulting pressure force contact on carrier strip  14  when it resides between drive wheel  232  and idler wheel  234  causes carrier strip  14  and terminals  12  attached to it (such as before application) to move as drive wheel  232  is rotated. An idler wheel release  236  can be rotated to raise idler wheel  234  away from drive wheel  232  to facilitate loading of terminal carrier strip  14  between drive wheel  232  and idler wheel  234 . A drive apparatus within a motor and electronics enclosure  240  (described hereinbelow with reference to drive mechanism  250 ) rotates drive wheel  232  in a controlled and appropriate manner to advance and properly position terminal  12  over anvil  208 . A user interface  280  is connected to motor and electronics enclosure  240  with a user interface cable  281  and is described in further detail hereinbelow with reference to  FIG. 12 . 
         [0084]    Drive wheel  232  and idler wheel  234  can be attached to motor and electronics enclosure  240 , all of which can be supported on an adjustable carriage (not shown). A feed carriage adjustment screw  238  typically provides front-to-back positioning control of drive wheel  232 , idler wheel  234 , and motor and electronics enclosure  240  on this carriage. Feed carriage adjustment screw  238  can be used by an operator during a set-up procedure to position drive wheel  232  and idler wheel  234  for proper engagement with terminal carrier strip  14 . When drive wheel  232  and idler wheel  234  are properly positioned, two conditions are satisfied. First, proper engagement of drive wheel  232  and idler wheel  234  is achieved to provide proper terminal progression through pressure contact. Second, clearances behind drive wheel  232  and idler wheel  234  are available for terminal  12  to pass without creating jams in the event terminal  12  was not removed from terminal carrier strip  14  after the crimp application process. 
         [0085]    Referring now to  FIG. 10 , a drive mechanism  250  can contain several elements for driving drive wheel  232 , most of which preferably reside inside motor and electronics enclosure  240  (the exceptions typically being drive wheel  232  and idler wheel  234 ). A motor  252  is provided and is preferably a stepper motor which rotates in small, discrete steps. The amount of motor  252  rotation is controlled by the number of pulses applied to an input to motor  252 . Each pulse delivered produces one increment of rotation. An example of motor  252  is motor model number 23MD106S-00-00-00 manufactured by ANAHEIM AUTOMATION™, wherein the smallest increment of rotation for this particular motor is 0.225 degrees for each pulse delivered. The rate at which pulses are delivered control motor  252  speed, with higher pulse rates producing higher motor  252  speeds. It is understood that motor  252  can additionally comprise any motor that can be used for controlling positions, such as servo motors, etc. Motor  252  is coupled to a drive shaft  262  using a motor pulley  254 , belt  256 , and drive shaft pulley  258 . Drive wheel  232  is attached to drive shaft  262  and thereby is driven by motor  252 . 
         [0086]    Referring now to  FIG. 11 , a controller  270  can be provided that contains electronic hardware with embedded software to communicate with user interface  280  via user interface cable  281 , monitor signals from ram sensor  224  and terminal sensor  222 , control motor  252 , and exchange data with an external device through data interface  272 . A power supply and power and ground connections is also provided (not shown). Controller  270  can include a microcomputer  274 , such as a single chip computing device capable of executing software instructions. Hardware elements contained within microcomputer  274  can include, but are not limited to, input and output data ports, processor, clock/oscillator, power-up reset circuits, and volatile and non-volatile memory storage for the software program and data. Controller  270  provides the “intelligence” to process signals from user interface  280 , external equipment, and sensors to control drive mechanism  250  to achieve proper terminal  12  progression. 
         [0087]    Referring now to  FIG. 12 , the construction and functionality of a user interface  280  contemplated in one embodiment will now be described. User interface  280  can contain a delay thumbwheel switch  282 , a speed thumbwheel switch  284 , multiple progression thumbwheel switches  286 , a “Power” LED  288 , a “Ready” LED  292 , and a manual switch  294 . Each of the thumbwheel switches can assume ten (10) states and each state is represented by displaying one of numbers 0 through 9. Two buttons on each thumbwheel switch allow the selected number to be incremented or decremented. User interface  280  can communicate with microcomputer  274  within controller  270  via user interface cable  281 . Manual switch  294  is a momentary contact switch. 
         [0088]    Power LED  288  is typically on if electrical power is applied to applicator  200  and Power LED  288  is off otherwise. Ready LED  292  is on whenever applicator  200  is in a state which will allow initiation of a feed cycle for terminal  12 , that is, advancing the next terminal  12  to be crimped to a proper position over anvil  208 . 
         [0089]    Speed thumbwheel switch  284  is used to select the speed at which terminals  12  are advanced, typically with selection “1” being the slowest and selection “9” being the fastest. Selecting “0” prevents feed cycles from being initiated. Ready LED  292  is typically off whenever speed thumbwheel switch  282  selection is “0.” Assuming a non-zero speed selection is made on speed thumbwheel switch  284 , a feed cycle is initiated when controller  270  senses the upward stroke of ram  204  as a result of monitoring ram sensor  224  or when manual switch  294  is depressed. Manual switch  294  facilitates setting up a production run by allowing an operator to initiate feed cycles without having to move ram  204 . 
         [0090]    Delay thumbwheel switch  282  enables an operator to introduce a delay between a stimulus to initiate a feed cycle (the stimulus being the upward motion of ram  204  or depression of manual switch  294 ) and the actual initiation of the feed cycle. A delay thumbwheel switch  282  selection of “0” typically provides no delay, a selection of “1” provides the shortest delay, and a selection of “9” provides the longest delay. Delays are provided to allow crimped terminal  12  and wire to be removed from the crimping zone of applicator  200  prior to initiation of the next feed cycle. 
         [0091]    When a feed cycle stimulus is received by controller  270  and a non-zero speed selection has been made and any selected delay has expired, controller  270  typically implements a feed cycle as follows. 
         [0092]    Pulses are delivered to motor  252  at a rate appropriate for the speed selection. Simultaneously, the output of terminal sensor  222  is monitored. Pulses are applied until the first occurrence of one of the following events: (A) terminal sensor  222  transitions from a state of light not being blocked to a state of light being blocked or other appropriate transition, or (B) a pre-determined number of pulses has been delivered to motor  252 . If event A occurs first, terminal  12  progression continues by delivering a number of pulses to motor  252  equal to the number specified in the progression thumbwheel switches  286  (at a rate appropriate to the selected speed). After the final pulse is delivered, controller  270  returns to monitoring ram sensor  224  and manual switch  294  in anticipation of another feed cycle. If event B occurs first, delivery of pulses to motor  252  stops and controller  270  returns to monitoring ram sensor  224  and manual switch  294  in anticipation of another feed cycle. This condition occurs when terminals  12  are no longer available, that is, such as when the end of the reel of terminals has been reached. It is noted that the feed cycle as described above may require sensing a terminal  12  (or some attribute of terminal carrier strip  14 ) to complete the cycle. As a result, if a positioning error exists, it will occur on each feed cycle, but the error will not be cumulative. 
         [0093]    In order to set-up applicator  200  for a given terminal  12  (different sized terminals, etc.), an operator must determine the correct number to load into progression thumbwheel switches  286 . This number is referred to as the progression number. In one embodiment, the progression number is stamped or printed on a terminal-specific tooling element of applicator  200 , such as insulation punch  214  or guide plate  218 . Other options for determining the progression number include, but are not limited to, the following: (1) use a trial and error method to determine the correct number; (2) obtain the number from published information or information available from the Internet; (3) implement a modified user interface which allows an operator to specify a terminal  12  by part number, wherein a database installed in controller  270  contains the progression number for the specified terminal  12 ; or (4) use a fully automatic method requiring no data input from an operator (as described in more detail hereinbelow). 
         [0094]    Referring now to  FIG. 13 , an elevation view of a terminal  12  on a terminal carrier strip  14  being fed past anvil  208  is presented. Since each pulse delivered to motor  252  results in a given angular displacement of motor  252  which results in a known, linear movement of terminal carrier strip  14 , distances shown in  FIG. 13  are represented by the number of pulses P delivered to motor  252 . Using this nomenclature, the distances shown in  FIG. 13  are as follows: 
         [0095]    P SA =Distance from center line CL 1  of terminal sensor  222  to center line CL 2  of anvil  208 . This distance is known from design information for applicator  200 ; 
         [0096]    P TW =Width of terminal  12  (at that portion of terminal  12  where terminal sensor  222  is located); 
         [0097]    P TS =Distance between terminals  12  on terminal carrier strip  14  (center line to center line); and 
         [0098]    P GAP =Distance between leading edge of the next terminal  12  to be crimped and center line CL 2  of anvil  208  when the leading edge of another terminal  12  is aligned with center line CL 1  of terminal sensor  222 . 
       Automatic Progression Number Determination 
       [0099]    After the operator has properly loaded terminals into applicator  200 , a fully automatic method can be used to determine the progression number (in lieu of manual entry as described hereinabove). In such a method, it is assumed that terminal sensor  222  is positioned such that terminal  12  will block the light path between the light emitter and the light receiver in terminal sensor  22  as opposed to terminal carrier strip  14 . 
         [0100]    Referring now to  FIG. 14 , a signal is illustrated that is provided by terminal sensor  222  as terminals  12  are advanced through terminal sensor  222 . A “high” signal level represents the state where terminal  12  blocks the light between the light emitter and light receiver in terminal sensor  222 . A “low” signal level represents the state where terminal  12  does not block the light between the light emitter and light receiver in terminal sensor  222 . 
         [0101]    To automatically determine the progression number, user interface  280  is modified to enable an operator to place applicator  200  in a “learning” mode. No further user input is required to determine the progression number. Referring further to  FIG. 14 , after applicator  200  has been placed into the learning mode, controller  270  advances terminals  12  until a low output from terminal sensor  222  is obtained, if necessary. Terminals  12  are then further advanced until a low to high transition from terminal sensor  222  occurs. If a low to high transition does not occur after a pre-determined number of pulses has been delivered to motor  252 , then an end of reel condition has been sensed. For this case, no additional pulses are sent to motor  252  and the learning mode is terminated. If a low to high transition does occur before a pre-determined number of pulses are delivered to motor  252 , this indicates that a terminal  12  has just blocked the light between the light emitter and light receiver of terminal sensor  222 . The “count” of motor  252  (that is, the number of pulses delivered to motor  252 ) is designated as 0 at this point to establish a reference. Terminals  12  are then further advanced (and motor  252  counts are tallied) until a high to low transition from terminal sensor  222  occurs. This indicates that a terminal  12  has just stopped blocking the light between the light emitter and light receiver of terminal sensor  222 . The motor  252  count at this point is stored in memory and is designated as P 1 . Terminals  12  are then further advanced (and motor counts continue to be tallied from the original reference value of 0) until a low to high transition from terminal sensor  222  occurs. This indicates that the next terminal has just blocked the light between the light emitter and receiver of terminal sensor  222 . The motor  252  count at this point is stored in memory and designated as P 2 . Controller  270  then performs the following calculation to determine the progression number P PROG : 
         [0102]    P SA =Known quantity (from design information of sensor  222  and anvil  208  positions) 
         [0103]    P TW =P 1    
         [0104]    P TS =P 2    
         [0105]    P GAP =[(P SA /P TS )−INT(P SA /P TS )](P TS ) 
         [0106]    P GAP =[(P SA /P 2 )−INT(P SA /P 2 )](P 2 ) 
         [0107]    P PROG =P GAP +0.5(P TW ) 
         [0108]    P PROG =P GAP +0.5(P 1 ) 
         [0000]    where INT is the greatest integer function (the greatest integer function returns only the whole number portion of the quotient). 
         [0109]    Half of the terminal width must be added to P GAP  because P GAP  is the distance from the forward-most edge of terminal  12 , not the center line of terminal  12 , to the center line of anvil  208  (see  FIG. 13 ). After moving a distance of P GAP , an additional distance equal to half of terminal  12  width must occur to center terminal  12  over anvil  208 . 
         [0110]    After completion of the learning mode, applicator  200  reverts to a normal mode during which controller  270  awaits initiation of a feed cycle by monitoring ram sensor  224  or manual switch  294 . 
         [0111]    Using a modified user interface  280 , an operator can input an offset value to modify the progression number determined during the learn mode. For this case, the progression number is calculated as: 
         [0000]        P   PROG   =P   GAP +0.5( P   1 )+Offset 
       Applicator Installation 
       [0112]    To crimp wires to terminals  12 , applicator  200  must be installed in a press, such as presses  50  or  130  described hereinabove. The press provides a means to physically secure applicator  200  and maintain it in a proper position. The press also provides the energy to cycle ram  204  first down toward anvil  208  and then away from anvil  208  to the original starting position to complete a crimping cycle. However, in all other respects, applicator  200 , as described thus far, has no other reliance on the press. Applicator  200  has the requisite mechanical and control elements, including user interface  280 , to allow proper set-up of and execution of production runs. This aspect supports use of applicator  200  in a wide variety of presses, including older presses which lack advanced features and capabilities of newer, modern presses. 
         [0113]    In those cases where applicator  200  is used in a modern press having advanced features and capabilities (such as the KOMAX® MCI  711  press), or is used in a press which is installed in an automatic wire processing machine (such as the KOMAX® Gamma 333 PC), data interface  272  in controller  270  can be used to obtain additional functional benefits. In such cases, applicator  200  can support bi-directional data exchange with external equipment, be it the press, automatic wire processing equipment, or other equipment. With this arrangement, additional functional capabilities include, but are not limited to, the following: (1) the external equipment can download data to trigger a feed cycle; (2) the external equipment can determine and download data to specify the progression number, delay and speed settings, or to recommend settings which an operator may modify before downloading; (3) the user interface on the external equipment can enable an operator to manually specify the progression number, delay settings, and speed settings and download that data to the applicator  200 ; (4) the user interface on the external equipment can enable an operator to manually initiate a feed cycle without having to move ram  204 ; (5) applicator  200  can send data to the external equipment to convey operational status, including end of reel conditions; and (6) with an appropriately modified applicator  200 , the external equipment can download data to control the release state of idler wheel  234  and the position of idler wheel  234  and drive wheel  232 . 
       Method for Advancing Terminals 
       [0114]    With reference to  FIGS. 9-12 , a method for advancing terminals will now be described. The method described herein typically relies on a pressure contact with terminal carrier strip  14 . Terminal  12  feeding methods used by other applicators contain elements that exploit specific design characteristics of a specific terminal  12  or its terminal carrier strip  14 . For example, prior art applicators typically include a feed paw designed to mate with a feed hole  16  of a certain size and spacing on terminal carrier strip  14 . Therefore, as a practical matter, most prior art applicators work with only one terminal  12  or, at best, a few terminals  12  within a family of terminals  12 . The feeding method as described herein is much more universal because the preferred pressure engagement with terminal carrier strip  14  is not dependent on any specific attribute of terminal carrier strip  14 . This aspect provides very significant benefit, as described hereinbelow. 
         [0115]    In accordance with an embodiment of the present invention, elements of applicator  200  which “touch” terminal  12 , that is, are unique to the terminal  12  being crimped, is limited to guide plate  218 , anvil  208 , conductor punch  216 , insulation punch  214  and, in some cases, cutter  212 . Generally, the remaining elements of applicator  200  are not terminal specific. Referring to guide plate  218 , anvil  208 , conductor punch  216 , insulation punch  214  and, in some cases, cutter  212  as a tool pack, a user of applicator  200  need purchase only one (or a few) applicators  200  even for a wide variety of terminal jobs. To handle specific terminals  12 , the user need purchase only the tool pack for each specific terminal  12 . As described hereinbelow, tool packs are installed in applicator  200  as required to accommodate different terminals. By avoiding the purchase of a complete applicator  200  for each terminal  12  to be crimped, the user enjoys substantial tooling savings. 
         [0116]    As an example of the set up of applicator  200  for a production run, an operator can perform the following steps. 
         [0117]    First, the appropriate tool pack (consisting of, for example, guide plate  218 , anvil  208 , conductor punch  216 , insulation punch  214  and, in some cases, cutter  212 ) is installed into applicator  200  and applicator  200  is installed in a press. Next, the operator loads terminals  12  on terminal carrier strip  14  into guide plate  218 , over anvil  208  and to idler wheel  234  and drive wheel  232 . Idler wheel release  236  is set to a position that raises idler wheel  234  away from drive wheel  232 . Terminal carrier strip  14  is placed between idler wheel  234  and drive wheel  232 . If necessary, feed carriage adjustment screw  238  is adjusted to align idler wheel  234  and drive wheel  232  with terminal carrier strip  14 . Idler wheel release  236  is set to a position that lowers idler wheel  234  against terminal carrier strip  14 . 
         [0118]    After this, crimp height adjustment dial  226  can be adjusted to the setting that provides the correct crimp height. The user can then load the correct progression number, such as that found printed on one of the tool pack elements, into user interface  280 . The desired speed and delay can then be loaded into user interface  280  and manual switch  294  can be pressed once to position a terminal over the anvil. At this point, applicator  200  is set up and ready for operation. 
       Alternative Embodiments 
       [0119]    Various alternative embodiments of the present invention are contemplated herein. In one embodiment discussed hereinabove, idler wheel  234  and drive wheel  232  are positioned to engage terminal carrier strip  14  post-termination or post-separation (that is, in a position downstream from anvil  208  of applicator  200 ). It is contemplated herein that idler wheel  234  and drive wheel  232  can be positioned to accept terminal carrier strip  14  pre-termination (that is, in a position upstream from anvil  208  of applicator  200 ). Likewise, in one embodiment discussed hereinabove, terminal sensor  222  is positioned in a location that is pre-termination. It is contemplated herein that terminal sensor  222  can be positioned in a location that is post-termination. In this latter alternative, terminal sensor  222  typically relies on attributes of terminal carrier strip  14 . 
         [0120]    In one embodiment discussed hereinabove, user interface  280  is typically tethered to motor and electronics enclosure  240  via user interface cable  281 . It is contemplated herein that user interface  280  could be configured as follows: (1) integrated within motor and electronics enclosure  240 ; (2) remain separate from motor and electronics enclosure  240  using a wireless link, such as an infrared link or radio frequency (RF) link; or (3) omitted entirely by relying solely on a user interface in the press or automatic wire processing equipment. 
         [0121]    In one embodiment discussed hereinabove, idler wheel  234  and drive wheel  232  are wheels (or rollers) as their names imply and thereby rely on rotary motion to advance terminal carrier strip  14 . Alternatively, non-rotary methods can be employed to advance terminal carrier strip  14  and still utilize a pressure contact with terminal carrier strip  14 . For example, a method is contemplated which includes two elements in which, at a first position, each moves toward terminal carrier strip  14  to capture or secure terminal carrier strip  14  by pressure. The two elements, while maintaining the hold on terminal carrier strip  14 , then move together to a second position that moves terminal carrier strip  14  to properly position the next terminal  12  over anvil  208 . The two elements then each move away from terminal carrier strip  14  to release the grip on terminal carrier strip  14 . The two elements, while maintaining no grip on terminal carrier strip  14 , return to the first position from which the feed cycle can be repeated. It is contemplated that these non-rotary feed cycles could be implemented pre-termination or post-termination. 
         [0122]    In one embodiment discussed hereinabove, terminal sensor  222  is in a fixed position relative to anvil  208 . It is contemplated that the distance of terminal sensor  222  relative to anvil  208  can be adjustable. To obtain proper positioning of terminal  12  over anvil  208  in this case, the operator would typically adjust the position of terminal sensor  222 . 
         [0123]    Finally, in one embodiment discussed hereinabove, all elements required to feed and crimp terminals  12  are included in applicator  200 . It is further contemplated that those elements related to feeding terminal  12  (drive mechanism  250 , including idler wheel  234  and drive wheel  232 ), feed carriage adjustment screw  238  and carriage, motor and electronics enclosure  240  (and all apparatuses contained therein), and user interface  280  are separated from applicator  200  and instead installed on the press. Since the press drives ram  204 , it therefore knows the position of ram  204  without the need for ram sensor  224 . Embodiments are possible with terminal sensor  222  remaining part of applicator  200  or being included with the press. 
         [0124]    It will be understood that various details of the present invention may be changed without departing from the scope of the present invention. Furthermore, the foregoing description is for the purpose of illustration only, and not for the purpose of limitation, as the present invention is defined by the claims as set forth hereinafter.

Technology Category: y