US3341926A

US3341926A - Terminal assembly apparatus

Info

Publication number: US3341926A
Application number: US393910A
Authority: US
Inventors: Helmut E Durr; Roger R Wahlberg
Original assignee: Western Electric Co Inc
Current assignee: AT&T Corp
Priority date: 1964-09-02
Filing date: 1964-09-02
Publication date: 1967-09-19
Anticipated expiration: 1984-09-19

Description

p 1967 H. E. DURR ETAL 3,341,926

TERMINAL ASSEMBLY APPARATUS Filed Sept. 2, 1964 9 Sheets-Sheet 1 p 197 H. E. DURR ETAL 3,341,926

TERMINAL ASSEMBLY APPARATUS Filed Sept. 2, 1964 74 ['L "IIIHI' *r' g H 9 Sheets-Sheet 2 H I 23 "I Mill/(111N01 p 1967 H. E. DURR ETAL 3,341,926

TERMINAL ASSEMBLY APPARATUS Filed Sept. 2, 1964 9 Sheets-Sheet 5 1 MM I p 1967 H. E. DURR ETAL 3,341,926

TERMINAL ASSEMBLY APPARATUS Filed Sept. 2, 1964 9 Sheets-Sheet 4 Se t. 19, 1967 H. E. DURR ETAL 3,341,926

TERMINAL ASSEMBLY APPARATUS Filed Sept. 2, 1964 9 Sheets-Sheet 5 p 19, 1967 H. E. DURR ETAL 3,341,926

TERMINAL ASSEMBLY APPARATUS Filed Sept. 2, 1964 9 Sheets-Sheet 6 Sept. 19, 1967 DURR E 3,341,926

TERMINAL ASSEMBLY APPARATUS Filed Sept. 2, 1964 9 Sheets-Sheet 7 p 1967 H. E. DURR ETAL 3,341,926

TERMINAL ASSEMBLY APPARATUS Filed Sept. 2, 1964 9 Sheets-Sheet 8 5 l g-ZE p 1967 H. E. DURR ETAL 3,341,926

TERMINAL ASSEMBLY APPARATUS Filed Sept. 2, 1964 9 Sheets-Sheet 9 United States Patent 3,341,926 TERMINAL ASSEMBLY APPARATUS Helmut E. Burr, Summit, Frank Wahl, North Bergen,

and Roger R. Wahlberg, Bloomfield, N.J., assignors to Western Electric Company Incorporated, New York,

N.Y., a corporation of New York Filed Sept. 2, 1964, Ser. No. 393,910 6 Claims. (Cl. 29203) ABSTRACT OF TIE DISCLOSURE An apparatus for forming J-shaped terminals and inserting them into apertures arranged in rows at opposite positions in an insulating member comprises an intermittent feeding means for feeding a plurality of wires, means for cutting the wires into predetermined lengths, and means for forming the cut wires into two groups of J-shaped terminals. Each group of formed terminals is fed a different distance such that the legs of the terminals are in alignment with rows of apertures in an-insulating member and the legs are then inserted into the apertures.

This invention relates to assembly apparatus and particularly to apparatus for automatically forming a plurality of terminals and inserting the formed terminals in electrical insulating members such as the terminal leads of repeating coils.

In the large-scale manufacture of electrical devices such as repeater coils, it is a time consuming and costly proposition to assemble a plurality of unconventionally shaped terminals within terminal heads. The terminal head is a plastic molded part which is attached to one end of the core of a bobbin on which a repeating coil is wound. In the manufacture of repeater coils, it is required that each leg of a plurality of substantially J-shaped terminals be inserted within apertures of the terminal heads. In this instance, each terminal leg must be located with reference to an aperture and the terminal forcibly assembled to the part. Alignment and assembly operations present difliculties which hinder the application of automatic assembly methods. It is to be noted that the normal manufacturing sequence presupposes the use of preshaped terminals which require a separate forming operation constituting an additional cost factor.

The advantages of automatically assembling a plurality of terminals in a part have been recognized by the prior art and a number of insertion machines have been developed for particular applications. However, these machines generally require that the terminals be formed and then fed at some stage of the process or individually inserted into the terminal apertures. No commercial machine is known to be available for automatically forming a plurality of terminals of a non-standard configuration, such as a J-shape, and assembling them simultaneously within a plurality of apertures. Consequently, terminal assembly operations still represent a disproportionately high percentage of the unit cost in the'manufacture of many electrical devices.

Accordingly, an object of this invention is to automatically form a plurality of terminals and assemble them in an electrical device.

Another object of this invention is to provide a method of intermittently feeding one or more wires, cutting the wires to size, notching and forming the wires and inserting the wires within apertures in an apertured insulating member.

A further object of this invention is a unique control arrangement for synchronizing a plurality of dilferent operations in the forming of terminals and their insertion in insulating members.

In its broader aspects, the invention comprises an apparatus for automatically feeding, forming and inserting a plurality of wire terminals within apertures in an insulating member such as a terminal head of a bobbin. The apparatus includes a reel supply arrangement, a stock straightener to simultaneously straighten a plurality of square terminal wires payed off the supply reels, a stock feeder to intermittently advance-the wires and a press having cut-ofi and forming die sections for supplying preshaped terminals to a work station where a plurality of formed terminals are simultaneously assembled to a clamped terminal head.

In general, the terminal assembly apparatus embodied herein provides a means for automatically feeding, form ing and inserting one or more substantially J-shaped square wire terminals into corresponding apertures of a terminal head such as a repeater coil head of molded plastic material. The apparatus includes a punch press having a sliding-type forming and cut-oft" die for cutting the terminal wires to the proper length, and notching and forming the terminals into the aforementioned configuration. The sliding die section is advanced to a work station where the formed terminals are inserted into apertures in a terminal head. The wires are fed initially from a plurality of supply reels through a two-direction wire straightener by a feeder unit which advances a predetermined length of wire to the first work station where the wires are notched, cut to size, and formed in a controlled sequence and then transported to a work station for insertion into a molded terminal head.

To initiate the assembly operation, a series of terminal heads are fed along a track to a work station, tripping a pair of switches and energizing a control circuit. The terminal head is moved downward and clamped in position while one or more previously formed terminals which are positioned within a plurality of die nests are driven upwardly into designated apertures in the terminal head. The completed terminal head assembly is then ejected from the apparatus. The die returns to a loading position and the feeder unit is energized to advance a succeeding group of straightened wires into the die nests where the Wires are cut to size and formed into a J- shaped configuration. The slidable die is moved along the die bed of the press to an insertion work station where a terminal head having a plurality of apertures is positioned thereover. The above steps are then repeated for succeeding parts.

These and other objects and advantages of the present invention will be apparent from the following detailed description when considered in conjunction with the following drawings wherein:

FIG. 1 is an isometric drawing of the cutting, forming and inserting portion of the apparatus with the movement of a repeater coil head being illustrated in phantom;

FIG. 2 is a sectional View taken along the line 22 of FIG. 1 to show a portion of the cutting and forming die;

FIG. 3 is a section taken along the lines 33 of FIG. 1 to illustrate another portion of the cutting and forming die;

FIG. 4 is a top view showing a portion of the reel arrangement plus a part of the wire straightener;

FIG. 5 is a top view showing another part of the wire straightener, a feed stop for the wire and a portion of the feeder unit;

FIG. 6 is a top view of the feeder unit and a cutting, forming and sliding die and inserting work station;

FIG. 7 shows the respective relationship of FIGS. 4, 5 and 6;

FIG. 8 is a side view of the reel supply and two-way wire straightener;

FIG. 9 is a side view partially in cross section of the wire friction arrangement, feeder unit, notching punch and the insertion work station;

FIG. 10 illustrates the respective arrangement of FIGS. 8 and 9;

FIG. 11 is a cutaway side view of the insertion work station;

FIG. 12 shows the electrical control system for the apparatus;

FIG. 13 shows the pneumatic control system for the apparatus; and

FIG. 14 shows a typical molded part having terminals assembled thereto.

With reference to FIGS. 4 to 10 of the drawings, the invention comprises an apparatus for automatically forming and inserting a plurality of I-shaped terminals 11 into apertures in parts'such as a terminal head 10 of molded plastic material. A typical terminal head 10 is shown in FIG. 1 and includes a base 13 and a pair of parallel vertically extending portions 14 uniformly spaced from opposite edges of the base 13. The vertically extending portions 14 include -a plurality of apertures 12 to receive the longer leg 16 of the J-shaped terminals 11 while the base portion 13 includes a plurality of apertures 17 to receive the shorter leg 18 of the terminals.

The apparatus includes a supply arrangement 20,.FIGS. 4 and 8, a wire straightening arrangement 25, FIGS. 4, 5 and 8, a feed unit 30, FIGS. 6 and 9 and a punch and die arrangement 40, FIGS. 6 and 9 for notching and cutting terminals to length, forming the terminals and inserting them within the apertures in the terminal head. The apparatus provides for a continuous flow arrange ment wherein the separate portions thereof are laid out as depicted in FIGS. 7 and 10, the former representing a top view and the latter a side view of the apparatus.

Referring to FIGS. 4 and 8, a plurality of square terminal wires 19 are payed off a plurality of reels 21 rotatably mounted to the vertical support 22 within a suitable supply arrangement 20. In the illustrated embodiment twelve wires 19 are being unwound from reels 21, two of which are shown. The invention could, of course, be readily adapted for use with any convenient number of wires 19 depending upon the number of terminals required. The wires 19 which are approximately .045 inch square are advanced through a straightening apparatus 25 comprising a first group of vertically mounted rollers 23 and a second group of horizontally mounted rollers 24. The wires 19 as shown in the drawings are divided into two groups of six. Each group is fed in vertical array through roller guides 26 to a series of vertically disposed straightening rollers 23 which are alternately positioned on opposite sides of the taut terminal wires 19 to exert a straightening pressure thereon. The wires 19 fan out in a horizontal plane as they emerge from a second pair of roller guides 27 after the straightening operation and are advanced into a plurality of guide slots 141 having tapered entrance portions 142. A plurality of horizontal rollers 24 straighten the wires 19 in a direction transverse to the first straightening plane.

Upon emerging from the straightener 25, the wires 19 pass through a friction device 28, FIGS. 5 and 9, which includes a plurality of adjustable plunger elements 29 loaded by springs 31. The plungers 29 are mounted within an overhead support member 32 and project therefrom a predetermined distance to contact the wires 19. The member 32 is secured to vertical portions 33 of the frame 34 at each end 36. The friction device 28 is designed to maintain pressure on the wires 19 to prevent any back movement thereof during the rest intervals of the feeding unit which provides an intermittent feed movement to the wires 19. During these intervals, the wires 19 are not held by the feed unit 30 and may tend to retract towards the reels 21.

The unit 30, as shown in FIGS. 5, 6 and 9, comprises a carriage 37 mounted on slide bars 38 and movable therealong upon actuation of cylinders 39 and a plurality of wire-gripping clamps 41 pivotally mounted to a shaft 4-2 within a recess 43 in the carriage 37. The clamps 41 include a forward gripping surface 44 which is actuable when air is supplied through inlet 47 to the one-way cylinders 48 actuating plungers 46. Each clamp 41 grips a predetermined length of wire 19 at a first position, feeds the wire 19 forward as the carriage 37 reciprocates along the slide bars 39 between stops 49 and 51 and releases the wire at a second position. Individual clamps are required to take care of slight variations in wire thickness.

An extending rear portion 52 of each clamp 41 engages the upper surface 53 of a ledge 54 on a pivotally mounted member 56 when the carriage 37 reaches the end of its forward travel. A threaded member 57 mounted to a bracket 58 on the ram 59 contacts a rear portion 61 of member 56 on the downstroke of the press pivoting member 56 about shaft 62. The ledge 54 is moved upwardly against the plunger 46 releasing the wires 19 while the carriage 37 returns to its initial starting position. A thread adjustment means 63 is provided to limit the movement of each clamp 41 to accommodate different size wires 19. To summarize, the clamp 41 engages the wires 19 in an initial position with the carriage 37 against stop 49 and carries the wires 19 until it reaches stop 51. The wires 19 are then released and held by friction device 28 during the work cycle of the press 58 and while the carriage returns to its initial position.

The punch and die arrangement 40 includes a base portion 64 having a die mounted thereon with a plurality of guide slots 66 with tapered entry portions 67 to receive the individual wires 19 from the feeder unit 30 and an overhead member 68 mounted to the base 64 to maintain the wires 19 within the slots 66. The die includes a pair of notching die

sections

69 and 71, one for each group of six wires. The notching

die sections

69 and 71 are spaced diagonally apart and each comprise an anvil portion 72 and a notching member 73 for forming a pair of notches 77 and 78 on the upper and lower surfaces of the wire in cooperation with the

punch elements

74 and 75, respectively. The anvil and notching

portions

72 and 73 are reversed on the

die sections

69 and 71 since the particular wire groupings are designed for insertion on opposite sides of the terminal head 10. The cooperating punch elements 74- and 76 for forming the terminal se curing notches 77 and 78 on the separate wire groups are shown in FIGS. 2 and 3 in an operative position.

The notched Wires 19 are fed forward on the next work cycle until the end portions rest in the alignment arrangement 154 which includes a comb-shaped entry portion 156 and a series of guide springs 157. Upon actuation of the press 50', the wires 19' are cut to terminal length by a pair of blades 79a and 79b mounted to the ram 59 by means 81a and 81b. The blades 79a and 79b each cut a group of six wires 19 as they descend into recesses 82a and 82b in the die on the downstroke of the press 50. Forming portions 83a and 83b on the punch lag slightly behind the blades 79a and 79b on the downstroke of the ram 59 to form the severed wires 19 into a J-shape with the legs extending upwardly substantially parallel to each other within forming die sections 84a and 84b. The die sections 84a and 84b include recesses 86 which retain the formed terminals 11 in an upright position for terminal insertion. The die section 84b is mounted on a reciprocable rod 87 and includes a transversely mounted pin 88 which projects into a recessed portion 89 of sec tion and imparts reciprocable movement thereto when it engages the end surfaces 91 or 92 during the to and from movement of section 8417. v

In operation, the two groups of wires 19 are formed in a substantially I-shaped configuration within the slots 86, see FIGS. 2 and 3, and section 8411 is driven forward to a terminal insertion position 90. The pin 88 engages the surface 91 on section 84a, as shown in FIG. 1, when section 8411 is positioned alongside and both sections 84a and 84b are moved into the position 90.

The parts ie the molded terminal heads are individually fed along a recess 93 on the feed platform 94 with the vertical portions 14 straddling the overhead member 96 until the leading edges of a molded head 10 trip both switches 101 and 102. The switches 101 and 102 are mounted to the member 96 which in turn is connected to the guide bars 97 by bolts 98. The head 10 is driven downwardly over the terminals 11 within the feed aperture 99 by member 96 while spring elements restrain the lateral movement of the head 10. The insertion punch 111 is actuated by pivotally mounted air cylinder 112 which pivots member 113 against the spring-loaded lower portion 114 forcing a plurality of prepositioned terminals 11 into a secure position with apertures 12 and 17 in the molded part 10. The assembled head 10 is ejected down the chute 114 by gravity by means (not shown) located on the base of the die.

With reference to FIGS. 12 and 13 of the drawings, the relay 120 is operated when the series connected switches 101, 102, 103, 104 and 106 are closed. The terminal head 10 is fed along the feed track recess 93 with the vertical portions 14 straddling the clamping member 96 as shown in FIG. 1 until the leading edges 15 of the vertical portions 14 trip switches 101 and 102. The switches 101 and 102 are connected in series so that the circuit is completed only by properly positioned parts 10 which operate both switches simultaneously. Switch 103, see FIG. 6, is closed by the shoulder portion 143 on the piston rod 87 of cylinder 144 when the slide die 84b is in a forward position. Switch 104 is closed by the contact member 146 mounted on bracket 147 when the feed unit carriage 37 returns to its initial position while the remaining series connected switch 106 is operated by the press shaft 148 to shut off the press cycle on the upstroke of the ram 59.

Relay 120 when energized closes

contacts

121, 122 and 123 operating the control circuit solenoid valve 125 and solenoid valve 126. Solenoid valve 125, when energized, moves the clamping member 96 and the terminal head 10 which is engaged thereby downwardly over the plurality of formed terminals 11 by means of cylinder 145, see FIG. 13. Solenoid valve 126, when energized, operates the individual clamping devices 41 for holding the plurality of square wires 19 in a fixed position. At the end of the downward movement of the clamping member 96, limit switch 107 is tripped by a contacting member 149 which is affixed to the guide bar mounting 151. Current is supplied through the closed switch 107 to energize relay 127 which closes contacts 128

operating solenoid valves

129 and 130. Solenoid valve 129 supplies air to cylinders 39 which include piston rods 35 connected to brackets 99 at one end for reciprocating the wire feeder unit 37 along slide bars 38 between stops 49 and 51. The carriage 37 is advanced against stop 51 upon actuation of cylinders 39 and remains in this position until the controlling valve 129 is de-energized.

Solenoid valve 130 supplies air to cylinder 112 moving the plurality of formed terminals 11 upward into the molded terminal head 10 which is positioned thereover by the clamping member 96. When the terminals 11 have been assembled to the head 10, limit switch 108 is tripped by member 152 energizing relay 131. Relay 131 closes associated relay contacts 132 to energize solenoid valve 133. The valve 133 actuates cylinder 144 to move sliding dies 84a and 84b from an inserting position to a forming position. The rear portion 153 of die 84a trips limit switch 109 energizing relay 136 which closes associated contacts 137. This energizes solenoid valve 138 releasing the punch press clutch (not shown) to permit the downward movement of the ram 59 for a forming and cutting operation.

On the upward stroke of the ram 59, limit switch 106 is tripped

de-energizing solenoid valves

125, 126, 129, 130 and 133 which control the feeding, forming and inserting circuit. When de-energized, solenoid valve 125 allows the air cylinder 145 to open returning the clamping device 96 to its original position. Solenoid valve 126 releases the wire clamps 41 and solenoid valve 129 allows the air cylinders 39 to open moving the wire feeder unit 30 to its initial feed position. Limit switch 104 is tripped by member 146 on the carriage 37 closing the circuit. Limit switch 104 also functions as a check feature to obtain a full length of wire 19 required for forming a terminal 11. Solenoid valve 130 de-energized, allows cylinder 112 to open returning the terminal insertion members 114 and downward to their original position. The assembled terminal head 10 is ejected down the chute 114 on the return movement of the dies 84a and 84b. Solenoid valve 133, de-energized, causes cylinder 114 to move the slide die from a forming position to an inserting position. At the end of this movement, limit switch 103 is tripped permitting the complete cycle to be repeated. As a safety precaution, the cycle cannot be started until the sliding die has moved to the forward position tripping limit switch 103.

While the operation of the apparatus has been shown with twelve wire terminals 11 and a particular repeater coil head 10, it is to be understood that the above-described arrangements are merely illustrative examples of the principles of the invention and any number of terminals could be inserted into differently designed parts without departing from the spirit or scope of the invention. It is also to be understood that the invention may be modified to form diverse terminal configurations and assemble these terminals to mating terminal blocks.

What is claimed is:

1. An apparatus for forming terminals with parallel legs and inserting the legs into apertures arranged in rows at opposite sides of an insulating member such as a terminal head comprising:

a plurality of wire supply reels,

means for intermittently feeding wires from the supply reels,

means for severing a predetermined length from the wires fed by the intermittent feeding means,

a pair of movable die means, each die means receiving a group of the predetermined lengths of wire and including a row of forming recesses,

means cooperating with the die means for forming the severed lengths of wires in the recesses such that terminals are provided having parallel legs protruding above the recesses,

means for receiving a terminal head,

means for transferring each die means a different distance to positions at opposite sides of the terminal head such that the legs of the terminals are in alignment with rows of apertures in the terminal head, and

means for causing relative movement of the terminal head receiving means and both die means to insert the terminal legs into the apertures at opposite sides of the terminal head.

2. An apparatus according to claim 1 wherein the means for intermittently feeding the wires comprises:

a supporting frame having a pair of bars extending parallel to the direction of wire movement,

a carriage slidably mounted on said bars, the carriage including:

a plurality of pivotally mounted clamps having a forward wire gripping surface and an elongated rear portion, and

means engaging the elongated rear portion to pivot the gripping surface into contact with the wires when the carriage is at its initial position,

means for driving the slidable carriage along the bars to a second position, and

means for releasing the gripping surface from the advanced wire at the second osition, the driving means thereupon returning the carriage to its initial position to feed another predetermined length of wire.

3. An apparatus in accordance with claim 1 wherein:

the movable die means comprises first and second slidable die sections positioned diagonally opposite one another, each receiving a group of wires of a predetermined length advanced by the feeding means,

the forming means is mounted above the die sections and cooperates therewith to form the terminal legs upward in a substantially J-shaped configuration, and

act-uable mean are provided to drive the forming means into cooperation with the die sections.

4. An apparatus in accordance with claim 1 wherein:

the receiving means comprises a feed platform having an aperture to receive a terminal head,

the means for causing relative movement comprises means mounted above the feed platform for driving the head into the aperture and positioning the terminals Within apertures in the terminal head, and

means are mounted beneath the head for driving the terminals into a secure fit within the terminal apertures.

5. An apparatus according to claim 1 comprising:

straightening means for straightening the wires before they reach the feeding means, and

means for forming notches in the Wires before they reach the severing means,

the die means and forming means being adopted to form the terminals into a J -shaped configuration. 6. An apparatus according to claim 1 wherein each die means is at a different osition in the direction of Wire 5 feed such that the forming apertures of each die means is in the same plane as rows of apertures in a terminal head in the receiving means.

References Cited UNITED STATES PATENTS Gilbert 29206 McCoy 140-1 Hanson 14071 Davis 140-71 Grinnell 14071 Smith et a1. 14071 Weiss.

luptner 29-155.5 X Van Rijsewijk 29203 Sloan 29-1555 X JOHN F. CAMPBELL, Primary Examiner.

THOMAS H. EAGER, Examiner.

Claims

1. AN APPARATUS FOR FORMING TERMINALS WITH PARALLEL LEGS AND INSERTING THE LEGS INTO APERTURES ARRANGED IN ROWS AT OPPOSITE SIDES OF AN INSULATING MEMBER SUCH AS A TERMINAL HEAD COMPRISING: A PLURALITY OF WIRE SUPPLY REELS, MEANS FOR INTERMITTENTLY FEEDING WIRES FROM THE SUPPLY REELS, MEANS FOR SEVERING A PREDETERMINED LENGTH FROM THE WIRES FED BY THE INTERMITTENT FEEDING MEANS, A PAIR OF MOVABLE DIE MEANS, EACH DIE MEANS RECEIVING A GROUP OF THE PREDETERMINED LENGTHS OF WIRE AND INCLUDING A ROW OF FORMING RCESSES, MEANS COOPERATING WITH THE DIE MEANS FOR FORMING THE SEVERED LENGTHS OF WIRES IN THE RECESS SUCH THAT TERMINALS ARE PROVIDED HAVING PARALLEL LEGS PROTRUDING ABOVE THE RECESSES, MEANS FOR RECEIVING A TERMINAL HEAD, MEANS FOR TRANSFERRING EACH DIE MEANS A DIFFERENT DISTANCE OF POSITIONS AT OPPOSITE SIDES OF THE TERMINAL HEAD SUCH THAT THE LEGS OF THE TERMINALS ARE IN ALIGNMENT WITH ROWS OF APERTURES IN THE TERMINAL HEAD, AND MEANS FOR CAUSING RELATIVE MOVEMENT OF THE TERMINAL HEAD RECEIVING MEANS AND BOTH DIE MEANS TO INSERT AND TERMINAL LEGS INTO THE APERTURES AT OPPOSITE SIDES OF THE TERMINAL HEAD.