Note: Descriptions are shown in the official language in which they were submitted.
~7~336
The present application is a division of Canadian
application 336,693.
The present invention relates to a method of and
a device for processing end portions of covered wires in a
wire harness.
A wire harness generally consists of a large number
of wlres combined togethcr to form branches of main lines.
Terminals connectors or ]ike members are connected to the
respective branches. Various automatic wiring methods have
heretofore been proposed to~save time and labor in the
production of such wire harnesses.
In principle, prior art uses wires precut to
a determined length and laid between intended terminals,
connectors, or like members. Such processes are time
consuming which is reflected by poor productivity.
An object of the present invention is to provide
a wire harness which is manufactured more economically in
point of view time and labor.
According to the present invention there is
provided a method of processing end portions of covered wires
in a wire harness comprising the steps of holding at least
one covered wire of the wire harness at a predetermined
position distant from one free end of the wire; nipping
said wire from above and below by a pair of cutting edges on
the free end side of said predetermined position; moving
said pair of cutting edges away from said predetermined
! position to stop the movement at a first position; cutting
! an insulative covering of said covered wire by said pair of
cutting edges; moving said pair of cutting edges further
away from said predetermined position to stop the movement
at a second position such that the insulative covering is
removed from a conductor portion of the covered wire
corresponding to the first position through the second position;
and cutting the conductor portion of the covered wire at the
~9t7~36
second position.
The present invention also relate to a device for
processing end portions of covered wires comprising: a base
plate having a disc; a wire holder provided on one side of
the base plate and adapt(~d to hold at least one covered wire;
a frame provided on the base plate movably toward and away
from said wire holder; and a pair of cutting edges attached
to the frame above and below said wire and adapted for horizontal
movement from a predetermined position along the held covered
wire. A first cam means is provided on the frame for
actuating the pair of cutting edges to close and open; a drive
source is provided on the frame to drive the cam means; and
a second cam means is connected to an axle of the drive source
and is adapted to abut against the disc for moving the frame
such that the cutting edges travel along the covered w1re
from the predetermined position through a first position to
a second position.
A preferred embodiment of the present invention
will now be described, as example only without any limitative
manner, having reference the attached drawings wherein:
FIG. l-A illustrates a wire harness prepared on
a worktable;
FIG. l-B is a perspective view of an embodiment
having a bridge engaging a wire thereon which is being
! subjected to a step of the method of FIG. l-A;
FIG. l-C is another example of a bridge;
FIG. l-D is a further example of a bridge;
FIG. 2 shows a wire harness prepared at a stage
subsequent to that shown in FIG. l-A;
1 30 FIG. 3 shows a wire harness prepared at a stage
; subsequent to that shown in FIG. 2;
FIG. 4 shows a wire harness prepared at a final stage
1~7~336
subsequent to that in FIG. 3;
FIG. 5 is a perspective view of a device for
preparing a wire harness;
FIG. 6 is an enlarged side view cross-sectioned
in part o a wirlng head nsed in the devlce of FIG. 5;
FIG. 7 is a plan view of the wiring head of FIG. 6;
FIG. 8 is an enlarged side view of a wiring jig
provided in the wiring head of FIGS. 6 and 7;
FIG. 9 is an enlarged side view of a mechanism for
the vertical reciprocation and rotation of a clamping jig
attached to the wiring head of FIG. 6;
FIG. 10 is an enlarged side view of the clamping jig
of FIG. 9;
FIG. 11 is a perspective view of one of wiring blocks
arranged on the worktable shown in FIG. l-A;
FIGS. 12-A, 12-B, 12-C show positional relationships
between the wiring block, the wiring jig, and the clamping
jig;
FIGS. 13-A to 13-E show a series of wiring steps by
using the wiring blocks, the wiring jig, and the clamping
I jig;
j FIGS. 14-A and 14-B show a situation where two wires
: are to be laid on one another and subjected to the cutting
steps;
FIG. 15-A is a plan view of another embodiment of
a wiring block to cope with the situation FIGS. 14-A and 14-B;
I
FIG. 15-B is a side view of the wiring block of
FIG. 15-A;
FIG. 15-C is a front view of the wiring block of
FIG. 15-A;
-- 3 --
~7936
FIG. 15-D is a cross section of the wiring block of
FIG. l5-s taken along the line d-d;
FIGS. 16-A to 16-E show the operation of an arm
provided on the wiring block of FIGS. 15-A to 15-D;
FIG. 17 shows another example of a wire harness obtained
by the wiring block of FIGS. 15-A to 15-D;
FIG. 18-A shows a fusing unit under which said
work table is adapted to travel;
FIG. 18-B is a front view of the fusing unit
of FIG. 18 A;
FIG. 19-A illustrates an engagement of the fusing
unit and the wiring block;
FIG. l9-B is a front view of FIG. l9-A;
FIG. 20 is a perspective view of a device for removing
an insulation covering of one end portion of each wire
of the wire harness and ~ixing a terminal thereon;
I FIG. 21 is a side view sectional in part of wire
3 uncovering and cutting unit provided in the device of
PIG. 20;
FIG. 22 is an illustration of cutting edges attached
to the unit of FIG. 21;
FIG. 23 is an illustration of a flat cam attached
to the unit of FIG. 21;
FIGS. 24-A to 24-D show an operation of the cutting
edges to remove an insulative covering of the wire and cutting
the wire conductor;
FIG. 25 is a front view of a terminal fixing unit
provided in the device of FIG. 20;
I
~ .
_ ~ _
~7~36
FIG. 26 is an illustration of a wire harness and
a train of interconnected terminal members which are supplied
into said unit;
FIG. 27 is a perspective view of the train of terminal
members supplied as shown ln FIG. 26
FIGS. 28-A to 28-E are illustrations of the operation
of a wire uncovering and cutting unit according to the present
invention; and -
FIGS. 29-A to 29-B are illustration of the operation
of terminal fixing unit.
The presen' invention will hereinafter be described
in detail with reference to the accompanying drawings.
Referring to FIG. lA, the reference numeral 1
designates a work table on which pins 2 and wiring blocds 3 are
positioned.
Lying on each of wiring blocks 3 is a bridge 4 which,
as viewed in FIG. lB, comprises a base 5 and multiple pairs
of parallel fusable holding pieces 6 spaced at common
perpendicular intervals and extending along the longitudinal
, 20 direction of the base. The holding pieces 6 in each pair
! have slants 7 on their outer top surfaces. In use,
the bridge 4 is suitably made for the intended number of
wires to be nested in the bridge. Preferably, the bridges
4 are formed of a thermoplastic resinous material similar
j to that employed for insulative coverings of wires.
However, the bridge may be made of any material if wire 8
is pasted between the holding pieces 6I by means of adhesive
K as shown in FIG. l-C. Alternatively, the bridge may
have a plurality of resilient holding pieces 6" such that
7 30 wire 8 are resiliently held therebetween when pressed in.
11~7~3~6
Wires 8 are securely nested in sequence in between
the cooperating pairs of pieces 6 on each brid~e 4
by a cooperative mechanism including the blocks 3 and
a programmable automatic machine, i.e. a wiring head with
a clamping jig. frhose portions of respective wire~ 8
extending beyond the bridge 4 are cut of~ at a predetermined
length 1 from the bridge. The wires are laid over
corresponding blocks 3 thereby constituting a wire harness
generally designated A in FIG. l-A.
After the installation of the wires 8, table 1 is
bodily moved to the next station in which a fusing unit
corresponding to each bloc~ 3 is activatèd to melt the pieces
6 of bridge 4 simultaneously onto insulative coverings of
wires ~. Strips of tape ~ for tem~orary fastening are
then wound round branching portion3 of the respective sets
of wires.
The procesure stated above yields a wire harness B
shown in FIG. 2. In harness B, wires 8 extend at predeter-
mined spacings and in predetermined numbers and the bridges
2Q 4 securely hold the corresponding sets of wires at a given
spacing.
The wires of the wire harness B are layed automatically
at the required spacings and numbers while their terminal
portions are neatly arranged and fixed by the bridges with
a predetermined length thereof extending beyond the bridges.
This type of wire harness s though only semiprocessed can
be stored and transported advantageously before it advances
to any subsequent step.
1~7~36
In a wire harness C illustrated in FIG. 3, each of
the wires 8 rigid on the bridge 4 has its insulative
covering removed at the end portion by an insulative co~erin~
removing unit, and, terminal member 10 is affixed to
the bare wire end by a terminal fixing unit.
Each bridge 4 in wire harness C retains the end portions
of each set of wires 8 permitting a plurality of terminal
members 10 to be àttached simultaneously to the individual
wires. Furthermore, as seen in FIG. 4, all the terminal
~o members can be connected to connector housing 11 simul-
taneously and easily.
A wire harness D in its fully processed state shown
in FIG. 4 has wires 8 whose aligned end portions are
securely Keld in the bridge 4 by fusion. Thus when a tenslle
force is applied locally to apeciflc one of the wires such
as wire 8~ as during transporation, storage or actual
installation in an automobile, the bridge 4 disperses
the tension to prevent the associated terminal member 10
from disengaging with the connector 11. However, if there
is expected no tensile force to be applied to a wire of
wire harness D in any subsequent step, bridge 4 may be
detachably provided on the wire harness.
Referring to FIGS. 5 to l9-s, a process according to
the invention will be described.
A wiring apparatus is shown in a general perspective
view of FIG. 5. The apparatus includes a pair of threaded
X shafts 12 extending along opposite longitudinal edges
Of the work table 1. Cross-beam 13 is movable on and along
~7~36
X shafts 12 and carries thereon threaded Y shaft 14
on which wiring head 15 is movably supported. X shafts 12
are driven for rotation by a first motor (not shcwn) whereas
Y shaft 14 is driven by a second motor (not shown). sy
suitably setting the amounts of rotation of shafts 12 and
14, wiring head 15 and wires 8 held by the head 15 can be
brought to any desired position among the respective biocks
3 arranged on table 1. A control unit 16 is adapted to
store an entire porcess ~or wiring programmed on a magnetic
tape (NC control). Reference numeral 17 is a reel station
where wires 8 whose insulative coverings have different
colors are stored on independent reels. Wires 8 are paid out
to wiring head 15 through corresponding capstans 18 which
serve to reduce the magnitude of tension imparted to
the wires being driven by a motor (not shown) in the intended
direction of wire feed.
~s depicted in side elevation in FIG. 6, wiring head
15 includes frame 19, a plurality of wiring jigs 24
located on top of frame 19 and clamping jig 45 positioned
below the frame l9i. The jigs 24 and 45 are commonly recipro-
cate and rotate relative to a predetermined position.
Annular member 21 for mounting wiring ji~s 24 is
mounted to frame 19 rotatably through a plurality of guide
rollers 20. Jig mount 21 is operatively connected to
a limited speed motor 22 to circulate in a horizontal plane.
Wiring~jigs 24 are passed through respective tubular
guides 23 which are spaced equidistant along the circumference
of jig mount 21. Each of the wiring jigs 24 is locked
-- 8
~17~
at a preselected level by a knock pin 25.
Differently colored wires 8 are paid out from
the reel station 17 to individual wiring jigs 24. Jig
mount 21 when driven by motor 22 will bring a selected
wiring jig 24 to a predetermined position P in FIG. 7.
Each jig 24 reaching the position P is reciprocated
vertically in accordance with the action of unit 26.
Denoted 27 is a motor adapted to drive capstan 33 provided
to the jig 24.
FIG. 8 illustrates a detailed construction of each
wiring jig 24. As shown, wiring jig 24 comprises tubular
member 29 having through bore 28 extending axially
therethrough to accommodate wire. Tube 29 carries on its
outer periphery bar 30 which is engagable with the raising
and lowering unit 26. Capstan head 31 and recoil prevention
assembly 35 are mounted above the t-~be 29. Mounted below
the tube 29 is nozzle or nosepiece 38.
Capstan head 31 has a gear wheel 32 which is driven
by motor 27 and capstan 33 is faced by slack preventing
piece 34. The recoil preventing assembly 35 has a pair
of pawls 36 constantly biased ~y spring 36a. Flexible wire
guide 37 is provided at the top of assembly 35. The nose-
piece 38 in the form of a coil spr;~ng with resiliency such
that a given intensity of tension resulting from a travel
of jig 24 causes a flexure of the nosepiece in a direction
opposite to the direction of travel and, upon the release
of the tension, the nosepiece recovers its position.
Preferably, nosepiece 38 is additionally capable of
straightening the wire 8 if it is bent.
1~7~36
Wire support 38c is nested in the tube 29 and carries
a nosepiece support tube 38a fastened to its lower end
by means of a screw 38b.
With this arrangement of wiring jig 24, wire 8
enters jig 24 through top wire guide 37 passes between
pawls 36, and is passed one turn round capstan 33. From
capstan 33, the wire extends downwardly through tubes 38c
and 38a and extends from lower end of nosepiece 38.
An end portion of wire 8 protruding from nosepiece
38 is retained by clamping pawls 52 mounted on block 3
in a manner described hereinafter. In this situation when
motor 27 is energized to drive the wiring jig 24 is caused
to run and impart a tension to wire 8, the tension is
controlled by the rotating capstan 33 promoting smooth
feed of the wire.
In the event w~re 8 is cut by cutting edge 48
of clamping jig 45 which will be discussed later, the ten-
sion in wire 8 is released abruptly. In this instance,
slack preventing piece 34 facing capstan 33 exerts a resilient
pressure force to prevent the recoil of the wire.
Consequently, a constant measure of wire 8 extends
from the outlet of the nosepiece.
Additionally, wiring jig 24 has in its upper portion
pawl palr 36 which is constantly biased by spring 36a.
Pawls 36 prevent wire 8 from falling out of jig 24 even
when the jig is stationary. Thus jig 24 positively holds
the wire irrespective of the operating condition.
A mechanism for two different kinds of movements of
clamping jig 45 is indicated in side elevation in FIG. 9.
-- 10 --
~1~7~36
sody 39 of the clamping jig is mounted to frame 19 of
the wiring head so as to reciprocate vertically relative
to the frame by the action of actuator 4Q associated
therewith. Annular ~ig mount 41 functions as a pulley and
is rotatably mounted to jig body 39 and in a position
where its center coincides with the axis o~ wiring jig 24
at the position P. The angular orientation of jig 45
is controlled by limited speed motor 42 which is provided
with timing pulley 43. Passed over this timing pulley 43
and the pulley 41 is endless belt 44. With this construc-
tion, motor 42 drives the-clamping jig 45 to a desired
position about wiring jig 24 while the actuator moves
the clamping jig up or down as desired~
As shown in FIG. 10, clamping jig 45 has front end
clamping plate 46, guide plate 47 with coil spring 47a,
cutting edge 48 and rear end clamping plate 49 arranged
in succession radially from the inner end to the outer end.
Guide plate 47 and cutiing edge 48 protrude slightly beyond
the lower ends of clamping plates 46 and 49 and positioned
in perpendicular relation to the clamping plates. Clamping
plates 46 and 49 are located symmetrically to each other
with respect to cutting edge 48.
Referring to FIG. 11, wiring block 3 has a plurality
of guide pins 50 at its front upper end and guide slots 54
at the rear end. Interposed between the guide pins 50
and guide slots 54 are recesses 51 for receiving a bridge
4, a series of clamping pawls 52 and a block 53 against
the top surface of which cutting edge 48 will abut.
Said block 53 is rigidly mounted on block 3 and
functions as an edge hearer. Block 3 is also provided
119~7~;~6
with bore 55 in the yicinity of one lateral end of recess
51; bore 55 is adapted to receive a fusing jig 60
which will be referred to hereinafter. Reference numeral
56 designates a screw for releasing clamping pawls 52.
Guide pins 50, guide slots 54 serve to guide the
the nosepieces 38 of respective wiring jigs 24 and are
provided in accordance with the intended number of wires.
Clamping pawls 52 retain wires during the wiring and ~mtil
a subsequent fusing step ;s over.
Positional relationships of blocks 3.1 and 3-2, wiring
jig 24 and clamping jig 45 are indicated in FIGS. 12A-12C.
A bridge 4 is nested in the recess 51 of block 3 prior to
a start of wiring operation. At a starting point of wiring
(FIG. 12-A), nosepiece 38 of wiring jig 24 is resiliently
deformed into engagement with the bridge 4 and in between
guide pins 50. A predetermined length of end portion
of wire 8 extends beyond the bridge 4 and is positioned
between neighboring clamping pawls 52.
As clamping jig 45 is then moved downwards as viewed
in FIG. 12-B, the free end of wire 8 is engaged by the guide
plate 47 which is projected beyond the bottom of clamping
plate 46. The guide plate therefore centralised wire 8
between the clamping pawls 52 then front end
clamping plate 46 positively presses the wire until pawls
52 nip the wire therebetween. The wire at this instant
is also retained between the corresponding pair of
confronting pieces 6 on bridge 4.
In this way, guide plate 47 and clamping plate 46
in cooperation allow the part of the wire projecting from
- 12 -
~9L7~t36
nosepiece 38 to be retained positively on the block 3
despite the slight wire flexure which has occurred in
the initial stage of wiring.
FIG. 12-C shows wiring block 3 which is located in
opposing relation to first-mentioned block 3 to define
a terminal point of the wiring path. At this point of
the wiring process, wire 8 paid out of nosepiece 38
has been layed under tension from the block 3-1 to the block
3-2 through pins 2 on the table 1 and guide pins 50 on
the blocks) (FIG. 13-A to FIG. 13-E). The nosepiece is
flexed into engagement with guide slot 54 of the block
3-2 as illustrated. Under this condition, wire 8 is
aligned with a central region between neighboring clamping
pawls 52 and that between pieces 6 on bridge 4.
When clamping jig 45 is lowered in the above situation,
its rear end clamping plate 49 urses wire 8 into the gap
between clamping pawls 52 while at the same time associated
cutting edge 48 in cooperation the surface of the block
53 cuts the wire to a predetermined length
Thereupon, motor 42 (see FIG. 9) is energized to
turn the clamping jig 45 to a position immediately to
the rear of wiring jig 24. This restores conditions
to an initial stage of wiring process.
Wiring procedures using wiring jig 24, clamping jig 45
and block 3 will now be described with re~erence to
the FIGS. 13A-13E.
- 13 -
7~336
1) A selected wiring ji~ 24 is brouyht to the predeter-
mined position P whereupon the unit 26 is driven to lower
jig 24 to a position rearwardly of block 3-1. (FIG. 13-A)
2) wiring jig 24 is moved along X shafts 12 and Y shaft
1~ until it reaches the col~dition for starting a wirlng
operation (see FIG. 12-A). Then clamping jig 45 is
lowered by the actions of actuator 40 thereby fixing
a predetermined len~th of wire 8 on the block 3-1' (,see
FIGS.12-A and 12-B¦ then ji~ 45 is raised and capstans
18 and 33 are driven. (:FIG. 13-C)
3) Wiring jig 24 is caused to travel toward wiring
block 3-2 while layi`ng out wire 8. (FIG. 13-C)
4) Wiring jig 24 is positioned at the terminal point of
wiring (,see FIG. 12-C), relative to block 3-2 whereupon
the clamping jig 45 is again lowered to 'oc~ and cut-
the wire 8 and then raised. Subsequently, the drive of
capstans 18 and 33 is interrupted. (FIG. 13-D)
5) The orientation of t~e clamping jig is as follows.
I~liring jig 24 moving along the X and Y shafts is shifted
to a position behind block 3-2 while the clamping jig 45
is brought to a position immediately to the rear of
the wiring jig 24. (PIG. 13-E)
6) ~loving along shafts X and Y toward another preselected
wiring block, wiring jig 24 is elevated by the action
of unit 26 and return to the shart position.
7) sy repeating steps (,1) to (6) with one or more of jigs
24 a desired wire harness A as presented in FIG. l-A is
now obtained.
~47~36
Referring to FIG. 14-A, wire 8 held between clamping
pawls 52 is supported by block 53 for cutting operation.
If end portions of wires are required to be held in bundle,
another wire is laid upon ti-le already cut wire as sho~n in
FIG. 14-B, preven~ing prope~ cutting oE wire 8. FIGS. 15~~
to 16-E show a modification of wiring block 3 in which
the above situation is avoided.
Wire retaining groove 57 is defined between iower
portions of neighboring clamping pawls S2 while edge bearing
member 59 faces recess 58 lying between the pawls 52 and guide
groove 54' and is capable of elevating and tilting movements.
Edge bearer 59 incluc~es a pair of arms 60 each of which
has a lower portion journalled to the body 3 by cam shaft
62 received in vertically elongate slOt 61 of the arm;
slot 61 has its upper end enlarged. Spring 63 is anchored
at one end to an intermediate portion of each arm 60
and at the other end to upper part of body 3. Arms 60 are
usually biased by springs 63 to hold a position inclined
toward guide groove 54' on top of body 3.
Wire guide groove 64 extends on that surface of
the edge bearer 59 which faces clamping pawls 52. Lugs
or cams 65 project upwardly from the edge bearer on opposite
sides of groove 64. These lugs 65 are adapted to pull
arms 6Q up from the inclined position when engaged by cutting
edge 48. The wiring block further includes pins 66 and 67
for retaining spring 63 and stop pins 68 adapted to limit
the tilting movement of. the arms 60.
7~
Operation of thw wiring block 3 haying the above
construction will be described hereinafter.
- (1) As sh~1n in FIG. 16-A, wire 8 is layed on the clamping
pawls 52 on wiring block 3 and edge bearer 59. In this
situation, each arm 60 is kept by the tension of the spring
63 in a position raised obliquel~ upwardly about the lower
end l of its elongate slot 61.
Laying of the wi e is performed by wiring ji~ 24 as
already`discussed in conjunction ~ith FIGS. 12A-12C.
(2) Under the above-mentioned condition, cutting edge 48
of clam~ing jig 45 is lowered lnto enga~ement with slan~s
65a of lu~s 65. The resultant horizontal component of
a force action on slants 65a causes arms 60 to pivot to
a raised position about point l of the corresponding
slots 61.
Thus, the tension and angular position of each spring
63 is preselected such that the following relations are
satisfied:
Fh > Th~ Fv v
Where Fh and Fv denote horizontal and vertical components
of a force action on the slant 65a, respectively, and Th
and TV horizontal and vertical components attributable to
the resiliency of the spring 63. This permits arms 60
to be raised about point l of the slots 61. (FIG. 16-B)
(3) Another lowering of cutting edge 48 moves arms 60
downwardly along slots 61 until 8 is cut off.
The center of pivotal movement of arm 60 is shifted by spring
63 from l to point 2 contained in an upper portion of
slot 6l. (FIG. 16-C)
~7~36
(4) When cutting edge 48 starts its upward or return
stroke, arm 60 is retained in the upright lowered position
through the upper enlarged portion of slot 61. Upon
the disengagement of cutting edge 48 from slant 65a, the arm
tilts backwardly about poin~ 2 under the action of
the spring 63. At this instant, cam shaft 62 leaves enlarged
portion 2 50 that arm 60 is eleva-ted obliquely along slot 61.
(FIG. 16-D)
(5) Raised by spring 63 while inclininq, arm 60 returns
to the initial position (FIG. 15-A) without pushing the cut
wire up. Moreover, cut wire 8 does not give any touch to
the edge bearer 60 owing to the guide groove 64. (FIG. 16-E)
Edge bearer 60 is thus always positioned above a wire which
has been cut off as shown in FIGS. 16-A and 16-B. Accor-
dingly, when overlayed on the cut wire, the next wirewill be cut off by cutting edge 48 while being pu$hed
down (FIG. 16-B). A plurality of wires can be retained
in superposed relation with the aid of the recess 64 defined
between lower portions of the clamp pawls 52.
The wiring block of this type is usuable in combination
with ones as shown in FIG. 11 to prepare a wire harness
which, as depicted in FIG. 17, has a desired configuration
such as block 3a in which end portions of wires 8 are held
at equal spacings on bridge 4 and block 3b in which
a plurality of wlres are retained in superposed relation.
A positional relationship between wiring block 3 and
a fusing unit is illustrated in FIGS. 18-A and 18-B.
A fusing jig 72 includes body 69 which is vertically mounted
to frame 70 to reciprocate through actuator 71.
.
11~7~36
The body 69 of the fusinq jig is provided therein
with a slidable plate 73 having a plurality of slots 74.
Accommodated in the respective slots 74 are pressing
bars 75 which are arranged in a comb-like configuration and
each having arcuate recess 76 at the lower end. These
pressing bars ?5 are reciprocated vertically following
the action of actuator 77. Device 78 for supplying hot
air is tiltably supported b'l body 69 of the jig.
Accommodating a heater (,not shown), the blasting
device 78 feeds air from ducts 7~ and blasts hot air onto
pieces 6 on bridge 4 thus fusing the insulative coverings
of wires 8 therewith. The fusing iig is also provided with pin 80
which is engagable in the previously mentioned bore 55
of block 3.
To fuse brid~e 4 ~nd wires 8 together, the fusing jig
72 will be explained as depicted in FIG. l9-A. In FIG.
l9-A, actuator 71 lowers pin 80 of jig 72 into engagement
in the bore 55 of the wiring block 3 and positions
the respective pressing bars 75 on bridge 4. The blasting
device 78 then blow hot air toward bridge 4.
After hot air processing actuator 77 is driven
to lower pressin~ bars 75 into recess 51 of block 3 where
bridge 4 is positioned~ The tops of the pieces 6 are
pressed against and fused to the insulative coatings of
the corresponding wires 8 by the arcuate recesses 76 of
bars 75 as viewed in FIG. l9-B. It will be recalled
here that the confronting pieces 6 on bridge 4 have
slants 7 (FIG. lB) along the upper edges thereof.
- 18 -
1~7936
Pieces 6 is engaged and deformed inwardly towards
each other to seal wire 8 therein by the recessed bottom
of the corresponding pressure bar 75. The fusing jig
72 may be provided corresponding to each of multiple
blocks 3 shown in FIG. l-A in order to perform all at
one time. Branching portions of respective wires 8 are
thereafter wound with strips of tape 9, yielding a wire
harness B as indicated in F~G. 2.
The thus obtained wire harness B is further subjected
to a insulative covering removing step, a terminal fixing
step, a connector housing attaching step.
Referring to FIG. 20, an apparatus embodying the present
invention includes outer framework supporter 81 and inner
framework supporter 82. Within inner framework supporter
82, there is pro~ided wire holder 83, uncovering and cutting
unit 8~ and termlnal attaching unit 85. These assemblies
84 and 85 function in cooperative relation with wire holder
83. Denoted by the reference numeral 86 is an electric
wiring extending from a control box (not shown) to
the respective units of the apparatus.
Detailed constructions and operations of the various
units will be stated in succession.
Wire holder 83 serves as a platform on which end
portions of wire harness B are held. A plurality of guide
pins 87 project upwardly from the rear end of the platform
while auxiliary clamp 88 is pivotted to the platform~in-
such a manner as to be movable toward and away from the series
of guide pins 87. I~ire holder 83 has leg 90 of a rectangular
- -- 19 --
` 1~47936
section supported through a spring and a knock pin (not
shown) by frame 90 which uprises from seat 91 of inner
framework supporter 82. Under usual condition, the wire
holder is urged upwardly by the spring and held at
a predetermined level by the knock pin. In the event
of attaching terminal members to wires, the knock pin is
retracted by a movement of terminal fixin~ unit 85 to
lower the wire holder whereby terminal members are allowed
to reach a station below uncovered portions of the wires.
88' designates a clamp adapted to press auxiliary clamp
88 from above.
Unit 84 is illustrated in partly sectioned elevation
in FIG. 21. Base plate 92 is positioned at the rear of
the wire holder 83.
Mounted rigidly to a rear portion of base 92 is cylinder
93 having piston 94 which is connected to lower plate 96
forming part of frame 95. Guides 99 extend along op~osite
sides of base 92 to guide the movement of lower plate 96
~as will be dèscribed hereinafter. Base 92 has in its
front portion recess lOQ in which disc 101 is rotatably
journalled. Cam 120 is engagable wit~ disc 101 to limit
the movement of frame 95 toward wire holder 83 caused
by cylinder 93.
Front plate 98 forming another part of frame 95
is formed with elongate slot 102 extending vertically
in an intermediate area of front plate 98. Upper edge
holder 103 and lower edge holder 103' are received vertically
slidably within slot 102.
- 20 -
~1~7~36
Reference numerals 104 and 104' designate upper and
lower cutting edges, respectively, each having a plurality
of equally spaced and V-shaped edge portions 105 (four
in the drawing) as viewed in FIG. 22. Edge members 104
and 104' are secured to the front ends of the corresponding
holders 103 and 103' such that their ed~e portions 105
confront each other while having their backs aligned
along a common axis. Meshing of lower cutting edge 104'
with upper cutting edqe 104 can be finely adjusted by
adjusting screw lQ6.
Cylindrical cam 108 is journalled to-upper and lower
plates 97 and 96 of frame 95 at opposite ends and is provided
with cam grooves 109 and 109' on its periphery. Arms 107
and 107' extending from the rear ends of the edge holders
103 and 103' are slidably engaged in the cam grooves 109
and 109', respectively.
The cam grooves 109 and lQ9' extend throughout
the circumference of cam 108 in vertically symmetrical
relation. Each of the cam grooves has four substantially
horizontal stepwise sections 109-A~ 109-B~ 109-C and 109-D
at re~ular spacings of 90 along the circumference of cam 108.
Accordingly, cam 108 in rotation causes the upper and lower
cutting edges 104 and 104' to move toward and away
from each other.
The horizontal sections 109-A to 10~-D of the grooves
109 and 109' have such levels as will be discussed in
conjunction with FIGS.24-A to 24-D. When arms 107 and 107'
associated with the corresponding edge holders move from
- 21 -
36
the section 109-A to the sections 109-D via sections
lQ9-B, 109-C, 109-D and back to 109-A in accordance with
each counterclockwise 90 movement of cam 108, upper and lower
cutting edges 104 and 104' are successively moved through:
i) a position remotest from wires 8 (FIG. 24-A),
ii) a position in which they touch insulative coverings
8a of the wires 8 from above and below (FIG. 4B),
iii) a position in which they cut into the coverings 8a
from above and below (FIG. 24-C),
iv) a position in which they overlap each other to cut
off conductors 8b of the wires (FIG. 24-D) and back to
the position i).
The rotation of cam 108 and corresponding movements
of the cutting edges 104 and la4! are regulated by
a reversible motor 110.
Capable of clockwise and counterclockwise movements
of 90, motor 110 is secured to lower plate 96 of frame
95 and has output shaftlll which rigidly carries in its
upper portion plate 112 having pawl 113. Gear 115 having
ratchet teeth 114 on its underside is rotatably coupled
over a cylindricai extension of plate 112.
The gear 115 is constructed such that a clockwise
movement of motor 110 causes gear 115 to turn in the same
direction as ratchet 114 meshed wîth pawl I13. Upon
a reverse rotation of the motor, however, pawl 113 releases
ratchet 114 to permit idling of gear 115. The clockwise
movement of motor 110 is transmitted to cam 108 through
gear 115 and gear 116 rigid on a shaft of the cam and
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1~4793~
meshing with gear 115, thereby varying the position of
cutting edges 104 and 104'. A reverse rotation of
the motor 110 however allows gear 115 only to idle without
displacing the cutting edges.
Flat cam 120 held in sliding engagement with disc 100
functions to regulate the operating positions of the cutting
edges 104 and 104'. As shown in FIG. 23, cam 120 has four
curved points a, b, c and d at equal angular spacings of 90
around the circumference. The distances from the center _
of the cam to the respective points a to d are selected
to satisfy the following relation and equation:
oa ~ ob ~ oc < od
oc - ob = d
where d indicates the length of the uncovered conductor 8b
of the wire 8.
In the situation depicted in FIG. 21, cam 120 is
slidably engaged with disc 100 at its point a so that
cutting edges 104 and 104' remain disengaged from each other
at the position where they touch the wires 8.~ Subsequent
20 reverse rotations of motor 110 cause cam 120 to turn reversely
by 90 each whereby the cutting edges are moved from
position O to position O3 via position l and position
2 as shown in FIGS. 28-A to 28-E~
Terminal attaching unit 85 is illustrated in partly
25 sectional front elevation in FIG. 25. Cylinder 122 is
rigidly mounted through bracket 121 to one end (right end)
of base 92. Piston rod 123 extending from cylinder 122
is connected through bracket 121' to one end of frame
124 so that frame 124 is ~odily movable laterally with
respect to and behind wire holder 83.
- 23 -
1~7936
Device 125 for pressing terminal members onto wires
is mounted to frame 124 in a position opposite to the piston
rod 123.
The pressing device as shown in FIG. 26 includes lower
die 126 and upper die 128 secured to holder 127. Upper
die 128 has on its underside grooves 129 and 130 which
correspond to individual portions 163 and 164 of terminals
162 as will be discussed hereinater. A shear blade 131 is
mounted through springs 133 to the outer periphery of lower
die 126. Shear blade 131 is formed with recess 132
for supporting terminals 162 in an upper portion of its
inner wall. Shear blade presser 134 projects downwardly
from die holder 127 and has grooves 135 on its underside
for accommodating the escape of wires. Die holder 127
is constantly urged by springs (not shown~ to a position
above lower die 126 and operated by hydraulic ram 136.
Reference numeral 137 denotes terminal conveyor unit
made up of platform 138, first pawl 140 for preventing
reverse travel of terminals and second pawl 148 for
feeding terminals.
Secured to frame-124 in the vicinity of lower die
126, platform 138 comprises two generally L-shaped parallel
side plates spaced suitably from each other. Each of
these side plates is ~ormed with a terminal supporting
recess (not shown) in the same way as shear blade 131.
First pawl 140 is afforded by a generally L-shaped
flat member having vertical arm 141 and horizontal arm 142
which has a downwardly inclined end portion 143.
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~1~7936
Part of the pawl 140 where arms 141 and 142 join is
pivotally mounted to a wall of window 145 formed through
a central area of pawl mount 144. Spring 147 is anchored
at one end to vertical arm 140 and at the other end to a pin
146 studded on pawl mount 144, whereby horizontal arm 142
is constantly biased to urge terminals 162 downwardly with
its lower surface.
Likewise, the second or feed pawl 148 takes the form
of a generally L-shaped flat member having vertical arm 149
and horizontal arm 150. Horizontal arm 150 has an upwardly
inclined end portion 151 which is contrastive to the down-
wardly inclined portion 143 of the first arm 140.
An intermediate bent portion of pawl 148 is pivotally
mounted to upper part of second pawl mount 152. This pawl
148 is biased by spring 154 retained by vertical arm 149
and pin 153 such that the upper surface of horizontal arm
150 constantly urges terminals 162 upwardly.
The second pawl mount 152 has a base portlon nested
in a groove 155 extending along the center of frame 124 and
is thus slidable along the groove while facing inner walls
of the confronting side plates 139 of the terminal support
138. Feed rod 156 extends $rom the rear end of pawl mount
152 through the brackets 121' and 121. A pair of cooperat-
ing adjuster pieces 157 and 158 are held in threaded engage-
25 ment on rod 156 on opposite sides of bracket 121 for
the adjustment of the amount of terminal feed.
Turning to FIG. 27, generally designated by reference
numeral 159 is a train of interconnected terminal members 162.
- 2~ -
~7~6
The terminals 162 are united together in parallel relation
at predetermined spacings by two parallel support pieces
160 and cross-pieces 161. The assembly 159 also includes
raised portions 153 and 164 for retaining conductors and
insulative coverings of wires when processed, respectively,
and electric contact portlons 165.
Reference will now be made to PIGS. 28-A to 29-B
for the description of a method of uncovering and cutting
end portions of wires and fixing terminal mem~ers to
the same.
1) Securely retained by bridge 4 except an end portion,
each wire 8 is loaded on the wire holder 83 and nipped
by guide pins 87 and auxiliary clamp 88. The cutting
edges 104 and 104' remain in a position spaced backwardly
from wire holder 83. (FIG. 28-Al
2) The cutting edges 104 and 104' in their open position
are moved toward wire holder 83 until the movement is
interrupted at position O. (FIG. 28-B)
To effect this movement of the cutting edges, frame 95
is adyanced by the action o$ cylinder 93 with arms 107
and 107' held in the sections 108-A of the grooves 109 and
109' as viewed in FIG. 24-A, causing the curved point _ of
flat cam 120 to abut against disc 101 and thus become haltec.
3) The cutting edges 104 and 104' are brought closer to
each other to lightly nip wire 8 from above and below
(position O) and then moved back to position l. (FIG. 28-C)
- 26 ~
7~36
More specifically, motor 110 is first turned 90~
clockwise so that cutting edges 104 and 104' nip the wire
therebetween (FIG. 24-B) in accordance with the rotation
(reverse) of cylindrical cam 108. Motor 110 is thereafter
turned 90 reversely whereby flat cam 120 is rotated (reverse)
to move the cutting edges backwardly to position 2
The drive pressure in this instance is preselected to be
of such a magnitude as to permit a retreat of piston rod
123 of cylinder 122 during the rotation of flat cam 120.
In the above procedures 2) and 3)., cutting edges 104
and 104' hold wire 8 which has been neatly nested in between
neighboring guide pins 87. Hence, the end portion of
the wire is nipped positively even if bent in any direction
and, moreover, the bent is corrected to straighten the wire.
In the position l the cutting edges are respectively
driven into the insulative covering 8a alone of the wire
and then moved back to position 2 Consequently, wire 8
has its conductor 8b exposed over the length 1-2 (FIG.
28-D).
More specifically, motor 110 is driven forwardly and
reversely in sequence to cause reverse rotations of
cylindrical cam 108 and flat cam 120. Frame 95 thus
recedes while the cutting edges uncover wire 8 (FIG. 24-C).
At position 2' the cutting edges cut the conductor
8b of the wire off and thereafter return to the initial
position remote from the wire holder. As a result,
the respective wires 8 are cut off at positions commonly
- 27 -
~ 47~36
distant from the bridge 4 to have their ends all aligned.
Also, the exposed lengths d o~ the conductors 8b are
the same as one another. (FIG. 28-E)
For the above procedure, motor 110 is again driven
~or successive ~orward and reverse rotations to turn
cylindrical cam 108 and fla~ cam 120 reversely causin~
the cutting edges to obtain the cutting state (FIG..24-D)
and then position O3. Subsequently, cylinder 93 is
actuated to move frame 95 rearwardly whereupon motor 110
is again turned forwardly and reversely to there~y allow
cams 108 and 120 and other members to restore the positions
indicated in 1).
The peeling and cutting of wires are completed in
the above-described manner. In short, motor 110 is driven
for successive ~or~-ard and reverse motions repeatedly four
times to cause one full rotation of each of cams 108 and
120; the cooperative mechanism of the cams 108 and 120
actuate the cutting ed~es for nipping, peeling and cutting
of wires in preselected positions.
6) Terminal attaching unit 85 is located to the right
of wire holder 83. (FI~. 16)
7) Frame 124 is moved ~y the action of the cylinder 122
until fixing unit 125 reaches a position at the rear of
wire holder 83.
Train 159 of terminals advance in correspondence with
the number of wires 8 under the actions of L-shaped pawls
140 and 148. (FIG. 29-A)
- 28 -
~1~7936
8) Individual terminals 162 in the train 159 are fixed
onto the end portions of respective wires 8 while, at
the same time, the connecting pieces 161 at opposite
ends of terminal 162 are cut off and separated from
the terminals.
~ore speci~ically, in FIGS. 29.-A to 29-B, ram 106
is actuated to lower upper die 128 onto lower die 126 so
as to press raised pieces 163 and 164 of terminals 162
firmly onto wires 8. Simultaneously, shear blade presser
10 134 is lowered to push shear blade 131 downwardly against
the action of springs 133 thereby cutting the connectiny
pieces 161 off from terminals 162. Meanwhile, wires 8
are received in and protected by grooves 135 of
shear blade presser 134.
15 9) Thereafter, ram 106 is elevated and shear blade 131
restores the ordinary raised level with the aid of
the springs 133. By the cylinder 122, unit 85 is bodily
moved away from wire holder 83 back to the position shown
in FIG. 29-A.
While the distance travelled by terminal attaching
unit 85 is QQl' the amount of movement of the feed pawl
148 of conveyor device 137 is limited to Q2Q3 by the adjuster
pieces 157 and 158. Hence a num~er of terminals 162
corresponding to the difference in distance QQl ~ Q2Q3
.(four in the illustrated case) will be supplied in the next
pressing step. In other words, a desired number of terminals
can be fed to lower die 126 merely by adjusting the spacing
between pieces 157 and 158.
~7~36
The steps 1)-91 discussed hereinabove will be repeated
in sequence. Thus, a plurality of wire end portions can be
subjected simultaneously to each step of removing
the insulative covering, cutting the conductive portion
and fixing terminals onto the exposed end portions. It
will readily occur to those who are skilled in the art
that such procedures can take plane automatically under
known sequence control or can be controlled manually for
each step. Terminal housing 11 can be attached to the thus
obtained wire harness C to accommodate the terminal members
and form completed wire harness D.
It will therefore be appreciated that a wire harness
obtainable by the present invention promotes easy connection
of terminal members and attachment of connectors and
the li'~e. Thus, as a whOle, productivlty is improved.
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