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Patent 2023131 Summary

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Claims and Abstract availability

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(12) Patent: (11) CA 2023131
(54) English Title: WIRE HARNESS MANUFACTURE
(54) French Title: FABRICATION DE FAISCEAU DE CABLAGE
Status: Expired and beyond the Period of Reversal
Bibliographic Data
(51) International Patent Classification (IPC):
  • H1B 13/00 (2006.01)
  • H1R 43/05 (2006.01)
  • H1R 43/052 (2006.01)
  • H1R 43/28 (2006.01)
(72) Inventors :
  • ALIGUE, JORDI CASAS (Spain)
  • VAZQUEZ, MANUEL AREVALO (Spain)
  • VIVES, JORDI BIGORRA (Spain)
  • HERNANDEZ, JAIME ULLOA (Spain)
  • VIDAL VERGE, RAMON M. (Spain)
(73) Owners :
  • MECANISMOS AUXILIARES INDUSTRIALES, S.A.
(71) Applicants :
  • MECANISMOS AUXILIARES INDUSTRIALES, S.A. (Spain)
(74) Agent: NORTON ROSE FULBRIGHT CANADA LLP/S.E.N.C.R.L., S.R.L.
(74) Associate agent:
(45) Issued: 1999-10-19
(22) Filed Date: 1990-08-10
(41) Open to Public Inspection: 1991-02-18
Examination requested: 1997-03-11
Availability of licence: N/A
Dedicated to the Public: N/A
(25) Language of filing: English

Patent Cooperation Treaty (PCT): No

(30) Application Priority Data:
Application No. Country/Territory Date
07/395,372 (United States of America) 1989-08-17
07/395,373 (United States of America) 1989-08-17
07/395,374 (United States of America) 1989-08-17
07/395,378 (United States of America) 1989-08-17
07/395,384 (United States of America) 1989-08-17

Abstracts

English Abstract


Wire harnesses are assembled by preparing
wires in a first region and assembling the harnesses
in a second region. The harnesses are assembled in
the second region by conveying the harnesses from one
end of a conveyor to the other, by providing multiple
work stations along the conveyor for manual work
functions, by providing local supplies of wires at
some work stations, by providing local supplies of
connectors at some work stations, and by connecting
some of the wires to some of the connectors at some
of the work stations and integrating them into a wire
harness. The local supplies of wires at some work
stations axe provided by transporting the wires from
the first region to the work stations. The conveyor
is incremented periodically and the work functions at
the various work stations are preselected to require
substantially equal time to perform. The prepared
wires for the harnesses are stored in channel trays
and may be transported and supported on mobile
carriages. The channel trays are U-shaped and may be
oriented horizontally or vertically.


Claims

Note: Claims are shown in the official language in which they were submitted.


The embodiments of the invention in which an exclusive
property or privilege is claimed axe defined as
follows:-
1. A wire storage and dispensing arrangement for
use in a system for the fabrication of wire harnesses
having multiple wires, the fabrication system
including a mechanical conveyor having multiple work
stations therealong, comprising:
means for (respectively) temporarily storing
quantities of wires at various ones of said working
stations, said wires being precut to various
appropriate lengths, said storing means being so
configured and said wires being so disposed therein as
to facilitate manual removal of respective said wires
for use at a work station, each said storage means
comprising a plurality of channel trays supported on a
carriage, said wires being of various different
function-type, the wires of a respective said
function-type being stored in a respective one of said
channel trays.
2. The arrangement of claim 1 wherein most of
said carriages are mobile.
3. The arrangement of claim 2 wherein said
channel trays are each generally U-shaped and open at
an end to provide manual access thereto for removing a
wire in a direction longitudinally of said channel.
4. The arrangement of claim 3 wherein each said
channel tray includes a base and a pair of generally
opposed side walls, the base portion connecting said
side walls being generally flat thereby to facilitate
even distribution of wires therein.
-42-

5. The arrangement of claim 3 wherein at least
some of said carriages each include horizontal shelves
at several levels, and respective channel trays are
freely supported horizontally on the respective said
shelves at various said levels.
6. The arrangement of claim 3 wherein said
channel trays are oriented substantially vertically on
at least some of said carriages and said wires
disposed in said channel trays extend beyond and hang
from the upper end therefrom to facilitate said manual
removal.
7. The arrangement of claim 6 wherein said
channel trays each include respective clamp means
affixed thereto near the respective upper end thereof
for releasably retaining the wires in the respective
channel trays in position for convenient manual
access.
8. The arrangement of claim 3 wherein a hinge
connects a pair of said channel trays at one end in
adjacent parallel relation, thereby to store in the
pair wires of greater length than the length of a
single channel tray of the pair.
9. The arrangement of claim 2 wherein said
carriages include base cross members at opposite ends,
rolling means being affixed to said base cross
members, and wherein at least one of said base cross
members is adjustable toward the other.
-43-

10. The method of assembling wire harnesses
comprising the steps of:
in a first region, precutting and terminating
quantities of the various wires of which a harness is
comprised; and
in a second region, assembling the wire harnesses
via the steps including:
providing a mechanical, conveyor line for
conveying the harnesses substantially from
inception in embryonic form at an upstream end to
completion at a downstream end;
providing a multiplicity of local work
stations along the conveyor at which operators
perform various manual assembly functions, said
functions being variable as required;
providing local supplies of wires at various
of said work stations for use in the assembly
function thereat, including transporting wires
from said first region to said respective said
work stations to provide said local supplies;
providing local supplies of connectors at
various of said work stations for use in the
assembly function thereat; and
connecting various of said wires to various
of said connectors at various of said work
stations and integrating said wires and
connectors into respective wire harnesses.
-44-

11. The method of claim 10 including the steps
of advancing the conveyor periodically and performing
said connecting and integrating steps in the interval
between said advancing of said conveyor.
12. The method of claim 11 including the step of
preselecting the assembly functions at each of said
work stations to require substantially equal times to
accomplish.
-45-

13. A system for the fabrication of wire
harnesses each having multiple wires, comprising:
a mechanized conveyor of particular width
having relative upstream and downstream portions
and multiple work stations therealong for the
progressive formation of said harnesses from
embryonic to completed states respectively;
means proximate at least some of said work
stations for providing wires, including some
terminated wires, for inclusion in a wire
harness, the length of at least some of said
wires being substantially greater than said
particular width of said conveyor; and
a trough adjacent at least one side of said
conveyor along at least said upstream portion
thereof whereby said wires of a said embryonic
harness may extend transversely of the conveyor
beyond its said particular width and into said
trough.
14. The system of claim 13 wherein said conveyor
includes means affixed thereto for positively engaging
and moving said embryonic harness therewith.
15. The system of claim 14 wherein said harness
engaging means comprises at least one pair of fingers
extending upwardly from said conveyor, the fingers of
a said pair being spaced from one another in the
direction in which the conveyor moves.
-46-

16. The system of claim 15 wherein said conveyor
includes multiple pairs of said fingers, each said
pair of fingers being spaced from the other said pairs
in the direction in which the conveyor moves.
17. The system of claim 13 wherein said trough
depends from the conveyor a distance greater than said
width of said conveyor, thereby to receive a
significant portion of said harness.
18. The system of claim 13 wherein said embryonic
harness includes a junction box connected thereto and
wherein the width of said trough is sufficient to
receive said junction box therewithin.
19. The system of claim 18 wherein said conveyor
includes first and second said troughs, said first
trough being adjacent one side of the conveyor and
said second trough being adjacent the other side of
said conveyor thereby to each receive a portion of
said embryonic harness therein.
-47-

20. The system of claim 14 herein said conveyor
includes multiple pairs of fingers, the fingers of a
respective said pair being spaced from one another in
the direction in which the conveyor moves and said
pairs of fingers being spaced from one another also in
the direction in which the conveyor moves, each said
pair of fingers being adapted to engage and move said
embryonic harness therewith, and said embryonic
harness may cross said conveyor in generally U-shape
form, with the two arms of the U-shape being engaged
respectively by two pairs of fingers, the nexus
portion of the U-shape being in one of said troughs
and the ends of said U-shape being in the other of
said troughs.
-48-

21. A system for the fabrication of wire
harnesses each having multiple wires, comprising:
a mechanized conveyor having multiple work
stations therealong for the progressive manual
formation of said harnesses;
means proximate at least some of said work
stations for providing wires, some of which are
terminated, for inclusion in wire harnesses; and
one or more loom tables each adjacent a
respective work station for facilitating the
fabrication of a multiwire harness subassembly
thereat for inclusion in the wire harness at the
respective work station.
22. The system of claim 21 wherein one or more of
said loom tables is pivotally mounted for selective
displacement between an operating position and an idle
position, said operating position disposing said loom
table so as to facilitate said fabrication of a said
harness subassembly and said idle position being
displaced from said operating position and disposing
said loom table in substantially non-interfering
relation at the work station for operations thereat
other than said fabrication of said harness
subassembly.
-49-

23. The system of claim 22 wherein a said loom
table comprises a platform member and a plurality of
wire supporting members mounted to and extending from
the platform member for receiving, supporting and
routing various wires of said multiwire subassembly.
24. The system of claim 23 wherein said platform
member is horizontal and each said wire supporting
member extends upwardly therefrom and includes a
respective bifurcation at its upper end for receiving
wires therebetween.
25. The system of claim 22 wherein said conveyor
includes a supporting frame and said loom tables are
each pivotally mounted to said frame.
-50-

26. A taping arrangement for the mechanized
wrapping of tape about an elongated bundle of wires
undergoing fabrication into a wire harness and
disposed on a conveyor, comprising, at a work station
adjacent the conveyor:
a taping machine, including a housing, a
drive motor connected to the housing, an orbiting
mechanism supported by the housing and driven by
the motor in an orbital path about a central
region in which the wire bundle is disposed, and
tape dispensing means mounted on the orbiting
mechanism for dispensing tape to the wire bundle
as the mechanism' orbits about the wire bundle;
mounting means for the taping machine to
facilitate manual displacement of the machine
longitudinally of the wire bundle to be taped;
and
the mounting means and taping machine being
positioned adjacent to the conveyor at least
during taping of a wire bundle.
27. The taping arrangement of claim 26further
including at least one gripping means mounted to
resist motion longitudinally of the wire bundle to be
taped, said gripping means being adapted to releasably
engage and grip the wire bundle to be taped
sufficiently to resist displacement of the wire bundle
during application of a tensile force thereto during
taping.
-51-

28. The taping arrangement of claim 27 wherein
said gripping means comprises a clamp which is
manually actuatable between clamping and release
positions.
29. The taping arrangement of claim 28 wherein
said taping machine mounting means includes support
platform, said support platform being positioned
adjacent to the conveyor, and said clamp being mounted
on and supported by said support platform.
30. The taping arrangement of claim 29 wherein
said support platform is mounted for pivotable motion
relatively toward and away from the conveyor between
respective operating and idle positions.
31. The taping arrangement of claim 30 wherein
said conveyor includes a stationary frame and said
support platform is pivotally mounted to said conveyor
frame.
32. The taping arrangement of claim 31 wherein
said mounting means for said taping machine further
includes a mounting frame, a pair of parallel rails
joined to and supported by the mounting frame, and a
bracket sliceably disposed on said parallel rails for
longitudinal motion therealong, said bracket being
connected to and providing the support for said taping
machine.
-52-

33. The taping arrangement of claim 32 including
selectively adjustable stop means positioned on at
least one of said rails for limiting the longitudinal
displacement of the bracket and thereby the taping
machine, supported by said bracket.
34. The taping arrangement of claim 26 wherein
said drive motor is pneumatically powered.
35. The taping arrangement of claim 26 wherein
said taping machine housing includes an annular and
substantially continuous race and said orbiting
mechanism comprises annular disc means having a
central opening at the central region through which
the wire bundle may extend.
36. The taping arrangement of claim 35 wherein
said orbiting annular disc means includes an annular
pattern of gear teeth on one face thereof, and wherein
said motor includes a pinion in driving engagement
with the gear teeth of skid orbiting annular disc
means for translating the axis of rotary motion
between the motor and the orbiting annular disc means.
37. The taping arrangement of claim 26 wherein
said mounting means for said taping machine includes a
mounting frame, at least one rail joined to and
supported by the mounting frame, and a bracket
sliceably disposed on said rail for longitudinal
motion therealong, said bracket being connected to and
providing the support for said taping machine.
-53-

38. A taping machine having housing, a motor, an
orbiting mechanism supported by the housing and driven
by the motor, and tape dispensing means mounted on the
orbiting mechanism for dispensing tape to an object to
be taped as the mechanism orbits about the object, and
wherein the housing is annular and comprises two
complementary arcuate portions joined in hinged
relation and movable between relatively open and
closed positions and the orbiting mechanism comprises
an annular plate having a central opening and being
divided into two separate complementary arcuate
portions substantially coinciding with said
complementary housing portions and being capable of
being moved with said housing portions between said
open and said closed positions.
39. The taping machine of claim 38 wherein the
motor includes a pinion connected thereto in driven
relation, each of said arcuate portions of said plate
includes a respective arcuate gear in a face thereof
and wherein said pinion is in driving engagement with
said gear on at least one of said arcuate portions of
said plate, the other of said arcuate portions of said
plate being pushed and driven by said one.
-54-

40. The taping machine of claim 39 further
including means for detecting a particular position of
rotation of said arcuate plate portions with respect
to said portions of said housing and for providing a
signal representative of that position, and means
responsive to said signal for stopping rotation of
said arcuate plate portions to substantially coincide
with said complementary housing portions.
41. The taping machine of claim 39 including
complementary locking means affixed to respective ones
of said complementary housing portions for releasably
locking said housing portions in said closed position.
42. The taping machine of claim 39 wherein said
motor is a pneumatic motor.
-55-

43. A terminal assembling tool for facilitating
the connection of multiple terminated wires to a
common bus connector, the terminated wires each
including a terminal for receiving a terminal of
complementary type, and the common bus connector
including multiple terminals of said complementary
type extending therefrom in substantially the same
direction, comprising:
a first jig for receiving said multiple
terminated wires;
a second jig for receiving said common bus
connector;
at least one of said first and second jigs
being movable relative to the other between
relative proximate and distant positions
respectively corresponding with a connecting
position and a load/unload position;
means for actuating said one of said first
and second jigs between said connecting and said
load/unload positions;
said first jig including means for
pre-positioning said terminated wires; and
said second jig including means for
pre-positioning said common bus connector,
whereby upon said actuation of said one of said
first and second jigs said terminated wires are
accurately and completely connected to respective
ones of said terminals on said common bus
connector.
-56-

44. The terminal assembling tool of claim 43
wherein said jig actuating means comprises a
pneumatically-powered liner actuator.
45. The terminal assembling tool of claim 44
including a base member and wherein said actuator
includes a housing and a reciprocable actuating arm,
said base member housing and said first jig being
substantially fixedly mounted to said base member and
said second jig being connected to said actuating arm
of said actuator for reciprocation between said
connecting and load/unload positions.
46. The terminal assembling tool of claim 43
wherein said terminals on said wires are of a female
type, said common bus connectors are of a male type
and said common bus connector includes a common base
portion, said multiple male terminals extending
forwardly from said base portion, and a pair of end
fingers being disposed at opposite ends of said base
portion and extending forwardly therefrom, and wherein
said second jig further includes retaining means
extending transversely of said common base portion end
fingers and forwardly thereof to engage said end
fingers and move said common base portion and
connected terminated wires rearwardly in unison for
unloading when said second jig is actuated from said
connecting position to said load/unload position.
-57-

47. The terminal assembling tool of claim 46
wherein said second jig is disposed for actuation in
the horizontal plane and said pre-positioning means
thereof comprise a cavity therein open at the top and
at the front of said second jig for receiving/
discharging the common bus connector via vertical
motion thereof and for closely orienting the common
bus connector when received in the cavity.
48. The terminal assembling tool of claim 47
wherein said first jig includes multiple, substantially
parallel slots in the upper surface thereof, a
respective said slot existing for each of said
terminated wires, said slots being substantially
aligned with respective said male terminals on said
common bus connector, and wherein each of said slots
is contoured at its forward end to retain a respective
female terminal therein in alignment with a respective
said male terminal.
49. The terminal assembling tool of claim 48
wherein said male terminals are of the spade type and
extend in a horizontal plane when disposed in said
second jig.
-58-

Description

Note: Descriptions are shown in the official language in which they were submitted.


The invention relates generally to the
fabrication of wire harnesses and more particularly
to methods and equipment for the manufacture of wire
harnesses.
The invention further relates generally to
the fabrication of wire harnesses and more particu-
larly to a system including certain equipment for the
manufacture of wire harnesses.
The invention still further relates
generally to the fabrication of wire harnesses and
more particularly to a wire harness manufacturing
system which include loom tables.
The invention still further relates
generally to taping arrangements and more
particularly to arrangements for the mechanized
wrapping of tape about an elongated object, such as a
bundle of wires undergoing fabrication into a wire
harness. The invention relates even more particu-
larly to a taping machine for use in a taping
arrangement.
The invention still further relates
generally to 'a terminal assembling tool and more
particularly to a terminal assembling tool for
connecting terminated wires to a common bus
connector.
The manufacture or fabrication of wire
harnesses has assumed many forms,and used various
techniques, ranging from being highly manual-labor
intensive to the use of a relatively significant
level of automation. The former may be acceptable
only if a low cost source of labor is available,
whereas the latter requires significant capital
expenditure and may be relatively inflexible. The
manufacture of high quality, cost-effective wire
- 2 -

~O~~~J~
harnesses for motor vehicles may be a challenge,
particularly where the high initial cost of equipment
and variations in harnesses because of differing
models of automobiles serve to argue against a high
degree of automation. Yet the relatively high cost
of the labor available also distates against an
inefficient use of such labor.
Thus, while it may be desirable for the
sake of flexibility to retain a manual system of
manufacture, it is important that the procedures and
machinery employed be as efficient and effective as
possible in order to be cost competitive.
Systems used in the prior art have involved
different persons or workers performing respective '
different batch functions at different locations,
i.e., one person cutting wires, another person doing
subassembly and another doing gross. assembly. More
recently this has been improved by a flow process in
which one worker might perform multiple functions, as
for instance cutting wires, preparing subassemblies
and preparing final wire harness assemblies.
However, this technique might also require can-
siderable expenditure of time and physical effort by
a worker or operator because of the amount of walking
required at a work station. Moreover, the time
required to train a worker to perform all of these
functions can be considerable.
Since the incorporation of numerous wires
in various routing arrangements is at the heart of
wire harness fabrication, the efficient handling of
those wires during the fabrication process is ,
particularly important.
- 3 -

~a~'3Z3I
Some types of wire harness manufacturing
processes of the prior art have employed one or more
so-called loom tables which are constructed to
facilitate the formation of portions of the wire
harness thereon. Those loom tables typically include
various supports positioned thereon in a pattern
which assists in establishing the formation of the
wire harness. Typically also, those loom tables are
large, stationary and serve to establish the location
of a work station, and the ma be
y y positioned at
various locations within the fabrication area.
Also, in the manufacture of wiring
harnesses and other bundles of elongated objects, it
is often~necessary to maintain the compactness of the
' 15 bundle by winding tape about it: In the formation of
wire harnesses, it has been common to perform the
taping of the wire bundle by manually winding the
tape about the bundle. Depending upon the size of
the bundle; the character of the tape and the number
of times the operation must be performed, such
operation may be extremely tiring and perhaps even
painful to the person performing it. In that regard,
motor driven taping machines have been provided for
the mechanized application of tape to a wiring
bundle. Those taping machines typically include a
framework or housing, a driving motor and some form
of orbiting mechanism within the housing which is
driven by the motor and causes a spool of tape to
orbit about a bundle of wires. To permit ingress and
egress of the wire bundle to the center region of the
machine, it has been common to provide one portion of
the machine with a permanently open mouth to that
central region. An example of such taping machine is
the ISOTAP BABX 040 which is marketed by Design
- 4 -

~0~3131
Equipments Representation France Internacional
(DERFI) of Cormeilles en Parisis, France. Such a
machine may be suspended by a cable or slidably
mounted on rails for the necessary translational
movement along the wire bundle.
While such taping arrangements may be
generally satisfactory, further refinement of the
taping arrangement generally, and of the taping
machine specifically, are desirable to contribute to
the ease, efficiency and accuracy with which'wire
harnesses and the like may be taped.
In the formation of wired circuits it is
often necessary or desirable to connect a number of
conductor wires to the same potential. This may
often be effected by connecting those wires to a
common bus, or common bus connector. Further, the
common bus connector may include a plurality of
terminals to which the individual wires, themselves
being terminated, are respectively connected. Such
connection'of several terminated wires to a common
bus connector often occurs in the formation of wiring
harnesses, as for instance wiring harnesses for
automotive vehicles:
The operation of. connecting terminated
wires to the respective terminals of a common bus
connector has often been performed manually, par-
ticularly where it is included as one of the steps in
the formulation of a wiring harness via a significant
use of manual labor. The manual interconnection of
terminated wires with the terminals of the common bus
connector may prove to be tiring to the operator,
particularly where respective terminals are indi-
vidually connected via the application of opposed
manual forces. This.may be further complicated if
- 5 -

~0~3~31
the positions of terminals on the connector are
closely adjacent one another such that they interfere
with or complicate the manual insertion of terminals.
Accordingly, it is a principal object of
the invention to provide improved method and
apparatus for the cost efficient manufacture of wire
harnesses of high quality.
It is a further object to provide such
method and apparatus with an acceptable degree of
flexibility to accommodate changes in the design of
the wire harness.
It is a still further object to provide
method and apparatus for the efficient handling of
wires used, and to be used, in the process of
fabricating wire harnesses.
It is a further principal object of the
invention to provide improved apparatus for the cost
efficient fabrication of wire harnesses of high
quality.
It is a further object to provide such
apparatus which facilitates the assembly and handling
of wire harnesses during the formative stages.
It is a still further principal object of
the invention to provide an improved system and
apparatus for the cost efficient fabrication of wire
harnesses of high quality.
It is a still further principal object of
the invention to provide an improved arrangement for
the mechanized wrapping of tape about an elongated
bundle of wires undergoing fabrication into a wire
harness. Included in this object is the provision ofo
apparatus, including a taping machine, which affords
relatively easy and accurate application of tape to a
wire harness bundle.
- 6 -

~o~~~~~
It is a.further object to provide an
improved taping machine which conveniently and
positively retains a wire harness bundle therewithin
for ease and accuracy of the wrapping of tape
thereabout.
In accordance with the invention there is
provided a taping arrangement for the mechanized
wrapping tape about an elongated bundle of wires
undergoing fabrication into a wire harness and
disposed on a conveyor. The taping arrangement is
disposed at a workstation adjacent the conveyor and
includes a mounting means for the taping machine to
facilitate its manual displacement longitudinally of
the wire bundle to be taped and wherein the mounting
means and the taping machine are positioned adjacent
to the conveyor at least during the taping of a wire
bundle.
It is a still further principal abject of
the invention to provide a terminal assembling tool
for facilitating the connection of multiple termi-
nated wires to a common bus connector.
It is a further object to provide such
terminal assembling tool which is capable of ,
interconnecting female terminations on the respective
wires with respective male terminals on the common
bus connector.
It is a still further object to provide an
improved terminal assembling tool which reduces the
amount and complexity of manual involvement in the
interconnection of terminated wires with the common ,
bus connector.
In accordance with the invention, there is
provided a wire storage and dispensing arrangement
for use in a system for the fabrication of wire

harnesses having multiple wires, the fabrication
system including a mechanical conveyor having
multiple work stations therealong, comprising:
means for (respectively) temporarily
storing quantities of wires at various ones of said
working stations, said wires being precut to various
appropriate lengths, said storing means being so
configured and said wires being so disposed therein
as to facilitate manual removal of respective said
1J wires for use at a work station, each said storage
means comprising a plurality of channel trays
supported on a carriage, said wires being of various
different function-type, the wires of a respective
said function-type being stored in a respective one
15 of said channel trays.
From a different aspect, and in accordance
with the invention, there is provided a method of
assembling wire harnesses comprising the steps of:
in a first region, precutting and termi-
20 nating quantities of the various wires of which a
harness is comprised; and
in a second region, assembling the wire
harnesses via the steps including:
providing a mechanical conveyor line for
25 conveying the harnesses substantially from
inception in embryonic form at an upstream end
to completion at a downstream end;
providing a multiplicity of local work
stations along the conveyor at which operators
30 perform various manual assembly functions, said
functions being variable as required;
providing local supplies of wires at
various of said work stations for use in the
assembly function thereat, including trans-
_ g

porting wires from said first region to said
respective said work stations to provide said
local supplies;
providing local supplies of connectors at
various of said work stations for use in the
assembly function thereat; and
connecting various of said wires to various
of said connectors at various of said work
stations and integrating said wires and
connectors into respective wire harnesses.
Further, in accordance with the invention,
there is provided a system for the fabrication of
wire harnesses each having multiple wires,
comprising:
a mechanized conveyor of particular width
having relative upstream and downstream portions
and multiple work stations therealong for the
progressive formation of said harnesses from
embryonic to completed states respectively;
means proximate at least some of said work
stations for providing wires, including some
terminated wires, for inclusion in a wire
harness, the length of at least some of said
wires being substantially greater than said
particular width of said conveyor; and
a trough adjacent at least one side of said
conveyor along at least said upstream portion
thereof whereby said wires of a said embryonic
harness may extend transversely of the conveyor
beyond its said particular width and into said
trough.
- 9 -

Still further, in accordance with the
invention there is provided a system far the
fabrication of wire harnesses each having multiple
wires, comprising:
a mechanized conveyor having multiple work
stations therealong for the progressive manual
formation of said harnesses;
means proximate at least some of said work
stations for providing wires, some of which are
1~ terminated, for inclusion in wire harnesses; and
one or more loom tables each adjacent a
respective work station for facilitating the
fabrication of a multiwire harness subassembly
' thereat for inclusion in the wire harness at the
respective work station.
Still further, in accordance with the
invention there is provided a taping arrangement for
the mechanized wrapping of tape about an elongated
bundle of wires undergoing fabrication into a wire
harness and disposed on a conveyor, comprising, at a
work station adjacent the conveyor:
a taping machine, including a housing, a
drive motor connected to the housing, an
orbiting mechanism supported by the housing and
driven by the motor in an orbital path about a
central region in which the wire bundle is
disposed, and tape dispensing means mounted on
the orbiting mechanism for dispensing tape to
the wire bundle as the mechanism orbits about
the wire bundle;
mounting means for the taping machine to
facilitate manual displacement of the machine
longitudinally of the wire bundle to be taped;
and
- 10 -

the mounting means and taping machine being
positioned adjacent to the conveyor at least
during taping of a wire bundle.
Still further, in accordance with the
invention there is provided a taping machine having
housing, a motor, an orbiting mechanism supported by
the housing and driven by the motor, and tape
dispensing means mounted on the orbiting mechanism
for dispensing tape to an object to be taped as the
mechanism orbits about the object, and wherein the
housing is annular and comprises two complementary
arcuate portions joined in hinged relation and
movable between relatively open and closed positions
and the orbiting mechanism comprises an annular plate
having a central opening and being divided into two
separate complementary arcuate portions substantially
coinciding with said complementary housing portions
and being capable of being moved with said housing
portions between said open and said closed positions.
Also, in accordance with the invention
there is provided a terminal assembling tool for
facilitating the connection of multiple terminated
wires to a common bus connector, the terminated wires
each including a terminal for receiving a terminal of
complementary type, and the common bus connector
including multiple terminals of said complementary
type extending therefrom in substantially the same
direction, comprising:
a first jig for receiving said multiple
terminated wires;
a second jig for receiving said common bus
connector;
- 11 -

~023.~3~.
at least one of said first and second jigs
being movable relative to the other between relative
proximate and distant positions respectively
corresponding with a connecting position and a
load/unload position;
means for actuating said one of said first
and second jigs between said connecting and said
load/unload positions;
said first jig including means for pre-
1~ positioning said terminated wires; and
said second jig including means for pre-
positioning said common bus connector, whereby upon
said actuation of said one of said first and second
jigs said terminated wires are accurately and
15 completely connected to respective ones of said
terminals on said common bus connector.
- 12 -

The invention will be better understood by an
examination of the following description, together with
the accompanying drawings, in which:
Fig. 1 is a plan view in general diagrammatic
form, of a wire harness assembling arrangement in
accordance with the invention;
Fig. 2 is a perspective view of a portion of the
wire harnesses assembling arrangement, taken at the
upstream end of Fig. 1;
Fig. 3 is a perspective.view of a carriage and
channel trays for wire storage and delivery, as used
in the wire harness assembling arrangement of Fig. 1;
Fig. 4 is an enlarged view of a hinged double
channel tray, as seen in Fig. 3;
Fig. 5 is a perspective view depicting an
alternate embodiment of the carriage and channel trays
of Fig. 4;
Fig. 6 is a perspective view of a portion of the
wire harness assembling arrangement of Fig. 1, showing
a pivotable loom table:
Fig. 7 is a side elevation view of a terminal
assembly tool employed in the wire harness assembling
arrangement of Fig. 1;
Fig. 8 is a tap view of the terminal assembly
tool of Fig. l, showing terminated wires and a common
bus connector prior to connection;
Fig. 9 is an enlarged perspective view of a
portion of Fig. 8 showing a jig, the terminated wires
and the common bus connector;
- 13 -

Fig. 10 is a perspective view of a portion of the
wire harness assembling arrangement of Fig. 1, showing
a taping machine in a taping arrangement;
Fig. 11 is a view of a taping machine of Fig. 10,
as viewed looking relatively upstream; and
Fig. 12 is a sectional view of a part of the
taping machine, taken along line 12-12 of Fig. 11.
Referring to the figures and initially to Fig. 1,
there is depicted in plan view and general
diagrammatic form, a wire harness assembling
arrangement or system 10 in accordance with the
invention. Typically the harness assembling
arrangement 10 will be situated in a common area
including at least a first region 11 for certain
preliminary functions and a second region 12
throughout which the harness assembling function
occurs. A third testing region 13 might also be
included.
The preliminary functions performed within the
first region 11 result in precut, terminated wires 4,
and typically include the large scale cutting of wires
to predetermined lengths, appropriate stripping of
insulation and the application and crimping of
terminals 6 (seen in other figures) to~one or both
ends of most wires. This is done by wire cutting,
stripping and terminal crimping machinery 14 of
conventional design, as for instance the Komax 40S.
The machinery 14 may prepare one or both ends of a
wire for receiving a terminal 6 or other termination
30, without actually making the termination. A human
- 14 -

~~~~~3~
operator 15 typically controls the operation of
cutting and terminating machinery 14. These wire
cutting and terminating functions might be undertaken
as batch operations.
Adjacent to the wire cutting and terminating
machinery 14 there is also provided initial storage
capacity for the temporary storing of wires 4 which
have been precut and terminated. This storage is
represented by the wire storage shelving 18. The
precut and terminated wires 4 stored in shelving 18
are stored in channel trays 20 to be described
hereinafter in greater detail. The precut and
terminated wires 4 are placed in respective channel
trays 20 in accordance with their respective length,
gauge, and/or type of termination.
Referring now to the wire harness assembling
region 12, there is depicted a mechanized conveyor
system 22. The conveyor system 22 consists of one or
typically a number of motorized conveyors 23, arranged
2o in a serial or continuous fashion. More specifically,
the conveyors 23 are arranged so as to form a line of
continuous mechanized transport from an upstream end
thereof designated 25 to a downstream end designated
26. In many respects, the conveyors 23 are of
conventional design, including supporting framework 27
(seen in Figs. 2 and 3), moving belts or the like 28,
.arid associated motors 29 for advancing the belts 28 in
accordance with a desired schedule. The motors 29 are
typically controlled by a controller of known design
which is preprogrammed to provide the desired schedule
of control. Typically such controllers also possess
- 15 -

the capability of manual override and control if such
ij desired.
A number of local work stations are situated or
located along conveyor 23 of conveyor system 22.
Since the present wire harness assembling system 10
relies principally upon a number of human operators 15
interacting with various types of tooling and
machinery along the conveyor system 22, those work
stations will, for convenience herein, be represented
by the same symbols and reference numbers which
represent the presence of a human operator 15. It
should be understood, however, that a work station 15
might also be represented in certain limited instances
by machinery.capable of automated operation and/or by
manually operated machinery to which an operator 15
moves from a different work station.
At each work station 15, wire harness
manufacturing and assembly equipment of various types
and capability is located depending upon the one or
2.0 more functions to be performed thereat.
Representative of such equipment are the terminal
dispensing and crimping machines 30, the stands or
mobile carriages (carts), 32 which typically support a
number of the channel trays 20 which in turn contain
the respective precut and terminated wires 4,
stationary worktables 34, loom tables and particularly
pivotable looms 36, one or more taping machines 38 and
various receptacles or containers 40 containing the
appropriate hardware to be included in the wire
harness at that location. Certain types of assembly
tooling, as for instance the terminal assembling
- 16 -
r,"::.. ..,t~:,~

~~~~~.~1
tool 42, may also be located at the work statyon 15,
and located upon a respective worktable 34.
It should be mentioned at this juncture that the
arrangement of the work stations 15 along the conveyor
system 22 and the work functions performed thereat,
are designed to minimize or eliminate the need for the
operator 15 at that work station to have to walk more
than a step or two. In many instances, the operator
may be able to be seated at the work stations. In
10 some instances, of course, it will be necessary for
the operator 15 to take a step or two in performing
the respective work function, but such movement is
generally quite limited. This characteristic exists
because most of the equipment required at a work
15 station 15 is closely arranged about that work station
on one or both sides of the conveyor 23 and further,
because conveyor belt 28 is advanced only periodically
so as to move the work in process from one work
station to the next.
The wire harness 8 undergoing fabrication at any
particular work station 15 is, generally speaking, at
rest while at that work station. For this reason, it
will be noted that the spacing between successive work
stations 15 along conveyor 23 is substantially the
same in most instances. It will be understood,
however, that some variation in this spacing may occur
to accommodate two operators at one or two work
stations 15 performing functions on the same wire
harness 8, but at opposite ends thereof. In the
system depicted herein, the space between successive
work stations is approximately 2-3 meters, the number
of work stations is in the range of 8-12, and the
- 17 -
.: ,r. ,T:..~....... ~, ...: :. ,...,:, '~'.:..',

~~~~1~~.
conveyor belt 28 is incremented or advanced from one
work station 15 to the next at intervals of several
minutes.
It will be understood that optimum efficiency is
obtained if each operator just completes their
allotted functions at the respective work station 15
immediately prior to the conveyor belt 28 being
incremented. This of course requires a judicious
balancing of the numbers and types of functions to be
performed at a work station 15, as well as a
consideration of the capabilities of the respective
operator 15 thereat. Because much of the equipment at
each work station 15 is mobile or relatively light
weight, it may be easily moved from one work station
to another during setup of the wire harness assembling
l0 for the manufacture of a particular type of wiring
harness. Indeed, it is the aforedescribed flexibility
of the present wire harness assembling~system 10 which
enables it to be employed economically to manufacture
wire harnesses of various sizes and configurations at
different times. Although the present system does
rely significantly upon acceptably-priced manual
labor, it does reduce the large capital cost and
inflexibility of a more automated system. Further,
the program of work flow and the equipment employed
herein provide the economies and flexibility desired.
In Fig. 1, the Wire harness 8 is depicted in its
completed form at or near the downstream end 26 of the
conveyor 23. ,Wire harness 8 has its beginning or
inception at the upstream end 25 of conveyor 23,
where, in its earliest "embryonic" form it is
identified as wire harness 8a. The wire harness takes
- 18 -

zo~~~~~
on additional form and detail at each of the
successive work stations and thus, is identified by a
successive alphabetical suffix following the basic
wire harness reference numeral 8. Moreover, the
portrayal of the wire harness assembling system 10 in
Fig. 1 depicts the conveyor 23 at the moment just
prior to it being advanced from one work station 15 to
the next. Thus, the wire harness at each work
station 15 is depicted in the condition or stage
representing completion of the work provided at that
work station. When the completed wire harness 8
appears at the downstream end 26 of conveyor 23, an
operator 15 removes the harness from the conveyor and
transports, it to a suitable test board 43 in testing
region 13 where it is tested for electrical accuracy
and integrity. In the illustrated embodiment, the
finished harness 8 is synonymous with an unused
reference suffix 81.
The completed wire harness 8 often includes
200-300 wires and may be more than 2 meters in length.
The harness 8 typically includes a number of different
"arms" or "branches", each being comprised of
differing numbers of wires. Typically, those branches
are physically, if not also electrically, collected in
a common region represented by a junction box 44
through which most of the circuits pass. The junction
box 44 may sometimes also be referred to as the "head"
of the harness 8. Still further, many of the branches
of the completed wire harness 8 terminate at their
opposite ends in respective multi-terminal connectors
46 of differing types and configurations. It will be
appreciated that the embryonic harness 8a includes a
- 19 -

202313.
junction box 44 and relatively few wires and is,
accordingly, relatively supple, deformable and of
light weight. On the other hand, as formation of the
harness 8 progresses, it becomes heavier and is
relatively less supple.
Referring further to Fig. 1, and additionally to
Fig. 2, it will be seen that the conveyor system 22 is
provided with at least a primary trough 50 and perhaps
also a secondary trough 52 on respectively opposite
sides of the conveyor 23 along that portion of the
conveyor toward its upstream end 25 in which the
embryonic wire harness 8a, 8b, 8c, etc. is formed.
Troughs 50 and 52 extend along the upstream portion of
conveyor 23 to permit the embryonic wire harnesses 8a,
8b, etc. to extend across, or transversely, of the
conveyor belt 28 in a back and forth U-shape or
serpentine fashion in which parts of the wire harness
extend beyond the sides of the conveyor and hang or
depend into the troughs 50, 52. It has been found
most convenient to arrange the first two or three work
stations 15 on one particular side of the conveyor 23
and to provide the primary trough 50 along that same
side of the conveyor.
The primary trough 50 is of a generally deep
U-shape in cross section and may typically extend
1.5-1.66 meter below the surface of the conveyor
belt 28. Primary trough 50 is sufficiently wide to
conveniently accommodate a large junction box 44
resting therein as depicted in Fig. 2. Moreover, the
trough 50 is sufficiently wide and smooth to
facilitate the sliding of the embryonic harnesses
8a, 8b and associated junction boxes 44 therewithin as
- 20 -

~a23131
the conveyor belt 28 advances. The depth of primary
trough 50 is sufficiently shallow that various parts
of the embryonic harness 8a, 8b and/or random
components to be affixed to the harness may rest upon
the bottom of the trough and are within reach of the
operator 15 thereat. Further, the vertical walls
inside of troughs 50 and 52, and particularly those
walls adjacent conveyor 23, are relatively smooth and
preferably continuous so as to prevent interference of
the conveyor frame 27 with the embryonic harness 8a
and junction box 44 as the corweyor belt 28 advances
and to prevent chafing of the harness on the troughs.
The secondary trough 50 on the opposite side of
conveyor 23 is somewhat more optional than the primary
trough 50, and serves to facilitate the smooth flow of
the embryonic harness 8a, 8b as it moves along the
conveyor 23. Moreover, trough 52 serves to "catch"
any components which may chance to fall free of the
harness on that side of the conveyor. Since it is
contemplated that the larger elements of the embryonic
wire harness 8a, such as the junction box 44, will be
in trough 50, the secondary trough 52 need not be as
wide as trough 50.
The troughs 50 and 52 may be formed of any
suitable material such as sheet metal, plastic or
fiberglass which is contoured to the appropriate
shape. The troughs 50 and 52 are affixed to the
conveyor frame 27 in a suitable manner, as by screws,
bolts and/or brackets such that they are adequately
supported at a level providing a smooth transition of
the embryonic harness 8a, 8b from the conveyor belt 28
into and out of the troughs 50, 52. In fact, troughs
- 21 -

50, 52 may be provided with curved lips at their
uppermost ends to prevent chafing and cutting the wire
harnesses 8a, 8b and/or the operators 15.
Referring to the initial construction of wire
harness 8a, a junction box 44 is taken from a storage
container 40 at the upstream end 25 of the ccnveyor.
Various wires 4 are taken from various ones of the
channel trays 20 supported on carriage 32 also located
near the upstream end 25 of conveyor 23. The wires 4
are then connected with the junction box 44 by the
first operator 15 to form the embryonic harness 8a.
It will be understood that additional operations on
the wire harness 8a at that work station may include
the application of additional terminals to one or more
1S of the wires 4 via the terminal dispensing and
crimping machines 30. One or more other containers 40
near the upstream end 25 of conveyor 23 may contain
various types of connectors 46 for connection with the
terminals at the opposite ends of some of the wires 4
connected to junction box 44.
Because the embryonic harnesses 8a, 8b may be
arranged across the conveyor belt 28 and thus
compressed in the longitudinal direction, the entire
length of the harness is easily within the reach of a
single operator 15 at the respective work station.
Thus, a single operator 15 may perform work functions
on the entire length of the embryonic harness 8a
without needing to move a significant distance within
the, work station. Moreover, the longitudinal extent
of the conveyor belt 28 occupied by the embryonic
harnesses 8a,8b, etc. is considerably less than will
- 22 -

20~3~.~~.
be required in the later. stages of formation farther
downstream.
Because portions of the embryonic harnesses
8a, 8b, etc. extend transversely of the conveyor belt
28, it has been found helpful to provide members on
the conveyor belt 28 in that region for engaging the
harness to assist with its positioning while work
functions are performed and to further assist with
moving the harness with the conveyor belt 28 when it
is advanced. These engaging elements may take the
form of the pairs of fingers 54 seen most clearly in
Fig. 2. Each finger pair 54 is affixed at its base to
the conveyor belt 28, as by a suitable bonding agent
and/or mechanical fasteners, and includes a pair of
fingers spaced from one another in the direction of
conveyor belt travel. In this way, a portion of the
harness 8a extending transversely of the conveyor belt
28 may be positioned between the fingers of member 54.
Each finger pair member 54 may be formed of rubber or
a rubberlike material and the dimensioning and
structure of the fingers is such that they may
resiliently engage the harness therebetween. The
spacing between successive finger pair members 54 may
be about 0.5 meter, more or less. Since the principal
advantage of the finger pairs 54 described above is in
the embryonic formation of the wire harness 8a,
8b, 8c, etc., they may be omitted from the conveyor
belt 28 downstream if the conveyor system is formed of
multiple separate conveyors 23 and associated conveyor
belts 28, as is typically the case.
Additional consideration is now given to the
structure and function of the channel trays 20 and the
- 23 -

~fl2313~
associated stands or carriages 32 upon which they are
supported, with particular reference to Figs. 3-S.
Each channel tray 20 typically receives precut
terminated wires 4 of a particular type and length.
In this way, there is no mixing of wires 4 of
different types within a single channel tray 20.
Channel trays 20 are generally U-shaped, are elongated
and are open at least at a discharge end, and
preferably at both ends. The channel trays 20 may be
of differing lengths, depending principally upon the
length of wires 4 to be stored therein, with the
majority ranging in length between 1 and 2 meters
although they may be shorter or longer. While the
classic rounded U-shape of continuous curvature is a
suitable contour for the cross section of channel
trays 20, as depicted specifically with respect to
channel tray 20a in Fig. 3, it has been found
preferable to employ a modified U-shape which includes
a flattened bottom and substantially vertical sides,
as the majority of such trays are depicted in the
various figures. Such flat-bottom U-shape
configuration appears to afford a more even
distribution of the wires 4 contained therein and
reduces the incidence of tangling which would
interfere with the removal of individual wires from
the tray. Perhaps the curved cross section of channel
tray 20a results in a greater number of wires 4 being
at the center of the tray and thus contributes
somewhat to tangling. The channel trays 20 are formed
of any suitable, relatively rigid and durable
material, as for instance, metal, plastic or
fiberglass.
- 24 -

20~3~.3~.
If the wires 4 in a particular channel tray 20
are terminated at only one end, it is that terminated
end which is presented to the operator 15 when the
tray 20 is supported in position on a carriage 32
adjacent to a particular work station. It will be
understood that supported channel trays 20 may be
positioned on either, or both, sides of the conveyor
22 relative to the position of the operator 15 who
will be drawing wires 4 from those trays. Perhaps the
most common arrangement and that which permits easiest
access by operator 15 to a relatively large number of
channel trays 20, is that in which the carriage 32
supporting those trays is positioned opposite the
operator 15 across the conveyor 23, as seen
specifically in Figs. 2 and 6.
In certain instances in which the length of a
wire 4 is unusually long and greatly exceeds the
length of a single channel tray 20, a pair of such
trays may be joined at their respective forward ends
by a suitable connector or fastener, such as hinge 55,
to form a double tray designated 20' in Figs. 3 and 4.
In that instance, one portion of each of the long
wires 4 is contained in one of the channel trays and
the remaining portion is contained in the other, with
the wires transitioning between trays just beyond the
forward ends of the trays in the region of the
hinge 55 so as to be readily available for removal by
an operator 15. The connecting hinge 55 provides a
convenient means for joining the two trays 20 forming
the combined unit 20' for ease of handling during
loading and transport.
- 25 -

The stands or carriages (carts) 32 upon which the
various channel trays 20 are supported may be of
relatively simple design and inexpensive construction.
In some few instances, the stands 32 may be
permanently stationary and thus have no requirement
for mobility. In most instances, however, it has been
found desirable for the stands or carriages 32 to be
mobile, and thus some form of rollers or wheels 56 are
provided on cross-members 57 at the base of
carriage 32. In some instances it may be desirable to
reduce or "sweep" the profile of the cross-members 57
and wheels 56, as by making them adjustable via struts
59 in the manner depicted in broken line in Fig. 3.
The channel trays 20 are simply rested upon
crossarms or shelves 58 which form part of the rigid
structural framework of the carriage. The flat base
of channel tray 20 may simply rest upon a flat surface
of a horizontal crossarm 58. In the event the curved
U-shape channel tray 20a is to be employed, it may be
appropriate to provide curved recesses on or in the
crossarms 58 to accommodate the curved bases of those
trays or alternatively, curved brackets might be
attached to the crossarms 58. To provide adequate
support for a tray 20, it is only necessary that there ,
be a pair of simple crossarms spaced fore and aft on
carriage 32, such that they support the channel tray.
A number of channel trays 20 may be supported in side
by side relation on any one crossarm 58, and the
carriages 32 typically also include crossarms 58 at
several levels to accommodate channel trays at those
differing elevations.
- 26 -

~~~3:~3~.
Although the carriages 32 described above provide
hori2ontal orientation of the associated channel trays
20, a carriage 32' is constructed such that the trays
20 are supported thereby in a near vertical
orientation, as depicted in Fig. 5. These stands or
carriages 32' may be of somewhat simpler construction
than the carriages 32 and, because of the vertical
orientation of trays 20, will occupy relatively less
floor space. On the other hand, in such vertical
orientation it is generally preferable to have only
one row or level of trays 20 and their length will be
limited to that which is within a reasonable height
range of the operators 15.
It has been found useful to mount resilient
clamps 60 on at least those channel trays 20 which are
intended for vertical orientation, fox the purpose of
retaining the forward or upper ends of the wires 4 in
position for easy access by an operator 15. More
specifically, clamps 60 may be mounted to the
undersurface of trays 20 at or near the forward,
upper, or discharge end thereof for engaging a bundle
of wires 4 which hangs over that same end of the
channel tray. In this. way the wires are prevented
from falling down within the channel tray 20 when it
is in its vertical orientation and the ends are
conveniently presented for easy removal.
puring the assembly of the wire harness 8, it is
occasionally necessary or desirable to provide
additional work surface for the connection of wires 4
to connectors 46 in the formation of various
subassemblies and to facilitate the integration of
such subassemblies into the main harness appearing on
- 27 -

the conveyor belt 28 at that work station 15. In some
instances, that work may be accommodated on simple
stationary worktables 3~4 if they are positioned
sufficiently near the operator 15. Also, additional
work surface is provided by loom tables 36 and 36'.
Each of the loom. tables 36 , 36' includes a number
of wire or harness-supporting jigs 62 mounted on the
upper surface thereof in a predetermined pattern for
aiding in the formation of the harness 8 or, more
likely, a subassembly or branch to become part of the
main harness. The jigs 62 typically include a base
portion 63 which is mounted to the loom table 36
or 36', and a vertical support portion 64 extending
upwardly therefrom and being bifurcated at its upper
end to form a pair of harness-supporting fingers 65.
The arrangement of the jigs 62 on loom tables 36, 36'
is such as to define multiple wiring and branch paths
during the formation of the harness or a harness
subassembly. The loom tables 36' are typically on
wheels to permit easy positioning and repositioning of
the tables in the region of the conveyor 23. In the
system diagram depicted in Fig. 1, movable loom tables
36' are positioned sufficiently close to the conveyor
23 that relatively few steps are required by an
operator 15 to move a harness or a harness subassembly
between the conveyor and the respective loom table.
On the other hand, it will be noted and understood
that the wheeled loom table 36'.is capable of general
movement in the region of a work station and may in.
fact be positioned such that an operator/work station
15 is positioned between the loom table 36' and the
conveyor 23.
_ 28 _

~0~~.~3~
On the other hand, the loom table 36 may be even
closer to the conveyor 23 and is capable of certain
limited displacement by an operator 15, as by being
pivoted, between an operating position and an idle
position, as depicted in Figs. 1 and 6 adjacent wire
harness 8f. In Fig. 6, the loom table 36 is
illustrated at its idle position in solid line, and at
its idle position in broken line. In this instance,
the operating position places the loom table 36
closely adjacent and parallel to the conveyor 23,
whereas the idle position is achieved when the table
36 is rotated approximately 90 degrees away from the
conveyor about a pivot axis 66 which is remote from
the operator 15 and generally near the conveyor 23.
1S In its operating position, the loom table is
positioned for easy access by the operator 15 to
perform the various work functions on the harness or
harness subassembly as required. On the other hand,
when such work is completed, the harness or
subassembly may be conveniently removed from the loom
table 36 and placed on the conveyor belt 28, and the
loom table may be pivoted to its idle position,
thereby affording the operator increased spaced for
the performance of other work functions at that
particular work station.
It has been found particularly convenient to
mount the loom table 36 to the frame 27 of conveyor 23
for pivotal rotation about pivot axis 66. More
specifically, a journal or gudgeon 68 may be mounted
to the conveyor frame 27 and a pivot pin or pintle 69
extends downwardly from the underside of loom table
and through the gudgeon 68 to provide the pivot
_ 29

axis 66. It may be desirable to provide some form of
lock or clamp or detent associated with gudgeon 68 and
pintle 69 so as to retain the table 36 at a selected
position about the pivot axis. One relatively simple
way of providing the detent is to provide a pin or dog
extending radially from the pintle 69 near its upper
end and to contour the upper end of the gudgeon so as
to provide detenting recesses for the pin at desired
angular locations thereabout.
Referring to Figs. 7-9, further attention is
given to a particular item of assembly tooling, that
being the terminal assembling tool 42. Tool 42 is
designed to easily and accurately accomplish the ,
connection, of several terminated wires 4 to a common
bus connector 70. Common bus connector 70 is utilized
to connect those several wires to a common electrical
potential, as for instance B+ or ground in an
automotive electrical system. In fact, the
current-carrying capacity of the wires 4 which are
connected to bus connector 70 is typically greater
than that of many of the other wires in the wiring
harness 8. The terminals 6 on the ends of the
respective wires 4 are of a female-type, and are
adapted to receive and be connected to the male,
spade-type terminals 71 of bus connector 70. The bus
connector 70 in the illustrated embodiment includes
three such male terminals 71 extending forwardly from
a common base portion 72 in substantially coplanar
parallel relation. Side or end fingers 73 extend
forward from each end of the common base 72 of
connector 70. For the illustrated connector 70, each
of the male terminals 71 extends from an edge of the
- 30 -

common base portion 72, whereas the end fingers 73 axe
created by respective 90 degree bends in that base
portion and thus extend in respective planes which are
perpendicular to the plane containing the male
terminal 71. The end fingers 73 may themselves
subsequently be placed in electrical connection with
other conductive members.
The terminal assembling tool 42 aids in
accurately positioning the terminals 6 relative to the
male terminals 71 of common bus connector 70 and
further contributes not only to the easy connection of
those elements but also, to the removal of the
connected terminals from that tool. Tool 42 includes
first and second jigs 75 and 77 respectively. Jig 75
is structured to receive the terminated ends of
several wires 4. Jig 77 is structured to receive the
common bus connector 70 oriented in a substantially
horizontal disposition. Jigs 75 and 77 are mounted on
a base member 78 in a manner allowing one of the jigs
to move relatively toward and away from the other
between relative proximate and distant positions
respectively corresponding with a connecting position
and a load/unload position. In this embodiment,
jig 75 remains stationary and jig 77 is capable of
linear motion transversely of base 78.
A pneumatic actuator, such as the piston and
cylinder 80, is connected with the base member 78 and
the jig 77 to effect and control the displacement of
that jig relative to jig 75. The piston arm 81 of
actuator 80 is positively connected to jig 77, as by
welding or threaded engagement or the like, to
positively reciprocably displace that jig. The
- 31 -

~~ ~0~3.~31
cylinder of actuator 80 is rigidly mounted and
provides significant lateral stability to jig 77.
However, to the extent that further lateral guidance
of that jig is required, a raceway may be machined in
the base member 78 to assure alignment with jig 75.
At the forward end of jig 77 there is provided a
chamber or cavity 82 which is open in both the forward
and upward directions. The cavity 82 is adapted to
receive a common bus connector 70 deposited from
above, and is open at its forward end to permit mating
engagement with the terminals 6 supported in jig 75.
With the common bus connector 73 disposed horizontally
as depicted in Fig. 7b, a clearance exists beneath the
undersurfaces of the male terminal 71 sufficient to
permit the insertion thereon of the female
terminals 6.
Jig. 75 includes several longitudinally extending
slots 83 in the upper surface thereof for receiving
the respective wires 4. More specifically, the
grooves or slots 83 define sidewalls 84 which are
undercut near their forward ends to provide seats 85
for the terminals 6. The undercut in the walls 84 is
such that the terminal seats 85 contain the terminals
6 captive in~both a vertical and lateral direction
when inserted and seated therein as depicted in
Figs. 8 and 9.
In Figs. 7-9, jig 77 is shown in its load/unload
position, displaced from jig 75. Thus, the terminal 6
of a terminated wire 4 may be loaded into jig 75 by
disposing the terminal forwardly of the forward end of
jig 75 and moving the terminal and the wire 4 downward
until the terminal is at the level of the terminal
- 32 -

~fl~3~3~
seat 85. Rearward tensioning of wire 4 then serves to
seat the terminal 6 in terminal seat 85. This same
operation is repeated for the other two terminated
wires (not shown) with respect to the other two slots
83 in jig 75. Similarly, the common bus connector 70
is loaded into jig 77 by dropping it into cavity 82 in
the orientation depicted in Fig. 7b. The rear and
sidewalls of jig 77 which define cavity 82 are sized
and configured to orient common bus connector 70 such
that its terminal 71 are in constant alignment with
the female terminals 6. Actuation of jig 77 via
actuator 80 serves to bring the male terminals 71 into
mated engagement with the female terminals 6, thus
completing the connection.
Retaining elements 86 are formed at the forward
end of the jig 77 by a pair of projections extending
transversely a short distance toward one another to
provide a partial closure to the forward end of
cavity 82. More specifically, retaining elements 86
extend across the forward ends of the end fingers 73
on the common bus connector 70. Following connection
of the terminals 6 and their associated wires 4 to the
common bus connector 70, actuator 80 operates to
withdraw arm 81 and move jig 77 rearward to the
load/unload position. During that motion, the
retaining~members 86 on jig 77 engage the end fingers
73 and the common bus connector 70 rearward also.
Such rearward displacement of a common bus connector
70.dislodges the female terminals 6 from their seated
positions in jig 75, thus facilitating removal of the
connected wires and connector from tool 42 by a simple
- 33 -

lifting upward of the several wires 4 in unison to
remove connector 70 from cavity 82,
At various stages in the formation of wire
harnesses 8, it is desirable and necessary to gather
and bind certain ones of the wires to form branches
within the harness. In some instances, those branches
will terminate in connectors or other types of
electrical termination. To bind the branches of a
wire harness 8, it has been conventional to bind or
wrap adhesive tape in a helical pattern about the
collection of wires which form the branch. In some
instances the tape is wound entirely manually, but in
other instances mechanized devices have been used. In
the present system, an improved taping arrangement is
depicted at the work station containing taping
machine 38 and adjacent to which the harness 8i is
positioned. Both the taping machine 38 and the
arrangement of which it is a part are of improved
design, as discussed in the following description with
particular reference to Figs. 10-12.
Referring to Fig. 10, there is depicted the
taping machine 38 mounted for translation along a pair
of rails 87 which are in turn mounted to and supported
by a platform 88. The platform 88 is pivotally
mounted to and supported by the frame 27 of conveyor
23 in the same way as pivotable loom tables 36, as by
a gudgeon 68 and pintle 69 of the type earlier
described. The work platform 88 may be long and
narrow and formed of a rigid material such as metal,
wood or plastic. Toward one end of the platform 88
there is mounted a bifurcated harness support 65 of
the same general type as earlier described with
- 34 -

respect to the loom tables 36. Relatively near the
other end of the work platform 88, there is positioned
a mechanism for gripping or clamping the harness, such
as the clamping mechanism 89.
The clamping mechanism 89 is rigidly mounted to
platform 88 and extends upwardly therefrom for
releasably engaging a bundle of wires which form a
branch of harness 8i, to pertnit~the application of a
tensioning force to the harness branch during the
taping thereof. The clamping mechanism 89 may be of
any suitable construction and typically includes a
pair of jaws 90a, 90b, one or both of which are
movable vertically between clamping and release
positions by means of a manual actuating arm 91.
Conveniently, the lower jaw 90a is stationary and the
upper jaw 90b is moved vertically by actuation of the
arm 91 in a vertical plane about a horizontal pivot
axis. Actuating arm 91 may be pivoted downward from
its release position shown in Fig. 10 to some
over-center locked position in which jaws 90a and 90b
firmly grip a branch of the harness placed
therebetween. The jaws 90a, 90b may be concavely
contoured to the general circular shape of a harness
branch. Further, a spring or other bias element is
typically associated with one or both of the jaws 90a,
90b such that they resiliently and yieldably engage
harness branches of differing diameters:
Platform 88 serves as a mounting frame for the
parallel rails 87, which in turn support the taping
machine 38 in sliding relation therewith via slide
bracket 92 which slides along the rails between a pair
of adjustable stops 93 positioned toward relative
- 35 -

~0~~~3~.
opposite ends thereof. The stops 93 may be positioned
cn only one of the rails 87 and are manually
adjustable as by thumbscrews.
Referring to Fig. 11, the taping machine 38 is
considered in greater detail. Generally speaking,
taping machine 38 includes a two-piece housing 94, a
two-piece orbiting disc or plate 95 and a tape
dispensing arrangement, such as the spool of tape 97
mounted on orbiting plate 95 via spindle 98.
l0 The orbiting plate 95 is driven by motor 96 via a
pinion 100 in driving engagement with an annular bevel
gear 99 on the face of plate 95. The orbiting plate
95 includes a circular central opening 102 through
which the branch of the wiring harness to be taped
extends during the taping operation. The plate 95 may
be of a suitable material such as metal, plastic or a
composite.
Although the housing and/or the orbiting plate 95
might be formed such as to be non-opening, it will be
appreciated that the harness branch to be taped would
require both insertion and removal axially through the
center opening 102. This may be both cumbersome and
limits the size of, connectors that may have been
previously connected to an end of that branch.
Instead, as depicted in Fig. 11, both the housing 94
and the orbiting plate 95 are formed of two pieces,
and the housing is hinged to permit being opened at a
forward end to create a mouth 104 through which a wire
harness branch may be admitted to and removed from the
central opening 102 without requiring axial movement
of the branch. In the illustrated embodiment, the
lower portion of housing 94 and of orbiting plate 95
- 36 -

are angularly coextensive and are less than
180 degrees, whereas the respective upper portions of
each are somewhat greater than 180 degrees. The
lower portion of housing 94 is connected to the upper
portion via a hinge mechanism 106. Hinge 106 is in
turn connected to a pneumatic actuator 108 via linkage
109. Operation of the actuator 108 serves to move the
lower portion of housing 94 up and down between closed
and open positions respectively.
As best seen in Fig. 12, the housing 94 is
C-shaped in cross section to provide a housing and
raceway for the two-piece plate 95 which orbits
therewithin. The outer circumference of the two-piece
orbiting plate 95 is sufficiently narrow to fit within
the housing 94, but sufficiently wide to include
several slots extending radially therein about the
circumference for the mounting of several.respective
roller bearings 110. The roller bearings 110 are
mounted in position by respective pins 112 which
extend in an axial direction through plate 95 and upon
which the bearings are mounted far rotation. The
roller bearings 110 provide the principal supporting
contact between the housing 94 and the orbiting plates
95. Additionally, to retain each of the orbiting
plates 95 captive within the respective housing
portion 94 when the housing is open, there'are
provided axially extending notches 114 in the opposite
sidewalls of the orbiting plates 95, and retaining
pins 116 mounted in the opposed sidewalk of the.
housing 94 extend therefrom into the~notches 114. A
connecting bracket 118, seen in Fig. 11, spans the two
halves of the housing 94 and includes a slotted keyway
- ~37 -

119 in which a key (not shown) associated with one of
the halves slides in order to guide a relative opening
and closing motion between the halves.
It will be understood that although the orbiting
plate.95 is formed in two complementary portions, the
portion which is being driven at any moment by pinion
100 serves to drive or push the other plate portion
such that it follows. Pinion 100 spans both halves of
the orbiting plate 95 at the two positions of
interface therebetween. Thus, when the two halves of
housing 94 are closed as shown in broken line in
Fig. 11, the operation of motor 96 drives the pinion
100 which.in turn drives the orbiting plates 95, to
thereby impart orbital motion to the spool of tape 97
about the wire harness branch positioned within the
central opening 102. Assuming the adhesive surface of
the tape has first been placed in engagement with the
wire harness branch, such orbital motion of the tape
spool 97 effects wrapping of the tape about the
branch.
To ensure that the housing 94 of taping machine
38 remains closed during operation, there is provided
an engaging hinge having a female fastener member 120
on one lip of the housing and a locking pin 121
controlled by pneumatic.actuator 122 positioned on the
other lip of the housing. Control of the actuator 122
serves to move the locking pin 121 into and out of
locking engagement with the female fastener member
120.
For the taping machine 38 to operate correctly,
it is important that the two portions of the orbiting
plate 95 each stop in positions which are angularly
- 38 -

coextensive with the two halves of the housing 94 when
the taping machine is to be opened. This assures that
the opening of mouth 104 is relatively wide and
further, that there is little or no likelihood of the
orbiting plate portions becoming separated from the
respective housing portions. To accomplish this end,
provision has been made for detecting the angular
orientation of the orbiting plate 95 within the
housing 94 and for stopping rotation of the plate at
to precisely the correct angle. Detection of the angle
is accomplished by an inductive detector 124 mounted
on the housing 94 for detecting a specific angular
position on the circumference of the orbiting plate
95. That position may be indicated by including a
piece of metal 125 on the orbiting plate periphery for
appropriate electromagnetic interaction with the
detector 124 in a known manner. This form of
detection is particularly suited to use with a plate
95 formed of non-metallic material.
Operating in conjunction with the detector 124 is
a pneumatic cylinder 126 positioned on the upper
portion of the housing 94. Cylinder 126 operates to
apply a braking/locking force to the upper orbiting
plate 95 to lockwit in correct angular position as
detected by detector 124. Pneumatic cylinder 126 may
act to move a brake or lock member into and out of
braking and/or locking engagement with the orbiting
plate 95.
Preferably, the motor 96, and the actuator
cylinders 108, 122 and 126 are pneumatically driven
and are controlled in accordance with an electric
program control provided by an OMRON C28K Controller
- 39 -

(not shown) in a manner commensurate with the present
description. Inputs to that control are provided by
START/STOP and OPEN/CLOSE control buttons (riot shown)
controlled by an operator 15 and additionally by an
electrical input from the inductive detector 124.
Appropriate actuation of the OPEN/CLOSE control
buttons effects the respective opening or closing of
the taping machine 38 via actuator 108 and the
respective unlocking or locking of fastener 120, 121
via actuator 122. Similarly, appropriate actuation of
the START control commences the orbital motion of the
tape spool 97 to wind tape about a wiring harness
branch, and actuation of the STOP control serves, via
detector 124, motor 96 and cylinder 126 to stop the
orbiting plate 95 at the correct position.
Thus, to effect the taping of a branch of wire
harness 8i, the work platform 88 will typically be
pivoted to a position adjacent the conveyor 28 and one
end of the branch to be taped will be clamped in the
clamping mechanism 89. The harness branch will then
be moved through the open mouth 104 of taping machine
38 into the central opening 102 and the other end of
that branch may then be supported in the bifurcated
support 65. The operator 15 may provide a manual
tensioning of the harness branch against the resisting
clamping force of the mechanism 89. The taping
machine 38 is then closed, the tape 97 is led to the
harness branch and the motor 96 is then energized to
begin the taping operation. The taping machine 38 is
manually moved along the rails 87 from one stop limit
93 to the other to perform the tape winding operation.
Upon reaching the other limit 93, the operator
- 40 -

~~~~~e~~
actuates the STOP button, then severs the tape, as
with a knife, and opens the taping machine 38 to
permit the removal of the harness branch and its
return to the conveyor belt 28.
S Although this invention has been shown and
described with respect to detailed embodiments
thereof, it will be understood by those skilled in the
art that various changes in form and detail thereof
may be made without departing from the spirit and
scope of the claimed invention.
- 41 -

Representative Drawing
A single figure which represents the drawing illustrating the invention.
Administrative Status

2024-08-01:As part of the Next Generation Patents (NGP) transition, the Canadian Patents Database (CPD) now contains a more detailed Event History, which replicates the Event Log of our new back-office solution.

Please note that "Inactive:" events refers to events no longer in use in our new back-office solution.

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Event History

Description Date
Inactive: IPC from MCD 2006-03-11
Inactive: IPC from MCD 2006-03-11
Inactive: IPC from MCD 2006-03-11
Time Limit for Reversal Expired 2002-08-12
Letter Sent 2001-08-10
Grant by Issuance 1999-10-19
Inactive: Cover page published 1999-10-18
Pre-grant 1999-05-14
Inactive: Final fee received 1999-05-14
Letter Sent 1998-11-20
Notice of Allowance is Issued 1998-11-20
Notice of Allowance is Issued 1998-11-20
4 1998-11-20
Inactive: Status info is complete as of Log entry date 1998-11-03
Inactive: Application prosecuted on TS as of Log entry date 1998-11-03
Inactive: Approved for allowance (AFA) 1998-10-14
Request for Examination Requirements Determined Compliant 1997-03-11
All Requirements for Examination Determined Compliant 1997-03-11
Application Published (Open to Public Inspection) 1991-02-18

Abandonment History

There is no abandonment history.

Maintenance Fee

The last payment was received on 1999-08-10

Note : If the full payment has not been received on or before the date indicated, a further fee may be required which may be one of the following

  • the reinstatement fee;
  • the late payment fee; or
  • additional fee to reverse deemed expiry.

Patent fees are adjusted on the 1st of January every year. The amounts above are the current amounts if received by December 31 of the current year.
Please refer to the CIPO Patent Fees web page to see all current fee amounts.

Fee History

Fee Type Anniversary Year Due Date Paid Date
MF (application, 7th anniv.) - standard 07 1997-08-11 1997-07-14
MF (application, 8th anniv.) - standard 08 1998-08-10 1998-07-31
Final fee - standard 1999-05-14
MF (application, 9th anniv.) - standard 09 1999-08-10 1999-08-10
MF (patent, 10th anniv.) - standard 2000-08-10 2000-07-20
Owners on Record

Note: Records showing the ownership history in alphabetical order.

Current Owners on Record
MECANISMOS AUXILIARES INDUSTRIALES, S.A.
Past Owners on Record
JAIME ULLOA HERNANDEZ
JORDI BIGORRA VIVES
JORDI CASAS ALIGUE
MANUEL AREVALO VAZQUEZ
RAMON M. VIDAL VERGE
Past Owners that do not appear in the "Owners on Record" listing will appear in other documentation within the application.
Documents

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Document
Description 
Date
(yyyy-mm-dd) 
Number of pages   Size of Image (KB) 
Description 1994-01-19 40 1,433
Abstract 1994-01-19 1 25
Cover Page 1994-01-19 1 17
Claims 1994-01-19 17 448
Drawings 1994-01-19 9 322
Representative drawing 1999-10-11 1 20
Cover Page 1999-10-11 1 58
Commissioner's Notice - Application Found Allowable 1998-11-19 1 164
Maintenance Fee Notice 2001-09-09 1 179
Correspondence 1999-05-13 1 48
Fees 1996-07-25 1 70
Fees 1994-08-07 1 75
Fees 1995-08-02 1 71
Fees 1992-07-29 1 62
Fees 1993-07-27 1 54
Fees 1994-09-22 1 34
Prosecution correspondence 1997-03-10 2 56
Prosecution correspondence 1997-05-11 4 199