US3004581A - Terminal crimping machine with improved switch - Google Patents

Description

Oct. 17, 1961 5. J. KROL ETAL 3,00 ,58

TERMINAL CRIMPING MACHINE WITH IMPROVED SWITCH Filed May '7, 1958 5 Sheets-Sheet 1 Invemors Stanley [00/ 8 John So/a TERMINAL CRIMPING MACHINE WITH IMPROVED swrrca Filed May 7, 1958 Oct. 17, 1961 5. J. KROL ETAL v QR mm w wk ,8 3/ mw/ A m 1 Y w w MN: R .U M w Oct. 17, 1961 5. J. KROL ETAL 3,004,581

TERMINAL CRIMPING MACHINE WITH IMPROVED SWITCH Filed May 7, 1958- 5 Sheets-Sheet .5

FIG 6 INVENTOR. Stanley Km/ 8 J0/m So/a Oct. 17, 1961 5. J. KROL ETAL 3,004,581

TERMINAL CRIMPING MACHINE WITH IMPROVED SWITCH 5 Sheets-Sheet 4 Filed May 7, 1958 e um EN QNN Oct. 17, 1961 J KRQL E 3,004,581

TERMINAL CRIMPING MACHINE WITH IMPROVED SWITCH Filed May 7, 1958 5 Sheets-Sheet 5 FIG 12 INVENTORS Stanley 370/ 8 John 60/(1 @Z W MW United States Patent 3,004,581 H TERMINAL CRIMPING MACHINE IMPROVED SWITCH Stanley J. Krol, Bensenville, and John B. Sola, Chicago,

111., assignors to Malco Manufacturing Company, Chicago, 111., a partnership Filed May 7, 1958, Ser. No. 733,712

Claims. (Cl. 153-1) This invention relates to machines for crimping terminal connectors on electric wires. More particularly, the invention relates tocrimping machines including control means embodying sensitive cycling switches of im proved construction. In addition, the invention relates to the improved switches themselves. I p

In the electrical and electronics industries it has become standard practice to secure metallic terminal consectors to electrical wires utilized for a myriad of purposes. Such terminal connectors are usually secured to the electric wires by crimping, using either handtools or crimping machines of various designs. When crimping machines are utilized, the terminals are ordinarily fed into the machines in connected chain form Where they are intermittently fed to suitable crimping dies and crimped by means of the dies on conductors inserted between the jaws of the dies.

One of the major problems encountered in connection with machines for crimping terminal connectors on electrical conductors has been proper control of the machines for high speed production. Often such machines are cycled by closing a switch actuated by the operators hand or foot after the operator has inserted a conductor in position for crimping. This type of control is not satisfactory for high speed production, from a time standpoint or from a safety standpoint, because of the" two steps involved, Obviously, more time is required for performing two steps than would be required for performing only one of these steps, and the additional time required is very undesirable in high production industries. Also, where two steps are involved, there is always danger of the operator becoming confused or fatigued, resulting in accidental cycling to produce scrap parts or to possibly cause some injury. I j

Recent attempts have been made to'combine theme chine actuation step with theconductor insertion step by 7 allowing the inserted conductor to actuate the cycling mechanism. When crimping machines, so actuated are electrically controlled, some sort ofsensitive switch must be employed to initiate the cycling. Here the difiiculty arises because if the cycling switches utilized are soiliciently sensitive to be tripped by relatively small con ductors, they are usually too sensitive and too delicate for use in connection with heavier conductors. Furthermore, it is well known that sensitive switches are ordinarily subject to rapidfatigue failure when cycled rapidly over long periods of time. To add to the problem, sensitive switches are often adversely affected by changes'in atmospheric conditions, are easily injured through corrosion or shock, and are expensive toobtain and maintain. On the other hand, if the crimping machines are cycled by more rugged, less sensitive switches, they are not satisfactory for crimping terminals on light leads.

Accordingly, it is an object ofthe present invention to provide an improved terminal crimping machine.

Another object of the invention-is to provide a terminal crimping machine embodying improved control means.

A further object of the invention is to provide a terminal' crimping machine embodying a cycling switch which can. be satisfactorily actuated by very light l trical leads and, at the same time, can be satisfactorily actuated without injury by much heavier. leadsi "ice An additional object of the invention is to provide an improved sensitive electrical switch adapted for continuous cycling.

Other objects, features and advantageswill be apparent from the following detailed description taken in conjunction with the accompanying drawings, in which:

FIGURE 1 is a perspective view of a' terminal crimping machine according to the present invention in which the terminals are fed'in chain form from the rear of the machine;

FIGURE 2 is a longitudinal sectional view of the terminal crimping machine of FIGURE 1;

FIGURE 3 is a front view of the improved cycling switch of the machine of FIGURE 1;

FIGURE 4 is a side view of the cycling switch of FIGURE 3; 1

FIGURE 5 is an enlarged, eXplod-edpcrspective view of the cycling switch of FIGURES 3 and 4;

FIGURE 6 is a perspective view of a modified form of rear-feed terminal crimping machine according to the present invention;

FIGURE 7 is an enlarged perspective view of the cycling switch of the machine of FIGURE 6; s

, FIGURE 8 is an exploded perspective view of the switch of FIGURE 7;

FIGURE 9 is a perspective view of a modified form of terminal crimping machine according to the present invention in which the terminals are fed in chain form from the side of the machine;

FIGURE 10 is fragmentary sectional View showing the relationship of the head terminal on the chain with respect to the cutter of the machine of FIGURE 9 and with a portion of the upper die member broken away to simplify the showing;

FIGURE 11 is an enlarged perspective view of the cycling switch of the machine of FIGURE 9; and

FIGURE 12 is a front elevational view of a modified form of side-feed terminal crimping machine, with parts broken away to show the cycling switch.

EMBODIMENT OF FIGURES 1-5 shown) and includes a lower bed portion 32 and an upper ram portion 34; The ram may be guided for vertical movement with respect to the bed through the usual posts 36 secured to the ram and received in close fitting guide sleeves 38' attached to the bed (one each shown).

The crimping die assembly 24 may include a lower die anvil 40, which is secured to the die set bed 3 2, and an upper die punch 42, which is secured to the die set rarn The die anvil and the die punch may be'of' any suitable construction for crimping terminal connectors to wiring'leads. The die assemblyis replaceable to accommodate different dies for crimping diiferentt'ypes and sizes of terminals. The particular dies shown are adapted for crimping terminals 44 to insulatedwire conductors 4,6, as described in the co-pending patent application of John B. Sola and Richard T. Krause, Serial No. 713,413, filed Feb. 5, 1958, and assigned to the assignee of the present invention.

The terminal chain feed assembly '26 is adapted for successively feeding the terminals 44, in connected chain form, to the crimping die assembly 24 where the terminals are crimped to the insulated Wire conductors 46. The feed assembly includes a bell crank lever 48 which is pivotally connected to an adjustable mounting block 50. The bell crank lever includes an actuating arm 52, which has a pin 54 secured at its outer end at right angles thereto, and a pawl arm 56, which is bifurcated at its outer end. A chain feed pawl 58 is pivotally secured in the bifurcated slot 60 of the pawl arm. The portion of the feed pawl 58 rearward of the pivot point is connected by means of a tension spring 62 to the upper portion of the arm 56, so that the spring resiliently urges a pawl finger 64 at the other end of the pawl into engagement with the chain of terminals 44. The pawl finger 64 is formed so that it will slip over the terminals as the bell crank lever 48 is pivoted in a counterclockwise direction as seen in the drawings, to move the feed pawl 58 rearwardly, but will engage a portion of one of the terminals to move the entire chain forwardly as the bell crank lever is pivoted in a clockwise direction, to move the feed pawl forwardly.

In order to actuate the bell crank lever as the ram 34 moves up and down, the pin 54 is disposed between a pair of spaced lugs 66 and 68 formed on a feed bracket 70 which is secured to the ram. The arrangement is such that as the ram moves upwardly after having performed a crimping operation, the lug 66 engages the pin 54 to pivot the bell crank lever 48 in a clockwise direction to feed the next terminal connector in the chain into position for being crimped by the crimping dies. When the ram 34 moves downwardly on the crimping stroke, the lug 68 engages the pin 54 to pivot the bell crank lever 48 in a counterclockwise direction to move the feed pawl 58 back into position for engaging the next rearward terminal in the chain, so that on the next stroke the chain will be fed forward the length of one terminal. The position of the mounting block 50 and the angular disposition between the bell crank arms 52 and 56 may be adjusted in any suitable manner (not shown) to accommodate terminals of different sizes and types.

It will be noted that there is a substantial space between the lugs 66 and 68, providing sufiicient dwell to permit separation of the crimping dies before the chain is fed into position for the next cycle.

The chain brake assembly 28 is adapted for preventing over-travel of the chain due to inertia, and for preventing reverse movement of the chain as the feed pawl is moved back to engage the next terminal to the rear. The brake assembly includes a mounting and guide block 72 secured to the die set bed 32 and having a fore-andaft, undercut guide channel 74 formed therein, through which the chain of terminals is threaded. If desired, the channel 74 may be of sufiicient size to accommodate terminals of various sizes. In order to frictionally brake the chain, a spring-pressed plunger 76 is disposed in an aperture 78 formed in the die set bed 32 below the block 72. The plunger frictionally engages the lower surface of the chain, causing the chain to frictionally engage the upper surface of the channel 74.

The frictional holding induced by the spring-pressed plunger 76 is sufficient to prevent inertia overtravel of the chain on the feed stroke and could also be sufiicient to prevent reversal of the chain. However, in this particular embodiment, an additional leaf spring stop 80 is secured by the block 72 to the die bed 32, in front of the block. The stop spring 80 has an upwardly and rearwardly slanted integral tab 82 which is disposed to slide over the top of the chain as it is fed in the forward direction. As the feed movement of the chain is completed, the forward edge 84 of the spring stop engages a suitable portion of the adjacent terminal to positively prevent reverse movement of the chain. As the chain is fed forward on the next stroke, the tab 82 rides over the next terminal, and the stop snaps into place when the forward movement is completed to again prevent reversal.

As the chain of terminals is fed to the crimping dies, it is guided by a chain guide block 86, which is secured to the dieset bed 32 immediately to the rear of the crimping dies, and the guide is provided with a fore-and-aft undercut guide channel 88 which receives and guides the chain. In addition, the guide block 86 prevents the chain from moving upwardly as the ram 34 is raised after a crimping stroke.

In order to sever the head terminal 44 from the chain as it is crimped on a wire lead 46, a shear or cutter blade 90 is secured to the ram 34 between the crimping dies 24 and the guide block 86. The shear blade 90 cooperates with' a shear slot 92 provided in a shear anvil 94 secured to the die set bed 32. As the ram 34 moves downwardly, the shear blade 90 severs the forwardmost terminal from the chain by shearing off a small integral connecting section 95, which is provided between successive terminals. The shear blade and the die set are so arranged that the. shearing operation is performed immediately prior to completion of the crimping operation, for example, in the last of an inch of movement of the ram.

The cycling switch assembly 30 includes a metallic base plate or ground or base member 96 having a thin metallic spring contact member 98 secured thereto. The plate 96 may be bridge shaped as shown and is secured to the die set bed 32 between the crimping dies 24 and the shear plate 90. This ground member 96 also serves as a stripper plate for the machine, having a bridge portion 100 disposed over the chain with sufficient clearance to allow feeding without interference. If the crimped terminal sticks in the punch portion of the crimping die as the ram moves upwardly, the terminal engages the bridge portion 100 of the stripper plate and is thus dislodged. The crimped terminal is then readily removed from the machine to make room for the next terminal.

The contact member 98 is of elongated rectangular configuration and is preferably formed of very thin spring metal, such as thin Phosphor bronze or the like. The contact is disposed in a horizontal channel 102 formed across the front face of the bridge, with the channel being of sufficient width to' provide substantial clearance for both edges of the contact. The contact is spaced from the face of the stripper plate by means of a pair of insulating washers 104, 104 disposed between the stripper plate and the opposite end portions of the contact, and is se' cured to the stripper plate by means of a pair of insulating studs 106, 106 which pass through the contact, the washers 104 and the stripper plate. The studs are secured at the rearward side of the stripper plate by any satisfactory means, such as by a pair of slip-on lock washers 108, 108.

One of the insulating studs 106 passes through a close fitting aperture 110 formed in the contact 98, so that this portion of the-contact plate is securely and firmly attached to the stripper plate, but spaced therefrom to prevent electrical contact. The other stud 106 passes through a horizontally elongated aperture 112 formed through the contact plate 98, providing clearance for a limited amount of horizontal slippage of this portion of the contact with respect to the stud and the stripper plate. This portion of the contact is also spaced from the strip per plate by means of one of the insulating washers 104- to prevent electrical contact.

The stripper plate 96 is electrically connected to one side, preferably the ground, of an electrical actuator system (not shown). The contact 98 is electrically connected by means of a lead 114 to the other, or hot side of the electrical actuation system. The system is of any suitable type, adapted for actuating the press (not shown) to move the ram 340m one complete stroke downwardly, to crimp a terminal on a lead, and then upwardly again to its unactuated position, thus completing one complete cycle of the machine.

The machine is cycled after momentary contact is made between the contact 98 and the stripper plate 96, and this momentary contact is made by pressing the face ofthe contact 98 rearwardly until it engages the face of the stripper plate 96. This is accomplished by moving a wiring lead .46 .endwise into the machine to engage the contact, causing it to flex inwardly and to slip slightly at the slot 112. It has been found by test that a switch such as this is so sensitive that it can be consistently actuated by endwise insertion of a very small diameter stranded, insulated wire, as small as 10, of an inch outside diameter, holding the wire one and one-half inches from its end.

In spite of the very light pressure required for achieving electrical contact to cycle the machine, release of this slight pressure immediately allows the thin spring contact 98 to move back to break the electrical connection. Inasmuch as, the spring contact is supported at both ends, it tends to flex evenly rather than co'ncen-' trating the flexing in one area, as would be the case if a cantilever spring were employed, drastically reducing bending fatigue. At the same time, the two-end support permits'use of a very thin spring contact, which provides for a very light contact pressure and at the same time additionally reduces bending fatigue in the spring. A switch of this type may be cycled many hundreds of thousands of times before repair or replacement is required, and, of course, the switch is constructed and arranged for ready contact replacement. By use of this improved cycling switch, the crimping machine may be consistently cycled with equal ease by inserting leads from the very smallest, to the very largest which can be accommodated by the machine.

OPERATION OF EMBODIMENT OF FIGURES 1-5 trical actuating system which is connected through and is A controlled by the cycling switch 30. The die set ram 34 is connected to the ram of the press and the die set bed 32 is connected to the bed of the press in any suitable manner.

In order to cycle the machine the operator inserts one of the wiring leads 46 through an aperture 116 in a safety or guard plate 118 which is secured to the bed. When the free end of the wire 46 is pressed lightly against the spring contact 98 of the cycling switch 39, an electrical circuit is completed through the actuating system of the press causing the ram to be actuated through one complete cycle. As the ram moves downward on the crimping stroke, the wire is engaged by the die punch 42 and is moved downwardly into place in the forwardmcst ter minal 44, which is disposed in proper position on the die anvil 40, Continued downward movement of the ram causes the dies to crimp the terminal on the wire, and at the same time the crimped terminal is severed from the chain.

During this. downward movement of the ram, the bell crank lever 4.8 is pivoted in a counterclockwise direction, as seen in the drawings, as the lug 68 of the feed bracket 70 pushes downwardly on the pin 54 of the bell crank lever. This causes the feed pawl 58 to be moved rearwardly until its pawl finger64 is brought into position to engage a portion of the next terminal in the chain to the rear. Rearward movement of the feed pawl does not cause any movement of the chain because of the action of the friction brake 76 and the stop spring 80. The pawl spring 62. extends when necessary in order to permit the pawl finger 64 to pass over projections or high spots on the terminals.

As the ram. 34 begins to move upwardly on the feed stroke there is: no immediate movement of the bell crank lever 48 because of the dwell between the lugs 66 and 68 of the feed bracket 70. This allows the .die punch to be moved up clear of the die anvil and also causes the crimped terminal to be stripped from thepunch as the terminal engages the bridge 100 of the stripper plate 9.6 so that the lead 46 with its crimped terminal 44 can be removed from the machine.

As soon as the ram has moved upwardly sufficiently to clear, the lug 66 of the feed bracket 70 engages the pin 54 of the bell crank lever 48 and causes the bell crank lever to be pivoted in a clockwise direction as seen in other figures. This causes the feed pawl 58 and the entire chain to be move-d forwardly to feed the forwardmost terminal on the chain into proper position on the die anvil 40. The chain may be fed from any suitable supply such as from a reel (not shown) which is connected to the press. When the ram 34 reaches the top of its stroke, the cycle is completed and the forwardmost terminal in the chain is properly located for the next cycle. The machine stays in this condition of readiness until the next wiring lead 46 is inserted into the machine against the cycling switch 30 to initiate the next cycle.

By reason of incorporation of the improved cycling switch 30, the machine can be cycled as fast as the operator can feed successive leads 46 into position in the machine. As explained above, the switch is capable of being continuouslyactuated over long periods of time, by wiring leads varying Widely in size, without malfunctioning or failure of the switch.

EMBODIMENT OF FIGURES 6-8 In FIGURE 6 is illustrated another embodiment of rear-feed type of terminal crimping machine according to the present invention. The machine is generally designated by the reference numeral 120 and includes generally a die set frame assembly 122, terminal crimping dies 124, a terminal chain feed assembly 126, a chain brake assembly 128 and a cycling switch assembly13li.

The die set frame. assembly 122 may be of any suitable construction for inserting into a punch press or the like (not shown). In this embodiment the die set assembly includes a cast frame 132 which acts as the bed portion of the assembly and also serves to guide an upper ram portion 134. It will be noted that the ram 134 is guided in an integral upright channel portion 136 of the frame 132. p

The crimping die assembly 124 may include a lower die anvil 140, which is secured tothe die set bed 122, and an upper die punch 142, which is secured to the die set ram 134. The die anvil and the die punch may be identical to the corresponding die anvil 40 and die punch 42 of the previous embodiment, or they may be of any other suitable construction for crimping terminal connectors to wire leads. The die assembly is replaceable as in the previous embodiment in order to accommodate different die sets for crimping dilferent kinds and sizes of terminals.

The terminal chain feed assembly 126 is adapted for successively feeding terminals 144, in connected chain form, to the crimping die assembly 124 where the terminals are crimped to insulated wire conductors 146. The feed assembly is quite similar to the feed assembly 26 of the previous embodiment and includes a bell crank lever 148 which is pivotally connected to a portion of the frame 132. y The bell crank lever includes an actuating arm 152, and a pawl arm 154. The actuating arm is adapted for actuation by a feed bracket 156, which is connected for movement with the ram 134. The mecha' nism for actuating the actuating arm 152 through the feed bracket 156 is not shown, but it may consist of any suitable means, such as that shown in connection with the previous embodiment, to provide pivoting of the bell crank lever 148 in response to up and down movement of the ram and at the same time providing a dwell in the same manner and for the same purpose as in the previous embodiment.

A chain feed pawl 158 is pivotally secured to the lower end of the pawl arm 154. A spring 162 is secured on the pawl arm 154 and has a finger portion pressing resiliently downwardly on the forward portion of the feed pawl 158 to urge a pawl finger 164 at the forward end of the feed pawl into engagement with the chain of terminals 144. The pawl finger 164 is formed so that it will slip over the terminals as the bell crank lever 148 is pivoted in a counterclockwise direction as seen in FIGURE 6, to move the feed pawl 153 rearwardly, but will engage a portion of one of the terminals to move the entire chain forwardly as the bell crank lever is pivoted in a clockwise direction to move the fed pawl forwardly. The arrangement is such that on each cycle of the machine the feed pawl 158 moves back to engage the next terminal rearward in the chain as the ram moves downward on the crimping stroke, and as the ram moves upwardly, after a predetermined dwell, the feed pawl moves forwardly to move the entire chain forward the length of one terminal.

The angular disposition between the bell crank arms 152 and 154 may be adjusted in any suitable manner, as by means of the adjustment screws 161} secured to the actuating arm 152 and riding in adjustment slots 168 formed in the pawl arm 154.

The chain brake assembly 128 is adapted for preventing over-travel of the chain due to inertia, and for preventing reverse movement of the chain as the feed pawl is moved back to engage the next terminal to the rear. The brake assembly includes a brake and guide block 170 which is secured to a portion of the frame 132 by means of a horizontal pivot 172. The block 170 has an undercut fore-and-aft guide channel 174 through which the chain of terminals is threaded. The channel 174 is of sulficient width to accommodate terminals of various sizes. In order to frictionally brake the chain, the upper surface of the channel 174 is adapted to rest on the chain.

For selective release of the chain brake the pivot 172 is fixedly secured to the block and is connected by means of a pivot arm (not shown) to an actuating arm 176 (only part of which is shown) which extends forwardly and is connected at its forward end to an actuating knob 178. The rod 176 is urged in a forward direction by means of a suitable spring (not shown), and, in turn, resiliently urges the block 170 downwardly on the chain to resiliently, frictionally press the upper surface of the block against the chain, thereby preventing inertia overtravel of the chain on the feed stroke, and preventing reversal of the chain on the crimping stroke.

As the chain of terminals is fed to the crimping dies, it is guided by a chain guide plate 180 having a fore-andaft channel 182 accommodating the chain. The channel 182 has an open top in the area of movement of the feed pawl finger 164, in order to allow the pawl finger to engage the chain and to intermittently feed the same.

In order to sever the head terminal 144 from the chain as it is crimped on a wire lead 146, a shear orcutter blade (not shown) is secured to the ram 134 behind the crimping dies, in any suitable manner, such as that shown in the previous embodiment.

The cycling switch assembly 130 includes a metallic base plate or ground member 184 having a thin metallic spring contact member 186 secured thereto. The plate 184 may be bridge-shaped as shown, and is secured to the die set frame 132 between the crimping dies 124 and the shear plate (not shown).

As in the previous embodiment, the ground member 184 also serves as a stripper plate for the machine, having a bridge portion 188 disposed over the chain, with sufficient clearance to allow feeding without interference.

The spring contact member 186 is of elongated rectangular configuration and is preferably of very thin spring metal such as thin Phosphor bronze or the like. The contact is disposed in a horizontal channel 1% formed across the front face of the bridge, with the channel being of suflicient width to provide substantial clearance for both edges of the contact.

In this embodiment of the cycling switch, the contact is spaced from the face of the stripper plate by means of insulating members 112 and 194 which are preferably molded to the opposite ends of the contact spring 186. The insulating members 192 and 194 may be of any suitable insulating substance, such as a phenolic plastic. The insulating member 192 is disposed in a mating recess 196 formed in the channel 190 and the insulating member 194 is disposed in a mating recess 198 formed in the other end of the channel, thus providing a raised contact face 2% between the recesses. The dimensions are such that when the insulating members are disposed in the recesses, as shown in FIGURE 7, the contact spring 186 is normally slightly spaced from the contact face 201), so that the contact spring and the contact face are normally not in electrical contact.

The insulating member 192 is secured to the stripper plate by means of a bolt 202 which provides the sole securing means, and when so secured the insulating member 192 fits snugly in the recess 196. However, sufiicient clearance is provided between the edge of the insulating member 194 and the opposing edge of the contact face 200 to allow limited longitudinal movement of this insulating member and the connected portion of the contact spring, in order to allow the contact spring to be flexed inwardly slightly to electrically engage the contact surface 200. Thus, the free end portion of the contact spring is supported as in the previous embodiment and is also permitted limited horizontal slippage for the same reason.

The stripper plate 184 is electrically connected to one side, preferably the ground, of an electrical press actuation system (not shown). The contact spring 186 is electrically connected by means of a lead 204 to the other, or hot side of the electrical actuation system. '11s shown in FIGURE 8, the end of the lead wire 204 is preferably molded in the plastic insulator 192. The actuation system is of any suitable type for actuating a press (not shown) carrying the crimping machine, such as described in connection with the previous embodiment.

The cycling switch operates in exactly the same manner as the switch 30 of the previous embodiment. In other words, an electrical contact is made by moving a wiring lead 146 endwise into the machine to engage the contact spring 186, causing it to flex inwardly and causing the portion connected to the insulator 194 to slip slightly to permit the spring contact to flex. The switch is equally sensitive and at least as rugged as that of the previous embodiment and, in addition, the contact spring and the molded insulators may be more readily and quickly replaced as a unit if necessary. I

The machine of FIGURES 6-8 operates in substantially the same manner as the machine of the previous embodiment, all of the corresponding elements performing the same functions with the exception of the chain brake assembly 128 which provides the sole braking means. When a new chain of terminals is to be threaded into the machine, the knob 178 is pushed toward the rear to raise the nose of the block to expedite threading of the chain. As soon as the chain is in place, the knob is released and the block 170 frictionally engages the chain.

EMBODIMENT OF FIGURES 9-11- The crimping machine of this embodiment is generally designated by the reference numeral 210 and is adapted for feeding a chain of terminal connectors from one side of the machine, rather than from the rear as in the previous embodiments. The machine includes generally a die set frame assembly 212, terminal crimping dies struction for inserting in a punch press or the like (not,

shown) and includes a lower bed portion 222 and an upper ram portion 224. The ram may be guided for vertical movement with respect to the bed through the usual posts 226 secured to the ram and received in close,

fitting guide sleeves 228 attached to the bed (one each shown). I w l The crimping die assembly 214 may include a lower die anvil 230, which is secured to the die setbed 222, and an upper die" punch 232, which is secured to the die set ram 224. The die anvil and the die punch may be of any suitable construction for crimping wire terminal connectors to wire leads. The die assembly is replaceable to accommodate different dies for crimping different types and sizes of terminals. The particular dies shown are adapted for crimping terminals 234 to insulated wire conductors 236 such as described in the copending patent application of Harold B. Kalmar, Harold R. Center and Edward I. 'Coulon for Terminal and Contact Wire Crimp and Method for Forming Same, Serial No. 688,347, filed October 4, 1957', and assigned to the assignee of the present invention.

The terminal chain feed assembly 216 is adapted for successively feeding the terminals 234, in connected chain form, to the crimping die assembly 214 where the terminals are crimped to the insulated wire conductors 236. It will be noted that in this embodiment of the invention the terminals are integrally connected to and laterally disposed from a flexible metallic feed strip 238, making it desirable for the chain to be fed from the side of the machine.

The feed assembly 216 includes a bell crank lever 240 I pivotally secured to a support block 242 and adapted for being pivotally actuated by a feed bracket 244 secured to the ram 224. The feed bracket provides a predetermined dwell as described in connection with the previous embodiments. A feed'pawl 246 is pivotally secured to the bell crank lever, and a tension spring 248 is operatively disposed between a portion of the pawl and the bell crank lever in order to resiliently urge a pawl finger portion 250 into engagement in respective, spaced feed apertures 252 formed in the chain flexible strip. The arrangement is such that on each upward or feed stroke of the ram, the chain is moved to the left as seen in FIGURE 9 a distance equal to the spacing of the successive terminals in order to feed the next terminal into position for being crimped.

As was the case in the previous embodiments, the feed assembly 216 is adjustable in any suitable manner (not shown) to accommodate terminals of different sizes and types and having different distances between terminals.

The chain brake assembly 218 is adapted for preventing overtravel of the chain due to inertia, and for preventing reverse movement of the chain as the feed pawl is'moved to the right to engage in the next feed aperture in the strip 238. The brake assembly includes a mount- 7 ing and guide block 256 secured to the die set 'bed 222 238. The frictional engagement by the plunger is sufiicient to prevent inertia. overtravel of the chain on the feed stroke, and is. also sufficient tov prevent reversal of the chain on the crimping stroke;

In order to sever the head terminal 234 from the flexportion of the strip and the terminal.

1'0 ible strip 238 as the terminal is crimped on the lead 236, also to cut off the associated portion of the flexible strip, a shear or cutter blade 262 is secured to the ram 224 behind. the crimping dies 214 and the cycling switch 220. The shear blade 262. cooperates with a rectangular shear slot 26.4 provided in a shear anvil 266 secured to the die set bed 222. As the ram 224 moves downwardly, the shear blade 262 severe the lead terminal from the chain by cutting off the lead end portion of the flexible strip 238 and by severing the connection between this Thus, the blade 262 not only severs the terminal from the chain but also cuts up the flexible strip in small, easily handled lengths of. scrap. The shear blade and the die set are so arranged that the shearing operation is performed immediately prior to the completion of the crimping operation,

, as described in connection with the previous embodiments.

The cycling switch assembly 220 is substantially the same as the switch assembly 30 of the first embodiment and includes a base or ground member 268, which provides a bridge, and a thin metallic spring contact 270. The arrangement and operation are the same as the first embodiment, with the exception that the bridge 268 is of cantilever configuration and is connected at the left side of the crimping dies only, as seen in FIGURE 9, in order to permit side feed of the terminals. The bridge 268 also serves as the stripper plate of the machine as described in connection with the previous embodiments.

It will be understood that the machine and the switch of this embodiment operate in the same manner as described in connection with the previous embodiments with the exception that the. chain of terminals is fed from the side of the machine. As before, the chain may be fed to the machine from reel or the like (not shown) connectedto the press which receives the machine.

EMBODIMENT OF FIGURE 12 The crimping machine of this embodiment is generally designated by the reference numeral 280 and is of the type for feeding terminal connectors from one side of the machine, such .as described in connection with the embodiment of FIGURES 9 -11. The machine includes generally, a die set frame assembly 282, terminal crimping dies 284, a terminal chain feed assembly 286, a chain brake assembly 288 and a cycling switch assembly 290. The elements and assemblies of this embodiment are substantially the same as those described in connection with the embodiment of FIGURES 6-8. However, the present embodiment is adapted for side feed as distinguished from rear feed, and, thus, the arrangement of the asesmblies is substantially as described in connection with the side feed embodiment of FIGURES 91l. The stripper plate, which forms the ground portion of the switch, is constructed for cantilever attachment in order to allow the chain to be fed from the right side of the machine as seen in FIGURE 12. I

The machineof the FIGURE 12 embodiment operates in exactly the same manner as the machine of FIGURES 9 11', except insofar as-thc particular assemblies are modified as described in connection with the embodiment of FIGURES 6-8. I

' I Summary I From the foregoing description it will be understood that the present invention provides four embodiments of an improved machine for crimping terminal connectors on wiring leads. In the first two embodiments the terminal connectors are fed in chain form from the rear of the machine, and in the latter twov embodiments they are fed in chain form from one side of the machine. In all cases lhe successive terminals are orimped on the successive leads on the downward or crimping stroke of the ram, and the chain is advanced to position the next terminal between the crimping dies on the up or feed stroke or the ram. .A dwell is provided in the feed assembly in order to permit the jaws of the dies to be separated sufliciently to clear the chain,. and to strip the crimped connector, before the chain is fed for the next crimping operation. A friction brake arrangement is provided in all cases to prevent inertia overtravel of the chain and also to prevent the [reverse movement of the chain. In one of the embodiments a positive stop is also provided to prevent reversal of the chain.

In all of the embodiments, the machine is cycled by means of an improved, sensitive cycling switch which is actuated by insertion of a lead between the crimping jaws. The switches of all embodiments are provided with thin spring contacts which are supported by insulating means at both ends, with one end portion permitted to slip slightly, longitudinally in order to accommodate flexing of the thin spring as it is engaged by the inserted wiring lead. The incorporation of this particular type of cycling switch greatly improves the operation of the machine by increasing production potential, decreasing shutdown time, reducing formation of scrap parts, and increasing safety. The improved switches themselves form important subcombinations.

Variations and modifications may be effected without departing from the scope of the novel concepts of the present invention.

We claim:

1. In a machine for crimping terminal connectors on wiring leads and including crimping means for acting on a crimping stroke to crimp the terminal connectors on respective leads and feeding means for acting on a feeding stroke to alternately feed the terminal connectors in connected chain form to the crimping means and also including actuating means for successively acuating the crimping means and the feeding means, the improvement comprising a sensitive electric switch for energizing the actuating means including a metallic plate member, a thin resilient electrical-conducting contact member, and means securing said members in closely spaced relation normally out of electrical contact to allow limited longitudinal deflection of a portion of said contact member when the contact member is transversely deflected to engage said plate member, said longitudinal deflection occurring prior to engagement of said contact member with said plate member.

2. A sensitive electric switch in a machine according to claim 1 wherein said securing means include insulating elements maintaining said contact member in said closely spaced relation on said plate member at two spaced positions.

3. A sensitive electric switch in a machine according to claim 1 wherein said securing means include a pair of insulating elements disposed in two substantially separated positions to provide an actuation portion therebetween and maintaining said contact member in said closely spaced relation on said plate. member, and an attachment element securing said contact member to said plate member adjacent one of said positions, whereby the portion of said contact member at the other of said positions is adapted to deflect longitudinally when said actuation portion is deflected toward said plate member.

4. A sensitive electric switch in a machine according to claim 1 wherein said contact member is formed of thin resilient metallic material, said plate member includes a flat metallic portion, and said securing means include insulating elements maintaining said contact member in spaced parallel relationship on said plate member at two substantially separated positions to provide a narrow gap between the members, and a stud securing said contact member to said plate member adjacent one of said insulating elements, whereby said contact member engages said plate member when the contact member is deflected toward the plate member and disengages when released.

5. A sensitive electric switch in a machine according to claim 1 wherein said plate member is disposed adjacent said crimping means closely spaced from the chain of terminal connectors, whereby when said crimping means have crimped a terminal connector on a wiring lead said plate'member engages the crimped terminal connector on the next feeding stroke to strip the crimped connector from the crimping means.

. 6. A sensitive electrical switch comprising a'flat metallic plate membena thin resilient metallic contact member, a pair of insulating elements maintaining said contact member in closely spaced relation on said plate member in two separated positions to provide an actuation portion therebetween, and means securing said contact member to said plate member adjacent one of said positions, whereby the portion of said contact member at the other of said positions deflectslongitudinally when said actuation portion is deflected toward said plate member.

7. A sensitive electric switch comprising a flat metallic plate member, a thin resilient metallic contact member, and means securing said members in norm-ally parallel closely spaced relation and maintaining said spaced relation at two longitudinally spaced positions to allow limited longitudinal deflection of a portion of said contact member between said spaced positions when it is transversely deflected to engage said plate member, said longitudinal deflection occurring prior to engagement of said contact member with said plate member.

8. A sensitive electric switch comprising a flat metallic plate member, a thin spring metal contact member, in sulating means supporting said contact member on said plate member at two separated positions to provide a narrow gap between the members, and means securing said contact member to said plate member to allow limited longitudinal deflection of a portion of the contact member when the contact member is deflected toward said plate member between said supporting means, wherebyv said contact member engages said plate member when so deflected and disengages when released.

9. A sensitive electric switch comprising a metallic plate member, a thin resilient metallic contact member, apair of thin insulating washers maintaining said contact member spaced from said plate member at two substantially separated positions, said contact member having a small aperture over one of said washers and a longitudinally extended aperture over the other of said washers, an insulating stud secured to said plate member and extending through one of said washers and said small aperture in snug relation thereto, and another insulating stud secured to said plate member extending through said other washer and slidably extending through said extended aperture to allow limited longitudinal deflection of the portion of said. contact member adjacent said extended aperture when the contact member is deflected toward the plate member between said washers, whereby said contact member engages said plate member when so deflected and disengages when released.

10. A sensitive electric switch comprising a metallic plate member, a thin resilient metallic contact member, a first thin insulating element molded over one portion of said contact member, a second thin insulating element molded over another portion of said contact member and substantially spaced from said first insulating element, a stud securing said second insulating element to said plate member so that said first insulating element engages said plate member, wherebydeflection of said contact member between said insulating elements toward said plate member causes said first insulating element to shift slightly longitudinally toward said second insulating element.

- References Cited in the tile of this patent UNITED STATES PATENTS 1,654,643 Gennoy Jan. 3, 1928 1,823,853 Cagliostro Sept. 15, 1931 2,631,213 Martines Mar. 10, 1953 2,681,447 Davis June 22, 1954 2,705,797 Handel Apr. 12, 1955 2,775,283 Greer Dec. 25, 1956 2,821,609 Kesserling Jan. 28, 1958 2,889,422 l Dibner June 2, 1959

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