US3771208A

US3771208A - Machine for crimping connectors to wires and connector supply arrangement

Info

Publication number: US3771208A
Application number: US00234113A
Authority: US
Inventors: J Taylor; J Golden
Original assignee: Reliable Electric Co
Current assignee: Reliable Electric Co
Priority date: 1972-03-13
Filing date: 1972-03-13
Publication date: 1973-11-13
Anticipated expiration: 1990-11-13
Also published as: ZA731714B; CA988688A; BR7301752D0; AR194306A1; GB1366626A; SE397234B; ES412548A1; FR2175931A1; JPS48102286A; AU5321473A; IT979814B; DE2312187B2; DE2312187C3; AU474886B2; DE2312187A1

Abstract

A machine is provided for crimping a U-shaped connector to a pair of conductor wires and wherein the connector is on a tape that carries a series of such connectors. The machine comprises an anvil for backing the tape and connector, a reciprocating ram, a wire-retaining guide carried by the ram for supporting the two wires in spaced apart relationship, and a shear block adjacent to the anvil and being movable relative to the anvil. The shear block has cutting edges cooperating with the ram for cutting the wires and has additional cutting edges cooperating with the anvil for cutting the tape. The ram also has die surfaces cooperating with the anvil for crimping the connector. The ram is driven by a primary piston which is in lost-motion connection with a member that actuates a valve to operate a secondary piston for feeding the tape following the forward stroke of the primary piston.

Description

[451 Nov. 13, 1973 United States Patent [191 Taylor et al.

[ MACHINE FOR CRlMPlNG CONNECTORS Primary Examiner-Thomas l-l. Eager TO WIRES AND CONNECTOR SUPPLY Attorney-Roy l-l. Olson et al. ARRANGEMENT [57] ABSTRACT A machine is provided for crimping a U-shaped con- [75] Inventors: James F. Taylor; James E. Golden,

both of Franklin Park, Ill.

nector to a pair of conductor wires and wherein the connector is on a tape that carries a series of such connectors. The machine comprises an anvil for back ingthe tape and connector, a reciprocating ram, a

v. n a n. m H am ea n. n hh k mn Ha er RF. e n .W S S A H 7 221 Filed: Mar. 13,1972

211 App]. No.: 234,113

wire-retaining guide carried by the ram for supporting the two wires in spaced apart relationship, and a shear block adjacent to the anvil and being movable relative to the anvil. The shear block has cutting edges cooperating with the ram for cutting the wires and has addi- Int. HOlr 43/04 203 tional cutting edges cooperating with the anvil for cut- [58] Field of Search....................

06/56 R ting the tape. The ram also has die surfaces cooperating with the anvil for crimping the connector. The ram [56] References Cited is driven by a primary piston which is in lost-motion UNITED STATES PATENTS connection with a member that actuates a valve to operate a secondary piston for feeding the tape following the forward stroke of the primary piston.

3,685,148 8/1972 Garfinkel.........................

19 Claims, 25 Drawing Figures PATENTEDNUV 13 I975 SHEET 5 BF 8 wow xv PATENTEDNBV 13 ms 3 7 71; 208

SHEET 7 BF 8 MACHINE FOR CRIMPING CONNECTORS TO WIRES AND CONNECTOR SUPPLY ARRANGEMENT BACKGROUND OF THE INVENTION This invention relates to improvements in machines for crimping connectors to conductor wires so as to form a spliced connection of the wires.

In the telecommunications industry it is often necessary to splice hundreds of wires together, notably during the installation of a new telephone cable. In such case, each wire of the existing cable must be spliced with a wire of the new cable. Such splicing operation requires positive electrical contact at the splice and also requires that each splice be insulated from the other splices in the cable. Since the splicing is carried out in the field, the operation is necessarily performed somewhat by hand, it being understood that hand operation includes the use of portable pneumatic equipment. In any event, the equipment or machine for the splicing operation must be one that is reliable in operation, easy to use, and makes it possible to form a large number of spliced connections in a short period of time.

OBJECTS AND SUMMARY OF THE INVENTION It is an object of the present invention to provide a machine for crimping channel-shaped connectors to a pair of conductor wires and wherein the connectors are mounted on a carrier or tape that is fed into the machine to position successive connectors for crimping.

It is a further object of the present invention to provide a machine of the type stated which is compact, easy to operate by relatively unskilled persons, and which can be readily operated in the field utilizing a source of air under pressure.

It is another object of the present invention to provide an arrangement of U-shaped connectors on a tape such that the tape serves to carry the connectors into the machine, and a portion of the tape remains with the connector to serve as an insulation preventing electrical contact of the connector with other crimped connectors of the cable following the splicing operations.

In accordance with the foregoing objects the machine comprises an anvil for backing the tape and a base of each connector, a reciprocating ram, a wire retaining guide carried by the ram for supporting a pair of juxtaposed wires, and a shear block adjacent to the anvil and being movable relative to the anvil. The shear block has cutting edges cooperating with the ram for cutting the wires and also has additional cutting edges cooperating with the anvil for cutting the tape. The ram has die surfaces cooperating with the anvil for crimping the connector by folding the sides of the connector and the tape bonded thereto such that portions of those sides and the tape are between the wires. The machine also includes a primary cylinder and piston for driving the ram through a forward stroke to (l) sever the tape with a connector thereon from the remainder of the tape, (2) insert the wires into the connector and with the wires having ends protruding from opposite ends of the connector, (3) cutting off the protruding end portions, and (4) crimp the connector to the wires by folding the sides of the connector, as aforesaid. In one form of the invention the ram has projecting pins for engaging the shear block to insure that the tape is severed should the wire ends be cut before the tape is cut. In another form of the invention the wires are pulled into the connector so that the cut ends of the wires are recessed in the connector when the latter is crimped. This prevents short circuits. The result is attained by the unique shear block and the manner in which it acts on the wires in conjunction with the operation of the ram.

The invention also contemplates the use of a secondary piston and cylinder for driving a feed wheel which advances the tape to position the next connector against the anvil preparatory to crimping. After the primary or ram piston completes its stroke, the secondary piston is operated to drive the feed wheel. The primary piston rod is in lost-motion connection with a rod which is driven by the primary piston rod near the end of its power stroke so as to actuate a valve and supply the air to the secondary cylinder.

Each connector has a U-shaped shell and a U-shaped insert telescoped within the shell, the insert having inwardly projecting prongs to bite through or pierce the insulation covering the wires to be crimped. The plastic tape has marginal strip portions and spaced parallel transverse sections joining the marginal strip portions. The tape also has openings between the transverse sections whereby the tape appears much like a ladder in which the rungs of the ladder are made up of the aforesaid transverse sections. These transverse sections are bonded to the base and sides of the outer shell of the connector and with those portions of the transverse sections that are bonded to the sides of the outer shell extending upwardly beyond the free ends of the sides of the shell. In the crimping and tape cutting opeation, the tape is cut adjacent to the marginal strip portions, which are discarded as scrap after they come out of the machine. Consequently, only a small portion of the tape is wasted since the bulk of the tape is retained by the connector to serve as an insulation for the same.

In general, the tape will be prepunched to form the ladder configuration prior to bonding the connectors to the transverse sections or runged portion of the ladder. The tape with the connectors thereon may then be rolled up into a reel or other supply container, as desired.

BRIEF DESCRIPTION OF THE FIGURES FIG. 1 is a perspective view of a crimping machine constructed in accordance with and embodying the present invention;

FIG. 2 is a fragmentary top plan view of the machine of FIG. 1;

FIG. 3 is a fragmentary sectional view taken approximately along line 33 of FIG. 2, but showing other parts broken away for purposes of clarity, and showing the ram in its normal or fully retracted position;

FIG. 4 is a fragmentary sectional view, on an enlarged scale, of a portion of FIG. 3 and showing the ram partially advanced toward the anvil or head preparatory to crimping the connector and cutting of the tape;

FIG. 5 is a fragmentary sectional view, on an enlarged scale, of a portion of the structure of FIG. 4 but showing the ram advanced to the position in which the tape is cut;

FIG. 6 is a fragmentary sectional view similar to FIG. 5 but showing the ram in the wire-cutting position;

FIG. 7 is a fragmentary sectional view similar to FIG. 6 and showing the ram in its fully advanced position and wherein the connector is fully crimped to the conductors;

FIG. 8 is an exploded perspective view of the wire ret'ainer, the ram, and a portion of the end of the ram rod;

FIG. 9 is an exploded perspective view of the head or anvil, the shear block, the anvil retainer plate, and certain parts associated therewith;

FIG. 10 is a fragmentary sectional view showing the primary piston and cylinder and toggle linkage associated therewith, the piston being in its normal or retracted position;

FIG. 11 is a sectional view similar to FIG. 10 but showing the primary piston approaching the end of its forward stroke;

FIGS. 12 and 13 are fragmentary sectional views, on an enlarged scale, taken approximately along lines 12-l2 and 13--13 of FIG. 3;

FIG. 14 is a fragmentary exploded perspective view of the feed wheel drive and indexing arrangement which form part of the present invention;

FIG. 15 is a fragmentary sectional view, on an enlarged scale, taken approximately along line 1515 of FIG. 3;

FIG. 16 is a perspective view, somewhat diagramatic in nature, and showing the pneumatic interconnections of the primary and secondary cylinders;

FIG. 17 is a top plane view showing the connectors mounted on the prepunched tape;

FIG. 18 is a side elevational view of the structure of FIG. 17;

FIG. 19 is a bottom plan view of the structure of FIG. 17;

FIG. 20 is a sectional view, on an enlarged scale, taken along line 20-20 of FIG. 17;

FIG. 21 is an elevational view of a splice formed by crimping a connector to a pair of insulated wires by the machine of and in accordance with the present invention;

FIG. 22 is a sectional view, on an enlarged scale, taken along line 2222 of FIG. 21;

FIG. 23 shows a modified form of ram;

FIG. 24 shows a modified form of a shear block; and

FIG. 25 is a fragmentary horizontal section showing the action of the ram and shear block of FIG. 24.

DETAILED DESCRIPTION Reference should be had to FIGS. 17-22 showing the ladder arrangement of channel-shaped connectors and tape. Each connector 2 comprises a U-shaped shell 4 having a base 6 opposed sides 8, l0 and inwardly projecting

opposed'flanges

12, 14 at the free end of the

sides

8, 10. The shell 4 is preferably formed of a soft deformable material such as copper or annealed brass.

Telescoped within the shell 4 and of slightly shorter length is a U-shaped insert 16 also having a base 18 opposed

sides

20, 22 and opposed flanges 24, 26. The insert 16 is preferably formed of a resilient somewhat harder material such as spring tempered phosphor bronze and includes a series of inwardly projecting prongs 28 that are formed by striking the insert material from the base 18 and

sides

20, 22.

As best seen in FIGS. 17-19, the connectors 2 are in spaced parallel relationship and are disposed along a carrier or tape 30. Preferably this tape 30 is a thin flexible sheet of polyethylene terephthalate resin commonly sold under the trademark Mylar. The tape 30 has parallel

marginal strip portions

32, 34 that are joined by parallel transverse sections 36. Each transverse section has a portion 38 that is bonded to a base 6 of a connector.

Also, each transverse section 36 has parallel projecting

portions

40, 42 which are bonded to the exterior surfaces of the sides 8, l0 and extend a substantial distance beyond the

flanges

12, 14. As best seen in FIGS. 17 and 19, the connectors 2 are spaced from the

marginal strip portions

32, 34 to leave parallel regions of

severence

44, 46 which are of reduced width as compared to the adjacent portion 38 and at which the tape will be severed parallel to the

strip portions

32, 34 in the crimping operation, as will be presently more fully described. The outwardly projecting

portions

40, 42 are formed by cutting or punching the tape with the result that a series of openings 48 are formed between the respective connectors and their associated transverse sections 36. Since the

porjecting portion

40, 42 are formed by slitting the tape, there is little waste of tape material, and it is a relatively simple matter to bond the

portions

38, 40, 42 to the connector in any suitable manner. Generally speaking, the tape comes with one side provided with a heat-bondable adhesive.

When opposed

insulated conductors

50, 52 are inserted into the connector 2, the machine (to hereinafter be described) deforms the connector 2 to the shape shown in FIGS. 21 and 22. As will be seen from the drawing, the crimping deforms the sides of the shell 4 and of the insert 16 and causes the

flanges

12, 14, 24, 26 to be positioned between the

conductor wires

50, 52. The projected portions, 40, 42am turned in between and are clinched by the

flanges

12, 14. The prongs 28pierce the insulation surrounding the wires and bite into the wires to form the electrical connection between the wires.

Referring now to FIGS. 1-7, the machine comprises a housing having side plates 54, 56 a top plate 58, and cover members 60, 62. The side plate, top plate and cover members may be suitably secured together by the screws shown. The cover member62 has an opening 64 through which the tape 30 enters the interior of the housing. At the upper edge of the opening 64 and secured to the cover member 62 is a tape guide 66 having opposed channels 68, 68 for receiving the

marginal portions

32, 34 to guide the tape 30 in an upwardly inclined fashion toward a feed wheel 70. The feed wheel 70 has circumferentially spaced peripheral teeth 72 for engagement in the openings 48 in the tape whereby the feed wheel 70 serves to drive positively the tape upwardly toward the top plate 58.

As best seen in FIGS. 14 and 15, the feed wheel 70 has a reduced diameter portion 74 with a series of notches 76 circumferentially spaced apart and equal in number to the number of teeth 72. The feed wheel 70 includes a shaft 78 that is joumaled in a bearing 80 mounted in the side plate 56. Mounted on the shaft 78 exteriorly of the side plate 56 (FIG. 2) is a hand wheel 82 for manually operating the feed wheel 70. Mounted on the underside of the top plate 58 is an index spring 84 which adapted to engage in one of the notches 76 to retain the feed wheel 70 in position each time it is rotated or indexed to advance the tape 30.

The feed wheel 70 is driven by a piston rod 86 of a secondary air cylinder 87, the operation of which will hereinafter be described. Suffice it to say for the present, however, that the secondary piston rod 86 is pivotally connected to an arm or link 88 which drives a shaft 90. The shaft 90 is coupled to the feed wheel 70 by a clutch roller bearing 92 of known construction. This clutch roller bearing 92 transmits torque in one direction and is overrunning in the opposite direction. Thus, clutch roller bearing 92 permits the shaft 90 to drive the feed wheel clockwise (FIGS. 3 and 14); however, when the shaft rotates counterclockwise upon retraction of the secondary piston rod 86, the shaft 90 rotates relative to the feed wheel 70, the latter then being held in position by the index spring 84. Since the clutch roller bearing 92 is a commercially available item, it is not shown or described in detail herein.

The secondary cylinder 87 is also of conventional design and is of a type such that the introduction of air pressure therein causes the piston rod 86 to move upwardly (FIG. 3) while removal of air pressure causes a coil spring (not shown) within the cylinder 87 to retract the piston rod 86. Referring to FIGS. 3 and 13, it will be seen that the secondary cylinder 87 has a base block 94 that pivotally receives a shoulder screw 96 that is threaded into one end of a spacer 98 located between the secondary cylinder 87 and the side plate 56. An additional screw 100 projects through the side plate 56 and is threaded into the other end of the spacer 98. The foregoing provides a pivotal connection of the secondary cylinder relative to but offset from the side plate 56. Referring to FIGS. 1-9, the machine includes a forming die or ram 102 that is driven by a ram rod 104 overlying the top plate 58. The ram rod 104 is powered by a primary piston rod 106 movable in a main or primary air cylinder 108. The ram rod 104 is guided for reciproeating movement in a bearing 110 and by guide blocks 112. Between the bearing 110 and guide blocks 112 is a return spring 114. The rear end of the ram rod 114 is connected to a toggle linkage of knowndesign. Suffree it to say, however, that a clevis 116 is threaded onto the rear end of the ram rod 102 and is guided between the

blocks

112, 112. The clevis 116 is pivotally connected by a pin 117 to a bell crank 124, and the bell crank 124 is pivotally connected by a pin 122 to a clevis 118. Clevis 118 is pivotally connected by a pin 120 to anchor blocks 119 on the top plate 58. The lower end of the bell crank 124 is pivotally connected by a pin 126 to a clevis 127 that is secured to the end of the primary piston rod 106.

In addition to the ram 102, the forward end of the ram rod 104 carries a wire retainer 128. This wire retainer 128 is a generally U-shaped member having forwardly extending legs 129, 129 (FIG. 8) and a bight 130 with a vertical hole 132 therein. The forward ends of the

legs

129, 129 are each provided with

leaf springs

134, 134 and pins 136, 136. Each spring 134 bears against its associated pin near the base thereof to provide a structure for retaining an insulated conductor that is placed between a spring 134 and its associated pin. It will be noted that the respective spring and

pin arrangements

134, 136 are offset from each other such that when a pair of insulated conductor wires, such as

wires

50, 52, are placed in the respective wire holders formed by the pins 136 and springs 134, the two conductor wires will be juxtaposed and, in general, roughly parallel.

The rear portion 138 (FIG. 8) of the ram 102 is of reduced height so as to fit under the bight 130 of the wire retainer 128, as may be seen from FIG. 4. Furthermore, the forward end 140 of the ram 102 is reduced and cut away to fit under the bight 130 and also in an arcuate recess 142 in the ram. A screw 144 passes through the hole 132 and through a transverse hole 146 in the rear portion 138 whereby the ram 102, the wire retainer 128, and the ram rod 104 are fastened together rigidly and with the ram 102 being disposed between the sides or

legs

129, 129 of the wire retainer 128.

As best seen in FIGS. 5-7 the forward end or face of 5 the ram 102 is provided with arcuate die surfaces 148, 148 that are separated by a ridge 150. These surfaces extend transversely of the ram 102 and are for the purpose of deforming the sides of the connector. Furthermore, the edges 152 which are formed at the intersection of the surfaces 148 and the sides of the ram 102 provide cutting edges at opposite sides of the ram 102 for cooperation with additional cutting edges (hereinafter described) for cutting off excess conductor wire.

Also mounted on the top plate 58 forwardly of the ram 102 is a head or anvil 154. The anvil 154 has a for ward vertical surface 156 which is flat and constitutes a backing for the tape and connector during the crimping operation, as illustrated in FIGS. 4-7. The anvil 154 is held in place by a retainer 158 that is secured by screws to the top plate 58. A screw 160 passes through a hole in the retainer 158 and through an elongated or oval-shaped vertical hole 162 in the anvil 154. The screw 160 is threaded into the top plate 58 to hold the anvil in place. The elongated hole 162 permits forward and rearward adjustment of the position of the anvil 154.

Also housed within the retainer 158 is a U-shaped shear block 164. As best seen in FIG. 9, the shear block 164 includes spaced

parallel arms

166, 168 and a bight 170. The shear block 164 is spring-biased for movement within the retainer 158 and relative to the anvil 154. For this purpose a pair of coil springs 172 are interposed between the bight 170 and retainer 158. The coil springs 172 may be seated in

recesses

174, 174 in the retainer 158. A like pair of recesses (not shown) are provided on the back side of the bight 170 for receiving the

springs

172, 172. An adjustment screw 176 is threaded into a hole 178 in the retainer 158 and passes freely through a hole 180 in the bight 170. The forward end of the screw 176 is adapted to abut the rear surface of the anvil 154 so that the latter may be positioned properly while the screw 160 is loose, after which the screw 160 may be tightened.

At their forward ends the

arms

166, 168 of the shear block are provided with

arcuate abutments

180, 180 against which the

insulated wires

50, 52 seat during the wire cutting portion of the crimping operation. It will be noted that these

abutments

180, 180 are offset just as are the wire retaining arrangements of the wire retainer 178. Thus, the abutments are offset such that one abutment receives one insulated conductor while the other abutment receives the other conductor. Furthermore, the side edges 182, 182 of the

abutments

180, 180 provide sharp edges that cooperate with the edges 152 of the ram to cut off the excess portions of wire projecting from the connector 2. Also formed in the arms of the shear block 164 are opposed

slots

184, 184 for receiving the

marginal strip portions

32, 34 of the tape 30. Also, the

vertical edges

186, 186 at the

slots

184, 184 provide cutting edges which cooperate with cutting

edges

188, 188 on the anvil at forward edges thereof for cutting the tape 30 at the

regions

44, 46 of the tape (FIG. 19).

The crimping and wire cutting operation of the machine will now be described with particular reference to FIGS. 4-7. With the ram 102 fully retracted as shown in FIG. 3 the tape portion 38 is against the anvil surface 156. The tape 30 has been previously fed by the feed wheel 70 upwardly through a slot 189 in the top plate 58. The

insulated conductors

50, 52 are placed in the wire retainer 128 with one conductor being held between each spring 136 and its associated pin 134. Since the distance between the

wire retainer arms

129, 129 is somewhat greater than the length of the connector 2, it is sufficient that each conductor extend approximately the full distance between the

arms

129, 129 so as to insure full reception of each conductor throughout the length of the connector.

Upon actuation of the cylinder 108 in a manner to be described, the ram rod 104, ram 102, and wire retainer 128 will move to the right (FIGS. 4-7). As the

conductors

50, 52 are carried forwardly, they engage respectively the

arcuate abutments

180, 180 on the shear block. Further movement of the ram then causes the shear block 164 to move to the right (FIG. 3) against the force of the springs 172. As the shear block so moves, the cutting edges 186 on the shear block cooperate with the cutting edges 188 on the anvil to slit the tape vertically along the regions of

severence

44, 46,

identified in FIG. 19. At this time the machine is in a position shown in FIG. 5. Further movement of the ram to the postion shown in FIG. 6 causes the cutting edges 152, 152 at the sides of the ram 102 to cooperate with the cutting edges 182, 182 on the shear block 164 to cut the protruding ends of the conductors. Further movement of the ram to the position shown in FIG. 7 results in completing the insertion of the conductors into the connector 2 and causes the die surfaces 148, 148 to crimp the connector, thereby to provide the splice shown in FIGS. 7, 21 and 22. Because of the shape of the die surfaces 148, 148 and the presence of the ridge 150, the

flanges

12, 14, 24, 26 of the connector as well as the

extended portion

40, 42 of the tape are forced between the two conductors. The ram is thereafter retracted, and the tape 30 is advanced by the feed wheel 72. i

Referring now to FIGS. 3, 1012 and 16 it will be seen that the primary cylinder 108 has opposed circular ears 190, one of which is shown in FIG. 12, the other being identical thereto. The ears 190 are joumeled in trunnions 192 that are provided on the

side plates

54, 56. Thus, the primary cylinder 108 pivots during the forward and reverse strokes of the ram rod 104. The piston rod 106 is connected to a primary piston 194 located within the cylinder 108. The rear end of the cylinder 108 is closed off by a valve housing 196 that contains a conventional valve structure, the operation of which will be hereinafter described. At the front end of the cylinder 108 is a closure disc 198 that constitutes abutment for one end of a return spring 200 that biases the piston 194 to its return position adjacent to the housing 196. This is the position shown in, FIG. 10. It will also be noted that the pistonrod 106 has a central bore 202 for coaxially mounting a rod 204 that also extends through the valve housing 196 and at its outer end has a stroke wheel 206 threadedly mounted thereon. The stroke wheel 206 may be adjustably positioned for actuating a valve tripping or operating button 208 on the housing 196.

Formed in the piston rod 106 are opposed, longitudinally extending slots 210, one of which is shown in FIGS. 10 and 11. The end of the rod 204 that is within the cylinder 108 has a cross pin 212 adapted to ride in the slots 210. A lost-motion connection is thus extablished between the piston rod 106 and the rod 204. When the piston 194 and rod 106 moves to the left (FIGS. 10 and 11) during the forward stroke of the ram rod 104, the rod 204 remains stationary until the cross pin 212, sliding in the slots 210, reaches the righthand ends of the slots 210, as shown in FIG. 11. At that time further movement of the piston rod 194 to the left causes the piston rod 106 and rod 204 to move together until the piston 194 reaches the end of its stroke at which time the stroke wheel 206 depresses the valvetrip button 208 to operate the valve arrangement within the housing of 196. On the return stroke of the piston 194 the rod 204 will remain stationary until the cross pin 212 engages the left hand end of the slots 210. The foregoing structure eliminates the need for a long actuating rod and thereby renders the machine more compact.

The air supply arrangement for the primary and

secondary cylinders

108, 87 is shown in FIG. 16. Air from a suitable source of compressed air is supplied through fitting 214 through flexible line 216 to the valve structure. The air passes through the valve structure to control

lines

218, 220 in which manually operated valves 224, 226 are located. It will be noted that these valves are in series and are mounted on the exterior surfaces of the

side plates

54, 56, one of the valves 224 beingillustrated in FIG. 1. The downstream line 228 from the valve 226 connects to a fitting 230 on the valve housing 196 for supplying air to the primary piston 194 for driving the piston 194 in its forward stroke. As a safety feature, both valves 224, 226 must be opened at the same time in order for the piston 194 to commence operation. When the stroke wheel 206 finally engages the trip button 208, air to the cylinder 108 is exhausted to atmosphere whereby the spring 200 returns the piston 194. Air from the valve arrangement will thereafter be supplied through secondary line 232 to the secondary cylinder 87 so that the piston therein and secondary piston rod 86 proceeds through its operating stroke to rotate the feed wheel and advanced the tape upwardly to position the next connector for subsequent crimping. As the primary piston 194 approaches the end of its return stroke, the strip button 208 is released, opening the supply line 232 to atmosphere whereby the spring within the secondary cylinder 87 returns the piston rod 86 to its normal position shown in FIG. 3.

The valve means within the housing 196 is of a known type used for operating two spring return air cylinders in sequence with the phasing or control of the valve being effected at the end of the stroke of the firstactuated cylinder. Accordingly, such valve means may simply be a four-way valve in which air is supplied to cylinder 108 if the trip button 208 is released and air is supplied to the cylinder 87 when the button 208 is depressed. Furthermore, the valve has a phase lag or inertia in operation due to damping thereof such that the ram 102 is able to move back out of the way to allow clearance for the next connector being advanced to its crimping position. Also, if desired, the secondary cylinder 87 may be somewhat slower acting as compared to the primary cylinder, which further allows for retraction of the ram 102 to provide such clearance for the advancing tape.

FIG. 23 shows a modified form of ram 102' which is similar to the ram 102, previously described. However, the ram 102' has laterally projecting,

parallel pins

250, 252 on opposite sides of the ram and located rearwardly of the cutting edges 152 and the front opening or recess 190' of the ram. The

pins

250, 252 are also forwardly of the rear portion 138 and are offset to engage respectively those portions of the forward ends of the

shear block arms

166, 168 that are adjacent to the

abutments

180, 180.

Thus, when the ram 102' moves through its forward stroke the protruding ends of the wires might be out before the tape is severed. If this occurs the

pins

250, 252 engage the

shear block arms

166, 168 to move the shear block and cut the tape. Consequently, the

pins

250, 252 insure cutting of the tape even if the wires are prematurely cut. Of course, the

springs

172, 172 could be designed with sufficient stiffness so that the wires will always be cut before the tape is cut.

While one conductor is shown secured to each wire retainer in the wire retaining guide 128, it will be apparent that more than one conductor can be secured between each spring 134 and its associated pin 136. In addition either ordinary or tap splices may be made.

Referring now to FIGS. 24 and 25, there is shown a modified form of shear block 164a that is similar to the shear block 164 except that the shear block 164a has projections that form arcuate,

convex surfaces

260, 262. These surfaces project toward the ram a substantial distance such that the crests of the arcs of those surfaces are but a short distance from the

arcuate abutments

180, 180, respectively. As will be explained subsequently, these

surfaces

260, 262 cooperate with the ram of FIG. 23 to draw the cut ends 270, 270 of the

conductors

50, 52 within the ends of the connector 2 prior to completion of the crimping operation. Accordingly, the cut ends of the conductors are recessed within the connector 2 and are shielded by the tape ends that extend beyond the ends of the connector. This prevents short circuits between adjacent splices where a number of spliced conductors are cabled together.

In the arrangement of FIG. 25, it is intended that the return springs 172 (FIG. 9) for the shear block 164a be sufficiently strong that the conductors will be out before the tape is cut. As the ram 102 moves forwardly to the position of FIG. 25, the conductors are cut, as previously described. Further movement of the ram may cause some initial crimping of the connector to take place, and in addition the conductors are carried within the connector by the wire retainer 128. As the conductors are being positioned in the connector, the

conductor portions

264, 266 that are outwardly of the connector engage the

arcuate surfaces

260, 262 causing the portions 264', 266 to bend. This results in axially shifting the cut ends 270 of the conductors since the cut ends 270 are free to move. The amount of axial shifting will depend upon the amount of bending produced by the

surfaces

260, 262. Thus, the

surfaces

260, 262 are shaped to bend the conductors so that the cut ends will lie well within the connector. Further movement of the ram causes the

pins

250, 252 to engage the shear block 164a to cut the tape and finally to crimp fully the connector about the conductors.

The invention is claimed as follows:

1. A machine for crimping a connector to a pair of conductor wires and wherein the connector is on a tape that carries a series of such connections, each connector being channel shaped with a base and opposed sides and with the tape being secured to said base and opposed sides, said machine comrpising an anvil for backing the tape and the base of the connector, a reciprocating ram, wire-retaining means carried by the ram for supporting said wires in juxtaposed relationship, a shear block adjacent to said anvil and being movable relative to sand anvil, said shear block having cutting edges cooperating with said ram for cutting said wires and having additional cutting edges cooperating with said anvil for cutting said tape, said ram also having means cooperating with said anvil for crimping said connector by folding the sides of the connector such that portions of the sides are between said wires, and means for driving said ram through a forward stroke to:

b. sever said tape with a connector thereon from the remainder of said tape;

2. insert said wires into said connector between said sides with the wires having respective ends protruding from opposite ends of the connector;

3. cut said protruding end portions; and

4. crimp said connector to said wires by folding said sides.

2. A machine according to claim 1 in which said shear block is movable toward said ram following cutting of said protruding end portions.

3. A machine according to claim 2 in which said shear block is spring biased toward said ram.

4. A machine according to claim 1 in which said shear block has opposed slots at the tape cutting edges thereof for receiving opposed margins of the tape.

5. A machine according to claim 1 in which said wireretaining means comprises for each wire a pin and a spring that provide a structure for gripping the wire.

6. A machine according to claim 1 in which said ram has a return stroke, and indexing means responsive to said return stroke for advancing the tape to position another conductor at said anvil.

7. A machine according to claim 6 in which said indexing means includes a feed wheel with peripheral teeth that engage openings in the tape between the conductors, said feed wheel being rotatable about an axis that is parallel to the path of reciprocation of said ram.

8. A machine fo crimping a tape-carried connector, means comprising a reciprocating ram, conductor retaining means carried by-said ram, an anvil, a shear block slidable relative to said anvil and being springbiased toward said ram, first cooperating means including said ram and cutting edges on said shear block and anvil for cutting said tape and for cutting said conductor means exteriorlyof said connector, and second cooperating means on said ram and said anvil for crimping said connector to said conductor means.

9. A machine according to claim 8 in which said shear block has slots for receiving opposed margins of the tape.

10. A machine for crimping to conductors connectors that are mounted on a carrier, said machine comprising first means for crimping a connector to a conductor and for severing the connector from the carrier, and second means for advancing the carrier in a stepby-step fashion to position connectors; said first means including a ram and a primary piston for driving said ram through an operating stroke; said second means including feed means for moving said carrier and a secondary piston for actuating said feed means; and means for operating said secondary piston upon completion of said operating stroke, said last-named means comprising a member having a lost-motion connection with said primary piston.

11. A machine according to claim in which said primary piston is movable relative to said member until said primary piston approaches the end of said operating stroke after which said member is moved by said primary piston.

12. A machine according to claim 11 including valve means triggered by said member upon completion of said operating stroke.

13. A machine according to claim 10 in which said member is coaxial with said piston, said piston carries a rod, said rod has a longitudinal slot, and said member has a pin in said slot.

14. In a structure for crimping connectors to wires and which includes a series of connectors, each connector having a U-shaped shell, the shell including opposed sides and a base, a continuous tape of nonconducting material having marginal strip portions and spaced parallel transverse sections joining said marginal strip portions, the tape having openings between said transverse sections, each transverse section being bonded to a base and opposed sides of a shell and with the transverse section extending outwardly beyond those ends of the opposed sides that are remote from said base, a ram and anvil means that form cooperating die members for crimping a connector to conductor wires and folding said transverse sections into the crimped connector, means forming a passage for movement of the connectors one-by-one to the space between the ram and the anvil means when the ram and anvil means are apart, means for gripping wires at regions that are spaced apart a distance that is greater than the distance between said marginal strip portions, means for driving said ram toward said anvil means, means for severing end portions of the wires that protrude from the connector, and means for severing the tape in regions between said marginal strip portions and a transverse section, the wire and tape-severing means being operable upon each stroke of the ram.

15. In a structure according to claim 14 in which each connector and shell has opposed flanges projecting toward each other and located at said lastmentioned ends of the opposed sides, and wherein the die members force said flanges into juxtaposed relationship and with the transverse sections being clinched by said flanges.

16. In a structure according to claim 14 including a U-shaped insert telescoped within said shell, the insert having inwardly projecting prongs for piercing insulation on the wires.

17. A machine according to claim 1 in which said ram has means for engaging said shear block to move the latter and cut the tape should said protruding end portions be cut prior to severance of said tape.

18. A machine according to claim 8 in which said shear block has means cooperating with said ram for longitudinally moving said conductor means to draw a cut end of said conductor means into said connector.

19. A machine according to claim 1 including means cooperating with the ram for drawing the cut ends of said wires into said connector.

Claims

1. A machine for crimping a connector to a pair of conductor wires and wherein the connector is on a tape that carries a series of such connections, each connector being channel shaped with a base and opposed sides and with the tape being secured to said base and opposed sides, said machine comrpising an anvil for backing the tape and the base of the connector, a reciprocating ram, wire-retaining means carried by the ram for supporting said wires in juxtaposed relationship, a shear block adjacent to said anvil and being movable relative to sand anvil, said shear block having cutting edges cooperating with said ram for cutting said wires and having additional cutting edges cooperating with said anvil for cutting said tape, said ram also having means cooperating with said anvil for crimping said connector by folding the sides of the connector such that portions of the sides are between said wires, and means for driving said ram through a forward stroke to: b. sever said tape with a connector thereon from the remainder of said tape; 2. insert said wires into said connector between said sides with the wires having respective ends protruding from opposite ends of the connector; 3. cut said protruding end portions; and 4. crimp said connector to said wires by folding said sides.

3. cut said protruding end portions; and

4. crimp said connector to said wires by folding said sides.

5. A machine according to claim 1 in which said wire-retaining means comprises for each wire a pin and a spring that provide a structure for gripping the wire.

8. A machine fo crimping a tape-carried connector, means comprising a reciprocating ram, conductor retaining means carried by said ram, an anvil, a shear block slidable relative to said anvil and being spring-biased toward said ram, first cooperating means including said ram and cutting edges on said shear block and anvil for cutting said tape and for cutting said conductor means exteriorly of said connector, and second cooperating means on said ram and said anvil for crimping said connector to said conductor means.

10. A machine for crimping to conductors connectors that are mounted on a carrier, said machine comprising first means for crimping a connector to a conductor and for severing the connector from the carrier, and second means for advancing the carrier in a step-by-step fashion to position connectors; said first means including a ram and a primary piston for driving said ram through an operating stroke; said second means including feed means for moving said carrier and a secondary piston for actuating said feed means; and means for operating said secondary piston upon completion of said operating stroke, said last-named means comprising a member having a lost-Motion connection with said primary piston.

11. A machine according to claim 10 in which said primary piston is movable relative to said member until said primary piston approaches the end of said operating stroke after which said member is moved by said primary piston.

14. In a structure for crimping connectors to wires and which includes a series of connectors, each connector having a U-shaped shell, the shell including opposed sides and a base, a continuous tape of non-conducting material having marginal strip portions and spaced parallel transverse sections joining said marginal strip portions, the tape having openings between said transverse sections, each transverse section being bonded to a base and opposed sides of a shell and with the transverse section extending outwardly beyond those ends of the opposed sides that are remote from said base, a ram and anvil means that form cooperating die members for crimping a connector to conductor wires and folding said transverse sections into the crimped connector, means forming a passage for movement of the connectors one-by-one to the space between the ram and the anvil means when the ram and anvil means are apart, means for gripping wires at regions that are spaced apart a distance that is greater than the distance between said marginal strip portions, means for driving said ram toward said anvil means, means for severing end portions of the wires that protrude from the connector, and means for severing the tape in regions between said marginal strip portions and a transverse section, the wire and tape-severing means being operable upon each stroke of the ram.

15. In a structure according to claim 14 in which each connector and shell has opposed flanges projecting toward each other and located at said last-mentioned ends of the opposed sides, and wherein the die members force said flanges into juxtaposed relationship and with the transverse sections being clinched by said flanges.