Continuous wire wrap system

Abstract

An apparatus for automatically receiving a continuous supply of insulated wire and converting it into predetermined lengths of wire with both ends stripped and simultaneously feeding said lengths to a termination wire wrap tool.

Description

This invention relates to an apparatus whereby the first and second ends of a stripped length of wire can be automatically fed to a wire termination tool.

Prior to the instant invention, most wire wrap apparatus has not been able to function fully automatically, that is, an operator was needed to aid in each or every other wrap.

The instant invention only requires an operator to initiate the cycle, the remaining operation being fully automatic until a complete circuit terminal board is wrapped.

A length of wire is fed into the stripper, which is then cycled and the free wire end is pulled from the mechanism. This leaves the continuous length of wire fed into the stripper with its end stripped, ready to be presented to the wrap tool for the first termination point.

For the first termination, the wire receiving slot in the wire wrap tool is on the left, which is called 0.degree. orientation. The wire is fed from the stripping mechanism a set distance. A pair of jaws grab the wire and insure proper orientation thereof to the wire wrap tool which is then cycled, capturing the wire. The tool then lowers to the correct level over a pin. The wire supply has has a low force resistance to feeding.

After a wrap, the head raises and the tool is stopped at 180.degree. orientation and is swung away from the line of feed a predetermined distance. The table repositions and the wire is drawn through the wire stripper. The wire is then clamped at the exit end of the stripper and the stripper then cycles, preparing the second end for wrapping and the first end of the next wire. The head assembly then moves back in place and engages the second stripped end of the wire. The tool is cycled closed and it lowers for the termination wrap. When the head finishes, it comes back up in a 0.degree. orientation.

Accordingly, it is an object of this invention to provide a fully automated terminal wire wrap apparatus.

It is a further object of this invention to provide a unique apparatus for implementing effective terminal wire wraps.

These and other objects of this invention will become readily apparent when reference is had to the accompanying specification and drawings in which:

FIG. 1 is a plan view of the apparatus;

FIG. 2 is a side view of the apparatus of FIG. 1;

FIG. 3 is a partial side view, partially in section, of the apparatus;

FIG. 4 is a perspective view of the wire stripping and severing mechanism;

FIGS. 5a-5c are partial plan sectional views showing the various component interrelationships of the wire stripping and severing mechanism;

FIGS. 6a-6c are end sectional views corresponding to FIGS. 5a-5c;

FIG. 7 is a front view of the wire wrap head;

FIG. 8 is a plan view of the wire wrap head;

FIG. 9 is a side view of the wire wrap head;

FIG. 10 is a partial sectional view of the wire wrap head; and

FIG. 11 is a front view of the various blades in the apparatus.

Referring now to FIG. 1, there is shown the wire preparation apparatus generally designated as 10. It consists of a planar base 11 having several subassemblies and components mounted thereon. These subassemblies and components can be attached to the planar base in any conventional manner, such as by machine screws, bolts or by welding.

The mechanism for advancing the wire includes a rotary air cylinder 13 mounted on a plate 12. Referring to FIG. 3, there is shown a shaft 14 depending from cylinder 13. A feed wheel 15 is mounted for rotation with shaft 14. Wheel 15 has a hub portion 16 and a reduced flange portion 17. A keyway 18 in shaft 14 receives a key 19 which receives a machine screw 20 in a hole (not shown) therein. As screw 20 is tightened, key 19 locks hub portion 16 to shaft 14.

Secured to feed wheel 15 by machine screws 23, 24 is a switch block 21. Block 21 has a projection 22 thereon which is adapted to engage the contacts of two microswitches 38 and 42. Machine screws 24, 23 actually clamp wheel 15 between block 21 and member 25. Both block 21 and member 25 rotate with wheel 15 when it is activated by rotary air cylinder 13. Member 25 has a projection 25' which is adapted to engage projection portion 32 of dog 30. The bulk of member 25 is adapted to engage stop blocks 26 and 27 (See FIG. 1). The wheel 15 has three positions: (1) when member 25 enages stop block 26, (2) when it engages stop block 27, and (3) when projection 25' engages portion 32 of dog 30. Both blocks 26 and 27 are secured, such as by machine screws, to base member 28 which, in turn, is mounted on base 11. A pivot pin 29 is fixed on member 28 and dog 30 pivots thereon. Dog 30 has an angled extension portion 31 with projection portion 32 on the end thereof. Another pin 33 connects dog 30 with clevis 34 which receives the threaded end of piston rod 35 and is secured against relative rotation therewith by nut 36. Piston rod 35 is connected to a piston inside of air cylinder 37. As shown in FIG. 1, projection portion 32 is in the arcuate path of portion 25' of member 25.

A microswitch 38 is mounted on plate 39 adjacent stop block 26. A plunger 40 extends from switch 38 along with spring rider 41. The microswitch 38 is of conventional construction. When member 25 is in engagement with stop block 26, projection 22 of block 21 acts to depress microswitch plunger 40. When member 25 abuts stop block 27, projection 22 has ridden over and depressed spring rider 45 to depress plunger 44 of microswitch 42 which is fixed on plate 43.

A pair of pressure wheels 46 and 47 are mounted for selective engagement with wheel 15. The wheels 46, 47 have grooves 48, 49 respectively, and have pivots 50, 51 respectively, pivotally securing them to one end of link 52. Link 52 is pivotally secured by pivot pin 53 to lever 54. Lever 54 is pivotally mounted to base 11 by pin 55 and the other end thereof is secured to clevis 58. Clevis 58 threadably receives the threaded end of piston shaft 61 of air cylinder 62. A nut 60 secures a contact member 59 (See FIGS. 1 and 2) to clevis 58. Member 59 and piston rod 61 travel between points determined by threaded stops 72, 74 which are locked in place on portions 70, 71 of block 69. The end of member 59 engages plungers 67, 68 of microswitches 63, 64, respectively, which are mounted on plates 65, 66.

Mounted adjacent member 12 and wheel 15 is wire stripping mechanism 80 shown in perspective in FIG. 4. It consists of two identical facing blocks 81, 82 having a central bore 84 which is counterbored as at 83. The blocks 81, 82 are constructed of one large block, hole 83 drilled, and then the large block separated into tow. Block 81 has slots 85 and 87 therein which align with corresponding slots in block 82. These slots accommodate double blades. A central slot 86 in block 81 is parallel to, but not aligned with, slot 86' in block 82.

FIG. 11 shows the configuration of the blades located in wire stripping mechanism 80. A pair of guide blades such as 89 are located at each end of the mechanism. Each guide blade has a short projection 90, a long projection 92, an indentation 91 and hole 93.

Mounted in the end slots adjacent the guide blades are a pair of stripping blades such as 94. Each stripping blade has an edge 95, a stripping notch 96 and aperture 97. Mounted in each of slots 86, 86' are a cutting blade such as 98 having a cutting edge 100 and aperture 99.

Each stripping blade has a projecting stud thereon such as 132 (See FIG. 5a) which is adapted to ride in slot enlargement 130, 131, 130' and 131'. As shown in FIG. 4, the apertures in the various blades receive a bar 100 on one side of mechanism 80 and bar 120' (FIG. 1) on the other side.

FIGS. 5a-5c and 6a-6c illustrate the three positions of the blocks 81, 82 and the various blades. In FIG. 5a, blocks 81 and 82 are shown as abutting, the guide blades such as 89' touching, the stripping blades such as 94' in stripping engagement so as to strip the insulation from a wire in bore 83 and the cutting blades, such as 98, 98', in severing relationship. In FIG. 6a, the blocks are shown as having coaxial bores such as 133 within which a tension spring 136 is secured by set screws 134, 135. In FIG. 6a, the tension spring 136 is shown as having pulled the blocks 81, 82 together.

FIG. 5b shows blocks 81, 82 separated by means to be described. All the blades are shown withdrawn in their respective slots in this view. The projection 132 is at the extreme end of the enlargement 131' whereas in FIG. 6b, the spring is shown as stretched and the bore separated.

FIG. 5c shows the blocks 81, 82 together but the blades in non-engaged position. The projection 132 is in a position between that of FIG. 5a and FIG. 5b. FIG. 6c shows the relationship of the blocks in FIG. 5c with spring 136 acting to pull the blocks 81, 82 together.

These, then, are the three positions of the blocks and blades. In FIG. 5a, the cutting position of the mechanism has not acted, in FIG. 5b, the mechanism has acted through the apertures in the blades to pull apart the blades and blocks. Note that the projections on the stripper blades act against the back wall of the slot enlargements to pull the blocks apart. In FIG. 5c, the mechanism has moved inward slightly to allow engagement of the blocks 81 and 82.

Referring to FIG. 1, 80' designates an additional slot cut in the base 11 to allow the stripped wire portions to fall down through the base when the blocks are in the position shown in FIG. 6b.

On one side of the mechanism 80 is a stripper clevis 103 having extension members 101 and 102 which receive bar 100. One end portion of the clevis rides between threaded stops 111, 113 secured by nuts 110, 112 in wing members 108, 109 of adjustable stop block 107. The opposite end of the clevis rides between plungers 116 and 119 of microswitches 114, 117, respectively, mounted on plates 115, 118, respectively. A nut 104 locks clevis 103 to shaft 105 of air cylinder 106. Clevis 120 has extending members 121, 122 receiving bar 120' which travels between upright wing members of a stop block 123. A nut 124 secures the clevis to the threaded end of piston shaft 125 of air cylinder 126.

Adjacent the exit of bore 84 is an aperture 140 through which the wire wrap head descends to engage a terminal on the circuit board.

An arm 141 is pivotally mounted to base 11 by pivot pin 142. It has an extension member 143 which has bracket 144 thereon. Mounted on bracket 144 is a small air cylinder 145 secured thereto by nut 146 on its threaded portion 147. The piston shaft extending therefrom has a clevis 148 which is secured, via pivot pin 149 to gripper arm 150. The end of arm 150 is secured to member 143 by pivot pin 151. A wire gripping projection 152 is adapted to cooperate with static gripping projection 154 of arm 153. The gripping portions grip a wire extending from bore 84 when cylinder 145 is activated.

The end of member 143 has a stud 155 thereon which rides in a slot 158 in pivot plate 157. Plate 157 is adapted to pivot on pin 156 and is secured at its corner, via pin 159, to clevis 160. Nut 162 secures the threaded end of piston rod 163 and a contact bar 161 to clevis 160. Bar 161 rides between and engages fingers 167, 170 of microswitches 165, 168, respectively, which are mounted on plates 166, 169, respectively. Piston rod 163 is connected to air cylinder 164. When cylinder 164 is activated, the pivot plate 157 swings and so does arm 143. This brings the gripper portions 152, 154 adjacent the end of bore 84. Cylinder 145 is activated to grip a wire extending therefrom and return to their initial position upon deactivation of cylinder 164. During this movement, the wire wrap head has moved from the center of aperture 140 to point X on FIG. 1.

The total movement of the mechanism is approximately one sixteenth of an inch, i.e., between the blade positions shown in FIGS. 5a and 5b. The blades move inwardly about one-thirty-second of an inch from the position shown in FIG. 5b to that in FIG. 5c.

FIGS. 7-10 show the wire wrap head 200. While the head does not form part of the invention, it will be briefly described. In FIG. 7, an air motor 201 is shown mounted by mount 202 on cover 204 of housing 203.

An air cylinder 205 is mounted by nut 207 to bracket 206 which is secured to housing 203. Nut 207 is theaded on extension portion 208 of cylinder 205.

Piston rod 209 extends from cylinder 205 and is adjustably secured via nuts 210, 211 to upright portion 212 of cam bracket 213. Lower housing portion 214 has guide support portion 215, the wrap bit B, a rod 218 which moves upwardly through the action of an air cylinder (not shown). A pair of links 216, 217 act to lift up the wrap bit B upon upward movement of shaft 218.

The cam bracket 213 slides within slot 214 of housing 203. Within housing 203 (FIG. 10) is enlarged portion 223 and hook portion 221 of cam bracket 213. A circular plate 220' is mounted within housing 203 and it has a central aperture 235. Within aperture 235 there is an off center shaft member 238 which rotates about the center of aperture 235. A cut-away portion 239 provides a notch 240. A pin 225 extends upwardly from plate 220' and is secured thereto by portion 226. Pin 225 rides in slot 224 of portion 223.

A pair of dogs 227, 231, having notches 229, 233, respectively, lugs 230, 234, respectively, are secured to plate 220' by pivot pins 228, 232, respectively. Extending between pin pin 228 and lug 234 is tension spring 237 and extending between lug 230 and pin 232 is tension spring 236. The springs pull the dogs together. When cam bracket 213 moves inwardly along pin 225, notches 240 and 233 disengage and shaft 238 rotates 180.degree. to allow the wrap bit to reposition itself 180.degree.. This occurs when notch 240 engages in notch 229.

OPERATION

The blocks 81 and 82 are closed but the stripper blades are open as shown in position 5c. The pressure wheels 46, 47 are opened, that is, pulled away from wheel 15 by activation of cylinder 62. The rotary cylinder 13 has member 25 abutting stop block 26.

The wire to be wrapped is manually fed between the feed and pressure wheels and then through bore 84 of mechanism 80. The stripper and cutting blades and then closed by air cylinders 106 and 123, cutting the wire and insulation as shown in FIG. 5a. Dog portion 32 is moved inwardly by the action of cylinder 37 and the rotary cylinder 13 moves counterclockwise (FIG. 1) to engage dog 32 with projection 25'. Since pressure wheels 46, 47 do not engage wheels 15, the wire does not move. The pressure wheels 46, 47 are then closed by deactivation of cylinder 62. The air pressure in cylinder 13 is still on, thereby biasing the member 25 toward stop block 27. Cylinder 37 is thus deactivated, thereby moving dog 32 outwardly and allowing rotation until member 25 engages block 27. This will retract or move one end of the wire up in FIG. 1 so as to strip one end of the wire approximately 1 inch. The cylinders 106 and 126 are then activated and blocks 81 and 82 are opened to the position shown in FIG. 5b.

The bit is then cycled to prepare to wrap (it always wraps clockwise) and the bit is at 0.degree.. All of the preceding steps are preparation for automatic operation. The following describes one operational cycle:

The cylinder 13 is then rotated clockwise to where member 25 engages stop block 26. The first piece of cut wire is discarded. The rotation of cylinder 13 advances about 4 1/8 inches of wire. The bit is then cycle closed.

The pressure wheels 46, 47 are then opened and dog 32 is moved to its in position. The bit is cycled to wrap the one end of the wire stripped in the precycle. The bit orientation is 180.degree. due to rotation of shaft 238 by cylinder 205. The gun assembly 200 is then shifted to point X. The cylinder 13 rotates until projection 25' engages dog 32.

At this point, the table carrying the studs or terminals to be wrapped is positioned. It should be noted that there is a 42-inch roll of loose wire (not shown) to allow for this movement. The 42-inches allows for a maximum distance wrap, that is, from corner to corner, diagonally. It should also be remembered that one terminal at this point has already been wrapped. The cylinders 106 and 126 are then activated and the blades closed to the position shown in FIG. 5a. This cuts the wire in the middle of mechanism 80 and cuts the insulation at either end. The pressure wheels 46, 47 are closed. Member 143 then is moved inwardly by activation of cylinder 164 and then cylinder 145 is activated to enable gripping portions 152, 154 to grip the wire. Member 143 is then moved back to its initial position, thereby drawing out the wire and stripping the second end of the process. Simultaneously, dog 32 is retracted and cylinder 13 moves counter-clockwise to stop 27 to strip one end of the next wire (as in the precycle). The gun assembly is then shifted to wrap position at 180.degree. orientation. This lays the stripped wire across the bit. The bit is then cycled closed, the wire entrapped and the gripping jaws 152 and 154 opened. The bit then descends, wraps and reorients to 0.degree.. The table is again positioned for the next wrap and the whole sequence is started over again.

While only one embodiment of the present invention has been shown and described, it will be obvious to those of ordinary skill in the art that many changes and modifications can be made without departing from the scope of the appended claims.

Claims

What is claimed:

1. An apparatus for preparing a continuous length of wire to be automatically wrapped in sections from point to point continually on a terminal board, said apparatus comprising means to sever said wire into a first and second section and to strip the trailing end of said first section and the leading end of said second section adjacent the point of severance and first position control means to control the position of the leading edge of said second section comprising a rotary advance wheel able to rotate between two fixed stops and a movable dog means to interrupt said movement between said two fixed stops in one rotary direction, said first position control means also functioning to supply said stripped leading end to a wire wrap tool.

2. The apparatus as in claim 1 wherein said first position control means includes movable pressure roller for selective engagement with said rotary advance wheel.

3. The apparatus as in claim 1 including a second position control means to control the position of the trailing edge of said first section and supply said trailing edge to said wire wrap tool.

4. An apparatus as in claim 3 wherein said second position control means comprises pivotally mounted jaw means adapted to grip said second wire section and pull it from the severing and stripping means, thereby stripping said trailing end and locating it on said wire wrap tool.

5. An apparatus as in claim 4 wherein said jaw means comprises a pivot member, means to pivot said member between two positions, a pivotable jaw member on said pivot member, a static jaw member on said pivot member and means to force said pivotable jaw member against said static jaw member.

6. An apparatus as in claim 1 wherein the severing and stripping means also includes a pair of block members, said block means being normally biased together, power means to pull said blocks apart, said blocks, when abutting, defining a wire receiving bore therebetween and severing blade means and stripping blade means associated with said block means and said power means.

7. An apparatus as in claim 6 wherein said block means has slot means located near each extremity thereof and one near the center thereof, said stripping blades being in the slot means at the extremities and the severing blades being in the center slot means.

8. An apparatus as in claim 7 and also including guide blades located in said extremity slot means.