US3763556A

US3763556A - Method and apparatus for manufacturing articles such as carbon brush assemblies

Info

Publication number: US3763556A
Application number: US00212109A
Authority: US
Inventors: J Respess
Original assignee: Morganite Inc
Current assignee: Morganite Inc
Priority date: 1971-12-27
Filing date: 1971-12-27
Publication date: 1973-10-09
Anticipated expiration: 1990-10-09

Abstract

In order to attach terminals to the ends of wires extending through helical springs from carbon brushes or the like, the springs are compressed in corresponding receptacles of a rack to project the wires from the receptacles, and the terminals are then secured to the wires, as by crimping. Parts are loaded, assembled, and unloaded by mass production techniques.

Description

United States Patent 1191 Respess 1 Oct. 9, 197 3 54 METHODAND APPARATUS FOR 1,708,193 4/1929 Sherwood 29/630 12 ux MANUFACTURING ARTICLES SUCH As CARBON BRUSH ASSEMBLIES Inventor: John H. Respess, Dunn, N.C.

Assignee: Morganitelncorporated, Dunn,

Filed: Dec. 27, 1971 Appl. N0.: 212,109

References Cited UNITED STATES PATENTS 7/1971 Folk et al 29/203 R 1,319,751 10/1919 Becker ..29/630E Primary Examiner-Charles W. Lanham Assistant Examiner-James R. Duzan AtzomeyG. Mallet Prevost ABSTRACT In order to attach terminals to the ends of wires extending through helical springs from carbon brushes or the like, the springs are compressed in corresponding receptacles of a rack to project the wires from the receptacles, and the terminals are then secured to the wires, as by crimping. Parts are loaded, assembled, and unloaded by mass production techniques.

49 Claims, 16 Drawing Figures PATENTED 9 73 SHEET 10F 7 m W y v III d 8 ww fioh H i w women a C m NM a a a M mi mm mm #m INVENTOR JOHN H RESPESS fieuosfi ATTORNEYS PATENTED B 5 3,763,555

' SHEET 20F 7 SHEET 5 0F 7 PATENTED 091 91973 SHEET 6 BF 7 PATENTEBBU elm Ill HMIMIHIIMH F FIG 14 PATENTEU 975 SHEET 7 [1F 1 METHOD AND APPARATUS FOR MANUFACTURING ARTICLES SUCH AS CARBON BRUSH ASSEMBLIES BACKGROUND OF THE INVENTION 7 This invention relates to a method and apparatus for forming assemblies in which a terminal is attached to a wire extending from a component through a helical spring.

In the manufacture of carbon brush assemblies, a shunt wire extending from the brush is inserted through a helical spring, and then a terminal is fastened to the free end of the wire. In order to make the connection between the wire and the terminal (or brush cap, as it is often called), the spring must first be compressed, to expose the end of the wire because the free length of the spring is greater than the length of the shunt wire. It has been common practice to compress the spring by hand and then to fasten the shunt wire to the terminal cap by soldering. This method, however, is slow, expensive, and difficult to automate. It has also been proposed to attach the wire to the terminal by crimping. Specifically, the wire from the compnent is pulled through the spring by means of a hook while the spring is manually compressed, and then the terminal is crimped to the portion of the wire protruding from the end of the spring. While a crimped connection is generally considered to be superior to the soldered connection, this terminal attachment technique has been slow and impractical.

SUMMARY OF THE INVENTION It is accordingly a principal object of the present invention to provide an improved method and apparatus for manufacturing assemblies in which a terminal is attached to a wire extending from a component through a helical spring.

More particularly, it is an object of the present invention to provide a method and apparatus of this character which facilitate automatic attachment of the terminal to the wire while the spring is'held compressed, and which permit the utilization of mass production techniques.

Specific objects of the invention include the provision of method and apparatus for receiving and compressing a plurality ofcoil springs and for retaining the springs while wires from components such as carbon brushes are inserted therethrough, the provision of method and apparatus for feeding groups of parts past a crimping station for the successive crimping of terminals to wires, and the provision of method and apparatus for unloading finished assemblies.

Briefly stated, a preferred embodiment of the invention employs a rack having a series of receptacles into which corresponding helical springs are compressed. In one embodiment the springs are first assembled with wires projecting from corresponding components, and a force is then applied to each component so as to insert the spring assembled therewith into an open end of a corresponding receptacle, whereupon the spring is compressed against a shoulder within the receptacle and the wire is passed through a receptacle aperture and exposed. In another embodiment the springs are first compressed within the receptacles by means of a spring-compressing tool and then the component wires are inserted through the compressed springs and projected from the receptacle apertures. The loaded rack is then mounted on a feed table of a crimping press and is moved past a crimping station at which a terminal is crimped to the exposed end of each wire. The rack is BRIEF DESCRIPTION OF THE DRAWINGS The invention will be further described in conjunction with the accompanying drawings, which illustrate preferred and exemplary embodiments, and wherein:

FIG. 1 is a perspective view of a carbon brush assembly manufactured in accordance with the invention;

FIG. 2 is a partially exploded perspective view illustrating a rack employed in a method and apparatus of the invention;

FIG. 3 is a transverse sectional view of the rack illustrating a first step in a method of the invention;

FIG. 4 is a similar sectional view illustrating another step in the method;

FIG. 5 is a perspective view showing a loaded rack supported upon the feed table of a crimping press and illustrating apparatus for unloading the rack from the feed table;

FIG. 6 is a perspective view illustrating the operation of the unloading apparatus;

FIGS. 7 and 8 are partially sectional end elevation views illustrating utilization of a fixture forv unloading finished assemblies from the rack;

FIG. 9 is a partially exploded perspective view illustrating a modified rack which may be employed in the invention;

FIG. 10 is a perspective view illustrating another rack embodiment which may be employed in the invention;

FIG. 11 is an'exploded perspective view illustrating the utilization of the embodiment of FIG. 10;

FIG. 12 is a fragmentary plan view illustrating the assembly of springs with a spring-compression tool of this embodiment;

FIG. 13 is a perspective view illustrating the manner in which compressed springs are retained within the receptacles of this embodiment;

FIG. 14 is a transverse sectional view showing the manner in which a spring is held compressed within its receptacle;

FIG. 15 is a perspective view illustrating a loaded rack in accordance with this embodiment; and

FIG. 16 is a partly sectional elevational view of apparatus for ensuring precise indexing of the feed table.

DETAILED DESCRIPTION OF THE INVENTION The invention will be describedwith particular reference to the manufacture of carbon brush assemblies, but it will be apparent to those skilled in the art that the principles of the invention are applicable to the manufacture of other types of assemblies, particularly those which require the attachment of a terminal to the end of a component wire extending through a compressible spring.

As shown in FIG. 1, a finished carbon brush assembly comprises a carbon brush component 22 having an end 23 shaped to engage a motor commutator, for example, and an end 24 from which a spring mounting post 26 extends. An elongated shunt wire 28 has one end thereof mounted in a hole (not shown) in the end face of post 26 in a manner well known in the art. The mounting post supports one end of a helical compression spring 32 which surrounds the post and the shunt wire. The free length of the spring 32 is greater than the length of the shunt wire 28, so that if the spring were not compressed, the end 34 thereof would extend beyond the end portion 30 of the wire member. However, as shown in FIG. 1, a button-type terminal element 36 is crimped at 38 to end portion 30 of wire 28, and the spring is maintained under partial compression between the terminal element and the end 24 of the carbon brush 22. It is to be understood that the buttontype terminal element is merely illustrative of many types of terminal elements which may be employed. The manner in which the assemblies are manufactured will now be described.

One embodiment of the invention employs a partholding rack 40 of the type shown in FIGS. 2 8. A number of such racks will normally be utilized, a loaded rack being fed past a terminal crimping press while other racks ae loaded and unloaded.

The rack apparatus 40 includes a base plate 42 having a spring-receiving structure 44 at one side thereof. This structure may be formed as a unitary member of machinable thermoplastic material, such as Synthane, or of aluminum, and may be secured by means of screws or cement to a shoulder 45 of the base plate (see FIG. 3). The spring-receiving structure 44 includes a row of spring receptacles 46 bored or otherwise formed in the structure. Each receptacle has a beveled entrance 48 at an open end thereof, the other end of the receptacle being closed by a wall 50 except for a central aperture 52. A tapered shoulder 54 leads to the aperture 52. Each receptacle has a longitudinal slot 56 communicating therewith for a purpose to be described later.

A retaining plate 58 is supported upon the base plate 42 and has an abutment edge 60 facing the entrance of the receptacles 46. The opposite edge of the retaining plate 58 is engaged by spacer plates 62 having upright posts 64, the purpose of which will appear hereinafter. Each spacer plate 62 is provided with a slot 66 which receives a set screw 68 threaded into a hole 69 of the base plate and provided with a washer 70. Spacer plates 62 may thus be adjusted to establish the distance between abutment edge 60 and the spring-receiving structure 44.

In the utilization of the rack apparatus 40, a spring 32 is placed over the wire 28 extending from a component 22 as shown in FIG. 3, and a force is applied to the end 23 of the component to push the assembled spring, wire, and component toward the entrance of a corresponding receptacle 46. The spring will be guided into the receptacle by engagement of the free end 34 of the spring with the beveled entrance 48 of the receptacle. As shown in FIG. 4, application of the force to the end 23 of the component 22 is continued until the component slips off of the retaining plate 58 onto the base plate 42 and engages the abutment edge 60. When the free end 34 of the spring engages the shoulder 54 of the receptacle, the spring becomes compressed. The end portion of wire 28 enters the aperture 52, being guided by the taper of the shoulder 54, and when component 22 has reached the position shown in FIG. 4, the end portion 30 of the wire has passed through the aperture 52 and is exposed to the desired extent. Back pressure of the spring 32 upon component 22 and abutment edge 60 assures that the assembly remains in the position shown.

After each of the receptacles 46 is filled in the manner just described, so that the rack 40 is fully loaded, a hold-down bar 72 may be brought down upon the components 22 as shown in FIG. 2 to assist in holding the component-wire-spring assemblies in place. The hold-down bar may be provided with holes 74 which receive posts 76 extending upwardly from the mounting plate 42. The hold-down bar 72 and the retaining plate 58 extend between side flanges 78 of the base plate. Each side flange is provided with a projecting pin 80, and the base plate has a hole 82 therethrough (see FIG. 3) adjacent to each side flange, the purposes of which will appear hereinafter.

The loaded rack apparatus is now ready to be fed to a termainl crimping press. For this purpose, the rack apparatus may be mounted on a feed table or carriage 84 as shown in FIG. 5. To locate the rack 40 in the proper position upon the feed table the feed table is provided with a locating bracket 86 at each end thereof, each bracket having a slot 88 which receives a corresponding pin of the rack. The brackets are pivotally supported upon the ends of the feed table and are normally held in the position illustrated in FIG. 5 with the slots 88 upright. The brackets are maintained in this position against stops (not shown) by means of tension springs extending between arms 90 of the brackets and an alignment bar 94 fixed to the feed table at one side thereof.

The feed table is supported for movement along

guide rods

96 and 98, which extend between

standards

100 and 101 mounted on a base 99. Any suitable means may be employed to move the feed table along a path which brings successive exposed wire end portions to a crimping press 102. For example, a pneumatic feed cylinder (not shown) may serve to move the feed table. The press includes a vertically reciprocating crimping tool 104 which cooperates with an anvil on the press bed 106 to crimp terminal elements 36 onto the exposed wire end portions 30 which protrude from the spring-receiving structure 44. In the illustrative embodiment, the terminal elements are supplied on a carrier strip 108 which is fed by conventional means to the crimping press. Each terminal element has a U-shaped connector 110 integral therewith, which is crimped about an exposed wire end by the crimping tool 104. During the crimping operation, the connector element is severed from the carrier strip 108, as is well known in the art. The crimping press 102 may be any suitable commercially available type. such as the Perkins Junior Press, a relatively small bench-type power press. In some cases it may be necessary to modify the press base slightly in order to position the parts rack and feed table close enough to the terminals being fed. It is not necessary that the terminals be strip fed to the press, individual terminal feed being suitable also.

The movement of the feed table past the crimping station and the actuation of the crimping press may be performed manually, or either or both operations may be performed automatically. Conventional systems which operate electrically, mechanically, pneumatically, or hydraulically, for example, may perform these operations with the desired degree of automation. For example, it may be assumed, as stated above, that the feed table is moved by a conventional pneumatic feed cylinder. After the parts rack is placed upon the feed table, the operator may close a start switch which controls a solenoid valve to admit air to the pneumatic feed over the connector 110 of a terminal 36 to be attached may comprise a series ofserews 200, the heads of which protrude from the side of the bar 94, being separated therefrom by spacer plate 202. Each screw is associated with a corresponding spring receptacle 46, and when the axis of a spring receptacle is brought approximately to the crimping station, the corresponding screw 200 engages a roller 208 (FIG. 16) upon the actuating arm 206 of a switch 204. The resultant actuation of switch 204 causes the solenoid valve to move to a neutral position at which air is released from both sides of the piston of the pneumatic feed cylinder. At the same time switch 204 energizes a solenoid valve which admits air to an alignment cylinder 210. This causes the piston rod 216 of the alignment cylinder to move upwardly, referring to FIG. 16, inserting the tapered end 214 of an alignment member 212 into one of a series of correspondingly tapered recesses 218 at the bottom of the alignment bar 94. This causes the feed table to advance or retract slightly as required to provide precise registration of an exposed wire end with the crimping tool 104.

As this alignment is achieved, a rod 220 extending from the other side of the piston within cylinder 210 brings an arm 222 into engagement with the actuator of a switch 224, which may be supported upon cylinder 210by means of a plate 226. The actuation of switch 224 provides a signal for energizing a solenoid clutch in the crimping-press, causing the crimping press to cycle once, to attach a terminal to a shunt wire. When the press tool returns to its starting position, raised above the press bed 106, it may close a switch which controls the solenoid valve for alignment cylinder 210, in order to retract alignment member 212, and which controls the solenoid valve for the feed cylinder to admit air thereto and to advancethe feed table to bring the next shunt wire to crimping position, with the next screw 200 engaged with switch 204. The cycle is repeated until all of the wire end portions are attached to terminals.

FIG. 5 illustrates an unloading mechanism which may be employed for moving a rack of finished assemblies from the feed table 84. In the form shown a pusher assembly 112 is provided at a rack unloading station beyond the crimping press 102. The pusher assembly comprises a pusher bar 114 parallel to the path of the feed table and having a pair of pusher fingers 116 at opposite ends thereof perpendicular to the path. Pusher bar 114 is mounted at the end of a rod 120 guided by a hole in a standard 118 mounted on base 99. A pneumatic cylinder 122 may be employed for causing the pusher assembly to reciprocate across the path of the feed table.

Actuation of the unloading mechanism is illustrated in FIG. 6. As fingers 116 push against the side of the rack apparatus 40, a force applied through pins 80 causes brackets 86 to turn, tipping slots 88 until the pins 80 slip out of the slots. Continued pushing motion causes the rack apparatus 40 to be pushed off of the feed table on to a stationary support (not shown). Actuation of the pusher mechanism may be accomplished automatically by means of a limit switch engaged by the feed table, for example. The limit switch may control a solenoid valve for introducing air to the unloading cylinder 122. Full extension of the unloading cylinder may be sensed by a further limit switch, which, through the solenoid valve,.retums the unloading cylinder to its starting position. At the same time, the solenoid valve which controls the feed table cylinder may be actuated to reverse the movement of the feed table and return it to its start position. At this time another loaded rack may be placed upon the feed table, and the entire cycle started again. I

As shown in FIGS. 7 and 8, a special fixture 124 may be employed to facilitate removal of the finished assemblies 20 from the rack 40. This fixture may comprise a pair of spaced abutments 128 and mounted on a base 126 which is inclined at an angle of 40. Abutment 128 engages a longitudinal edge of rack 40 as shown in FIG. 7 and positions the rack transversely of the fixture so as to provide transverse alignment of the holes 82 with posts 132 extending upwardly from the fixture. Longitudinal alignment may be provided by side plates of the fixture (not shown) for guiding the ends of the rack. The distance between

abutments

128 and 130 is sufficient to accommodate the rack 40 therebetween and is somewhat greater than the width of the rack as will appear hereinafter.

When the unloading fixture 124 is employed, as shown in FIG. 7, a longitudinal edge of base plate 42 is placed against an opposing edge of abutment 128, with the base plate 42 tipped upwardly from the base 126 of the fixture. The rack 40 is then lowered to the position of FIG. 8, posts 132 entering openings 82, engaging the retainingplate S8 and pushing it upwardly so as to free the retaining plate from the spacer plates 62. The retaining plate 58 will then slide downwardly until it engages posts 64, which will prevent plate 58 from sliding off of the rack into a delivery chute (not shown) for completed assemblies 20. The removal of plate 58 will release the compressed springs in the re ceptacles of the spring-receiving structure 44, permitting the springs to project out of the receptacles, holddown bar 72 having been removed previously.

As the rack 40 is lowered to the position of FIG. 8, the exposed ends 30 of the wires 28 and the attached terminals 36 are deflected upwardly by engagement with abutment 130, ultimately attaining the position shown in FIG. 8. The carbon brush components 22 tend to assume the upwardly inclined position illustrated in FIG. 8. The longitudinal slots 56 of the receptacles 46 (see FIG. 4) are of sufficient width to permit the passage of the wires 28 therethrough. To remove the completed assemblies from their receptacles it is merely necessary to slide the wires through the slots 56. Completed assemblies may be grabbed by the handful as they are freed from the rack and placed in a delivery chute. The rack may then be returned to a loading station for re-use.

FIG. 9 illustrates a modified rack 40'. In this embodiment the spring-receiving structure 134 is split longitu- .dinally so as to provide upper and lower plates 136 and separated. The structure and utilization of the rack 40' may otherwise be identical to the rack 40.

In the embodiments described above, the springs are assembled with the wires and carbon brush components before compression of the springs. in the embodiment of H6. 15, which will now be described, the springs are compressed first. As shown in FIG. 10, the modified rack apparatus 140 includes a base plate 142 having a spring-receiving structure 144 along one side thereof. Structure 144 provides a plurality of recesses 146, each of which may have a configuration like or similar to the receptacle configuration described previously, and each of which may have a longitudinal slot 156 as described previously. Plate 142 is provided with side flanges 150 from which the mounting pins 158 protrude as before.

ln the utilization of the rack 140, a special spring compression implement or tool 160 is positioned between the side flanges 150 at the side of the base plate 142 opposite to the spring-receiving structure 144. The spring compression implement 160 includes a bar 162 from which project a plurality of spring compression rods 164, each of which is aligned with a receptacle 146 and has a spring mounted extension 166. Individual springs 32 are mounted on extensions 166 as shown in FIG. 12. After the spring compression implement 160 is fully loaded with springs, it is pushed toward spring-receiving structure 144 to insert springs 32 into receptacles 146. The pushing movement is continued until the springs are substantially fully compressed within the recesses. At this time, a spring retaining bar 168 is placed upon the top surface of the springreceiving structure 144 to position pairs of depending pins 170 across the receptacle entrances as shown in FIGS. 13 and 14. The spring retaining bar may be held in position in any suitable manner, as by posts extendingupwardly from structure 144 through holes in the bar 168. Before placement of the spring retaining bar 168, the spring compression implement 160 may be held in position by pressing the pins 158 inwardly through the flanges 150 and behind the bar 162. After placement of the spring retaining bar 168, pins 158 may be moved outwardly again to release the spring compression implement 160.

With the springs retained within their receptacles by the spring retaining bar 168, the compression implement 160 is removed. As shown in FIG. 15, it is replaced by a carbon brush receiver plate 172 having a series of notches 174 into which the carbon brush components 22 are placed, with the wires thereof aligned with the axes of the spring receptacles 146. Plate 172 is then moved toward the receptacles so as to insert the wires through the compressed springs and project the ends of the wires beyond the spring-receiving structure. The wires enter the receptacles in the space between the spring-retaining pins 170 associated with each receptacle. Pins 158 may then be pushed in again so as to enter recesses (not shown) in the ends of plate 172 and hold the plate in position. Then the spring retaining bar 168 may be removed, releasing the springs sufficiently to permit them to slide over the spring mounting posts of the carbon brushes. For purposes of illustration, the brush receiver plate 172 in FIG. is shown positioned so as partially to expose the springs (some of which are shown broken away). It will be understood that the position of plate 172 is selected to maintain the desired degree of compression of the springs and exposure of the wire ends beyond structure 144. The loaded rack may be placed upon the feed table previously described and moved past the crimping press 102 to attach the terminals 36 to the wire ends.

While preferred embodiments of the invention have been shown and described, it will be apparent to those skilled in the art that changes can be made without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims. For example, instead of employing the racks disclosed herein, individual tool nests may be employed to retain the springs in receptacles, the receptacles being arranged on a circular tooling plate which indexes parts in front of the terminal press. Other means, such as retractable pins or detents, may be employed to position the racks properly upon the feed table and yet to permit the racks to be removed automatically from the feed table.

The invention claimed is:

l. A method of manufacturing an assembly having an elongated member extending from a component at one end of the assembly and through a compressible spring to an element at the other end of the assembly, which comprises providing a receptacle for the spring with an aperture large enough to pass the elongated member therethorugh, but not the spring, compressing the spring into the receptacle, pushing the elongated member extending from the component through the compressed spring by applying a pushing force to said elongated member adjacent to said component and remote from a free end portion of said elongated member until the free end portion of said elongated member projects through the aperture, and attaching said element to said end portion.

2. A method in accordance with claim 1, wherein the spring is first placed over the elongated member so that the member extends therein, and the spring and elongated member are then inserted together into an entrance of the receptacle.

3. A method in accordance with claim 2, wherein a force is exerted upon said component to insert the spring and elongated member into said receptacle, and the component is thereafter held in position relative to the receptacle to maintain the spring compressed within the receptacle.

4. A method in accordance with claim 3, wherein said component is held in position by placing a side of said component remote from said receptacle against an abutment spaced from said receptacle.

5. A method in accordance with claim 4, wherein said. abutment is provided by an edge of a plate upon which said component is moved toward said receptacle.

6. A method in accordance with claim 1, wherein said spring is guided into said receptacle by engagement with a beveled entrance thereof.

7. A method in accordance with claim 1, wherein said elongated member is guided into said aperture by engagement with a tapered shoulder adjacent to the aperture.

8. A method in accordance with claim 1, wherein said component is held in position relative to said receptacle during the attaching of said element by the application of a hold-down bar to said component.

9. A method in accordance with claim 1, wherein said receptacle is provided with a longitudinal slot and said elongated member is moved through said slot to free the elongated member from the receptacle after the attaching of said element.

10. A method in accordance with claim 1, wherein the spring is first compressed into the receptacle and retained therein, and thereafter the elongated member is inserted into the receptacle through the compressed spring.

11. A method in accordance with claim' 10, wherein the spring is compressed into said receptacle by placing one end of the spring upon a mounting post and moving said mounting post toward an entrance of said receptacle.

12. A method in accordance with claim 10, wherein the spring is retained in said receptacle by blocking at spaced points a receptacle entrance through which the spring is inserted.

13. A method in accordance with claim 12, wherein said elongated member is inserted into the receptacle between said spaced points and said component is thereafter held in position relative to said receptacle.

14. A method in accordance with claim 1, wherein said receptacle is provided between a pair of separable members, and the spring is released from said receptacle by separating said members.

15. A method in accordance with claim 1, wherein said element is attached to said elongated member by crimping.

16. A method in accordance with claim 1, the recited steps being performed in multiple.

17. A method in accordance with claim 16, wherein plural receptacles are provided upon a rack and said rack is moved relative to a station at which the elements are attached to the elongated members.

18. A method in accordance with claim 17, wherein said rack is moved relative to said station upon a carriage and is unloaded from said carriage after said elements have been attached to said elongated members.

19. A method in accordance with claim 17, wherein said elements are attached to said elongated members seriatim, and each receptacle is aligned with said station during the attachment of the corresponding element.

20. A method of manufacturing assemblies each having an elongated member extending from a component at one end of the assembly and through a compressible spring to an element at the other end'of the assembly, which comprises providing upon a rack a plurality of receptacles for the springs, respectively, each receptacle having an aperture large enough to pass an elongated member therethrough, but not the spring, compressing the springs into the receptacles, pushing the elongated members extending from the components through the compressed springs, respectively, until free end portions of said elongated members project through the apertures, attaching said elements to said end portions, respectively, said rack having a base plate supporting the receptacles and components and the components being held in position relative to the receptacles by back pressure of said springs urging said components against an abutment displaceably supported over an opening on said base plate, and releasing said springs by inserting a post through said opening and displacing said abutment from said base plate.

21. A method in accordance with claim 20, said post being provided upon a base, said rack being brought ments, one of which is engaged with a side of said rack as the rack is brought down upon said base and the other of which engages end portions of said elongated members projecting from said receptacles and bends the same upwardly. l

22. A method in accordance withclaim 21, wherein each receptacle is provided with a longitudinal slot, and the elongated members are pulled through said slots to release said members from said rack.

23. A method in accordance with claim 21, wherein said base is inclined andsaid rack is brought downwardly upon said base by tipping the rack about said one abutment.

24. A method in accordance with claim 1, wherein said component is a brush, said elongated member is a wire extending therefrom, and said element is a terminal.

25. Apparatus for forming an assembly including an elongated member which extends from a component at one end of the assembly through a compressible spring to an element at the other end of the assembly, which comprises a receptacle having an aperture adapted to pass said elongated member but not said spring, means for holding said spring compressed within said receptacle, means for supporting said component and said elongated member in axial alignment with said receptacle and said spring and with said elongated member extending from said component toward said receptacle, and means for pushing upon said component and thereby pushing said elongated member through said spring and said aperture so as to provide an exposed end of said elongated member beyond said aperture.

26. Apparatus in accordance with claim 25, said receptacle having a shoulder adjacent to said aperture against which the spring is compressed.

27. Apparatus in accordance with claim 26, wherein said shoulder is tapered to guide said elongated member toward said aperture.

28. Apparatus in accordance with claim 25, said receptacle having an entrance tapered to guide said spring into said receptacle.

29. Apparatus in accordance with claim 25, wherein said receptacle has a longitudinal slot to permit said elongated member to be withdrawn therethrough.

30. Apparatus in accordance with claim 25, wherein said receptacle is formed between a pair of parts which may be separated to release the spring therefrom.

31. Apparatus in accordance with claim 25, said means for holding said spring compressed in said receptacle comprising an abutment for engaging a side of said component remote from said receptacle.

32. Apparatus for forming a plurality of assemblies each including an elongated member which extends from a component at one end of the assembly through a compressible spring to an element at the other end of the assembly, which comprises a rack having a plurality of receptacles, each receptacle having an aperture adapted to pass an elongated member but not a spring, and means for holding said springs compressed within said receptacles, respectively, with said elongated members extending from said components, respectively, through said springs and said apertures, respectively, so as to provide exposed ends of said elongated members beyond said apertures, respectively.

33. Apparatus in accordanc with claim 32, said rack having a base plate with said receptacles located along one side of said base plate and having entrances at one said receptacles, said abutment plate having an edge facing said entrances for engaging an end of said components and receiving back pressure of the compressed springs upon said components.

35. Apparatus in accordance with claim 33, said rack having means for supporting a plurality of springs at one end of the springs with the opposite end of the springs facing said entrances, the last-mentioned means being supported on said base plate for movement toward said entrances to insert said springs alone in said receptacles.

36. Apparatus in accordance with claim 35, said rack having means for retaining the springs compressed in said receptacles after they are inserted.

37. Apparatus in accordance with claim 36, said retaining means comprising means for blocking the entrances to said receptacles at spaced points and for permitting insertion of said elongated members into said receptacles between the associated points.

38. Apparatus in accordance with claim 37, said rack having means for supporting a plurality of components with elongated members extending therefrom toward the entrances of said receptacles, the last-mentioned means being movable toward said receptacles to insert said elongated members into said receptacles, respectively.

39. Apparatus in accordance with claim 32, further comprising means for attaching terminals to exposed ends of said elongated members.

40. Apparatus in accordance with claim 39, the last mentioned means comprising a crimping press.

41. Apparatus in accordance with claim 39, further comprising a carriage for supporting said rack for movement past said terminal attaching means.

42. Apparatus in accordance with claim 41, further comprising means for precisely aligning each receptacle with the terminal attaching means.

43. Apparatus in accordance with claim 41, further comprising means for unloading said rack from said carriage after said elements have been attached to said exposed ends of said elongated members.

44. Apparatus in accordance with claim 39, further comprising means for unloading said assemblies from said rack.

45. Apparatus in accordance with claim 44, said rack having a base plate with said receptacles located along one side of said base plate and having entrances at one end of the receptacles facing the opposite side, said apertures being located at the other end of said receptacles, said means for holding said springs compressed comprising an abutment plate on said base plate, said abutment plate having an edge facing said entrances for engaging an end of said components and receiving back pressure of the compressed springs upon said components, said base plate having an opening beneath said abutment plate, said unloading means comprising a base having a post adapted to enter said opening and dislodge said abutment plate as said base plate is placed upon said base.

46. Apparatus in accordance with claim 45, said base having means for engaging an edge of said rack for positioning said opening relative to said post.

47. Apparatus in accordance with claim 45, said base having means for bending said exposed ends of said elongated members away from said base plate as said post enters said opening.

48. Apparatus in accordance with claim 47, wherein said receptacles have slots for permitting the elongated members to pass therethrough to free the assemblies from the rack.

49. Apparatus in accordance with claim 39, wherein said components are electrical brushes, said elongated members are wires extending therefrom, and said elements are terminals.

Claims

1. A method of manufacturing an assembly having an elongated member extending from a component at one end of the assembly and through a compressible spring to an element at the other end of the assembly, which comprises providing a receptacle for the spring with an aperture large enough to pass the elongated member therethorugh, but not the spring, compressing the spring into the receptacle, pushing the elongated member extending from the component through the compressed spring by applying a pushing force to said elongated member adjacent to said component and remote from a free end portion of said elongated member until the free end portion of said elongated member projects through the aperture, and attaching said element to said end portion.

5. A method in accordance with claim 4, wherein said abutment is provided by an edge of a plate upon which said component is moved toward said receptacle.

11. A method in accordance with claim 10, wherein the spring is compressed into said receptacle by placing one end of the spring upon a mounting post and moving said mounting post toward an entrance of said receptacle.

20. A method of manufacturing assemblies each having an elongated member extending from a component at one end of the assembly and through a compressible spring to an element at the other end of the assembly, which comprises providing upon a rack a plurality of receptacles for the springs, respectively, each receptacle having an aperture large enough to pass an elongated member therethrough, but not the spring, compressing the springs into the receptacles, pushing the elongated members extending from the components through the compressed springs, respectively, until free end portions of said elongated members project through the apertures, attaching said elements to said end portions, respectively, said rack having a base plate supporting the receptacles and components and the components being held in position relative to the receptacles by back pressure of said springs urging said components against an abutment displaceably supported over an opening on said base plate, and releasing said springs by inserting a post through said opening and displacing said abutment from said base plate.

21. A method in accordance with claim 20, said post being provided upon a base, said rack being brought down upon said base to insert said post in said opening, said base being provided with a pair of spaced abutments, one of which is engaged with a side of said rack as the rack is brought down upon said base and the other of which engages end portions of said elongated members projecting from said receptacles and bends the same upwardly.

22. A method in accordance with claim 21, wherein each receptacle is provided with a longitudinal slot, and the elongated members are pulled through said slots to release said members from said rack.

23. A method in accordance with claim 21, wherein said base is inclined and said rack is brought downwardly upon said base by tipping the rack about said one abutment.

33. Apparatus in accordance with claim 32, said rack having a base plate with said receptacles located along one side of said base plate and having entrances at one end of the receptacles facing the opposite side, said apertures being located at the other end of said receptacles.

34. Apparatus in accordance with claim 33, said means for holding said springs compressed comprising an abutment plate on said base plate for supporting said components for movement toward the entrances of said receptacles, said abutment plate having an edge facing said entrances for engaging an end of said components and receiving back pressure of the compressed springs upon said components.

40. Apparatus in accordance with claim 39, the last-mentioned means comprising a crimping press.