A photoirradiation device includes an insertion path for inserting a wire rod; a first reflector having a circular arc shape centered on a point shifted from a center of the insertion path by a first distance, one side of the first reflector facing the insertion path being a reflective surface; a second reflector disposed adjacent open edges of the first reflector and having a circular arc shape centered on a point shifted from the center of the insertion path by a second distance that is different from the first distance, one side of the second reflector facing the insertion path being a reflective surface; and a light source that is positioned on an opposite side of the insertion path from the first reflector and that projects light toward the wire rod.

Disclosed is a method for forming a square-wire conductor, which includes: providing a circular conductor with a diameter d; passing the conductor through a gap of a longitudinal calendaring roller to longitudinally calender the conductor up and down to form a conductor with flat upper and lower surfaces, the gap L1 of the longitudinal calendering roller is 0.886 d to 0.911 d; longitudinally and transversely straightening the conductor; passing the conductor through a gap of a transverse calendering roller to transversely calender the conductor left and right to form a conductor with flat left and right surfaces, the gap L2 of the transverse calendering roller is 0.886 d to 0.911 d; and longitudinally and transversely straightening the conductor.

An automated system for processing an end of a cable. The system includes: a cable delivery system; a cable processing module; a pallet supported by the cable delivery system; a drive wheel rotatably coupled to the pallet; a motor operatively coupled for driving rotation of the drive wheel; and an idler wheel rotatably coupled to the pallet and forming a nip with the drive wheel. The cable processing module includes cable processing equipment and a computer system. The computer system is configured to: (a) cause the drive wheel to rotate in a cable pushing direction to cause a specified length of cable to be inserted into the cable processing equipment; (b) activate the cable processing equipment to operate on the cable end; and (c) cause the drive wheel to rotate in a cable pulling direction to cause the length of cable to be removed from the cable processing equipment.

A wire harness assembly work cell includes a wire harness assembly work table with a pneumatically powered or spring-fed universal applicator tool for mass terminating sets of wires into insulator wafers. The insulator wafers may be assembled in stacks to form cable-end connector headshells. Insulation displacement terminals (IDT) are designed to receive wide ranges of wire diameters so that larger varieties of wire sizes may be received into these connector assemblies while using fewer different sizes of terminals, thus reducing the number of items in a bill of material (BOM) and substantially reducing the volumes and overhead costs of testing and quality control documentation dedicated to each individual BOM item.

A rotary body including a drum and a wire support member winds a wire by rotation. A spacer is provided on the rotary body and is displaceable to a first position and a second position in the rotary body. When the spacer is in the first position, the wire is wound on the rotary body not via the spacer, and hence the wire is wound with the first diameter. When the spacer is in the second position, position, the wire is wound on the rotary body via the spacer, and hence the wire is wound with a second diameter larger than the first diameter.

An apparatus configured to twist a first wire about a second wire is presented herein. The apparatus includes a securing mechanism configured to secure ends of the first wire and the second wire. The first wire is arranged parallel to the second wire along a longitudinal axis. The apparatus further includes a gripping mechanism configured to grip central portions of the first and second wires, a tensioning mechanism configured to apply a lateral offsetting force to the gripping mechanism, thereby deflecting the central portions of the first and second wires orthogonally from the longitudinal axis, and a rotating mechanism configured to rotate the gripping mechanism, thereby twisting the first and second wires about one another. A method of twisting a pair of wires is also presented.

A removal trough for a wire processing system receives wires processed by a wire processing machine of the wire processing system, wherein side walls of the removal trough each have one or more recesses and/or indentations formed therein for mechanical gripping of the wires in the removal trough by a gripping arm.

Provided is a twisted wire including a plurality of covered wires twisted together, each covered wire including a conductor and an insulator covering the periphery of the conductor, wherein the twisted wire satisfies Inequality (1): y<A×x/(z/500)+B (wherein x: a pitch length (mm) of the twisted wire, y: a collapsing rate (%) of the insulator, z: an elastic modulus (MPa) of the insulator, A: Constant A=−1, and B: Constant B=11.5).

A cable end sensing apparatus and a method of sensing a cable end of a cable in a cable preparation device. The cable end sensing apparatus includes cable clamps for clamping and moving the cable and a movable sensing device. The movable sensing device has a first position in which the movable sensing device is positioned in line with an axis of insertion of the cable to engage the end of the cable and to prevent the cable from moving beyond the movable sensing device. The movable sensing device has a second position in which the movable sensing device is moved away from the axis of insertion of the cable when the cable end is properly positioned to allow the cable to move beyond the sensing device.

A process for manufacturing finished wire and cable having reduced coefficient of friction and pulling force during installation, includes providing a payoff reel containing at least one internal conductor wire; supplying the at least one internal conductor wire from the reel to at least one extruder; providing the least one extruder, wherein the at least one extruder applies an insulating material and a polymerized jacket composition over the at least one internal conductor wire, wherein the polymerized jacket composition comprises a predetermined amount by weight of nylon; and at least 3% by weight of a silica providing a cooling device for lowering the temperature of the extruded insulating material and the polymerized jacket composition and cooling the insulating material and the polymerized jacket composition in the cooling device; and, reeling onto a storage reel the finished, cooled, wire and cable for storage and distribution.