An assembly apparatus (10) is provided. The assembly apparatus (10) includes a first feeding mechanism (12) arranged in use to feed a series of first components (14), a holding mechanism (16) arranged in use to hold consecutive ones of the first components (14) in place, a cutter (18) arranged in use to separate individual ones of the first components (14) while being held in place by the holding mechanism (16), an inserter (20) arranged in use to push a separated first component (14) into a corresponding opening in a second component (22), and a drive mechanism (24) coupled to each of the first feeding mechanism (12), the holding mechanism (16), the cutter (18) and the inserter (20). The drive mechanism (24) is arranged in use to synchronise movement of the first feeding mechanism (12), the holding mechanism (16), the cutter (18) and the inserter (20).

An assembly apparatus (10) is provided. The assembly apparatus (10) includes a first feeding mechanism (12) arranged in use to feed a series of first components (14), a holding mechanism (16) arranged in use to hold consecutive ones of the first components (14) in place, a cutter (18) arranged in use to separate individual ones of the first components (14) while being held in place by the holding mechanism (16), an inserter (20) arranged in use to push a separated first component (14) into a corresponding opening in a second component (22), and a drive mechanism (24) coupled to each of the first feeding mechanism (12), the holding mechanism (16), the cutter (18) and the inserter (20). The drive mechanism (24) is arranged in use to synchronise movement of the first feeding mechanism (12), the holding mechanism (16), the cutter (18) and the inserter (20).

A connector (140) is provided with a holding component (141), a support component (148), a terminal (144) electrically connected to a contact of a guide wire (130) held by the holding component (141), and a guide component (147) rotatable around an axial line (130A) of the guide wire (130) with respect to the support component (148). The holding component (141) is provided with a body (150) having an insertion hole (150a) for the guide wire (130) and a holding piece (151) extending along an axial line of the insertion hole (150a) from the body (150) and capable of being elastically deformed inward in a radial direction with respect to the axial line. The guide component (147) has a guide surface (165a) guiding the holding piece (151) inward in the radial direction. The holding component (141) is slid along the axis line of the insertion hole (150a) with respect to the guide component (147), whereby the holding piece abuts on the guide surface (165a) to be elastically deformed inward in the radial direction.

A connector (140) is provided with a holding component (141), a support component (148), a terminal (144) electrically connected to a contact of a guide wire (130) held by the holding component (141), and a guide component (147) rotatable around an axial line (130A) of the guide wire (130) with respect to the support component (148). The holding component (141) is provided with a body (150) having an insertion hole (150a) for the guide wire (130) and a holding piece (151) extending along an axial line of the insertion hole (150a) from the body (150) and capable of being elastically deformed inward in a radial direction with respect to the axial line. The guide component (147) has a guide surface (165a) guiding the holding piece (151) inward in the radial direction. The holding component (141) is slid along the axis line of the insertion hole (150a) with respect to the guide component (147), whereby the holding piece abuts on the guide surface (165a) to be elastically deformed inward in the radial direction.

A gas sensor includes a sensing element having an electrode pad a metal terminal, and a separator that has insertion holes in which the metal terminal is held. The metal terminal includes a main body and an elastic portion that is integrally connected to the main body and is elastically connected to the electrode pad at a predetermined contact point. The main body includes a front-end-side restricting portion and a rear-end-side restricting portion that restrict the movement of the main body by contacting wall surfaces of the insertion hole when the main body moves in a direction intersecting the direction of an axial line. The contact point is located between the front-end-side restricting portion and the rear-end-side restricting portion in the direction of the axial line. The front-end-side restricting portion and the rear-end-side restricting portion are connected to each other so that a flat board portion is interposed therebetween.

A gas sensor includes a sensing element that includes an electrode pad, a metal terminal, and a separator. The metal terminal includes a lead-wire-connecting portion, a main body, a protruding piece that protrudes from a front-end side, and an elastic portion connected to an end of the protruding piece and to the electrode pad. An area S1 of a first opposed surface of a primary surface facing an insertion hole of the separator is larger than an area S2 of a second opposed surface of a secondary surface facing the insertion hole, and a part of the second opposed surface contacts an inner circumferential surface of the separator forming the insertion hole, and the first opposed surface is separated from the inner circumferential surface, where surfaces of the main body and the protruding piece that are located opposite the elastic portion are the primary surface and the secondary surface.

A gas sensor includes a sensing element that includes an electrode pad, a metal terminal, and a separator. The metal terminal includes a lead-wire-connecting portion, a main body, a protruding piece that protrudes from a front-end side, and an elastic portion connected to an end of the protruding piece and to the electrode pad. An area S1 of a first opposed surface of a primary surface facing an insertion hole of the separator is larger than an area S2 of a second opposed surface of a secondary surface facing the insertion hole, and a part of the second opposed surface contacts an inner circumferential surface of the separator forming the insertion hole, and the first opposed surface is separated from the inner circumferential surface, where surfaces of the main body and the protruding piece that are located opposite the elastic portion are the primary surface and the secondary surface.

A method of manufacturing a lead. The method includes providing a supporting tube, and disposing a conductive strip on an outer surface of the supporting tube such that the conductive strip extends in an axial direction along a length of the supporting tube. The method also includes mounting a chip having a first conductive contact pad and a second conductive contact pad to the supporting tube such that the first conductive contact pad is in contact with the conductive strip. The method further includes fitting an electrode to the supporting tube such that the electrode is in contact with the second conductive contact pad, and coupling a conductor to each end of the supporting tube such that each conductor is in contact with the conductive strip. The method also includes covering at least one of the chip and the conductors with a sheath to provide the lead.

A method of manufacturing a lead. The method includes providing a supporting tube, and disposing a conductive strip on an outer surface of the supporting tube such that the conductive strip extends in an axial direction along a length of the supporting tube. The method also includes mounting a chip having a first conductive contact pad and a second conductive contact pad to the supporting tube such that the first conductive contact pad is in contact with the conductive strip. The method further includes fitting an electrode to the supporting tube such that the electrode is in contact with the second conductive contact pad, and coupling a conductor to each end of the supporting tube such that each conductor is in contact with the conductive strip. The method also includes covering at least one of the chip and the conductors with a sheath to provide the lead.

The device, system and process of the present invention greatly reduces the time and space necessary to assemble a wire harness enables efficient manufacture of wire harnesses. The present invention comprises at least a wire viewer module, a machine vision and optical character recognition module, a cassette tray platform, designed to receive and hold in place a cassette tray, having one or more receptacles designed to receive and hold in place a wire harness connector, having multiple pin-hole cavities illuminated from below or behind by a light source mounted on a two-axis translation stage or gantry to identify a cavity for wire insertion. Moreover, the present invention may further comprise a portable, computer-implemented system capable of executing a series of automated process steps designed to identify wire markings and guide the error-free insertion of identified wires into wire harness connector pin-hole receptacles for assembly of a wire harness.