BACKGROUND OF THE INVENTION Electrical connectors are used in exterior environments to connect wires with various devices. The exterior environments may include automobiles, trucks, agricultural equipment, construction equipment, or other vehicles that may be exposed to the weather, such as, moisture and temperature extremes. In addition, such electrical connectors are subject to vibration from the engine or the movement of the vehicle. Thus, the electrical connector should withstand these operating conditions.

In addition, it is necessary to attach the electrical connector to the individual wires.

Specifically, the individual wire is attached to an electrical contact. The electrical contact with the attached wire is then assembled into the housing for the electrical connector. This process may be performed by an individual and therefore, can be relatively expensive.

Accordingly, electrical connectors utilized in such vehicles require an efficient and reliable means to test the mechanical and electrical features of each connector.

For example, the electrical connector type and polarity, i. e. orientation, must be verified. The presence of a bolt used for mounting the electrical connector must be confirmed. Similarly, the presence and position of

secondary locks must also be confirmed. Further, the wire connections and configuration must be verified.

SUMMARY OF THE INVENTION According to the teachings of the present invention, the testing device may include a connector block, a pin block, a slide block, a slide gate, a key plate, an insertion assembly, a latching assembly, a release assembly, and a plurality of cover plates.

The testing device accepts an electrical connector for testing. The slide gate secures the electrical connector once the connector is installed into the connector block. The slide gate is associated with the face of the connector block and is normally closed. The slide gate may include chamfered keyways. The electrical connector may include protrusions.

The protrusions interface with the normally-closed slide gate to open the slide gate. Specifically, the protrusions engage chamfered keyways on the slide gate.

Further insertion of the electrical connector into the slide gate translates the slide gate until it opens. Once the electrical connector is installed, the slide gate returns to its closed position and provides equalization of holding forces, eliminating the side loading associated with the prior art.

The key plate allows utilization of the same testing device for different types of electrical connectors. The key plate is installed in the connector block and includes keyways. The number and the spacing of the keyways correspond to the ribs on a specific type of electrical connector. By changing the installed key plate with another key plate, the testing device can accept a different type of electrical connector.

The prior art testing devices possess fixed keyways that require harness shops to stock individual testing devices for each electrical connector polarization. To change the type of electrical connector being tested using a prior art testing device, one testing device must be removed from an analyzer. A second testing device then must be connected to the analyzer. The inventive testing device offers the harness shop, where the electrical connectors are tested, the advantage of purchasing one testing device with replaceable, inexpensive key plates.

The key plate provides savings in time and equipment cost over the prior art.

The release assembly includes contact release pins and compression springs located in bores within the connector block. Each pin is associated with a compression spring. When the electrical connector is installed in the connector block the electrical connector engages the pins and compresses the springs. The electrical connector is thereby held against the slide gate by the spring force of the springs.

The electrical connector may include a bolt and secondary locks. The secondary locks can be positioned in a pre-loaded, open position or a closed position. To allow installation of wire assemblies in the electrical connector, the secondary locks are in the open position.

When the connector is installed in the connector block, the testing device can confirm that the bolt and the secondary locks are present and in the proper position.

The pin block includes a test face, a rear face, and an array of spring-loaded pin switches. Each switch has a pair of ends. The ends protrude from the faces of the pin block. The ends protruding from the test face engage the bolt and the secondary locks. The testing device provides a diagnostic function and allows electrical signals to

pass to a remote logic analyzer. The ends protruding from the rear face can be electrically wired to the analyzer to signal the presence and correct position of the bolt and the secondary locks.

The testing device allows access to a backplate of the installed electrical connector. The backplate includes apertures through which wire assemblies can be loaded. The electrical connector includes a locking tab for each corresponding aperture. The locking tab is located within an opening which is associated with each aperture. The wire assembly can be inserted into the electrical connector such that a contact of the wire assembly and the locking tab engage, thereby preventing removal of the wire assembly from the electrical connector.

The insertion assembly includes a handle, a pair of side bars, a pair of side links, dowel pins, and spring members. The side bars both have an end pinned by the dowels to the connector block. The handle is attached to the sidebars at the other end of both sidebars and is located between the side bars. The side bars and handle can rotate about the ends of the side bars pinned to the connector block.

Both side links include a pair of ends. One side link is attached to one side bar. One end of the side link is attached to the side bar such that the side link is parallel to the longitudinal axis of the testing device. The other end of the side link is attached to the slide block. The slide block is attached to the pin block.

Moving the handle toward the face of the connector block moves the slide block and the pin block toward the connector block and compresses the spring members.

By moving the handle toward the face of the connector block a sufficient distance, the testing device can be placed in a wire assembly diagnostic mode. The testing device inspects the electrical connector for fully-locked wire assemblies, proper wire assembly position, and closed secondary locks.

The pin block holds spring-loaded pin switches projecting from the faces of the pin block at a specified dimension and in a specified configuration. Each switch aligns with a corresponding wire assembly. The switches physically contact the individual contact of the wire assembly once the handle is moved a sufficient distance toward the face of the connector block.

The pin block simultaneously closes the secondary locks as it tests the wire assemblies. The pin block acts on the secondary locks of the electrical connector, asserting enough compression force to close the secondary locks but not enough to damage the wire assemblies. The prior art has no moving or spring-loaded blocks and does not incorporate a sequenced moving feature.

Activation of the release assembly can remove the electrical connector from the connector block. The release assembly also includes a toggle, a lever, and a compression spring. The toggle and the lever are attached to the normally-closed slide gate. The compression spring acts on the lever and biases the toggle, the lever, and the slide gate. The compression spring provides the normally-closed position of the slide gate. Moving the toggle in a direction which compresses the spring opens the slide gate.

The contact release pins provide electrical connector removal assistance. With the slide gate open, the compressed springs associated with the pins exert a spring

force on the electrical connector, forcing the electrical connector out of the connector block.

The testing device moves back into the starting position and is ready to accept another electrical connector concurrently with the connector removal operation. When the toggle is released, the spring associated with the lever acts to bias the lever, the slide gate, and the toggle. The slide gate is thus returned to its normally-closed position.

The testing device can interface with the analyzer such that the analyzer will electrically signal the test operator if the proper electrical connector test sequence is not followed. For example, if an electrical connector is inserted into the connector block and the wire diagnostic mode is not run, the analyzer can be programmed to shut down.

These and other objects, features, and advantages of the present invention will become more readily apparent upon reading the following detailed description of exemplified embodiments and upon reference to the accompanying drawings herein.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a side elevational view of a testing device constructed in accordance with the teachings of the present invention; FIG. 2 is a front elevational view of the testing device in FIG. 1; FIG. 3 is a front elevational view of the testing device as in FIG. 2 but with an electrical connector inserted into the testing device; FIG. 4 is a plan view of the key plate; FIG. 5 is a mating end view of the electrical connector;

FIG. 6 is an exploded view of the testing device; FIG. 7 is a cross-sectional view of the testing device taken along line 7-7 in FIG. 6; FIG. 8 is a cross-sectional view of the testing device taken along line 8-8 in FIG. 6 FIG. 9 is an end view of the slide bock looking toward the connector block of the testing device; FIG. 10 is a cross sectional view of the slide block taken along line 10-10 in FIG. 9; FIG. 11 is a top plan view of the testing device opened and unloaded and of the electrical connector with the secondary locks in a pre-load position; FIG. 12 is a cross-sectional view of the testing device and of the electrical connector taken along line 12-12 in FIG. 11; FIG. 13 is a cross-sectional view of the testing device taken along line 13-13 in FIG. 11 and of the electrical connector as in FIG. 12 but with the electrical connector inserted into the testing device; FIG. 14 is an enlarged fragmentary cross-sectional view of the electrical connector inserted into the testing device as in FIG. 13; FIG. 15 is an enlarged fragmentary cross-sectional view of the electrical connector inserted into the testing device as in FIG. 13 but with the wire assemblies inserted into the electrical connector; FIG. 16 is a top plan view of the testing device and of the electrical connector as in FIG. 13; FIG. 17 is a cross-sectional view of the testing device and of the electrical connector taken along line 17-17 in FIG. 16; FIG. 18 is an enlarged fragmentary cross-sectional view of the electrical connector inserted into the testing device as in FIG. 17;

FIG. 19 is a top plan view of the testing device and of the electrical connector; FIG. 20 is a cross-sectional view of the testing device and of the electrical connector taken along line 20-20 in FIG. 19; and FIG. 21 is an enlarged fragmentary cross-sectional view of the electrical connector inserted into the testing device as in FIG. 20.

DESCRIPTION OF THE EMBODIMENTS A testing device 30 constructed in accordance with the teachings of the present invention is illustrated in FIG. 1. As shown in FIGS. 1 and 2, the testing device 30 may include a connector block 32, a pin block 34, a slide block 36, a slide gate 38, a key plate 40, an insertion assembly 42, a latching assembly 44, a release assembly 46, and a plurality of cover plates 48,50,52,54.

The connector block 32 is a rectangular and hollow conduit. The connector block 32 may be made from any suitable material, such as acetal, nylon, or polyester, for example, with Delrin made by DuPont Engineering Polymers of Wilmington, Delaware, being a specific example of an acetal. The connector block 32 includes a connector face 60, a key plate surface 62, sides 64, a top 66, and a pin face 68. The face 60 includes a plurality of keyways 70. The sides 64 are similar to each other and include grooves 78. Referring to FIG. 8, the grooves 78 run between the sides 64 and retain the slide gate 38. The keyways 70 extend from the face 60 inward to an amount beyond the grooves 78 described below. Bores 72 extend through the connector block 32 and can be used for mounting the testing device 30. Referring to FIG. 12, the connector block 32 includes a connector portion 88 and a pin block portion 90. The key plate surface 62 is located

between the portions 88 and 90. Referring to FIG. 2, the key plate 40 is attached to the surface 62 by a plurality of screws 92.

Referring to FIG. 11, the release assembly 46 includes a toggle 100, a lever 102, and a compression spring 104. The toggle 100 and the lever 102 may be made from any suitable material, such as acetal, nylon, or polyester, for example, with Delrin made by DuPont Engineering Polymers of Wilmington, Delaware, being a specific example of an acetal. The top 66 of the connector block 32 includes a channel 106. The toggle 100, the lever 102, and the compression spring 104 are located in the channel 106.

Referring to FIGS. 2 and 11, a plurality of screws 108 attach the toggle 100, the gate 38, and the lever 102.

The toggle 100, the gate 38, and the lever 102 are thereby interconnected and move as a unitary grouping.

Alternatively, the toggle 100 and the lever 102 could be an integral, one-piece arm that could be attached to the slide gate 38, such as with screws, in a manner similar to the manner in which the toggle 100 and the lever 102 are attached.

Referring to FIG. 11, the lever 102 includes a bore 110. The spring 104 is inserted into the bore 110 and is trapped between the lever 102 and a first wall 112 of the channel 106. The spring force of the compression spring 104 forces the lever 102, the gate 38, and the toggle 100 away from the wall 112 and places the lever 102 and the toggle 100 into contact with a second wall 114 of the channel.

Referring to FIGS. 2,6, and 12, the release assembly 46 also includes a plurality of contact release pins 116 and a corresponding plurality of compression springs 118.

The pins 116 may be made from bronze, steel, or aluminum,

for example, or any other suitable material. Bores 120 each accept the pin 116. The bore 120 travels through the key plate 40 and from the key plate surface 62 through the connector block 32 out to the pin face 68. Bores 122 in the pin block 34 are aligned with the bores 120. The spring 118 is loaded in the bore 122 first and is followed by the pin 116. A retaining ring 124 is inserted around the pin 116 and is located between the connector block 32 and the pin block 34. The retaining ring 124 prevents the pin 116 from being withdrawn from the bores 120,122 toward the face 60. The ring 124 is positioned on the pin 116 such that the pin 116 contacts the spring 118 and extends through the bore 120, protruding from the key plate 40 towards the face 60.

Referring to FIG. 3, the testing device 30 can accept an electrical connector 130, such as the connector described in U. S. Patent 5,871,373 to Pacini et al. The electrical connector 130 is installed into the connector block 32. The slide gate 38 retains the electrical connector 130. The normally-closed, spring-loaded slide gate 38 is a rectangular frame that is preferably made from aluminum. The slide gate 38 includes a plurality of chamfered keyways 132.

As shown in FIG. 3, the slide gate 38 is in the normally-closed position and includes four chamfered keyways 132. Each chamfered keyway 132 is associated with the corresponding keyway 70 of the connector block 32. To achieve the normally-closed position of the gate 38, the chamfered keyway 132 is slightly offset from the corresponding keyway 70.

To load the electrical connector 130 into the connector block 32, the electrical connector 130 is inserted into the sliding gate 38. Referring to FIGS. 5 and 11, the electrical connector 130 includes an insulator

housing 140 and a plurality of protrusions 142 projecting from the housing 140. Referring to FIG. 3, the electrical connector 130 can be inserted into the connector block 32 until the protrusions 142 interface with the chamfered keyways 132.

The protrusions 142 come in physical contact with the chamfered keyways 132 and bear against the keyways 132.

The chamfered keyways 132 translate the installation force applied longitudinally on the electrical connector 130 into a sliding force applied transversely on the gate 38.

The gate 38 thereby translates in an opening direction 144 as shown in FIG. 2. Thus, the toggle 100 and the lever 102 also translate, thereby compressing the spring 104.

Further insertion of the electrical connector 130 continues to translate the gate 38 until the chamfered keyways 132 are aligned with the keyways 70. The electrical connector 130 can pass through the gate 38.

Once the protrusions 142 pass through the slide gate 38, the protrusions 142 cease to bear against the keyways 132.

The spring 104 exerts force upon the lever 102. The spring force of the spring 104 thereby returns the slide gate 38 in a return direction 146 to its normally-closed position.

Referring to FIGS. 5,6, and 14, the insulator housing 140 of the electrical connector 130 includes projections 146. During the insertion of the electrical connector 130 into the connector block 32, the projections 146 engage the pins 116 and move the pins 116 toward the pin block 34, thereby compressing the springs 118. The pins 116 push against the installed electrical connector 130 with a force applied toward the face 60 of the connector block 32. The closed gate 38 retains the electrical connector 130. The chamfered keyways 132 are chamfered such that the keyways 132 open toward the face

60. Once the electrical connector 130 is installed in the connector block 32, the protrusions 142 interferingly engage the gate 38 as shown in FIG. 3. The pins 116 thereby remain in the compressed position while the electrical connector 130 is installed in the connector block 32 and the gate 38 is closed.

Referring to FIG. 12, the connector portion 88 includes a top surface 150, a bottom surface 152, and side surfaces 154. Referring to FIG. 13, the insulator housing 140 of the installed electrical connector 130 is closely associated with the surfaces 150,152,154, the key plate 40, and the gate 38. The electrical connector 130 is thereby retained in place within the connector block 32 and substantially held in a fixed orientation.

Referring to FIG. 14, when the electrical connector 130 is installed in the connector block 32, a backplate 156 protrudes slightly from the face 60. The backplate 156 is attached to the insulator housing 140. Referring to FIG. 3, the backplate 156 of the electrical connector 130 installed in the connector block 32 is accessible through the gate 38. The backplate 156 accepts terminated wires for installation into the electrical connector 130.

Referring to FIG. 14, the gate 38 interfaces with the installed electrical connector 130 at the protrusions 142.

The interface between the gate 38 and the protrusions 142 provides uniform holding forces. The protrusions 142 interferingly engage the gate 38 at the points 158. The gate 38 applies holding forces against the electrical connector 130 at each of the points 158. The points 158 are configured such that the points 158 are located along at least two different axes. The points 158, therefore, exert holding forces against the electrical connector 130 along at least two axes.

The holding forces exerted on the electrical connector 130 by the gate 38 at the points 158 stabilize the electrical connector 130 and facilitate wire installation through the backplate 156. The prior art testing devices applied holding forces along only one side, i. e., one axis, of the electrical connector. With the prior art testing devices, the electrical connector could be improperly aligned which could impair wire assembly insertion into the electrical connector and affect test results and assembly procedures that depend upon the orientation of the electrical connector.

Referring to FIGS. 2 and 4, the testing device 30 can be used to test different types of the electrical connectors. The key plate 40 ensures the proper type of electrical connector is selected and tested. The key plate 40 is keyed to accept only one type of connector.

The key plate 40 may be made from any suitable material such as fiberglass-impregnated resin, aluminum, steel, or polyester, for example. The key plate 40 is mounted within the connector block 32 by the screws 92 and can be replaced by another key plate which can accept a different type of electrical connector. A key plate can be made for each type of connector to be tested. Indicia 158 can differentiate one key plate from another.

Referring to FIG. 4, the key plate 40 includes a plurality of keyways 160,162,164,166. Referring to FIG. 5, the insulator housing 140 of the electrical connector 130 includes a plurality of ribs 170,172,174, 176. The number and the spacing of the ribs 170,172, 174,176 can give the connector a polarity and can be used to identify a connector with a specific wiring configuration.

Referring to FIGS. 2,4, and 5, the keyways 160,162, 164,166 correspond with the polarizing ribs 170,172,

174,176, respectively. The keyways 160,162,164,166 on the key plate 40 match the ribs 170,172,174,176, respectively, and allow the electrical connector 130 to be inserted in only one orientation, providing a mating polarity to the testing device 30.

Referring to FIGS. 11,12,13, and 14, the testing device 30 can be used to confirm that the electrical connector 130 includes a bolt 180 and secondary locks 182.

Referring to FIG. 7, the pin block 34 includes a bolt- detecting switch 184, a pair of secondary lock-detecting switches 186, a test face 188, and a rear face 190 and a bore 192. The pin block may be made from any suitable material, such as acetal, nylon, or polyester, for example, with Delrin made by DuPont Engineering Polymers of Wilmington, Delaware, being a specific example of an acetal. The switch 184 includes a pair of ends 194,196.

The switch 186 includes a pair of ends 198,200.

The switches 184,186 are attached to the pin block 34, for example, by a friction fit with the pin block 34.

The switch 184 is aligned with the bore 192 and positioned such that the ends 194,196 protrude into the bore 192 and away from the rear face 190, respectively. The switches 186 are positioned such that the ends 198,200 protrude away from the faces 188,190, respectively.

In order to perform diagnostic functions, the switches 184,186 of the testing device 30 can be electrically wired to a remote logic analyzer. The ends 196,200 can be connected, such as by solder, to wires which are connected to the analyzer. The test operations are thus electrically conducted through the analyzer. The switches 184,186 are spring-loaded pin switches. The ends 194,198 are spring loaded and can be compressed longitudinally such that the ends 194,198 move closer to the ends 196,200, respectively. Electrical continuity is

established across the switches 184,186 once the ends 194,198 have been compressed a predetermined amount.

Referring to FIGS. 13 and 14, the testing device 30 can inspect the electrical connector 130 to confirm that the bolt 180 is present and mechanically secured to the connector 130. When the electrical connector 130 is inserted into the connector block 32, the bolt 180 contacts the switch 184. As shown in FIG. 14, the switch 184 moves from the open position, which is shown with dashed lines 185, to the closed position, which is shown with solid lines. The spring force of the switch 184 is sized to offer a specified resistance to the bolt 180. If the bolt 180 is positioned correctly and secured mechanically to overcome the spring force, the switch 184 closes, signaling to the analyzer that the bolt 180 is present and secured.

As described in U. S. Patent 5,871,373, the secondary locks 182 are attached to the insulator housing 140. The secondary locks 182 aid in mechanically securing terminated wires to the electrical connector 130. The secondary locks 182 can be attached to the housing 140 in a pre-wire load, open position. In the open position, the secondary locks 182 are retained by the housing 140 but only partially inserted into the housing 140. When the secondary locks 182 are in the open position, the wires can be inserted into the electrical connector 130. When the secondary locks 182 are in the closed position, the wires can not be inserted into the connector 130. The testing device 30 can ensure that the secondary locks 182 of the electrical connector 130 are present and in a pre- wire load, open position.

When the electrical connector 130 is inserted into the connector block 32, the secondary locks 182 contact the switches 186. As shown in FIG. 14, the switch 186

moves from the open position, which is shown with dashed lines 187, to the closed position, which is shown with solid lines. The spring force of the switches 186 is sized to offer a specified resistance to the secondary locks 182 such that the secondary locks 182 can compress the ends 186 but that the secondary locks 182 are not forced into the closed position by the switches 186. If the secondary locks 182 are positioned correctly in the open position, the switches 186 close, signaling the analyzer that the secondary locks 182 are present and in the open position.

The analyzer can be programmed so that no further testing can be done on the electrical connector 130 until the characteristics of the bolt 180 and the secondary locks 182 have been tested. In other words, the analyzer can be programmed to not perform additional tests until the switches 184,186 have been activated.

Referring to FIG. 15, once both the bolt-detecting switch 184 and the secondary lock-detecting switches 186 are activated, the operator of the testing device 30 can wire the electrical connector 130. The electrical connector 130 can accept terminated wire assemblies 210, 212,214 through the backplate 156. Referring to FIGS. 3 and 15, the backplate includes an array of apertures 216.

Each aperture 216 can accept a wire assembly. The backplate 156 can include indicia 218,220. The electrical connector 130 can be wired by using the indicia 218,220 to follow a predetermined wiring configuration.

Referring to FIG. 15, the wire assemblies 210,212, 214 each include a wire 228 terminated by a contact 230 and can be inserted through the aperture 216 into the insulator housing 140 of electrical connector 130. The insulator housing 140 includes openings 234 and locking tabs 235,236,237 with one opening and one locking tab

for each aperture 216. The opening 234 includes a groove 238 to correctly align the contact 230 in one specific orientation. The locking tabs 235,236,237 each include a ramp 240. The ramp 240 can engage the contact 230.

Each contact 230 includes an opening 244 which can accept the ramp 236.

During insertion of the contact 230 toward the pin block 34, the contact 230 engages the ramp 240 as shown by the wire assembly 214. Continued insertion of the contact 230 thereby deflects the locking tab 235 out of the opening 234 as shown by the wire assembly 210. As the contact 230 continues to move toward the pin block 34, the ramp 240 engages the opening 244 in the contact 230 as shown by the wire assembly 212. A stop 246 prevents the contact 230 from moving further toward the pin block 34.

The opening 244 of the contact 230 and the ramp 240 of the locking tab 236 thereby prevent the contact 230 from being removed from the electrical connector 130.

Referring to FIGS. 15-21, once the electrical connector 130 is wired, the testing device 30 can be placed in a diagnostic mode. In the diagnostic mode, the testing device 30 can inspect the electrical connector 30 to confirm that the connector 30 has wire assemblies with fully-locked contacts located in the proper position in the array of apertures and that the connector 130 has secondary locks 182 in the closed position.

Referring to FIGS. 1,3, and 6, the insertion assembly 42 includes a handle 250, a pair of side bars 252, a pair of side links 254, and spring members 258, 260. Both side bars 252 include a pair of ends 264,266.

The side bars 252 may be made from steel, for example, or any other suitable metal or suitable plastic. The dowel pins 268 attach the side bars 252 at the ends 264 to the connector block 32. The handle 250 is attached to the

side bars 252 at the ends 266. The handle 250 is located between the side bars 252. The handle 250 may be made from aluminum, for example, or any other suitable metal or suitable plastic. The side bars 252 and the handle 250 can rotate about the ends 264.

Referring to FIGS. 1 and 11, the side bars 252 are located in tapered grooves 270 on the connector block 32.

The groove 270 includes walls 272,274. The walls 272, 274 are sized such that the height of the walls 272,274 is substantially equivalent to the thickness of the side bars 252. The side bars 252 and the handle 250 can rotate about the ends 264 within the arc described by the walls 272,274.

Referring to FIG. 1, both side links 254 include a pair of ends 278,280. The side links 254 may be made from steel, for example, or any other suitable metal or suitable plastic. One side link 254 is attached to one side bar 252 at the end 278 with a dowel pin 282 such that the side bar 252 can rotate relative to the side link 252 and the side link 254 can translate along an axis substantially parallel to the longitudinal axis of the testing device 30. The end 280 of the side link 254 is attached to the slide block 36.

Referring to FIGS. 6 and 13, the slide block 36 is associated with the pin block 34 such that the slide block 36 and the pin block 34 are interrelated but that the pin block 34 can move independent of the slide block 36. The slide block 36 may be made from any suitable material, such as acetal, nylon, or polyester, for example, with Delrin made by DuPont Engineering Polymers of Wilmington, Delaware, being a specific example of an acetal.

The bolts 284,286 interrelate the slide block 36, the pin block 34, and the connector block 32. The bolt 284 passes through the slide block 36, the spring member

260, and the pin block 34, and the spring member 258 and is attached to the connector block 32. The bolt 286 passes through the pin block 34 and the spring member 260 and is attached to the slide block 36. The bolts 284,286 include heads 288,290, respectively.

Referring to FIGS. 9 and 13, the bolt 284 is sized such that when the bolt 284 is attached to the connector block 32, the spring members 258,260 are partially compressed. Referring to FIG. 10, the head 288 is inserted into a bore 289 and can interferingly engage the bore 289. Referring to FIGS. 9 and 13, the head 288 retains the slide block 36 and prevents the spring members 258,260 from returning to a relaxed position. The slide block 36 is thereby retained a predetermined distance from the connector block 32 by the bolts 284. The slide block 36 can move closer to the connector block 32 by compressing the spring members 258,260 but can not travel further away from the connector block 32 than the length of the bolt 284 protruding from the connector block 32.

The bolt 286 is sized such that when the bolt 286 is attached to the slide block 36, the spring member 260 is partially compressed. Referring to FIG. 7, the head 290 is inserted into a bore 291 and can interferingly engage the bore 291. Referring to FIGS. 6 and 13, the head 290 retains the pin block 34 and prevents the spring member 260 from returning to a relaxed position. The pin block 34 is thereby retained a predetermined distance from the slide block 36 by the bolts 286. The pin block 34 can move closer to the slide block 36 by compressing the spring member 260 but can not travel further away from the slide block 36 than the length of the bolt 286 protruding from the slide block 36.

Referring to FIGS. 16 and 17, moving the handle 250 toward the face 60 of the connector block 32 rotates the

side bars 252 and translates the side links 254, the slide block 36 and the pin block 34 toward the face 60 of connector block 32 thereby compressing the spring members 258,260.

By moving the handle 250 toward the face 60 of the connector block 32 a sufficient distance, the testing device 30 can be placed in a wire assembly diagnostic mode. The testing device 30 inspects the electrical connector 130 for fully-locked wire assemblies, proper wire assembly position, and closed secondary locks.

Referring to FIGS. 16-21, the testing device 30 is activated into the wire assembly diagnostic mode by moving the handle 250. The testing device 30 attempts to close the secondary locks 182 of the electrical connector 130.

Once the secondary locks 182 arrive at the closed position, the testing device 30 interfaces individually with all of the wire assemblies in the electrical connector 130.

Referring to FIGS. 6 and 7, the pin block 34 includes an array of wire assembly switches 294. The switch 294 is a spring-loaded pin switch and includes a pair of ends 296,298. The switches 294 are attached to the pin block 34, for example, by a friction fit with the pin block 34.

Each switch 294 aligns with a corresponding wire assembly.

The ends 296,298 project from the faces 188,190, respectively, at a specified dimension and in a specified configuration. The switches physically contact the individual contact of the wire assembly once the handle 250 is moved a sufficient distance toward the face 60 of the connector block 32.

In order to perform diagnostic functions, the switches 294 of the testing device 30 can be electrically wired to a remote logic analyzer which controls the testing device 30. The ends 298 can be wired to the

analyzer. The test operations are thus electrically connected to the analyzer. Electrical continuity is established between the wire assemblies and the analyzer through the switches 294. Electrical continuity is established across the switches 294 once the ends 296 have been compressed a predetermined amount.

Referring to FIGS. 17,18,20, and 21, the pin block 34 simultaneously closes the secondary locks 182 of the electrical connector 130 as it tests the wire assemblies 210,212,214. The prior art has no moving or spring- loaded blocks and does not incorporate a sequenced moving feature. Referring to FIG. 18, the switches 294 pass through apertures 300 in the secondary locks 182 and apertures 302 in the insulator housing 140. The testing face 188 of the pin block 34 contacts the secondary locks 182 of the electrical connector 130, asserting enough compression force to close the secondary locks 182 but not enough to damage the wire assemblies 210,212,214.

Referring to FIGS. 15 and 21, the secondary lock 182 includes three shelves 303,304,305. The housing 140 includes openings 306 which can accept the shelves 304.

Referring to FIG. 21, the shelves 303,304,305 are adjacent to the locking tabs 235,236,237, respectively, when the secondary lock 182 is fully inserted. The shelves 303,304,305 prevent the locking tabs 235,236, 237 from deflecting into the openings 306 and releasing the contacts 230. Thus, the secondary lock 182 provides additional retention of the contacts 230 retained by the locking tabs 235,236.

Referring to FIG. 16, the latching assembly 44 includes a lever 310, a compression spring 312, and retaining posts 314,316. A dowel pin 320 pins the lever 310 to the connector block 32. The lever 310 may be made from steel, for example, or any other suitable metal or

any suitable plastic. The lever 310 can rotate about the pin 320. The lever 310 is located within the channel 106, a channel 318 on the pin block 34, and a channel 319 on the slide block 36.

Referring to Fig. 6, the lever 310 includes a bore 322. Referring to FIG. 16, the spring 312 is retained within the bore 322 and engages the first wall 112 of the channel 106. The lever 310 includes steps 324,326. The post 314 is attached to the pin block 34. The post 314 may be made from steel, aluminum, or bronze, for example, or any other suitable metal or any suitable plastic. The post 314 is in contacting relation with the step 326. By bearing against the lever 310, the post 314 maintains the spring 312 in a compressed position. The post 316 is attached to the slide block 36. The post 316 may be made from steel, aluminum, or bronze, for example, or any other suitable metal or any suitable plastic.

In addition, the lever 310 includes the ends 330, 332. Stops 334,336 are located at the ends 330,332, respectively.

Referring to FIGS. 16 and 19, the latching assembly 44 can be latched by moving the handle 250 toward the face 60 of the connector block 32 in a direction 333 as shown in FIG. 20. The pin block 34 moves toward the connector block 32 and brings the post 314 along. Referring to FIG.

19, a wall 342 is located between the steps 324,326.

Once the handle 250 is moved a sufficient distance, the post 314 slips past the step 326 and the wall 342. The spring 312 acts on the lever 310, and the lever 310 rotates about the dowel pin 320. The stop 334 contacts the lever 102, and a step 340 contacts the post 316.

In this latched position, the stop 336 retains the slide block 36. The stop 336 engages the post 316, thereby preventing the slide block 36 from moving away

from the connector block 32 after the handle 250 is released.

Referring to FIGS. 20 and 21, when the latching assembly 44 is brought into the latching position, the pin block 34 is in a position in relation to the connector block 32 such that the switches 294 can interface with the wire assemblies. In other words, the latching assembly 44 allows the testing device 30 to be latched in place in the wire diagnostic mode. The pin block 34 and the slide block 36 will remain in the wire diagnostic mode even if the handle 250 is released. The spring members 258,260 are compressed when the latching assembly 44 is latched.

Referring to FIGS. 16,17, and 19, the handle 250 can be moved closer to the face 60 of the connector block 32 to unlatch the latching assembly 44. Referring to FIG.

19, the posts 314,316 are drawn away from the wall 342 and the stop 336, respectively. Referring to FIGS. 16, 17, and 19, an unlatching post 348 projects from the lever 310. Referring to FIG. 19, the post 348 can be moved toward a wall 350 of the channel 319 to rotate the lever 310 such that the wall 342 and the stop 336 are offset from the posts 314,316, respectively. The posts 314,316 are free to translate away from the connector block 32.

Moving the handle 250 away from the face 60 of the connector block 32 moves the post 314 closer to the step 326. Referring to FIG. 16, once the post 314 has moved beyond the wall 342 and is aligned with the step 326, the latching assembly 44 is unlatched and the post 348 can be released.

The compressed spring members 258,260 exert spring forces on the blocks 34,36 and can assist in returning the testing device 30 to the unlatched position as shown in FIG. 1.

Referring to FIGS. 16,17, and 18, the testing device 30 can detect whether the contacts 230 are properly engaged with the locking tabs 235,236,237. FIG. 16 illustrates the testing device 30 in the unlatched position. The post 314 is located in contacting relation with the step 326. The lever 310 can not rotate about the dowel pin 320.

Referring to FIGS. 17 and 18, the locking tab 235 is in interfering contact with the shelf 303. The opening 244 of the wire assembly 210 is not aligned with the ramp 240 of the locking tab 235. As a result, the locking tab 235 is deflected further into the opening 306. As the handle 250 was moved closer to the face 60 of the connector block 32, the pin block 34 acted to insert the secondary locks 182 into the housing 140. Once the shelf 303 came into interfering contact with the locking tab 235, the pin block 34 could not be drawn closer to the face 60 of the connector block 32. As a result the switches 294 can not be placed in contacting relation with the contacts 230. Referring to FIG. 16, the post 314 can not be aligned with the step 324. Therefore, the latching assembly 44 can not be latched. Thus the testing device 30 provides mechanical and electrical signals to indicate the presence of a partially-inserted wire assembly. The position of the wire assembly 210 is sometimes referred to in the industry as a"short-unseated wire." If the latching assembly 44 will not latch, then the operator will attempt to remedy the situation. The operator will push on all of the wire assemblies in order to insert fully any partially-inserted wire assemblies.

The operator will then move the handle 250 toward the face 60 of the connector block 32 and attempt to latch the latching assembly 44. Thus, the testing device 30 reduces

the manufacture of electrical connectors with partially- inserted wire assemblies.

Referring to FIGS. 19,20, and 21, the testing device 30 can detect whether the contacts 230 are properly installed in the housing 140. The testing device 30 can confirm that the wire assembly is installed in a mechanically sufficient manner and in an electrically proper configuration. FIG. 19 illustrates the testing device 30 in the latched position.

Referring to FIGS. 20 and 21, the secondary locks 182 are fully inserted into the housing 140. The locking tabs 235,236,237 are in a relaxed position and allow the shelves 303,304,305, respectively, to translate within the openings 306 until the secondary locks 182 are fully seated. The testing device 30 is in wire diagnostic mode.

The wire assemblies 210,212 both make contact with the switches 294. As a result the analyzer confirms the presence of the wire assemblies 210,212 and determines whether the assemblies 210,212 are in the proper configuration.

The wire assembly 214 does not contact the corresponding switch 294 associated with the assembly 214.

The lack of an electric signal from the wire assembly 215 to the analyzer indicates the presence of an improperly installed wire assembly. The position of the wire assembly 214 is sometimes referred to in the industry as a "long-unseated wire. "Thus, the testing device 30 reduces the manufacture of electrical connectors with partially- inserted wire assemblies.

If the analyzer indicates that no wire assembly is present or that a wire assembly is in the wrong location, the operator can remove the electrical connector. The operator can re-install the wire assemblies according to the information provided by the analyzer until the wire

assemblies of the electrical connector 130 are mechanically and electrically correct.

Referring to FIGS. 2,3, and 11, activation of the release assembly 46 can remove the electrical connector 130 from the connector block 32. The toggle 100 and the lever 102 are attached to the normally-closed slide gate 38. The compression spring 104 acts on the lever 102 and biases the toggle 100, the lever 102, and the slide gate 38. The compression spring 104 provides the normally- closed position of the slide gate 38. Moving the toggle 100 in the opening direction 144 compresses the spring 104 and opens the slide gate 38.

The contact release pins 116 provide electrical connector removal assistance. With the slide gate 38 open, the chamfered keyways 132 are aligned with the keyways 70 and the protrusions 142. The compressed springs 118 associated with the pins 116 exert a spring force on the electrical connector 130, forcing the protrusions 142 of the electrical connector 130 out of the connector block 32. The electrical connector 130 can be readily removed from the connector block 32.

Referring to FIGS. 2 and 11, the testing device 30 moves back into the starting position and is ready to accept another electrical connector 130 concurrently with the connector removal operation. When the toggle 100 is released, the spring 104 acts to bias the lever 102, the slide gate 38, and the toggle 100. The slide gate 38 is thus returned to its normally-closed position.

The testing device 30 can interface with the analyzer such that the analyzer will electrically signal the test operator if the proper electrical connector test sequence is not followed. For example, if the electrical connector 130 is inserted into the connector block 32 and the wire

diagnostic mode is not run, the analyzer can be programmed to shut down.

If an operator removes the electrical connector 130 without completing the sequence of pulling the handle 250 toward the face 60 of the connector block 32, the electrical connector 130 can be removed from the connector block 32 and another electrical connector can be mechanically installed. However, the analyzer will shut down. The operator must reset the analyzer to use the testing device 30.

When the electrical connector 130 is installed in the connector block 32, the bolt-detecting switch 184 and the secondary lock-detecting switches 182 close and electrically signal the analyzer. If the handle 250 is not moved toward the face 60 of the connector 32, the wire assembly switches 294 in the pin block 34 will not physically contact the wire assemblies 210,212,214.

Accordingly, the analyzer will not receive a signal regarding the condition of the wire assembly configuration. If the operator removes the electrical connector 130 from the connector block 32, the bolt- detecting switch 184 and the secondary lock-detecting switches 186 will open and the electric signal to the analyzer will stop. The analyzer can be programmed to shut down if the switches 184,186 are closed and then subsequently opened without the wire assembly switches 294 sending an intervening signal to the analyzer.

This feature reduces the possibility that a non- diagnosed electrical connector is manufactured. Thus, the number of parts rejected by the customer is reduced and approaches zero. The prior art has not provided an electrical lock-out feature.

From the foregoing it will be understood that modifications and variations may be effectuated to the

disclosed structures-particularly in light of the foregoing teachings-without departing from the scope or spirit of the present invention. As such, no limitation with respect to the specific embodiments described and illustrated herein is intended or should be inferred.

Indeed, the following claims are intended to cover all modifications and variations that fall within the scope and spirit of the present invention. In addition, all references and copending applications cited herein are hereby incorporated by reference in their entireties.