A peg apparatus is described that is suitable for use with an electrical wire harness peg board. The pegs are utilized on a wire harness peg board during the assembly of a wire harness, and are particularly well suited for use in an automated assembly of the electrical wire harness where a constant upward, downward or lateral tension is desired without altering the free ends of each wire of an assembled wire harness.

A method of manufacturing a cable harness may comprise the steps of providing a plurality of cables, wherein each cable comprises a cable inner and a coating, wherein each cable inner comprises at least one conductor, locating at least a portion of each of the plurality of cables within a mould tool, heating the portions of each of the plurality of cables such that the coating of each cable consolidates to form a common harness with a solid cross section, wherein the cable inners are arranged within the common harness.

The present invention provides a technology that is capable of constraining a reduction that occurs in the vicinity of a branch portion in the degree of freedom of electrical wires that extend from the branch portion. A wire harness includes a wire harness main body in which a plurality of electrical wires are wired while forming a branch portion; and a sheet member that is mounted on an exterior of the wire harness main body. The sheet member includes a sheet main body that is kept in an overlapping state where the sheet main body sandwiches a region that includes the branch portion and portions in crotches on the periphery of the branch portion, and the sheet member has an incision that reaches an outer edge from an interior of the sheet main body formed at portions of the sheet main body positioned at the portions in the crotches.

A wire harness assembly system is disclosed. The wire harness assembly system includes a grid tile designed to receive repositionable accessories to route wires along the grid tile. The grid tile includes a plurality of keyed holes extending from the top of the grid tile, through the grid tile, to the bottom of the grid tile. The grid tile also includes a locking surface on the bottom of the grid tile. The locking surface complements the plurality of keyed holes to receive the repositionable accessory and to maintain the repositionable accessory in a locked position.

Provided are methods for forming a rigid cable harness. An example method includes providing a curable sleeve comprising a curable compound, an adhesive, and a backing; wherein the curable adhesive tape has a longitudinal direction. The method further includes placing a plurality of cables on the sleeve in the longitudinal direction and wrapping the curable sleeve around the placed plurality of cables to form a cable harness, wherein the wrapping comprises wrapping the plurality of cables with the curable sleeve in the longitudinal direction. The method additionally includes positioning the cable harness into a desired shape and curing the curable compound of the cable harness to form the rigid cable harness, wherein the rigid cable harness has the desired shape.

A composite harness includes a composite cable that includes a plurality of first electric wires, a multicore wire formed by covering a plurality of second electric wires having a smaller diameter than the plurality of first electric wires with one urethane-based resin inner sheath to be in contact with the first electric wires, and a jacket covering an outer periphery of the plurality of first electric wires and the multicore wire, and a molded resin provided at an end portion of the composite cable so as to cover an outer surface of the inner sheath at an end portion of the multicore wire. The outer surface of the inner sheath is irregularity-formed at least at a portion in contact with the plurality of first electric wires and a portion covered with the molded resin.

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.

A method is disclosed for additively manufacturing a composite wiring harness. The method may include directing a plurality of conductors through a print head, directing at least one reinforcement through the print head, and coating at least one of the plurality of conductors and the at least one reinforcement with a matrix material. The method may also include discharging the at least one of the plurality of conductors and the at least one reinforcement with the matrix material from the print head, and exposing the matrix material during discharging to a cure energy to cause hardening of a sheath around the plurality of conductors.

A wiring harness assembly includes a plurality of separated conductors formed of an electrically conductive material, a substrate formed of a dielectric material encasing the plurality of separated conductors, a location feature integrally formed with the substrate and an opening defined in the substrate having a predetermined size and shape. A section of the plurality of separated conductors is exposed within the opening. The opening is precisely located relative to the location feature.

The invention relates to a wiring harness (1010), a motor vehicle component (1000), a mold (15) for manufacturing a wiring harness (1010), a mold system (10) and a method for manufacturing the wiring harness (1010), the wiring harness (1010) comprising at least one bunch (1020) of at least two cables (1025) and a sheath (1030), at least some sections of the bunch (1020) of cables being embedded in the sheath (1030).