A method of manufacturing a wiring harness assembly includes the steps of forming a plurality of electrically conductive wires encased within a substrate formed of a dielectric material, forming an opening in the substrate located and sized such that a section of the plurality of electrically conductive wires is exposed within the opening, disposing a support segment within the opening, securing a connector segment including a plurality of terminals to the support segment, and placing the plurality of terminals in mechanical and electrical contact with the plurality of electrically conductive wires.

There is provided a wiring harness assembly comprising a main trunk cable assembly, a branch cable assembly and at least one connector. The main trunk assembly defines opposite terminal ends thereof and comprises main trunk wires. The branch cable assembly defines opposite terminal ends thereof and comprises branch wires. The at least one connector provides for connecting the main trunk cable assembly and the branch cable assembly. The connector comprises an outer housing and an inner wiring harness positioned within the housing. The wiring harness comprises main trunk wire segments and branch wire segments interconnected at mutual connecting points thereof. The main trunk wire segments define terminal ends thereof for being connected to the main trunk wires at one of the terminal ends of the main trunk cable assembly. The branch wire segments define terminal ends thereof for being connected to the branch wires at one of the terminal ends of the branch cable assembly. A method of making the wiring harness assembly is also provided.

Examples disclosed herein generally relate to methods and apparatus for the insertion of one or more wires into a cavity of a fixture of a structure or component. The wire insertion apparatus includes a grommet, a gripper adapted to interface with the grommet, and at least a first vibrating element. The first vibrating element is connected to and vibrates one or more of the apparatus, the grommet, the gripper, the wire, and/or a component of the apparatus. Vibration, induced in any direction, enables the cavities to shift position during insertion relative to the contact, thus increasing the tolerance of the cavity, reducing the failure rate of wire insertion, and reducing total production time. The vibration breaks the static friction of the contact in the grommet or dielectric opening, creates the positive locating required to insert the contact in the grommet and/or dielectric, and/or pivots the contact.

A wire harness-producing device configured to produce a wire harness by displaying a wire laying-out image in a full size in a length direction on a plurality of display devices, and laying out electric wires along the wire laying-out image. The wire harness-producing device includes an electric wire-feeding device to allow the electric wires to be manually pulled out, a storage section to store operation recipe information therein, and a displaying control section to perform a displaying control on the display devices. The operation recipe information includes lengths of the electric wires. When each of the electric wires to be laid out is pulled out, the displaying control section displays, on the display devices, a starting end location indicator indicating a location for a front end portion of each of the electric wires having been pulled out, based on the lengths of the electric wires in the operation recipe information.

An object of the present invention is to provide a technique with which at least part of an assembling process of a wire harness can be automated with a simple device. A method for manufacturing a wire is a method for manufacturing a wire harness by bundling a wiring body of the wire harness, the wiring body being in a state before a branch is formed. The method includes a process of moving the terminal portion in a predetermined draw-out direction by a holding portion moving portion of the size-measurement mechanism in a state where one of terminal portions is held by a terminal holding portion of a size measurement mechanism, and measuring a length from the one terminal portion to the position of one branch point.

A system for the automated production of a cable set, which has a branched structure of a plurality of individual line elements. In a modular set-up in the first part, a plurality of first processing stations, and in the second part, a plurality of second processing stations are arranged. In the first part, there is an automatic preparation of the individual line elements, which are then collected in a buffer station at the end of the first part. In the second part, the prepared individual line elements are assembled into the cable set. The line elements are plugged into connector casings in a connector station and transferred to second transporters, and via which the branched structure of the cable set is then formed by moving along second tracks. In this spread-out branched structure, a fixing of the line elements to one another takes place in a fixing station.

A wiring harness assembly includes a plurality of electrical conductors having wires enclosed within insulative sheaths that are integrally formed of an electrically insulative material. The assembly also includes a lattice support structure that is attached to the insulative sheaths at multiple locations. The lattice support structure is configured to maintain a desired shape of the assembly. The lattice support structure is formed of filaments that may be formed using an additive manufacturing process The filaments may be arranged such that lattice support structure defines a plurality of hexagonally shaped apertures. A process for manufacturing the wiring harness assembly and an apparatus configured to manufacture the wiring harness assembly is also presented.

A method for assembling and installing a wire bundle assembly group (WBAG) is disclosed. The method includes placing a first grouping of components of a first WBAG on a first assembly panel of a fabrication table. The method also includes assembling the first WBAG from the first grouping of components and attaching the first WBAG to the first assembly panel. The method also includes actuating a pivot of an assembly frame supporting the first assembly panel to rotate the first assembly panel about a longitudinal axis. The method further includes placing a WBAG receiving panel of a transport tool adjacent the first WBAG and the first assembly panel. The method also includes releasing the first WBAG from the first assembly panel and dropping the WBAG onto the WBAG receiving panel. Finally, the method includes attaching the first WBAG to the WBAG receiving panel.

In a method for creating at least one low-voltage path of a cell contacting system, where the cell contacting system contains a main body, a guide head having a discharge opening for discharging an electrical conductor is provided. The guide head is guided by a machine in a predefinable path relative to the main body, and the conductor is discharged from the guide head and laid on the main body to form the low-voltage path.

A method of twisting a pair of wires includes the steps of arranging a first wire parallel to a second wire along a longitudinal axis, securing ends of the first and second wires, and gripping outer surfaces of central portions of the first and second wires. The inner surfaces of the central portions of the first and second wires are in contact with one another. The method further includes deflecting central portions of the first and second wires orthogonally from the longitudinal axis and rotating the central portions of the central portions of the first and second wires, thereby twisting the first and second wires about one another.