A wiring module production plant includes a rotatable support supported so as to be capable of rotating and having N stages (where N is an integer equal to or greater than two) on which an object (such as a base wiring module and a bracket) involved in production of the wiring module can be arranged, the stages being provided corresponding to each of N positions having N-fold rotational symmetry. N stations are provided so as to respectively correspond to each of the N positions having N-fold rotational symmetry centered around a rotation axis of the rotatable support. The N stations include a manual work station which allows manual work to be performed on the object, and a mechanical work station which allows mechanical work to be performed on the object.

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.

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 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 wire harness manufacturing method includes manufacturing a standard-size electric wire in which a terminal-equipped electric wire which is connected to a terminal is manufactured in lot units for each type, clamping the terminal-equipped electric wire to a pair of electric wire clips, dispensing a plurality of terminal-equipped electric wires respectively clamped by the electric wire clamps to electric wire holders, storing the plurality of the terminal-equipped electric wires temporarily in the electric wire holders, locking the both end portions of the terminal-equipped electric wire to an electric wire clip tool respectively and aggregating an electric wire group configuring a wire harness at the electric wire clip tool to form a harness set, and detaching the end portions of the terminal-equipped electric wire from the harness set and inserting the terminal connected and fixed into a terminal accommodating chamber of a connector housing.

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.

A method and an apparatus relate to 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.

The wiring harness production mounting, includes: at least one screen for displaying data aiding in the production of wiring harnesses, and at least one attachment surface associated with the at least one display screen, the at least one attachment surface being configured to receive at least one cable-routing element.