Systems and methods for designing and assembling form boards with attached wire routing devices for use in wire bundle assembly. The assembly method comprises: (a) establishing a coordinate system of a form board having a multiplicity of holes; (b) using a computer system to determine locations of form board devices of different types with reference to the coordinate system of the form board based on engineering data specifying a wire bundle configuration; and (c) fastening the form board devices of different types to respective holes of the form board having centers closest to respective locations determined in step (b). The form board devices may be inserted robotically or manually.

A routing element for a cable harness manufacturing system includes an assembly board having an attachment surface configured for receiving tooling components to support and locate a cable harness during manufacture. The routing element includes: an upper fixture support having an aperture for receiving a tooling component to support the cable harness during manufacture; and a lower suction holder including two suction cups for attaching the routing element to the assembly board. The lower suction holder and the upper fixture support are located axially about a central vertical axis of the routing element. The lower suction holder extends outwardly relative to the upper fixture support, such that the area covered by the lower suction holder is greater than that of the upper fixture support. Also provided is a cable harness manufacturing system and a kit including routing elements, spacer elements and support plates for a cable harness assembly board.

A table includes a frame, a rotatable component, and a rotation mechanism. The frame has a pair of rotation bearings. The rotatable component has a first rotation position and a second rotation position. The rotatable component includes a pair of pivot portions supported by the pair of rotation bearings. The rotatable component further includes a first work surface configured to support preparation of a first wiring harness in the first rotation position. The rotatable component further includes a second work surface configured to support preparation of a second wiring harness in the second rotation position. The rotation mechanism is coupled with the rotatable component and is configured to rotate the rotatable component between at least the first rotation position and the second rotation position.

Systems and methods for designing and assembling form boards with attached wire routing devices for use in wire bundle assembly. The assembly method comprises: (a) establishing a coordinate system of a form board having a multiplicity of holes; (b) using a computer system to determine locations of form board devices of different types with reference to the coordinate system of the form board based on engineering data specifying a wire bundle configuration; and (c) fastening the form board devices of different types to respective holes of the form board having centers closest to respective locations determined in step (b). The form board devices may be inserted robotically or manually.

A wire harness manufacturing system includes a display unit, a wire cutting machine that draws an electric wire from a wire feed reel and cuts the electric wire to a predetermined length, a control unit that directs the display unit to display a wire laying image and wire work identification information for identifying a work regarding each electric wire, the wire laying image including a plurality of wire images showing the plurality of electric wire in the laid state and the wire work identification information being displayed in the vicinity of the corresponding wire image, and a memory unit that stores the wire laying image and work instruction information so as to correspond to the wire work identification information, the work instruction information including cut length of the electric wire. The control unit sends the cut length information to the wire cutting machine.

Wire holders removably retaining at least one wire for assembling a wire harness and methods for assembling a wire harness are provided. In one example, the wire holder includes a base section having a base bottom for positioning on a wire harness layout sheet. The wire harness layout sheet includes a wire routing pattern for forming the wire harness. A clip section extends generally upwardly from the base section and at least partially surrounds a clip channel having a channel diameter. The base section has a base height defined from the base bottom to a lowest point of the clip channel. A ratio of the channel diameter to the base height is from about 6:1 to about 9:1.

Virtually-integrated wire harness design and automated production systems and methods that achieve completely integrated data management by automatically producing scripts to dynamically propagate production commands and data to various subsystems for handling assembling necessary circuits and wire harness layout boards to produce corresponding batches of wire harnesses while script-based methods control configuring, testing, and using wire harness layout boards, and assembling, testing, reworking, and delivering wire harnesses. Augmented reality is used to assist in the assembly of layout boards and wire harnesses.

Systems and methods for designing and assembling form boards with attached wire routing devices for use in wire bundle assembly. The assembly method comprises: (a) establishing a coordinate system of a form board having a multiplicity of holes; (b) using a computer system to determine locations of form board devices of different types with reference to the coordinate system of the form board based on engineering data specifying a wire bundle configuration; and (c) fastening the form board devices of different types to respective holes of the form board having centers closest to respective locations determined in step (b). The form board devices may be inserted robotically or manually.

Systems and methods for designing and assembling form boards with attached wire routing devices for use in wire bundle assembly. The assembly method comprises: (a) establishing a coordinate system of a form board having a multiplicity of holes; (b) using a computer system to determine locations of form board devices of different types with reference to the coordinate system of the form board based on engineering data specifying a wire bundle configuration; and (c) fastening the form board devices of different types to respective holes of the form board having centers closest to respective locations determined in step (b). The form board devices may be inserted robotically or manually.

Systems and methods for designing and assembling form boards with attached wire routing devices for use in wire bundle assembly. The assembly method comprises: (a) establishing a coordinate system of a form board having a multiplicity of holes; (b) using a computer system to determine locations of form board devices of different types with reference to the coordinate system of the form board based on engineering data specifying a wire bundle configuration; and (c) fastening the form board devices of different types to respective holes of the form board having centers closest to respective locations determined in step (b). The form board devices may be inserted robotically or manually.