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. As derived from CAD-created specifications, the production system uses a programmable, automated wire C&C center prepares individual wire circuits. While automatic wire indexing, sorting, and delivery systems transfer circuits into, and retrieve circuits from, a transportable programmable, automated, indexed storage system equipped with an array of individual circuit tubes, and a script-controlled assembly system sends visual, aural, and other cues to help an assembler populate and configure a wire harness layout board with connector blocks and turn posts, and guides the assembler in building, testing, reworking, and delivering the corresponding batch of wire harnesses.

A conductive wire piece set forming method includes: a bending step of bending a conductive wire piece set in a second bent portion; a restraining step of restraining the second bent portion of the conductive wire piece set and a portion adjacent thereto with a clamp portion; and a twisting step of twisting the conductive wire piece set by rotating the clamp portion. The restraint of the conductive wire piece set is performed in such a way that the conductive wire pieces form a predetermined angle with each other.

A coil winding system that comprises a rotational movement element of the needles and a head (4) mounted thereon, the rotational movement element of the needles comprising a movement shaft (2a), arranged so as to move the head (4) linearly and rotationally. The rotational movement element of the needles further comprises an electro-magnetic element of rotational movement of the head (4) integrated to the movement shaft (2a).

An apparatus for applying an elastic tubular sleeve onto a splicing region between at least one pair of cables, wherein the tubular sleeve is supported in a radially expanded condition on at least one supporting element, may include axial-movement devices configured to axially move the at least one supporting element relative to the tubular sleeve at an adjustable speed, so as to cause a radial elastic shrinkage of the tubular sleeve capable of inducing an axial ejection thrust on the at least one supporting element, and counter devices configured to counteract the axial ejection thrust induced by the elastic shrinkage of the tubular sleeve.