A wire harness assembly work cell includes a wire harness assembly work table with a pneumatically powered or spring-fed universal applicator tool for mass terminating sets of wires into insulator wafers. The insulator wafers may be assembled in stacks to form cable-end connector headshells. Insulation displacement terminals (IDT) are designed to receive wide ranges of wire diameters so that larger varieties of wire sizes may be received into these connector assemblies while using fewer different sizes of terminals, thus reducing the number of items in a bill of material (BOM) and substantially reducing the volumes and overhead costs of testing and quality control documentation dedicated to each individual BOM item.

A method of producing a conductive path on a substrate including depositing on the substrate a layer of material having a thickness in the range of 0.1 to 5 microns, including metal particles having a diameter in the range of 10 to 100 nanometers, employing a patterning laser beam to selectably sinter regions of the layer of material, thereby causing the metal particles to together define a conductor at sintered regions and employing an ablating laser beam, below a threshold at which the sintered regions would be ablated, to ablate portions of the layer of material other than at the sintered regions.

The device and the method are used for the automatic assembly of an in particular twisted pair of wires, wherein the pair of wires has two wire elements each with a contact element arranged at one end of a wire end. The respective contact elements are brought into a predetermined rotary position by gripping the wire pair with a main gripper which has an axis of rotation about which it can rotate, and wherein the wire ends are each gripped by a gripping element. The respective contact element is brought into the predetermined rotary position by rotating the pair of wires by way of the main gripper.

A method of mounting a module to a land grid array is provided. The method includes installing a tool to a fixture. The tool includes at least one alignment member and at least one cavity partially defined by the at least one alignment member. The at least one cavity of the tool is aligned with one or more corresponding sockets of the land grid array. The method further includes installing a module through the cavity such that the module is substantially aligned with the socket as it is connected to the land grid array.

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.

A cable-laying device for producing wiring or cable harnesses of different types includes a laying plane for positioning lines of a wiring or cable harness, a plurality of transport units which can be moved relative to the laying plane in an at least partially automated manner, and a control device which is configured to control the transport units. A method for producing cable harnesses of different types by using a cable laying device is also provided.

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.

An apparatus and method for coupling ends of two insulated conductors includes coupling a core of a first insulated conductor to a core of a second insulated conductor. Exposed portions of the cores are located inside a box. Electrically insulating powder material is placed into the box and a force is applied to first and second plungers to compact the powder material. Additional electrically insulating powder material may placed into the box and a subsequent force applied to compact the powder material into compacted powder material that surrounds the exposed portions of the cores. The compacted powder material is formed into a substantially cylindrical shape. A sleeve is placed over the compacted powder material and coupled to the jackets of the insulated conductors.

A method of producing a conductive path on a substrate including depositing on the substrate a layer of material having a thickness in the range of 0.1 to 5 microns, including metal particles having a diameter in the range of 10 to 100 nanometers, employing a patterning laser beam to selectably sinter regions of the layer of material, thereby causing the metal particles to together define a conductor at sintered regions and employing an ablating laser beam, below a threshold at which the sintered regions would be ablated, to ablate portions of the layer of material other than at the sintered regions.

A module installation assembly for installing a module into a socket of a land grid array includes a tool having a mounting bracket for connecting the tool to an adjacent fixture, an alignment member connected to the mounting bracket, and cavity defined at least partially by the alignment member. The cavity is substantially aligned with a socket of the land grid array such that the module is configured to pass through the cavity when being connected to the socket.