Abstract: A wiring harness assembly includes a plurality of electrically conductive wires encased within a substrate formed of a dielectric material, a location feature integrally formed with the substrate, and an opening defined in the substrate located within a predetermined tolerance relative to the location feature. A section of the plurality of electrically conductive wires is exposed within the opening.

Abstract: A wiring harness assembly includes a first flexible planar wire cable. The first flexible planar wire cable has a first plurality of separated conductors formed in a first insulating layer. The first insulating layer includes a first flat exterior surface. The first flat exterior surface defines first apertures that expose at least a portion the first plurality of separated conductors. The first apertures are sized, shaped, and arranged such that arranging a second flat exterior surface of a second flexible planar wire cable in contact with the first flat exterior surface enables an electrical connection between the first plurality of separated conductors and a second plurality of separated conductors formed in a second insulating layer of the second flexible planar wire cable.

Abstract: A clip includes first and second portions that are joined to one another by a living hinge. A snap includes first and second coupling elements that are respectively provided on the first and second portions. The first and second coupling elements are decoupled from one another in a closed clip position and are coupled to one another in an open clip position. Each of the first and second portions define an elongated slot that extends through a width of the clip that has an open end and a closed end. The open ends face a same direction. Each of the first and second portions include a first and second spring respectively. The first and second springs face one another. The first and second springs are configured to clamp about a wiring in the closed clip position.

Abstract: An electrical cable assembly is presented herein. The electrical cable assembly includes a multiconductor flat cable including a first and second electrically conductive wire arranged in a coplanar fashion with each other and encased within a planar dielectric structure. A slot is defined in the planar dielectric structure intermediate the first and second wires, thereby forming first wing features in the dielectric structure extending from the first wire and second wing features extending from the second wire. Exposed portions of the first and second wires extend beyond the first and second wing features. A method of forming the electrical cable assembly, an apparatus for forming the electrical cable assembly, and an electrical terminal configured for use in the electrical cable assembly is also presented.

Abstract: 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.

Abstract: A process of manufacturing an electrical wiring assembly includes the steps of cutting an elongate strip from a sheet of metal and cutting a mesial slit in an end of the uninsulated segment, thereby forming a pair of distal projections flanking the mesial slit. The mesial slit and the pair of distal projections form a forked split blade terminal.

Abstract: A wiring-harness includes an electrical-connector and a staging-device. The staging-device has a cavity defining a flexible-member in compressive contact with the electrical-connector. The flexible-member is configured to removably retain the electrical-connector within the cavity. The cavity locates the electrical-connector in a predetermined-position within the staging-device, such that the electrical-connector is presented to an assembler in the predetermined-position. The staging-device is particularly useful in automated, i.e. robotic, installation of the wiring-harness.

Abstract: A method of manufacturing a twisted pair wire cable includes the step of arranging a first wire cable in a parallel orientation with a second wire cable. The first and second wire cables each have a conductive inner core and an insulative jacket surrounding the inner core. The method further includes the steps of applying a curable adhesive, such as a urethane acrylate oligomer based adhesive, to the jackets of the first and second wire cables, twisting the first and second wire cables one about the other, and curing the adhesive.

Abstract: 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.

Abstract: An apparatus includes an electronic controller having a memory device and an extruding device connected to the electronic controller. The extruding device has a dispensing head configured to dispense a dielectric material though an orifice in the dispensing head as commanded by the electronic controller. A wire feed device is connected to the electronic controller and the extruding device and is configured to feed a conductive wire through the orifice as commanded by the electronic controller. A cutting device is connected to the electronic controller and the extruding device. The cutting device severs the wire after it is fed through the orifice as commanded by the electronic controller. An electromechanical device is connected to the electronic controller and to the extruding device. The electromechanical device is configured to move the extruding device, the wire feed device, and the cutting device within a 3D space as commanded by the electronic controller.

Abstract: A wiring-harness includes an electrical-connector and a staging-device. The staging-device has a cavity defining a flexible-member in compressive contact with the electrical-connector. The flexible-member is configured to removably retain the electrical-connector within the cavity. The cavity locates the electrical-connector in a predetermined-position within the staging-device, such that the electrical-connector is presented to an assembler in the predetermined-position. The staging-device is particularly useful in automated, i.e. robotic, installation of the wiring-harness.

Abstract: A method of manufacturing a twisted pair wire cable includes the step of arranging a first wire cable in a parallel orientation with a second wire cable. The first and second wire cables each have a conductive inner core and an insulative jacket surrounding the inner core. The method further includes the steps of applying a curable adhesive, such as a urethane acrylate oligomer based adhesive, to the jackets of the first and second wire cables, twisting the first and second wire cables one about the other, and curing the adhesive.

Abstract: A wiring-harness includes an electrical-connector and a staging-device. The staging-device has a cavity defining a flexible-member in compressive contact with the electrical-connector. The flexible-member is configured to removably retain the electrical-connector within the cavity. The cavity locates the electrical-connector in a predetermined-position within the staging-device, such that the electrical-connector is presented to an assembler in the predetermined-position. The staging-device is particularly useful in automated, i.e. robotic, installation of the wiring-harness.

Abstract: 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.

Abstract: A wiring-harness retaining device is configured to retain a predetermined-point of a wiring-harness in a predetermined-position. The device includes a substrate and a retention-feature. The substrate defines a surface. The retention-feature is disposed on the surface. The retention-device is configured to retain the wiring-harness to the surface until a removal-force applied to the wiring-harness exceeds a predetermined-threshold. The predetermined-point of the wiring-harness is presented to an assembler in the predetermined-position.

Abstract: A wiring-harness includes a wire cable, a connector, and a dress cover. The connector is attached to a portion of the wire cable. The connector has a terminal-face and a wire-cable-face with a body between the terminal-face and the wire-cable-face. The dress cover is attached to a portion of the body. An extension of the dress-cover overlays the wire-cable-face. The extension is configured to guide the wire cable in a predetermined direction. The extension is further configured to be releasably retained by a robotic assembler. The dress cover is further configured to transmit an insertion-force from the robotic assembler to the connector when the terminal-face is inserted into a mating-connector.

Abstract: A cable-retaining-device is configured to use with a robotic actuator. The cable-retaining-device includes a generally cylindrically shaped body defining a longitudinal-axis. A mesial-portion of the body defines a passage configured to receive a cable extending longitudinally along an entire length of the body. A distal-portion of the body defines a slot extending radially about the longitudinal-axis. The cable-retaining-device also includes a cable-retaining-band disposed within the slot and radially encircling the cable-retaining-device.

Abstract: A cable-retaining-device is configured to use with a robotic actuator. The cable-retaining-device includes a generally cylindrically shaped body defining a longitudinal-axis. A mesial-portion of the body defines a passage configured to receive a cable extending longitudinally along an entire length of the body. A distal-portion of the body defines a slot extending radially about the longitudinal-axis. The cable-retaining-device also includes a cable-retaining-band disposed within the slot and radially encircling the cable-retaining-device.

Abstract: A wiring-harness includes an electrical-connector and a staging-device. The staging-device has a cavity defining a flexible-member in compressive contact with the electrical-connector. The flexible-member is configured to removably retain the electrical-connector within the cavity. The cavity locates the electrical-connector in a predetermined-position within the staging-device, such that the electrical-connector is presented to an assembler in the predetermined-position. The staging-device is particularly useful in automated, i.e. robotic, installation of the wiring-harness.

Abstract: A conductor harness assembly having a main trunk that branches into a first and second branch and a unitary sheath that is formed of a flexible material. A first, second, and third portion of the sheath is circumferentially wrapped about the main trunk, the first branch and the second branch respectively. The sheath may be formed of a woven cloth material, a thermoelastic material, or a combination of the two. The sheath may include attachment features such as barbed pins formed integrally with the sheath.