Abstract: An apparatus for cutting a previously flared shield conductor of a shielded electrical cable includes a two-piece clamping die having an aperture in which the shielded electrical cable is secured and a cutting surface. The clamping die is opened and closed around the shielded electrical cable. The apparatus further includes a cutting tube configured to be pressed against the cutting surface while the flared shield conductor is between the cutting tube and the cutting surface, thereby cutting a portion of a free end of the flared shield conductor. Alternatively, the apparatus may include a die comprising a cutting surface and an aperture in which the end of the shielded electrical cable is received. The cutting tube has two parts that are closed about the shielded electrical cable and pressed against the cutting surface while the flared shield conductor is disposed between the cutting tube and the cutting surface.

Abstract: A high-voltage electrical cable assembly includes a central wire strand containing at least seven wires formed of a first alloy and a plurality of outer wire strands twisted around the central strand. At least one outer wire strand of the plurality of outer wire strands contains at least seven wires formed of a second alloy different from the first alloy. There is an electrochemical potential of about 2 volts between the first alloy and the second alloy. A method of assembling a high-voltage electrical cable assembly is also presented herein.

Abstract: An apparatus for cutting a previously flared shield conductor of a shielded electrical cable includes a two-piece clamping die having an aperture in which the shielded electrical cable is secured and a cutting surface. The clamping die is opened and closed around the shielded electrical cable. The apparatus further includes a cutting tube configured to be pressed against the cutting surface while the flared shield conductor is between the cutting tube and the cutting surface, thereby cutting a portion of a free end of the flared shield conductor. Alternatively, the apparatus may include a die comprising a cutting surface and an aperture in which the end of the shielded electrical cable is received. The cutting tube has two parts that are closed about the shielded electrical cable and pressed against the cutting surface while the flared shield conductor is disposed between the cutting tube and the cutting surface.

Abstract: A splice connector assembly configured to conduct more than 1 kilowatt of electricity includes a terminal having a connection portion configured to interconnect with a corresponding mating terminal. The terminal also has an attachment portion. The attachment portion has a planar shape. The attachment portion is attached to a first wire electrical cable and is also attached to a second wire electrical cable. The first cable has a different cross-sectional area than the second cable. The splice connector assembly also includes a dielectric housing defining a cavity in which the terminal is disposed.

Abstract: A splice connector assembly configured to conduct more than 1 kilowatt of electricity includes a terminal having a connection portion configured to interconnect with a corresponding mating terminal. The terminal also has an attachment portion. The attachment portion has a planar shape. The attachment portion is attached to a first wire electrical cable and is also attached to a second wire electrical cable. The first cable has a different cross-sectional area than the second cable. The splice connector assembly also includes a dielectric housing defining a cavity in which the terminal is disposed.

Abstract: An automated wire harness machine is capable of manufacturing a wire harness in an automated process. The wire harness is generally a plurality of bundled, preferably un-stripped, insulated wires. Each un-stripped end portion of each wire is preferably terminated by an electrical terminal in one of a series of electrical connectors of the wire harness. Each connector has at least one wafer which houses a plurality of terminals. The wire harness machine utilizes a pallet that holds all of the wafers of one wire harness. A conveyor transports the pallet and wafers through a series of stations which perform automated manufacturing steps. The first station is a terminal inserter which inserts and locks the terminals within pre-assigned cavities of the wafers. The next station is an automated wire loader which measures, cuts and crimps the two ends of each wire into the respective terminals of the loaded wafer assembly.

Abstract: An automated wire harness machine is capable of manufacturing a wire harness in an automated process. The wire harness is generally a plurality of bundled, preferably un-stripped, insulated wires. Each un-stripped end portion of each wire is preferably terminated by an electrical terminal in one of a series of electrical connectors of the wire harness. Each connector has at least one wafer which houses a plurality of terminals. The wire harness machine utilizes a pallet that holds all of the wafers of one wire harness. A conveyor transports the pallet and wafers through a series of stations which perform automated manufacturing steps. The first station is a terminal inserter which inserts and locks the terminals within pre-assigned cavities of the wafers. The next station is an automated wire loader which measures, cuts and crimps the two ends of each wire into the respective terminals of the loaded wafer assembly.