Abstract: An electrical connector includes wiring with multiple wires. Each wire has a conductor covered in insulation. Each wire has a stripped portion that exposes the conductors. The stripped portions are stacked on top of one another. A housing has first and second housing portions. The first housing portion receives the stripped portions. The second housing portion includes a spring that is configured to urge the stripped portions into engagement with one another when the first and second housing portions are secured to another in an assembled connector condition. In one example, an external electrical terminal is mounted to the first housing portion and is electrically connected to the stripped portions.

Abstract: Electrified vehicle electrical systems and formatting methods include arranging a first layer including one or more first electrical transmission lines each configured to carry electrical power at a first voltage to one or more electrical powertrain components of the electrified vehicle, arranging a second layer above at least a portion of the first electrical connection layer, wherein the second layer includes one or more second electrical transmission lines each configured to carry electrical power at a second voltage to one or more electrical power distribution components of the electrified vehicle, and arranging a third layer above at least a portion of the first and second layers, wherein the third layer includes one or more third electrical transmission lines each configured to carry electrical power at a third voltage to one or more input/output device components of the electrified vehicle.

Abstract: An electrical connector includes wiring with multiple wires. Each wire has a conductor covered in insulation. The insulation includes webbing that interconnects the wires to one another. The insulation has an aperture that provides a first locating feature. The wires have a stripped portion that exposes the conductors. A housing receives the stripped portion. The housing includes a projection that provides a second locating feature that cooperates the first locating feature to orient and locate the stripped portion within the housing.

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 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 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: 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 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 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 high voltage and interlock loop assembly has first and second high voltage connector housings complementarily constructed for releasable engagement with each other and for having a high voltage circuit running therethrough. First and second connectors for an interlock loop circuit are complementarily constructed for releasable engagement with each other with one of the interlock loop connectors being mounted on one of the high voltage connector housings. The first and second interlock loop connectors have complementarily abutment shoulders with one abutment shoulder being on a flexible tab. The flexible tab is movable to misalign its abutment shoulder from the other abutment shoulder when the high voltage connector housings are properly engaged together to allow full engagement of the first and second interlock loop connectors.