Abstract: A wiring assembly fixture and system, and a method for assembling wiring assemblies, are disclosed. A wiring assembly fixture includes at least two fixture blocks that are operable to retain wire adjacent a connector or a wire termination position to define lengths of wire extending between the fixture blocks. At least one of the fixture blocks is further operable to receive a wire cutting tool to cut the lengths of wire to form wire leads adjacent one of the connectors or wire termination positions. A method for assembling a wiring assembly may include positioning first and second wiring assembly connectors and weaving wire about the first and second wiring assembly connectors to define lengths of wire extending therebetween. The method may further include cutting the lengths of wire adjacent at least one of the wiring assembly connectors to form wire leads adjacent the wiring assembly connector.

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.

Abstract: The present invention is an automated wire harness machine (40) capable of manufacturing a wire harness (42) unique in-part due to the automation process. The novel wire harness is generally a plurality of bundled, preferably un-stripped, insulated wires (46). Each un-stripped end portion (180, 182) of each wire is preferably terminated to one of a series of electrical connectors (44) of the wire harness. Each connector has at least one wafer (52) which houses a plurality of terminals (54) preferably crimped and electrically terminated to the ends of the wires. The wire harness machine preferably utilizes a pallet (56) which holds all of the wafers of one wire harness. A conveyor (58) transports the pallet and wafers through a series of stations which perform automated manufacturing steps. The first station is a terminal inserter (64) which inserts and locks the terminals within pre-assigned cavities (114) of the wafers.

Abstract: A methodology for applying ultrasonic welding processes to insulation jacketed wires without firstly stripping them. A preferred acronym therefor is “UWTI” (Ultrasonic Welding Through Insulation). A wire with its insulation jacket thereon and intact is placed upon a top surface of a base of a terminal to which it is to be bonded and the staking wings of the terminal are staked down onto the wire. The operator places the insulation jacketed wire and terminal combination into a conventional ultrasonic welder, such that the a bottom surface of the base rests upon the anvil and the insulation jacketed wire is aligned with the tip. The operator then causes the sonic welder to automatically sequence so as to provide an ultrasonic weld of the wire to the terminal.

Abstract: A methodology for applying ultrasonic welding processes to insulation jacketed wires without firstly stripping them. A preferred acronym therefor is “UWTI” (Ultrasonic Welding Through Insulation). A wire with its insulation jacket thereon and intact is placed upon a top surface of a base of a terminal to which it is to be bonded and the staking wings of the terminal are staked down onto the wire. The operator places the insulation jacketed wire and terminal combination into a conventional ultrasonic welder, such that the a bottom surface of the base rests upon the anvil and the insulation jacketed wire is aligned with the tip. The operator then causes the sonic welder to automatically sequence so as to provide an ultrasonic weld of the wire to the terminal.

Abstract: The present invention is an automated wire harness machine capable of manufacturing a wire harness unique in-part due to the automation process. The novel wire harness is generally a plurality of bundled, preferably un-stripped, insulated wires 46. Each un-stripped end portion of each wire is preferably terminated to one of a series of electrical connectors of the wire harness. Each connector has at least one wafer which houses a plurality of terminals preferably crimped and electrically terminated to the ends of the wires. The wire harness machine preferably utilizes a pallet which 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.

Abstract: An electrical connector forms a permanent electrical connection between a flat cable having multiple conductors and a plurality of round wires. The connector comprises a first connector half and a second connector half. The first connector half has a flat cable channel and at least one flat cable access window in communication with the flat cable channel. The second connector half has a plurality of wire channels for receiving round wires, and at least one wire access window in communication with one of the wire channels. Each cable access window is aligned with at least one wire access window to facilitate a permanent connection between a conducting strip of the multiple conductor flat cable and a conducting core of the round wire.