NL2013215B1

NL2013215B1 - Wire harness.

Info

Publication number: NL2013215B1
Application number: NL2013215A
Authority: NL
Inventors: Wilhelmus Jansen Hendrikus
Original assignee: H W J Holding B V
Priority date: 2014-07-18
Filing date: 2014-07-18
Publication date: 2016-07-14
Also published as: WO2016010427A1; EP3195330B1; EP3195330A1; DK3195330T3; EP3195330B8

Abstract

A wire harness comprising a plurality of wires and a longitudinal axis, which wire harness comprises a elongate structure extending along the longitudinal axis from a harness starting location on the longitudinal axis to a harness ending location on the longitudinal axis, wherein each of the wires comprises a starting end, an ending end, a length, a base starting location on the wire, a base ending location on the wire, and a base wire part extending along the longitudinal axis from the base starting location located at a respective longitudinal starting location on the longitudinal axis to the base ending location located at a respective longitudinal ending location on the longitudinal axis, for each of the wires only the base wire part extends along the longitudinal axis, and the rest of the wire is located at a distance from the longitudinal axis to form one or two branching wire parts, the base wire parts of the wires are interconnected to each other, for each of the wires the base starting location is located nearer to the harness starting location than the base ending location when seen in a direction along the longitudinal axis.

Description

Title: Wire harness FIELD OF THE INVENTION

The invention relates to a method of producing a wire harness. Wire harnesses are used in many different applications and for different types of devices.

BACKGROUND OF THE INVENTION

The invention is based on the insight that the production process which is used for the known wire harnesses tend to be complex, especially when these methods are (partly) automated.

SUMMARY OF THE INVENTION

The invention has the objective to provide an improved or alternative method of producing a wire harness.

This objective is reached by the method of producing a wire harness comprising a plurality of wires and having a longitudinal axis, which wire harness comprises a elongate structure extending along the longitudinal axis from a harness starting location on the longitudinal axis to a harness ending location on the longitudinal axis, wherein; - each of the wires comprises a starting end, an ending end, a length, a base starting location on the wire, a base ending location on the wire, and a base wire part extending along the longitudinal axis from the base starting location located at a respective longitudinal starting location on the longitudinal axis to the base ending location located at a respective longitudinal ending location on the longitudinal axis, - for each of the wires only the base wire part extends along the longitudinal axis, and the rest of the wire is located at a distance from the longitudinal axis to form one or two branching wire parts, - the base wire parts of the wires are interconnected to each other, - for each of the wires the base starting location is located nearer to the harness starting location than the base ending location when seen in a direction along the longitudinal axis, which method comprises the steps of; A. defining the harness starting location and the harness ending location on the longitudinal axis and for each of the wires defining the longitudinal starting location and the longitudinal ending location on the longitudinal axis, B. for each of the wires defining the length and defining the base starting location and the base ending location on the wire, C. providing the wires, D. forming a part of the elongate structure that defines the harness starting location, and if for one or more of the wires the longitudinal starting location is located at the harness starting location, then the base starting location of said one or more wires is placed at the harness starting location and connected to the elongate structure, E. moving from the harness starting location and along the longitudinal axis towards the harness ending location while forming the rest of the elongate structure and when; -- the longitudinal starting location of one of the wires is reached, then the base starting location of said wire is placed at said longitudinal starting location and connected to the elongate structure, and -- the longitudinal ending location of one of the wires is reached, then the base ending location of said wire is placed at said longitudinal ending location and connected to the elongate structure.

This method allows that the wire harness is produced in a relative simple and efficient manner. In addition to this, the method allows that the production process of the wire harness can be (partly) automated.

In an embodiment of the method, in step D the part of the elongate structure located at the harness starting location is formed at a connecting location and in step E the rest of the elongate structure is also formed at the connecting location while the part of the elongate structure located at the harness starting location is moved away from the connecting location.

In an embodiment of the method ; - the elongate structure is formed by base wire parts of the wires which are interconnected to each other such that said interconnected base wire parts extend along the longitudinal axis from the harness starting location to the harness ending location, - the base starting location of one or more of the wires is in step D placed at the harness starting location to form the elongate structure, and - the in step E placed base starting locations are connected to the base wire part of at least one of the wires and the in step E placed base ending locations are connected to the base wire part of at least one of the wires.

In an embodiment of the method, if the base starting location of more than one of the wires is in step D placed at the harness starting location to form the elongate structure, then said base starting locations are connected to each other.

In an embodiment of the method ; - the elongate structure is formed by a reference cable extending along the longitudinal axis from the harness starting location to the harness ending location, - in step D the reference cable is provided, - if the base starting location of one or more wires is in step D placed at the harness starting location, then said one or more base starting locations are connected to the reference cable, and - the in step E placed base starting locations and placed base ending locations are connected to the reference cable.

In an embodiment of the method ; - in step D the reference cable is placed at the connecting location to form the harness starting location, - if the base starting location of one or more wires is in step D placed at the harness starting location, then said one or more base starting locations are connected to the reference cable at the connecting location, and - in step E the rest of the reference cable is moved through the connecting location, and the in step E placed base starting locations and placed base ending locations are connected to the reference cable at the connecting location.

In an embodiment of the method, step C comprises producing the wires at their length and storing each wire such that its base starting location is positioned in a respective engagable position allowing said base starting location to be engaged.

In an embodiment of the method, the method comprises storing the wires at a distance from each other in the horizontal direction and positioning each stored wire at a first vertical position, a second vertical position or a third vertical position, which first vertical position, second vertical position and third vertical position are located at a distance from each other in the vertical direction.

In an embodiment of the method, the method comprises storing the wires at a distance from each other in the vertical direction and positioning each stored wire at a first horizontal position, a second horizontal position or a third horizontal position, which first horizontal position, second horizontal position and third horizontal position are located at a distance from each other in the horizontal direction.

In an embodiment of the method, each wire is spooled on at least one storing reel, and the at least one storing reel only carries said wire.

In an embodiment of the method, each wire which has its base starting location located between its starting end and its ending end, is spooled on a pair of storing reels with the base starting location of said wire located between the pair of storing reels.

In an embodiment of the method, step C is completed before step D is started.

In an embodiment of the method, the formed elongate structure and the thereto connected wires are spooled on a harness reel.

The invention further relates to a wire harness comprising a plurality of wires and a longitudinal axis, which wire harness comprises a elongate structure extending along the longitudinal axis from a harness starting location on the longitudinal axis to a harness ending location on the longitudinal axis, wherein; - each of the wires comprises a starting end, an ending end, a length, a base starting location on the wire, a base ending location on the wire, and a base wire part extending along the longitudinal axis from the base starting location located at a respective longitudinal starting location on the longitudinal axis to the base ending location located at a respective longitudinal ending location on the longitudinal axis, - for each of the wires only the base wire part extends along the longitudinal axis, and the rest of the wire is located at a distance from the longitudinal axis to form one or two branching wire parts, - the base wire parts of the wires are interconnected to each other, - for each of the wires the base starting location is located nearer to the harness starting location than the base ending location when seen in a direction along the longitudinal axis.

The construction of the wire harness allow that it can be produced in a relative simple manner.

In an embodiment of the wire harness, the elongate structure is formed by base wire parts of the wires which are interconnected to each other such that said interconnected base wire parts extend along the longitudinal axis from the harness starting location to the harness ending location.

In an embodiment of the wire harness, the elongate structure is formed by a reference cable extending along the longitudinal axis from the harness starting location to the harness ending location.

In an embodiment of the wire harness, the base wire parts are interconnected via the reference cable

The invention further relates to a system for producing the wire, said system comprising; - a wire supply to supply wire material, - a length measuring unit to measure the length of the supplied wire material, - a cutting unit to cut the supplied wire material to form the wires of the wire harness, - a storing device configured to store the cut wires with their base starting locations in a respective engagable position, and - a connecting device defining a connecting location, which connecting device is configured to form the wire harness by connecting the wires to the elongate structure at the connection location and to move the formed wire harness away from the connecting location.

In an embodiment of the system, the storing device is configured to store the wires at a distance from each other in the horizontal direction and to position each stored wire at a first vertical position, a second vertical position and a third vertical position, which first vertical position, second vertical position and third vertical position are located at a distance from each other in the vertical direction.

In an embodiment of the system, the storing device is configured to store the wires at a distance from each other in the vertical direction and to position each stored wire at a first horizontal position, a second horizontal position and a third horizontal position, which first horizontal position, second horizontal position and third horizontal position are located at a distance from each other in the horizontal direction.

In an embodiment of the system, the storing device comprises multiple storing reels and is configured to spool each wire on at least one storing reel, and the at least one storing reel only carries said wire.

In an embodiment of the system, the storing device comprise multiple pairs of storing reels and is configured to spool each wire which has its base starting location located between its starting end and its ending end on one of the pair of storing reels such that the base starting location of said wire is located between the pair of storing reels.

In an embodiment of the system, the system comprises a labelling unit configured to label the cut wires at their base starting location and base ending location.

In an embodiment of the system; - the system comprises a control unit with a memory and input means to store in the memory; - the harness starting location and the harness ending location on the longitudinal axis and for each of the wires the longitudinal starting location and the longitudinal ending location on the longitudinal axis, and - for each of the wires stored in the storing device where the base starting location is located, - the connecting device is configured to determine the movement of the formed elongate structure away from the connecting location, - the control unit is in communication with the connecting device, - the system comprises a transfer device which is in communication with the control unit, comprises a gripper to engage the base starting locations of the wires stored in the storing device, and is configured to transfer the gripped base starting location to the connecting location, - the control unit is configured to control the transfer device such that when the longitudinal starting location of one of the wires is located at the connecting location, the base starting location of said wire is placed at the connecting location by the transfer device.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the method, the wire harness and the system according to the invention will be described by way of example only, with reference to the accompanying schematic drawings in which corresponding reference symbols indicate corresponding parts, and in which:

Figure 1A schematically shows a view of a first embodiment of the wire harness according to the invention,

Figure 1B schematically shows a view of the longitudinal axis of the wire harness of fig. 1A,

Figure 1C schematically shows a view of an alternative embodiment of the wire harness of fig. 1A,

Figure 1D schematically shows a view of a further alternative embodiment of the wire harness of fig. 1A,

Figure 2 schematically shows a top view of a first embodiment of the system according to the invention,

Figures 3A schematically shows a side view of the system of fig. 2,

Figures 3B schematically shows a further side view of the location unit of the system of fig. 2, the Figures 4-24 schematically show a first embodiment of the method according to the invention, the Figures 25 and 26 schematically show side views of a second embodiment of the method according to the invention,

Figures 27 schematically shows a top view of a second embodiment of the system according to the invention, and

Figures 28 schematically shows a side view of the system of fig. 27.

DETAILED DESCRIPTION OF THE DRAWINGS

Figure 1 shows a view of a first embodiment of the wire harness 1 according to the invention. The wire harness 1 comprises a longitudinal axis 3 and four wires 2 (a first wire 2A, a second wire 2B, a third wire 2C, and a fourth wire 2D). In another embodiment of the wire harness 1, a different number of wires 2 can be provided.

The wire harness 1 comprises an elongate structure 4 extending along the longitudinal axis 3 from a harness starting location 5 on the longitudinal axis 3 to a harness ending location 6 on the longitudinal axis 3. Each of the wires 2 comprises a starting end 7, an ending end 8, a length, a base starting location 10 on the wire 2, a base ending location 11 on the wire 2, and a base wire part 12 extending along the longitudinal axis 3 from the base starting location 10 located at a respective longitudinal starting location 13 on the longitudinal axis 3 to the base ending location 11 located at a respective longitudinal ending location 14 on the longitudinal axis 3. For each of the wires 2 only the base wire part 12 extends along the longitudinal axis 3, and the rest of the wire 2 is located at a distance from the longitudinal axis 3 to form one or two branching wire parts 15.

For each of the wires 2, the base starting location 10 is located nearer to the harness starting location 5 than the base ending location 11 when seen in a direction along the longitudinal axis 3. The elongate structure 4 is formed by a reference cable 17 extending along the longitudinal axis 3 from the harness starting location 5 to the harness ending location 6.

The base wire parts 12 of the wires 2 are interconnected to each other. This means that the base wire parts 12 can be directly or indirectly (such as via the reference cable 17) connected to each other. In the wire harness 1 of figure 1 A, the base wire parts 12 are directly interconnected to each other. This means that if the reference cable 17 would be removed, the base wire parts 12 would still be interconnected to each other. In the wire harness 1 of figure 1 A, the base ending location 11 of the first wire 2A and the base starting location 10 of the third wire 2C are located at the same location on the longitudinal axis 3 of the wire harness 1. If the base ending location 11 of the first wire 2A would be moved to the harness starting location 5 so that it would be located at a distance from the base starting location 10 of the third wire 2C, the base wire parts 12 of the first wire 2A and third wire 2C would be interconnected via the reference cable 17 (indirectly interconnected). This situation is shown in figure 1D.

The first wire 2A has its base starting location 10A located at the harness starting location 5. The base starting location 10A is connected to the reference cable 17 and to the second wire 2B. The base starting location 10A is located at a distance from the starting end 7 A of the first wire 2A. The part the first wire 2A extending between its starting end 7A and its base starting location 10A forms a branching wire part 15A. The part of the first wire 2A extending between its base starting location 10A and its base ending location 11A forms the base wire part 12A. The base ending location 11A is connected to the reference cable 17 and the third wire 2C. The base wire part 12A of the first wire 2A may be connected at several additional locations to the reference cable 17 in order to further attach the base wire part 12A to the reference cable 17. The base ending location 11A is located at a distance from the ending end 8A of the first wire 2A. The part of the first wire 2A extending between its base ending location 11A and its ending end 8A forms a further branching wire part 15A. This means that the first wire 2A has two branching wire parts 15A.

The second wire 2B has its base starting location 10B located at the harness starting location 5. The base starting location 10B is connected to the reference cable 17 and to the first wire 2A. The base starting location 10B is located at the starting end 7B of the second wire 2B. The part of the second wire 2B extending between its base starting location 10B and its base ending location 11B forms the base wire part 12B. The base ending location 11B is connected to the reference cable 17 and the first wire 2A. The base wire part 12B of the second wire 2B may be connected at several additional locations to the reference cable 17 in order to further attach the base wire part 12B to the reference cable 17. The base ending location 11B is located at a distance from the ending end 8B of the second wire 2B. The part of the second wire 2B extending between its base ending location 11B and its ending end 8B forms a branching wire part 15B. This means that the second wire 2B has one branching wire part 15B.

The base starting location 10C of the third wire 2C is connected to the reference cable 17 and to the first wire 2A. The base starting location 10C is located at a distance from the starting end 7C of the third wire 2C. The part of the third wire 2C extending between its starting end 7C and its base starting location 10C forms a branching wire part 15C. The part the third wire 2C extending between its base starting location 10C and its base ending location 11C forms the base wire part 12C. The base ending location 11C is connected to the reference cable 17 and located at the harness ending location 6C. The base wire part 12C of the third wire 2C may be connected at several additional locations to the reference cable 17 in order to further attach the base wire part 12C to the reference cable 17. The base ending location 11C is located at a distance from the ending end 8C of the third wire 2C. The part of the third wire 2C extending between its base ending location 11C and its ending end 8C forms a further branching wire part 15C. This means that the third wire 2C has two branching wire parts 15C.

The base starting location 10D of the fourth wire 2D is connected to the reference cable 17 and to the third wire 2C. The base starting location 10D is located at a distance from the starting end 7D of the fourth wire 2D. The part of the fourth wire 2D extending between its starting end 7D and its base starting location 10D forms a branching wire part 15D. The part the fourth wire 2D extending between its base starting location 10D and its base ending location 11D forms the base wire part 12D. The base ending location 11D is connected to the reference cable 17 and the third wire 2C. The base wire part 12D of the third wire 2D may be connected at several additional locations to the reference cable 17 in order to further attach the base wire part 12D to the reference cable 17. The base ending location 11D is located at a distance from the ending end 8D of the fourth wire 2D. The part of the fourth wire 2D extending between its base ending location 11D and its ending end 8D forms a further branching wire part 15D. This means that the fourth wire 2D has two branching wire parts 15D.

Figure 1B shows a view of the longitudinal axis 3 of the wire harness 1 of fig. 1 A. The harness starting location 5 and the harness ending location 6 are defined on the longitudinal axis 3. For each of the wires 2, the longitudinal starting location 13 and the longitudinal ending location 14 are defined on the longitudinal axis 3.

Figure 1C shows an alternative embodiment of the wire harness 1 of figure 1A. The wire harness 1 only differs from figure 1 in that it does not have a reference cable 17. The elongate structure 4 is formed by the base wire parts 12 of the wires 2, which base wire parts 12 are interconnected to each other such that said interconnected base wire parts 12 extend along the longitudinal axis 3 from the harness starting location 5 to the harness ending location 6.

Figure 2 shows a top view of a first embodiment of the system 20 according to the invention, and figure 3A shows a side view of the system 20 of fig. 2.

The system 20 is configured to produce the wire harness 1 according to the invention. The system 20 comprises a wire supply 22 to supply wire material 34. The wire supply 22 is formed by a wire supply reel 33 provided with sufficient wire material 34 to form the wires 2 by cutting the wire material 34. Also a cable supply reel 35 is provided to supply cable material 36 to form the reference cable 17. It is also possible to use the wire material 34 from the wire supply reel 33 to form the reference cable 17. In said situation the cable supply reel 35 is not required. In another embodiment, the wire supply 22 comprises multiple wire supply reels 33, each having a different type of wire material 34. This way, a wire harness 1 with different types of wires 2 can be produced.

The system 20 comprises a length measuring unit 23 to measure the length of the supplied wire material 34 and a cutting unit 24 to cut the supplied wire material 34 to form the wires 2 of the wire harness 1. Also a labelling unit 27 configured to label the cut wires 2 at their base starting location 10 and base ending location 11 is provided. The length measuring unit 23 and the cutting unit 24 can also be used to cut the reference cable 17 from the cable material 36.

The system 20 comprises a storing device 25 configured to store the cut wires 2 with their base starting locations 10 in a respective engagable position 18 (see figure 10). The storing device 25 comprises multiple pairs of storing reels 19 and is configured to spool each wire 2 which has its base starting location 10 located between its starting end 7 and its ending end 8 on one of the pair of storing reels 19 such that the base starting location 10 of said wire 2 is located between the pair of storing reels 19. Each pair of storing reels 19 is formed by a wire reel unit 38. Each wire 2 is spooled on at least one storing reel 19, and the at least one storing reel 19 only carries said wire. This means that each wire reel unit 38 will only carry one wire 2.

The system 20 further comprises a connecting device 26 defining a connecting location 16, which connecting device 26 is configured to form the wire harness 1 by connecting the wires 2 to the elongate structure 4 at the connecting location 16 and to move the formed wire harness 1 away from the connecting location 16. The connecting device 26 comprises a location unit 37 defining the connecting location 16 and a harness reel 21 to spool the formed wire harness 1. The figure 3B shows a further side view (Ill-Ill) of the location unit 37.

The figures 4-24 show a first embodiment of the method according to the invention to produce the wire harness 1 of figure 1A with the system 20 of figure 2. The method comprises the steps of; A. defining the harness starting location 5 and the harness ending location 6 on the longitudinal axis 3 and for each of the wires 2 defining the longitudinal starting location 13 and the longitudinal ending location 14 on the longitudinal axis 3, B. for each of the wires 2 defining the length and defining the base starting location 10 and the base ending location 11 on the wire, C. providing the wires 2, D. forming a part of the elongate structure 4 that defines the harness starting location 5, and if for one or more of the wires 2 the longitudinal starting location 13 is located at the harness starting location 5, then the base starting location 10 of said one or more wires 2 is placed at the harness starting location 5 and connected to the elongate structure 4, E. moving from the harness starting location 5 and along the longitudinal axis 3 towards the harness ending location 6 while forming the rest of the elongate structure 4 and when; - the longitudinal starting location 13 of one of the wires 2 is reached, then the base starting location 10 of said wire is placed at said longitudinal starting location 13 and connected to the elongate structure 4, and - the longitudinal ending location 14 of one of the wires 2 is reached, then the base ending location 11 of said wire is placed at said longitudinal ending location 14 and connected to the elongate structure 4.

This method allows that the wire harness 1 is produced in a relative simple and efficient manner.

In the figures 4-24, the method steps are performed by a person while using the system 20 of figure 2. The method can also be (partly) automated. An example is discussed in relation with the figures 27 and 28.

The steps A and B are preparation steps performed by the person. The result of the step A is shown in figure 1B. This information will be used to construct the wire harness 1 in the steps D and E. On basis of the information of step B, the individual wires 2 can be provided in step C.

Figure 4A shows a top view of the system and figure 4B shows a side view of the system as indicated by IV-IV in figure 4A. In the figures 4A and B, the cable material 36 of the cable supply reel 35 is moved through the length measuring unit 23. The length measuring unit 23 measures the length of the provided cable material 36, so that it is cut by the cutting unit 24 at the predetermined length (equal to the distance between the harness starting location 5 and the harness ending location 6 along the longitudinal axis 3) to form the reference cable 17. The cut reference cable 17 is spooled on a reel of a cable reel unit 39. The cable reel unit 39 has the same construction as the four wire reel units 38. The cable reel unit 39 has a pair of storing reels 19 formed by an upper reel 40 and a lower reel 41. The reference cable 17 is spooled on the upper reel 40.

Step C is shown in the figures 5-10. In figure 5, the wire material 34 of the cable supply reel 35 is moved through the length measuring unit 23. The length measuring unit 23 measures the length of the provided wire material 34, so that it is cut by the cutting unit 24 at the predetermined length to form the first wire 2A. With the labelling unit 27 labels 48 are provided on the cut first wire 2A at its base starting location 10A and base ending location 11 A. The cut first wire 2A is spooled on the upper reel 40 of a wire reel unit 38 for the first wire 2A.

In figure 6, the wire material 34 of the cable supply reel 35 is moved through the length measuring unit 23. The length measuring unit 23 and the cutting unit 24 are used to provide the predetermined length of wire material 34 to form the second wire 2B. The labelling unit 27 is used to provide labels 48 on the cut second wire 2B at its base starting location 10B and base ending location 11B. The second wire 2B is spooled on the upper reel 40 of a wire reel unit 38 for the second wire.

In figure 7, the length measuring unit 23 and the cutting unit 24 are used to provide the predetermined length of wire material 34 in order to form the third wire 2C. The labelling unit 27 is used to provide labels 48 on the cut third wire 2C at its base starting location 10C and base ending location 11C. The third wire 2C is spooled on the upper reel 40 of a wire reel unit 38 for the third wire 2C.

In figure 8, the length measuring unit 23 and the cutting unit 24 are used to provide the predetermined length of wire material 34 to form the fourth wire 2D. The labelling unit 27 is used to provide labels 48 on the cut fourth wire 2D at its base starting location 10D and base ending location 11D. The third wire 2C is spooled on the upper reel 40 of a wire reel unit 38 for the fourth wire 2D.

Figure 9 shows the result of the previous steps. The four wires 2 are spooled on the upper reel 40 of their wire reel unit 38. Also the reference cable 17 is spooled on the upper reel 40 of the cable reel unit 39.

Subsequently, the base starting location 10 of each of the wires 2 is positioned between the upper reel 40 and the lower reel 41 of its wire reel unit 38. For each wire 2 which has its base starting location 10 located between its starting end 7 and its ending end 8, this means that the starting end 7 of the wire is spooled on the lower reel 41 until the base starting location 10 is located between the upper reel 40 and the lower reel 41. For each wire 2 which has its base starting location 10 located at its starting end 7, the starting end 7 (and thus also the base starting location 10) is lowered from the upper reel 40 such that it is located between the lower reel 41 and the upper reel 40 of its wire reel unit 38. This way, the base starting locations 10 of the wires 2 are located in a respective engagable position 18. This means that the base starting location 10 of each wire is located in such a position that it can easily be engaged by a person or a device. The reference cable 17 is placed with its first cable end 42 between its upper reel 40 and lower reel 41. The first cable end 42 is therefore also located in an engagable position 18. This situation is shown in figure 10 showing a side view as indicated by X-X in figure 9. The base starting locations 10 of the wires 2 are located at a distance from each other along a straight line extending through the base starting locations 10. This means that each base starting location 10 has an unique position on the straight line extending through the base starting locations 10.

Step D is shown in the figures 11-14. In figure 11A, the first cable end 42 of the reference cable 17 is placed at the connecting location 16 defined by the location unit 37. The first cable end 42 forms the part of the elongate structure 4 that defines the harness starting location 5. This situation is also shown in fig. 11B by the side viewXI-XI of figure 11 A. The connecting location 16 is the location where the wire harness 1 is formed, starting at the harness starting location 5 (figures 11-14) and subsequently moving along the longitudinal axis 3 to form the rest of the wire harness 1 until the harness ending location 6 is reached (figures 15-24). During the construction of the wire harness 1, the formed part of the harness cable is moved away from the connecting location 16 allowing that the rest of the wire harness 1 is formed at the connecting location 16. A pulling cable 46 attached to the harness reel 21 is at the connecting location 16 connected to the first cable end 42 of the reference cable 17. The pulling cable 46 and harness reel 21 are used to move the formed wire harness 1 away from the connecting location 16.

In the situation that the wire harness 1 does not have a reference cable 17, the base starting location 10 of at least one of the wires 2 will form the part of the elongate structure 4 that defines the harness starting location 5.

In figure 12A, the base starting location 10A of the first wire 2A is placed at the connecting location 16 and connected to the reference cable 17. This situation is also shown in fig. 12B by the side view XII-XII of figure 12A, wherein only the first wire 2A is shown.

In figure 13A, the base starting location 10B of the second wire 2B is placed at the connecting location 16 and connected to the reference cable 17. This situation is also shown in fig. 13B by the side view XIII-XIII of figure 12A, wherein only the second wire 2B is shown.

It is of course also possible that the base starting locations 10A, 10B of the first wire 2A and the second wire 2B are simultaneously placed at the connecting location 16 and attached to the reference cable 17. Other combinations are also possible, for example that the first cable end 42, the first wire 2A and the second wire 2B are simultaneously placed at the connecting location 16 and attached to each other.

Figure 14A shows the top view of part A of figure 13 and figure 14B shows the side view XIV-XIV of figure 14A. The first cable end 42 of the reference cable 17 and the base starting locations 10A, 10B of the first wire 2A and the second wire 2B are located at the connecting location 16 and connected to each other by a connector 47. This defines the harness starting location 5 of the wire harness 1.

Step E is shown in the figures 15-24. In figure 15, a further part of the elongate structure 4 is formed. The formed wire harness 1 is moved away from the connecting location 16 by the pulling cable 46 and the harness reel 21. A measuring unit 49 is provide on the harness reel 21 to measure the length of the trajectory along which the harness starting location 5 is moved. This way, it is possible to continuously determine which position along the longitudinal axis 3 of the wire harness 1 is located at the connecting location 16. The branching wire part 15A of the first wire 2A is rolled up and moves along with the formed part of the wire harness 1. The base ending location 11B of the second wire 2B is approaching the connecting location 16.

Figure 16 shows a top view of the section XVI indicated in figure 15 in the situation that the base ending location 11B of the second wire 2B is located at the connecting location 16. The label 48 indicating the base ending location 11B of second wire 2B is removed. The base ending location 11B of the second wire 2B is connected to the reference cable 17 and the first cable by a connector 47. On basis of the information of the measuring unit 49, it can be checked if at this moment the longitudinal ending location 14B of the second wire 2B is indeed located at the connecting location 16. If this is not the case, it indicates that the wire harness 1 is not formed according to the information of the method step A (see figure 1B). In figure 16 it is also shown that the base wire parts 12A, 12Bofthe first wire 2A and second wire 2B are connected at several locations to reference cable 17 by connectors 47. This is to ensure that the base wire parts 12A, 12B of the first wire 2A and the second wire 2B and the reference cable 17 do not get intertwined.

In figure 17, a further part of the wire harness 1 formed. The formed wire harness 1 is spooled on the harness reel 21. The branching wire part 15B of the second wire 2B is removed from its wire reel unit 38 and rolled up so that it can move along with the formed wire harness 1. The base ending location 11A of the first wire 2A is approaching the connecting location 16.

In figure 18, the base ending location 11A of the first wire 2A is located at the connecting location 16. From fig. 1B and the information of the measuring unit 49, it is known that now also the longitudinal starting location 13C of the third wire 2C is located at the connecting location 16. The base starting location 10C of the third wire 2C is therefore placed at the connecting location 16. The base ending location 11A of the first wire 2A, the base starting location 10C of the third wire 2C and the reference cable 17 are interconnected to each other at the connecting location 16.

In figure 19, a further part of the wire harness 1 formed. The branching wire parts 15A, 15C of first wire 2A and the third wire 2C are rolled up.

In figure 20, the wire harness 1 is further formed and the longitudinal starting location 13D of the fourth wire 2D is located at the connecting location 16. The base starting location 10D of the fourth wire 2D is therefore placed at the connecting location 16 and connected to the third wire 2C and the reference cable 17.

In figure 21, the wire harness 1 is further formed and the base ending location 11D of the fourth wire 2D is located at the connecting location 16 and connected to the third wire 2C and the reference cable 17. As mentioned before, on basis of figure 1B and the information of the measuring unit 49 it is possible to check if the longitudinal ending location 14D of the fourth wire 2D is at that moment indeed located at the connecting location 16.

The branching wire part 15D of the fourth wire 2D is rolled up.

In figure 22, the wire harness 1 is further formed. Also the further branching wire part 15D of the fourth wire 2D is rolled up. The base ending location 11C of the third wire 2C is approaching the connecting location 16.

In figure 23, the harness ending location 6 is located at the connecting location 16, the second cable end 43 of the reference cable 17 is located at the connecting location 16, and the base ending location 11C of the third wire 2C is located at the connecting location 16. The third wire 2C and the reference cable 17 are connected to each other at the connecting location 16.

In figure 24, the wire harness 1 is completed and being spooled on the harness reel 21. The further branching wire part 15C of the third wire 2C is removed from the wire reel unit 38 of the third wire 2C and rolled up.

To produce the wire harness 1 without the reference cable 17 (see figure 3C), the same steps as shown in the figures 11-24 need to be performed with the difference that instead of the first cable end 42 of the reference cable 17 (see figure 11) the base starting location 10A of the first wire 2A and/or the base starting location 10A of the second wire 2B (which both are located at the harness starting location 5) need to be connected to the pulling cable 46. The in step E placed base starting locations 10 are connected to the base wire part 12 of at least one of the wires 2 and the in step E placed base ending locations 11 are connected to the base wire part 12 of at least one of the wires 2. In the produced wire harness 1, the elongate structure 4 is formed by base wire parts 12 of the wires 2 which are interconnected to each other such that said interconnected base wires part 12 extend along the longitudinal axis 3 from the harness starting location 5 to the harness ending location 6.

As shown in the side views of the figures 25 and 26, the pair of storing reels 19 are located at a distance from each other in the horizontal direction 44 and each pair of storing reels 19 can be moved at a first vertical position 51, a second vertical position 52 and a third vertical position 52. The first vertical position 51, second vertical position 52 and third vertical position 52 are located at a distance from each other in the vertical direction 45. This allows that the direction in which the base wire parts 12 of the wires 2 are guided towards the connecting location 16 can be changed. This can facilitate the connecting of the base starting locations 10 and base ending locations 11 of the wires 2 to the elongate structure 4 at the connecting location 16. This can be used to prevent that the wires 2 get intertwined. This is especially advantageous in the situation that the wire harness 1 has a very large number of wires 2 and/or in the situation that a large number of branching wire parts extend away from the elongate structure 4 at the same longitudinal starting location 13 or the same longitudinal ending location 14. This furthermore facilitates that the branching wire parts 15 extending from the same longitudinal starting location 13 or the same longitudinal ending location 14 are connected to each other. In figure 26, the situation is shown which has a positive effect during the performing of the steps shown in the figures 11-24.

In another example of system 20, the pair of storing reels 19 are located at a distance from each other in the vertical direction 45 and each pair of storing reels 19 can be moved at a first horizontal position, a second horizontal position and a third horizontal position, which first horizontal position, second horizontal position and third horizontal position are located at a distance from each other in the horizontal direction 44.

The figure 27 and 28 show a second embodiment of the system 20 according to the invention. The system 20 differs from the system 20 shown in the figures 2 and 3 in that; - the system 20 comprises a control unit 28 with a memory 29 and input means 30 (such as a keyboard) to store in the memory 29; -- the harness starting location 5 and the harness ending location 6 on the longitudinal axis 3 and for each of the wires 2 the longitudinal starting location 13 and the longitudinal ending location 14 on the longitudinal axis 3, and - for each of the wires 2 stored in the storing device 25 where the base starting location 10 is located, - the control unit 28 is in communication with the connecting device 26, - the system 20 comprises a transfer device 31 which is in communication with the control unit 28, comprises a gripper 32 to engage the base starting locations 10 of the wires 2 stored in the storing device 25, and is configured to transfer the gripped base starting location 10 to the connecting location 16, - the control unit 28 is configured to control the transfer device 31 such that when the longitudinal starting location 13 of one of the wires 2 is located at the connecting location 16, the base starting location 10 of said wire is placed at the connecting location 16 by the transfer device 31.

The measuring unit 49 of the connecting device 26 is configured to determine the movement of the formed elongate structure 4 away from the connecting location 16. The control unit 28 is in communication with the measuring unit 49 and the transfer device 31 via communication lines 50. The transfer device 31 is formed by a robotic arm provided with the gripper 32. This way the steps shown in the figures 11-24 can be automatic.

The steps shown in the figures 4-10 can in a similar manner be automatic with a further control unit and a further transfer device, such as a further robotic arm.

As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting, but rather, to provide an understandable description of the invention.

The terms "a" or "an", as used herein, are defined as one or more than one. The term plurality, as used herein, is defined as two or more than two. The term another, as used herein, is defined as at least a second or more. The terms including and/or having, as used herein, are defined as comprising (i.e., open language, not excluding other elements or steps). Any reference signs in the claims should not be construed as limiting the scope of the claims or the invention.

It will be apparent to those skilled in the art that various modifications can be made to the method, the wire harness and the system without departing from the scope as defined in the claims.

Claims

A method for manufacturing a cable harness (1) comprising a plurality of wires (1) and having a longitudinal axis (3), which cable harness comprises an elongated structure (4) which extends along the longitudinal axis of a tree start location (5) at the longitudinal axis to a tree end location (6) on the longitudinal axis, wherein; - each of the wires comprises a start end (7), an end end (8), a length, a basic start location (10) on the wire, a basic end location (11) on the wire, and a basic wire part (12) extending along the longitudinal axis of the basic start location located in a respective longitudinal start location (13) on the longitudinal axis to the basic end location which is located in a respective longitudinal end location (14) on the longitudinal axis, - for each of the wires only the basic thread part extends along the longitudinal axis and the remainder of the wire is spaced apart from the longitudinal axis to form one or two branched wire portions (15), - the base wire portions of the wires are attached to each other, - for each of the wires, the base start location is closer to the tree start location then lies the base end location viewed in a direction along the longitudinal axis, which method comprises the steps of; A. determining the tree start location and tree end location on the longitudinal axis and for each of the wires determining the longitudinal start location and the longitudinal end location on the longitudinal axis, B. for each of the wires determining the length and determining the basic start location and the base end location on the wire, C. providing the wires, D. forming a part of the elongated structure that determines the tree start location, and if the longitudinal start location is in the tree start location at one or more of the wires, then the base start location of the one or more wires placed in the tree start location and attached to the elongated structure, E. moving from the tree start location and along the longitudinal axis to the tree end location while forming the rest of the elongated structure and when; - the longitudinal start location of one of the wires is reached, then the basic start location of that wire is placed in the longitudinal start location and attached to the elongated structure, and - the longitudinal end location of one of the wires is reached, then the basic end location of that wire placed in the longitudinal end location and attached to the elongated structure.

A method according to claim 1, wherein in step D the part of the elongated structure in the tree start location is formed in a mounting location and in step E the rest of the elongated construction is also formed in the mounting location while the part of the elongated construction in tree start location is moved away from the confirmation location.

The method of claim 1 or 2, wherein; - the elongated structure is formed by base wire portions of the wires connected to each other such that the interconnected base wire portions extend along the longitudinal axis from the tree start location to the tree end location, - the base start location of one or more of the wires in step D is placed in the tree start location to form the elongated structure, and the base start locations placed in step E are attached to the base wire portion of at least one of the wires and the base end locations placed in step E are attached to the base wire portion of at least one of the wires.

The method of claim 3, wherein if the base start location of more than one of the wires in step D is placed in the tree start location to form the elongated structure, then those base start locations are attached to each other.

The method of claim 1 or 2, wherein; - the elongated structure is formed by a reference cable that extends along the longitudinal axis from the tree start location to the tree end location, - the reference cable is provided in step D, - if the basic start location of one or more wires is placed in the tree start location in step D the one or more base start locations attached to the reference cable and - the base start locations and base end location placed in step E are attached to the reference cable.

The method of claim 5, wherein; - in step D the reference cable is placed in the acknowledgment location to form the tree start location, - if the base start location of one or more threads is placed in the tree start location in step D, then the one or more basic start locations in the confirmation location are attached to the reference cable, and - in step E, the remainder of the reference cable is moved by the mounting location, and the base start locations placed in step E and base end location placed in the mounting location are attached to the reference cable.

A method according to any one of the preceding claims, wherein step C comprises producing the wires at their length and storing each wire so that its base start location is in a respective engaging position that allows the base start location to be engaged.

The method of claim 7, wherein the method comprises storing the wires spaced apart in the horizontal direction and placing each stored wire in a first vertical position, a second vertical position or a third vertical position, which first vertical position, second vertical position and third vertical position are spaced apart in the vertical direction.

The method of claim 7, wherein the method comprises storing the wires spaced apart in the vertical direction and placing each stored wire in a first horizontal position, a second horizontal position or a third horizontal position, said first horizontal position, second horizontal position and third horizontal position spaced apart in the horizontal direction.

The method of any one of claims 7-9, wherein each wire is wound on at least one storage coil and the at least one storage coil carries only that wire.

The method of any one of claims 7-10, wherein each wire having its base start location between its start end and its end end is wound on a pair of storage reels with the base start location of that wire between said pair of storage reels.

A method according to any one of the preceding claims, wherein step C is completed before step D is started.

A method according to any one of the preceding claims, wherein the elongated structure formed and the wires connected thereto are wound on a tree reel.

A cable harness comprising a plurality of wires and having a longitudinal axis, said cable harness comprising an elongated structure extending along the longitudinal axis of a tree start location on the longitudinal axis to a boom end location on the longitudinal axis, wherein; - each of the wires comprises a lead end, an end end, a length, a basic start location on the wire, a basic end location on the wire, and a basic wire part which extends along the longitudinal axis of the basic starting location which is located in a respective longitudinal starting location on the longitudinal axis to the base end location which is in a respective longitudinal end location on the longitudinal axis, - for each of the threads only the base thread portion extends along the longitudinal axis, and the rest of the thread is spaced from the longitudinal axis to form one or two branched wire parts, - the basic wire parts of the wires are attached to each other, - for each of the wires the basic start location is closer to the tree start location than the basic end location seen in a direction along the longitudinal axis.

The cable harness according to claim 14, wherein the elongated structure is formed by base wire portions of the wires connected to each other such that said interconnected base wire portions extend along the longitudinal axis from the boom start location to the boom end location.

The cable harness according to claim 14, wherein the elongated structure is formed by a reference cable that extends along the longitudinal axis from the tree start location to the tree end location.

The cable harness according to claim 16, wherein the base wire parts are attached to each other via the reference cable. A system for manufacturing a cable harness according to any of claims 14-17, wherein the system comprises; - a wire feeder for feeding wire material, - a length measuring unit to measure the length of the wire material supplied, - a cutting unit to cut the wire material supplied to form the wires of the cable harness, - a storage device adapted to store the cut wires with their basic start locations in a respective engaging position, and - a fastening device which determines a fastening location, which fastening device is adapted to form the cable harness by fixing the wires in the fastening location to the elongated structure and to move the formed cable fastener away from the fastening location .

The system of claim 18, wherein the storage device is adapted to store the wires spaced apart in the horizontal direction and to place each stored wire in a first vertical position, a second vertical position and a third vertical position, first vertical position, second vertical position and third vertical position are spaced apart in the vertical direction.

A system according to claim 18, wherein the storage device is arranged to store the wires spaced apart in the vertical direction and to place each stored wire in a first horizontal position, a second horizontal position and a third horizontal position, which first horizontal position, second horizontal position and third horizontal position are spaced apart in the horizontal direction.

A system according to any of claims 18-20, wherein the storage device comprises a plurality of storage reels and is adapted to wind each wire onto at least one storage reel and the at least one storage reel only carries that wire.

A system according to any one of claims 18-21, wherein the storage device comprises a plurality of pairs of storage reels and is adapted to wind each wire having its basic start location between its start end and its end end on one of the pairs of storage reels such that the basic start location of that wire between those pair of storage reels.

The system of any one of claims 18-22, wherein the system comprises a labeling system adapted to label the cut wires in their base start location and base end location.

A system according to any one of claims 18-23, wherein - the system comprises a control unit with a memory and input means for storing in the memory; - the tree start location and the tree end location on the longitudinal axis and for each of the wires the longitudinal start location and the longitudinal end location on the longitudinal axis, and - for each of the wires stored in the storage device where the basic start location is located, - the mounting device is arranged to determine the movement of the elongated structure formed away from the mounting location, - the control unit is in communication connection with the connecting device, - the system comprises a moving device which is in communication connection with the control unit, comprises a gripper for the basic start locations of the storage locations stored in the storage device to engage wires, and is adapted to move the engaged basic start locations to the mounting location, the control unit is arranged to control the moving device such that when the longitudinal starting location of one of the wires is in the mounting location, the basic start location of that wire is placed by the moving device in the mounting location.