Apparatus and Method for Automated Manufacturing of a Cable Harness

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This invention describes a fully automated system and method for manufacturing cable harnesses (complex electrical wire assemblies), particularly those with branched structures such as those used in vehicles. The system is modular and consists of two main parts: the first prepares and processes individual wire elements (cutting, stripping, adding contacts), and the second assembles these elements into the final harness layout using robots, transport systems, and specialized stations for tasks such as arranging, fixing, and packaging the harness.

Use CasesContent extracted from patent full text and abstract with AI.

• Automated manufacturing of automotive wire harnesses for custom vehicle configurations
• Production of complex cable sets for industrial machinery, aerospace, or railway vehicles
• Manufacturing wire harnesses for home appliances, electronics, or communication equipment
• Production of specialized electrical assemblies for renewable energy installations (e.g., wind turbines, solar panels)
• High-volume manufacturing in sectors requiring rapid turnaround and customization of wire/cable assemblies

BenefitsContent extracted from patent full text and abstract with AI.

• Significantly reduces manual labor and associated errors in cable harness production
• Enables fast and flexible manufacturing, supporting customized or just-in-time orders
• Improves production consistency, precision, and quality through process automation
• Modular design allows for easy system reconfiguration or expansion for different cable types or harness layouts
• Integrated transport and processing leads to increased throughput and reduced production time
• Automated quality and process control increases production yield and reduces waste

Technical Classifications (CPCs)

Inventors & Applicants

Patent Abstract

The system (2) functions for the automated production of a cable set (3), which has a branched structure formed by multiple individual line elements (22). The system (2) has two parts (4, 6), wherein, in a modular set-up, multiple first processing stations (A to D) are arranged in the first part (4) and multiple second processing stations (E to K) are arranged in the second part (6). In the first part (4), an automatic preparation of the individual line elements (22) occurs, which are then collected in a buffer station (D) at the end of the first part (4). In the second part (6), the prepared individual line elements (22) are combined to form the cable set (3). For this, the line elements (22) are introduced into connector housings (76) in a connector station (E), and transferred to second transporters (48), and the branched structure of the cable set (3) is then formed by means of these second transporters (48) by moving along second tracks (50). In this spread branched structure, inter alia, a fixing of the line elements (22) to one another occurs in a fixing station (G).