Method for making a wire harness

Claim 1

A method of routing a wire with a robot into a particular position in a wire harness assembly, wherein the wire harness assembly includes at least one connector having a plurality of pin-receiving points, comprising the steps of: (a) cutting the wire to a predetermined length; (b) terminating both ends of the wire length, at least one end being terminated with a pin; (c) positioning the pin of the wire with a robot adjacent to the connector, including the substeps of: (1) acquiring the terminated wire with a tool on the robot; (2) moving the robot to position the tool adjacent to the connector; (3) identifying a predetermined, pin-receiving point on the connector with the robot; and (4) positioning the pin end of the wire with the robot in alignment with the predetermined pin-receiving point; (d) inserting the pin of the wire with the robot into the first predetermined pin-receiving point on the connector, including the substeps of: (1) securing a first point of the wire with a first foot of the tool; (2) sliding a second foot of the tool to a second point of the wire removed from the first point; (3) securely holding the wire at the second point with the second foot; (4) moving the second foot from the second point to a point adjacent the first foot while allowing the wire to slide through the first foot to insert the wire into the connector; (e) thereafter laying the wire with the robot into its particular position within the wire harness assembly; and (f) releasing the wire from the robot.

Claim 2

A method of routing a wire with a robot into a particular position in a wire harness assembly, wherein the wire harness assembly includes at least one connector having a plurality of pin-receiving points, comprising the steps of: (a) cutting the wire to a predetermined length; (b) terminating both ends of the wire length, at least one end being terminated with a pin; (c) positioning the pin of the wire with a robot adjacent to the connector, including the substeps of: (1) acquiring the terminated wire with a tool on the robot; (2) moving the robot to position the tool adjacent to the connector; (3) identifying a predetermined, pin-receiving point on the connector with the robot; and (4) positioning the pin end of the wire with the robot in alignment with the predetermined pin-receiving point; (d) inserting the pin of the wire with the robot into the first predetermined pin-receiving point on the connector, including the substeps of: (1) securing a first point of the wire with a first foot of the tool; (2) sliding a second foot of the tool to a second point of the wire removed from the first point; (3) securely holding the wire at the second point with the second foot; (4) moving the second foot from the second point to a point adjacent the first foot while allowing the wire to slide through the first foot to insert the wire into the connector; (e) thereafter laying the wire with the robot into its particular position within the wire harness assembly; and (f) releasing the wire from the robot.

Claim 5

A method for making a wire harness assembly, comprising the steps of: (a) positioning a plurality of connectors on a form board; (b) positioning at least one turn gate on the form board; (c) selecting a first wire for the harness; (d) marking the wire; (e) cutting the wire to a predetermined length; (f) pin terminating the pre-cut wire at both ends; (g) inserting a first pin end of the terminated wire into a first connector on the form board; (h) routing the wire over the form board through the turn gate to a second connector; and (i) inserting a second pin end of the terminated wire into the second connector, wherein each inserting step includes: (1) securing a first point of the wire with a first foot of a robot; (2) sliding a second foot of the robot to a second point of the wire removed from the first point; (3) securely holding the wire at the second point with the second foot; (4) moving the second foot from the second point to a point adjacent the first foot while allowing the wire to slide through the first foot to insert the wire into the connector.

Claim 6

A method for making a wire harness assembly, comprising the steps of: (a) positioning a plurality of connectors on a form board; (b) positioning at least one turn gate on the form board; (c) selecting a first wire for the harness; (d) marking the wire; (e) cutting the wire to a predetermined length; (f) pin terminating the pre-cut wire at both ends; (g) inserting a first pin end of the terminated wire into a first connector on the form board; (h) routing the wire over the form board through the turn gate to a second connector; and (i) inserting a second pin end of the terminated wire into the second connector, wherein each inserting step includes: (1) securing a first point of the wire with a first foot of a robot; (2) sliding a second foot of the robot to a second point of the wire removed from the first point; (3) securely holding the wire at the second point with the second foot; (4) moving the second foot from the second point to a point adjacent the first foot while allowing the wire to slide through the first foot to insert the wire into the connector.

Claim 9

A method for making a wire harness assembly using a robot, comprising the steps of: (a) cutting a wire for the harness to a predetermined length; (b) pin terminating both ends of the cut wire; (c) acquiring the terminated wire with the robot; (d) moving the wire adjacent a firt connector with the robot; (e) identifying the location of a predetermined pin receiver on the first connector with the robot; (f) inserting a first pin end of the wire into the pin receiver with the robot, including the substeps of: (1) aligning the pin end with the pin receiver; (2) clamping the wire with a first foot of the robot; (3) moving a second foot of the robot to a position away from the first foot; (4) clamping the wire with the second foot of the robot; (5) unclamping the wire with the first foot; and (6) moving the clamped second foot to a position adjacent the first foot while permitting the wire to slide through the first foot; (g) routing the wire to a second connector; (h) identifying the location of a predetermined pin receiver on the second connector with the robot; (i) inserting a second pin end of the wire into the pin receiver of the second connector with the robot; and (j) releasing the wire from the robot.

Claim 10

A method for making a wire harness assembly using a robot, comprising the steps of: (a) cutting a wire for the harness to a predetermined length; (b) pin terminating both ends of the cut wire; (c) acquiring the terminated wire with the robot; (d) moving the wire adjacent a firt connector with the robot; (e) identifying the location of a predetermined pin receiver on the first connector with the robot; (f) inserting a first pin end of the wire into the pin receiver with the robot, including the substeps of: (1) aligning the pin end with the pin receiver; (2) clamping the wire with a first foot of the robot; (3) moving a second foot of the robot to a position away from the first foot; (4) clamping the wire with the second foot of the robot; (5) unclamping the wire with the first foot; and (6) moving the clamped second foot to a position adjacent the first foot while permitting the wire to slide through the first foot; (g) routing the wire to a second connector; (h) identifying the location of a predetermined pin receiver on the second connector with the robot; (i) inserting a second pin end of the wire into the pin receiver of the second connector with the robot; and (j) releasing the wire from the robot.