Patent Publication Number: US-11029671-B1

Title: Integrated wire harness batch production using augmented reality

Description:
CLAIM OF PRIORITY TO PRIOR APPLICATION 
     This application claims the benefit of prior filed U.S. Provisional Application Ser. No. 62/721,361, filed Aug. 22, 2018. The entire disclosure, including the claims and drawings, of U.S. Provisional Application Ser. No. 62/721,361 is hereby incorporated by reference into the present disclosure as if set forth in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to manufacturing of wire harnesses using augmented reality. More particularly, the present invention relates to systems and methods for complete data management integration in readily-changeable computer-controlled batch production of wire harnesses, from design and raw wires and terminals to final assembly and quality control. 
     BACKGROUND 
     Wire harness assembly has long been a labor intensive exercise which has not fully benefited from integrated data management methods due to long-standing mindsets and formidable obstacles. Wire harness assembly personnel have selected, measured, cut, crimped, bent, labeled, and finally placed, connected, and tied tens, and sometimes hundreds, of individual wires of varying lengths, gauges, and types to form a completed wire harness. If even a single wire in the harness is flawed, the harness may have to be repaired or discarded. Over the years, numerous inventions have attempted to automate some or all of wire harness assembly, with varying degrees of success. Some inventions have focused on separately preparing wire circuits (i.e., the individual wire segments with terminals) apart from the wire harness assembly process. In automated wire circuit preparation inventions, machines are used to select, measure, and crimp roll wire into wire circuits, and then other means are used to transport the circuits to an assembly station. The individual wire circuits are sometimes stored on reelettes or held by clamps, but these methods have inefficiencies and complexities that have long needed improvement. Their complex structures, difficulty in adapting to varying wire circuit specifications, expense of acquisition, use, and maintenance have long needed to be improved. For example, winding wire circuits onto reelettes may introduce anomalous spring tension and irregular bends. Thus, retrieval systems must either have additional complexity to adapt to the varying wire circuit lengths based on unintended bends and spring tension, or risk failures to retrieve some wire circuits. Winding wire circuits onto reelettes may also result in plastic deformation of metal wire. This work hardening may cause immediate wire failure, or may leave a latent defect. The circuit may pass its initial continuity test, but later fail well before its design life due to the residual stress. Further, the winding, storage, and retrieval systems must consistently secure each wire circuit&#39;s ends when the circuit lengths can vary due to anomalies introduced by the winding process itself. 
     Other inventions do not wind the wire circuits; rather, they use clamps to hold each outstretched circuit. This requires much more storage space than a reelette because of the need to accommodate the full length of outstretched wires, isolate each circuit, and provide separation distance between circuits&#39; clamps. The relatively low storage density for the wire circuits can force increased workspace areas, with corresponding increases in overhead costs. Positioning equipment must precisely place the wire circuit for proper clamping, and the clamps must hold the wire circuit securely. In case of system misalignment or error, the clamps may damage circuit ends when the circuit is clamped or retrieved. Because the number of clamps is directly proportional to the number of circuits to store or transport, the quantity of clamps brings a corresponding number of mechanical failures. To prevent costly failures, operators must incur the costs of monitoring, repairing, and replacing the clamps. Further, clamps may fail to successfully grip one or more of the circuit&#39;s ends. In such cases, operating machinery may become fouled by untethered wire circuits. 
     When wire circuits are prepared apart from the wire harness assembly area, the wire circuits must be moved to the assembly station. The wire circuits can be transported singly or in batches, but each circuit must be uniquely identified so that it can be properly processed. Existing systems suffer from unnecessary complexities and limitations in maintaining or transferring the data, as well as in effectively presenting the wire circuits in assembly order to a human or machine. 
     The systems and methods of the present invention overcome many of the problems and limitations of the prior art. Furthermore, the addition of augmented reality displays increases the accuracy, speed, and efficiency of previous inventions. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention includes systems and methods which provide completely integrated data management. The methods include producing machine-readable, standardized scripts that are dynamically propagated throughout the entire production system. The present invention also automates many of the steps in configuring, labeling, testing, and using wire harness layout boards, and in assembling, testing, reworking, and finishing wire harness assemblies. Aspects of the present invention use pneumatic means to load individual wire circuits into a storage and transport system, such as a batch cart, for later assembly into one or more wire harnesses. The batch cart has an array of individual tubes that are pneumatically loaded with individual wire circuits, one or more circuits to a tube. The cart contains a memory device that stores identifying information for each wire circuit including its position in the tube array. The tubes may vary in diameter or length, but each tube is of sufficient length to accommodate the wire circuit, or circuits, with which it is loaded. The batch cart supports wire circuits of varying types, lengths, and end connectors without the limitations and complexities required for coiling the circuits or for individually clamping each circuit&#39;s ends. The batch cart provides a high storage density for the wire circuits and minimizes the materials and space needed to store and transport the circuits. Further, a series of batch carts can receive wire circuits from an entire production shift and conveniently store the circuits for subsequent assembly. 
     When the wire harnesses are to be assembled, the batch cart is transported to the assembly area. A pneumatic means automatically retrieves each circuit from the indexed tube array and presents it to a human or robotic assembler in the order it is to be installed into the wire harness assembly. The assembly area includes a double buffer assembly that greatly reduces the wait time for the assembly personnel for each circuit element. 
     A preferred embodiment uses augmented reality glasses to superimpose information over real-life programmable modules into the field of view of the user. Augmented reality glasses may be used to provide visual cues for installation of tool posts (smart jigs) and turning posts in smart boards (programmable modules). In an alternative embodiment, augmented reality glasses can display information and visual cues in a specific location, such as the top right corner of one lens. In this alternative, the user is able to look at the real-life assembly and look to the corner of the lens for guidance. This embodiment differs because the information is displayed on the glasses but is not “superimposed” directly over the real-life assembly. Further, the augmented reality glasses are capable of displaying images that provide visual direction to the personnel carrying out the wire harness assembly to direct them to place a given circuit element in a given position and to connect it to the specific bundles and/or connector in place on the physical harness assembly table. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a view of a wire harness assembly table and a view of a user looking through an augmented reality display of a particular wire harness assembly in process. 
         FIG. 2A  is a view of two programmable modules or smart boards isolated from the rest of wire harness assembly as seen through augmented reality glasses on an augmented reality display. 
         FIG. 2B  is a view of an augmented reality display with superimposed prompts for instructing the user to install tool posts (smart jigs) and the corresponding wire harness connectors. 
         FIG. 2C  is a view of an augmented reality display with superimposed prompts for instructing the user to install turning posts and tool posts. 
         FIG. 3A  is a view of augmented reality display as seen through augmented reality glasses. 
         FIG. 3B  is a view of the illuminated portion of a tool post for providing guidance to a user for placing a wire harness connector. 
         FIG. 3C  is a view of the illumination of the location where the first end of a wire should be placed. 
         FIG. 4  is a view of the augmented reality display with a superimposed indication of successful verification and testing of a circuit element. 
         FIG. 5  is a view of the augmented reality display with a superimposed indication of failure of verification and testing of a circuit element. 
         FIG. 6  is an overhead view of a side of a tool post disconnected from an assembly. 
         FIG. 7  is a view of use of the augmented reality display in a field installation. 
         FIG. 8A  is a partially schematic perspective view of the circuit manufacturing sub-system (C&amp;C centers) of the present invention. 
         FIG. 8B  is a partial schematic perspective view of the wire harness assembly sub-system (assembly table) of the present invention. 
         FIG. 8C  is a perspective view of a computer-controlled X-Y indexing platform  24  for moving each of three storage buffers to direct each individual circuit from the crimp center into a unique corresponding tube location in the buffers. 
         FIG. 9  is a schematic block diagram of the circuit manufacturing and wire harness assembly sub-systems of the present invention. 
         FIG. 10A  is a detailed perspective view of a typical block tool (connector jig) for use on the assembly table of the present invention. 
         FIGS. 10B &amp; 10C  are detailed partial cross-sectional views of alternate embodiments of the block tool (connector jig) for use on the assembly table of the present invention. 
         FIG. 11  is a mixed view hardware/software method flowchart of the overall system and method of the present invention. 
         FIGS. 12A-12C  are flowcharts of production process steps for circuit manufacturing, circuit indexing and storage, and guided wire harness assembly. 
         FIG. 13A  is a partially schematic perspective view of an alternative embodiment of the circuit manufacturing sub-system (C&amp;C centers) of the present invention. 
         FIG. 13B  is a partial schematic perspective view of an alternative embodiment of the wire harness assembly sub-system (assembly table) of the present invention. 
         FIG. 13C  is a detailed side plan view of one of the circuit indexing sub-systems of the alternative embodiment shown in  FIGS. 12A and 13B . 
         FIG. 14  is a partial schematic perspective view of an improvement to the wire harness assembly sub-system (assembly table) as depicted in  8 B. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     As indicated above, it is an objective of the present invention to provide for an extremely flexible manufacturing and tooling system for the design and production of wire harnesses. The system is designed to allow the same set of tooling structures to be utilized in conjunction with a wide variety of wire harness designs and configurations, and at the same time to maintain a high level of quality control and a highly efficient manufacturing process. The systems and methods described allow for the rapid re-tooling of the system to accommodate small or large manufacturing runs and rapid change-over to the production of a new wire harness design. The systems and methods further facilitate the immediate testing and verification of the manufactured wire harnesses as well as the tracking and training of personnel involved in the production process. The following drawing figures provide an overview of the hardware and software systems utilized to carry out the methods of the present invention. 
     The construction of a harness generally comprises the collection, bundling, and association of a large number of circuit elements (wires with terminal ends) that are collected and assembled into various types of standard and custom connectors that are positioned on the wire harness table according to a pre-determined layout and configuration. Various components positioned on the wire harness table facilitate the placement, positioning, bundling, and insertion of the circuit elements into the various connectors. As indicated above, existing wire harness assembly systems typically rely upon the complete manual construction of a wire harness on an assembly table after which the completed harness is removed from the table and tested in a separate location, wire by wire, or connector by connector. The present invention improves the efficiency of the manufacturing process by carrying out testing and verification of the wire harness immediately upon placement and connection of each circuit element within the wire harness structure. 
     The system of the present invention further provides prompts, directions, and other instructions to the assembly personnel constructing the wire harness by way of a number of visual and aural prompts and confirmations. The aural and visual prompts in the present invention are provided using a number of different elements in the augmented reality display  500  of a wire harness assembly sub-system. 
     As shown in  FIG. 1 , one of the embodiments of the present invention includes an augmented reality display  500  (bottom right corner) of a wire harness assembly sub-system. Shown above the augmented reality display  500  is the physical wire harness assembly  50 . The display  500  is viewed by a user through augmented reality glasses  560 , preferably using Microsoft HoloLens augmented reality software. In this embodiment, a user wears augmented reality glasses  560  which superimpose information over real-life programmable modules (“smart boards”)  54   a ,  54   b  into the field of view of the user. The terms “smart board” and “programmable module” are used herein interchangeably. The smart boards  54   a ,  54   b  may wirelessly transmit information via wireless connection  100  that is then displayed on augmented reality glasses  560 . Such information includes directions and visual cues for assembly of the wire harness. The augmented reality glasses  560  are capable of displaying images that provide visual direction to the personnel carrying out the wire harness assembly to direct the personnel to place a given circuit element in a given position and to connect it to the specific bundles and/or connectors in place on programmable modules  54   a ,  54   b  on the physical harness assembly table  52 . The display  500  of both the real-life view and other information superimposed is defined here as the Augmented Reality User Interface (“ARUI”). 
     In an alternative embodiment, augmented reality glasses  560  can display information and visual cues in a specific location, such as the top right corner of one lens. In this alternative, the user is able to look at the real-life assembly and look to the corner of the lens for guidance. This embodiment differs because the information is displayed on the glasses but is not “superimposed” directly over the real-life assembly. 
     Customization of the wire harness according to specific needs related to specific connectors and terminal ends, such as the placement of ultrasonic soldering to non-typical connector assemblies, typically will take place off of the assembly table  52 . Other embodiments may employ mechanisms placed on tooling configuration system  60  (as shown in  FIGS. 7B, 13B, and 14 ) so as to be made accessible to any portion of the assembly table programmable modules  54   a  &amp;  54   b . Tooling configuration system  60  is preferably positioned in an overhead track-mounted gantry as illustrated. The process of assembling a wire harness  64  in production through to completion is partially automated according to the prompting and instruction systems described above, but is ultimately within the manual control of the assembly personnel who initiate and terminate the automated system by activating assembly table start/stop control  68 . 
     Turning to  FIG. 2A , there is shown a view of programmable module  54   a  and programmable module  54   b  as would be seen on the augmented reality display  500 . The display  500  illustrates that the programmable modules  54   a  and  54   b  are blank while the wire harness assembly  50  is turned off or prior to the beginning of the process of creating a wire harness assembly. In this view on the augmented reality display  500 , the programmable modules  54   a  and  54   b  are shown in their entirety. When wire harness assembly begins, the augmented reality display  500  may superimpose instructive features onto the view of programmable modules  54   a ,  54   b . In other embodiments, augmented reality display  500  zooms in to a smaller area of the programmable modules  54   a  and  54   b , particularly in the area where placement of the wire harness assembly components is to take place, the zoomed view preferably changing to different physical locations on programmable modules  54   a ,  54   b  based on the placement requirements of additional wire harness assembly components. 
     Turning to  FIG. 2B , there is shown augmented reality display  500  with prompts for instructing the user to install tool posts (smart jigs)  62  and the corresponding wire harness connectors. The dashed rectangle  619  represents the location on the assembly table for placing a tool post  62  (shown in  FIG. 2C ). Each different type of wire harness connector (into which a bundle of completed circuit elements may be positioned) will have a specific tool post  62  that interfaces between the connector and the assembly table programmable module  54   a . On the bottom of augmented reality display  500 , there is shown a text box  622  that is adapted to provide written instructions and feedback for correct placement and orientation of tool post  62 .  FIG. 2B  shows the proper location  619  of first tool post  62  and subsequent tool posts will be placed in a similar manner. Once a tool post  62  is correctly placed, the user then follows instruction for placement of additional tool posts  62 . Similarly, augmented reality display  500  will show the appropriate locations for placement of additional tool posts. 
     Turning to  FIG. 2C , there is shown augmented reality display  500  with prompts for instructing the user to install turning posts  66 . The dashed circle  659  represents the location on the assembly table for placing turning post  66 . In addition to tool posts  62  variably positioned on assembly table programmable modules  54   a  &amp;  54   b  (as shown in  FIG. 1 ), harness assembly turning posts  66  may likewise be positioned to facilitate the placement and positioning of the circuit elements (wires with terminal ends). On the bottom of augmented reality display  500 , there is shown a text box  622  with instructions and feedback for correct placement and orientation of tool post  62 .  FIG. 2C  shows the proper location  659  of one turning post  66  and subsequent turning posts will be placed in a similar manner. 
     The use of augmented reality glasses  560  allows a user to continue looking down at the physical wire harness assembly  52  while receiving visual prompts displayed on the glasses  560 . The augmented reality display  500  is an improvement because users do not have to continuously look up at a separate display while assembling. This augmented reality process is more thoroughly explained in the following paragraphs describing the wire harness assembly. 
     Turning to  FIG. 3A , there is shown augmented reality display  500  as seen through augmented reality glasses  560 . The user views display  500  while looking down at wire harness assembly table  52 . It is important to note that virtual prompts displayed in display  500  are limited to the immediate area around the particular tool post being utilized at a given time. In this case, for active tool post  62   a , the text box  622 , wire harness path  610 , and lighting directing the placement of harness connector  92  are all virtually displayed to the user being superimposed on the actual view of the physical programmable modules  54   a ,  54   b . The additional components visible in augmented reality display  500  are the real-life components, such as programmable modules  54   a ,  54   b  and all the tool posts  62 . The text box  622  gives instructions to the user to retrieve a particular wire harness connector  92  from a bin array (not shown) and to place the connector into tool post  62   a . Text box  622  preferably appears directly above the placement location. Various tool posts  62  are positioned on the assembly table programmable modules  54   a  &amp;  54   b  and provide lighted indicators associated with the various connector ports directing the assembly personnel to insert a circuit element terminal end into a particular port on a particular harness connector  92 . The system selectively illuminates individual wire ports in the tool posts  62  when the next step in the physical assembly  50  requires connection at the illuminated port. Such port illumination serves to ease the assembly process by designating the next succeeding step in the assembly, as appropriate. Turning posts  66  are also illuminated with at least four bright LEDs to assist in illuminating path  610 . If the wire makes a right angle at turning post  66 , only three LEDs would illuminate corresponding to the two directions along which the wire should be routed. In this manner, for example, the automated system of the present invention may provide a multi-faceted visual prompt to direct the placement of a particular circuit element along a physical path  610  associated with the physical assembly  50 . Once the circuit has been positioned along the appropriate wire harness path  610 , the individual attachment of the terminal ends of the circuit to the appropriate connectors may be directed by way of illuminated tool posts  62  which hold the individual connector structures. The user may then insert the appropriate terminal ends of the circuit element  64  (shown placed in position in  FIG. 4 ) into the appropriate connector port as prompted by the illumination. 
     With reference to  FIG. 3B , there is shown the illuminated portion of tool post  62  for providing guidance to a user for placing wire harness connector  92  (not shown). Tool post  62  is depicted and described in greater detail in  FIG. 6  and ensuing paragraphs. Each tool post  62  has a translucent panel on its side that glows, and has at least four translucent dots  300  on top that glow brightly. The translucent dots  300  indicate to the user to “place the harness connector here.” A pushbutton switch  621  allows the user to respond affirmatively to prompts and can “lock” harness connections in place. 
     With reference to  FIG. 3C , there is shown the illumination of the location  311  where the first end of a wire should be placed. The translucent dots  300  and location  311  are both illuminated. Within the cavity  310  of the connector, the hollow cavity probe (not shown) transmits light from a very high intensity LED. The light shines all the way through the cavity  310  of the connector and serves to illuminate location  311  which will receive a circuit element  64  (as shown in  FIG. 4 ). 
     Turning to  FIG. 4 , there is shown the augmented reality display  500  resulting from successful verification and testing of a circuit element  64   a . Circuit element  64   a  is connected to harness connector  92  and tool post  62   a  and wraps around turning posts  66 . Another end of circuit element  64   a  is connected to tool post  62   b . Once these connections are made for circuit element  64   a , the single board computer  720  (shown in  FIG. 6 ) inside tool posts  62   a ,  62   b  interfaces with programmable modules (smart boards)  54   a ,  54   b  and verifies that the proper connections were made. Next, the circuit element  64   a  is tested to ensure that it is functioning properly and there are no faults in the wiring. A single board computer  720  in tool post  62   b  transmits information regarding verification and testing to augmented reality glasses  560 . In this case, the circuit element  64   a  was placed correctly and tested successfully. Therefore, there is a green indicator light  650  virtually displayed above tool post  62   b  indicating a successful connection. 
     Turning to  FIG. 5 , there is shown the augmented reality display  500  resulting from failure of verification and testing of a circuit element  64   b . Connecting circuit element  64   b  to tool post  62   c  is the next step in the wire harness assembly  50 . Once again, a single board computer  720  within tool post  62   c  transmits information regarding verification and testing to augmented reality glasses  560 . In this case, the circuit element  64   b  was connected correctly but tested faulty. There is a red indicator light  651  virtually displayed above tool post  62   c  indicating failure. There is also a text box  622  display that provides instructions that informs the user that the circuit element  64   b  was placed correctly but there was a testing failure. Similarly, a red indicator light  651  will be virtually displayed if circuit element  64   b  was not connected correctly. The user can then disconnect circuit element  64   b  and connect it to whichever tool post  62  is proper. 
     To enable taping and loom assembly on the wire harness, corresponding instructions are displayed on the augmented reality glasses  560  at the appropriate step in assembly, and the user manually indicates completion of the taping or loom application step rather than an automated sensing. In addition, taping and looming steps are facilitated by the incorporation of stand-off blocks (illustrated schematically on each tool post  62  in  FIG. 8B ) which provide a separation of at least a half-inch (preferably at least 1.5 inches) between the plane of the smart boards  54   a  and  54   b  and the point on the block tool  62  where circuit terminals connect to the block tool  62 . Such minimum separation helps to allow enough space for assembly personnel to fit their fingers beneath the wire assembly to enable taping and looming. 
     Another possible feature of the augmented reality glasses is a camera device and a transmitter. The camera can view the wire harness assembly  50  and capture images during the assembly process. The transmitter can send images to the computer system  40  so that it can verify the connections of circuit elements  64 . In this manner, the camera can act as a redundant verification to the primary verification executed on harness assembly table  52  and provided by tool posts  62 . 
     Turning to  FIG. 6 , there is shown an overhead view of a side of a tool post  62  disconnected from an assembly. A support post (aluminum shaft)  700  protrudes from tool post  62  through the top surface of a smart board (such as programmable module  54   a ). Tool post  62  preferably incorporates a single chip set  730  with orthogonal accelerometers that enables tool post  62  to report its orientation. In alternate embodiments, in order to determine the placement of tool post  62 , and as a backup for determining the orientation of tool post  62 , the bottom end of support post  700  can be cut in a specific way in order to reflect light in a preferential direction from an infrared (“IR”) emitter in the center of each smart board orientation detection array. This enables IR optical sensors inside the smart board to determine which way the tool is pointing. Aluminum is preferably used as the material for support post  700  because of its IR reflectivity. Steel and stainless steel absorb much more IR and would not be able to function as a support post  700 . A clamp (not shown) can be used to affix tool post  62  to the top surface of a smart board. Although not shown, other methods of securing the position of tool post  62  may be used. For instance, a metal plate may be positioned below the surface of the programmable modules  54   a ,  54   b . At or near the bottom surface of tool post  62 , there may be positioned a rare earth magnet. Upon placement of tool post  62 , the magnet contacts the metal plate, thereby securing tool post  62  in place. 
     By industry standards, connector blocks are designed to receive a particular wire harness connector. Here, the connector block  710  is modified with hollow contact test probes which can transmit light into each connector cavity. The connector block  710  also has a locking device in order to retain wire harness connectors  92 , and other sensors to check the status of various locks and other accessories that may be installed into the harness connector  92 . 
     Another major feature of tool post  62  is the single board computer  720  (inside tool post  62 ) that interfaces with a smart board and acts as an interpreter between the various connector test contacts and the system network. A cable  725  connects the single board computer  720  to the smart board. The single board computer  720  also monitors connector accessory and lock switches and reports their statuses to the network. Additionally, the single board computer  720  also routes test signals delivered via the network to the appropriate connector cavity, and evaluates electrical characteristics at each contact to determine whether or not they might be connected via the harness assembly to other tool posts and connectors distributed over the smart board  54 . This process enables the system to perform continuity, tensor impedance, and frequency response tests between cavities of multiple connectors installed at various locations across the smart board  54  during wire harness assembly. The network of multiple single board computers  720  is able to test for errors at all points in a wire harness assembly  50  and effectively take “snapshots” of the whole smart board  54 . Electrical shorts can be specifically identified and illuminated so that the user can make any necessary adjustments. 
     Additionally, tool post  62  has a high intensity LED board (not shown) that accepts signals from the single board computer  720  and illuminates various portions of the tool post  62 , along with the cavity fiber optics. An enclosure  750  mounts the support post  700 , clamp, computer circuit boards  720 , and connector block  710  together. At least one pushbutton switch  621  (not shown here) is mounted to the enclosure  750 , which allows the user to respond affirmatively to prompts. 
     In alternative or supplemental embodiments, the system operates in another mode where instead of or in addition to the wire harness assembly on the board, there are one or more wire harness terminations or connections that are completed in the field, particularly at or near the time of installation of the wire harness assembly in the equipment for which the wire harness assembly is made. For example, as illustrated in  FIG. 7 , there is shown an open panel  900  on an aircraft wherein a wire harness assembly is to be installed. Using augmented reality glasses  560 , an installer is able to view the relevant interior portion of the aircraft, and augmented reality display  500  superimposes the images of the wire harness assembly components and the appropriate connections are also highlighted in the augmented reality display  500 . Furthermore, as with the embodiment described in  FIG. 3A , a text box  622  is shown on augmented reality display  500  to provide written instruction to assist the installer in making the appropriate connections. Using augmented reality glasses  560  serves to reduce or prevent faults and misconnections in the field when installing a completed wire harness assembly. 
     Reference is now made to  FIGS. 8A &amp; 8B  for an overview of the various sub-systems that collectively are engaged in the overall process for the production of wire harnesses according to the present invention.  FIG. 8A  is a partial schematic view of the circuit manufacturing sub-system (C&amp;C centers)  12  of the present invention involving the manufacture of the individual wire/terminal circuits  20  that collectively go together to make up a wire harness. In general, reference herein to a circuit  20  refers to the manufactured combination of a length or lengths of wire provided with (where applicable) one or more terminal ends (typically one length of wire with terminals at each end), that are collectively gathered into and make up the components within a wire harness. The terminal ends are variable in configuration and may simply involve a wire end stripped and tinned (with solder) for purposes of later attachment to a terminal block or circuit board. In most instances, however, a circuit comprises a length of wire that terminates at each end with a crimp-on metal terminal, typically of a pin or spade type. The crimp-on terminals may be either male or female. These metal terminals are most frequently designed to be collectively integrated into what will herein generally be referred to as a connector, which forms the end of a bundle of wires within a wire harness. 
       FIG. 8A  shows the circuit manufacturing sub-system  10  as incorporating automated C&amp;C center  12 . This C&amp;C center is in turn associated with indexed circuit storage system (cart/magazine)  36 . These basic sub-systems collectively serve to manufacture the circuit elements utilized in the production of the wire harness and store them, preferably in a manner that can be readily and robotically retrieved for final assembly. Automated C&amp;C center  12  is preferably a combination of subsystems assembled from a number of different commercially available automated wire cutting systems and automated stripping and crimping machines as well as wire labeling systems. Numerous manufacturers are known with various tools (for example, the Schunk-Minic, Schleuniger and Curti lines) that can be combined to achieve the described functionality of C&amp;C system  12 . The C&amp;C center  12  preferably includes an array of wire supply reels (auto feed)  14  and an associated array of wire terminal supply cartridges (rolled bands of pre-cut sheet metal terminals with tabs, often referred to as “bandolier” rolls)  16 . 
     Although some of the different supply reels  14  have different wire gauges, insulation and ratings than other reels  14 , as is input and known by the programming of C&amp;C system  12  (or that of the overall system  10 ), the wire insulation on all the wire supply reels  14  of C&amp;C center  12  is preferably blank and of a white (or, alternatively, an assortment of solid pale colors) so that a wire label print can be applied to all the circuits  20  by C&amp;C center  12  as the circuits are being cut, stripped and crimped. Tag labels as are known in the industry may also be applied by C&amp;C center  12 , to the extent required in the circuit specifications. Although not illustrated, those of skill in the art will understand how C&amp;C center  12  is adapted to perform such label printing and application before the circuits  20  are stored in buffer  36 . 
     Automated C&amp;C center  12  will typically have at least one means for programming the device. The device may be programmed by operator commands entered into C&amp;C center programming terminal  18 . In another embodiment, automated C&amp;C center  12  may be programmed from a remote data input terminal device  40 . In yet another embodiment, automated C&amp;C center  12  may be programmed by importing files from CAD software  104  (shown in  FIG. 11 ). 
     Automated C&amp;C center  12  produces a completed wire/terminal circuit  20  of a length, gauge, and terminal type, as specified by the programming provided to automated C&amp;C center  12 . Such programming is versatile and can direct automated C&amp;C center  12  to produce a large number of a single type of circuit  20  or a long list of entirely distinct circuits that together might be eventually bundled to form a wire harness. In the present invention, a very efficient operation of automated C&amp;C center  12  would be to produce a long list of individual circuits required to construct one particular type of wire harness. The C&amp;C center may produce a number of circuit sets that are indexed and stored (as described in more detail below) and then later utilized to produce a number of the same type of wire harness. 
     Automated C&amp;C center  12  provides a completed wire/terminal circuit  20  which is delivered into an indexed circuit storage system  36  by way of an associated pneumatic conduit  22  and a circuit indexing sub-system  24  (shown in  FIG. 13A ). The indexed circuit storage system  36  is preferably embodied as a magazine, also referred to as a “buffer,” that includes numerous single-circuit containers  39  into which the production system deposits individual circuits  20 , storing a record of which circuits  20  or types of circuit  20  are stored in which containers  39  so that those circuits  20  can later be retrieved from the buffer  36  when needed to make the final wire harness assemblies. Although some of such containers  39  may be sized differently than others according to the production needs, in the most preferred embodiment, such containers  39  are embodied as an array of identical tubes  39 . Each such identical tube  39  is long enough to contain the longest wire that would be required in the wire harness batch being assembled (ten feet is typically sufficient) and is sized roughly ⅝ or 9/16 of an inch in inside diameter so that the largest of typical circuit terminals fit loosely within the tubes  39  but are still within fairly close tolerances in order to optimize space as well as the efficiency of the pneumatic system used to move the circuits  20  into and out of each tube  39 . The tubes (or at least their interior surfaces) are preferably made of a low-friction material such as PVC or better in order to minimize the possibility of a circuit  20  hanging up or getting stuck in a tube  39  when the pneumatic conveyance system is attempting to move it. 
     Buffer  36 , hence, is configured with a large array of linear tubes  39 , each of which preferably only holds a single circuit  20 , configured in a fixed, parallel arrangement. (It is envisioned that alternative, albeit less beneficial, embodiments may hold one or more completed wire/terminal circuits  20  in individual containers  39  while still appreciating some of the benefits of certain aspects of the invention.) This array of storage tubes  39  operates in conjunction with circuit indexing sub-system  24  such that every tube  39  within the array  38  of the cart/magazine is identified and indexed to contain a known type of circuit element  20 . In this manner, indexed circuit storage system  36  may be loaded with a full circuit element set appropriate for the manufacture of one or more particular batch(es) of wire harnesses. Wire harnesses may of course come in a variety of configurations having less than ten circuit elements to hundreds of circuit elements. Indexed circuit storage system  36  is designed to accommodate simple or complex wire harness circuit sets. 
     The combination of a circuit indexing sub-system  24  (shown in  FIG. 13A ) and pneumatic conduit  22  deliver completed wire/terminal circuits  20  from the automated C&amp;C center  12  into a properly indexed storage tube  39  within indexed circuit storage system  36 . In one embodiment, a circuit is transported from the automated C&amp;C center into storage system  36  by pneumatic tube  22 . Circuit  20  enters tube  22  at  22   a  where optical sensors  77  and  78  detect its entry into tube  22 . Device  83  is a means for supplying pneumatic pressure into tube  22  to transport circuit  20  through tube  22  from entry at  22   a  to exit at  22   b . As the circuit exits tube  22 , optical sensors  79  and  80  detect its passage. In one embodiment, circuit  20  is inserted into a particular tube, for example tube  39   a , in storage system  36  by moving storage system  36  such that the longitudinal axis of tube  39   a  is generally aligned with the longitudinal axis of pneumatic tube  22  and the receiving end of storage tube  39   a  is close enough to discharge end  22   b  to reliably receive the circuit. Arrows  811   a ,  811   b , and  811   c  show how storage system  36  is moved in an X-Y coordinate system to align a receiving tube with the discharge end  22   b  of tube  22 . Movements of storage system  36  are controlled by a computer system that maintains the index system and is able to move storage system  36  across the X-Y coordinate system to align any individual tube to receive a circuit. The vertical surface plane of storage system  36  (formed by the tube ends including tube  39   a  and  39   b ) is maintained in a vertical orientation which results in the surface plane being generally normal to the longitudinal axis of pneumatic tube  22 . To insert a circuit into tube  39   b , storage system  36  is moved vertically, but not horizontally, so that the receiving end of tube  39   b  is aligned with discharge end  22   b  and is ready to receive a circuit. As mentioned above, the entire indexing system may be programmed and may be controlled by way of a computer system  40 . In some embodiments, a computer system  40  may be located on storage system  36 . In a preferred embodiment, computer system  40  is a computer server system. Regardless of where computer system  40  is located or its particular configuration, each completed wire/terminal circuit  20  from the respective C&amp;C center  12  may be directed into a known and indexed storage tube  39  where it may be held until such time as the manufacturing of that particular wire harness assembly is carried out. 
     In some embodiments, the indexes and circuit descriptions are stored in a memory device downloaded to and physically located in or on storage system  36  so that the cart can be temporarily stationed in a holding area and its data can be retrieved whenever it is ultimately wheeled into position for wire harness assembly (as depicted in  FIG. 8B ). In a preferred embodiment, however, the data pertaining to a particular buffer  36  loaded with circuits  20 , including the descriptive information for each circuit  20  and the location of its tube  39  within storage system  36  is stored in computer server system  40 . Each storage system  36  entity is marked with a bar code that uniquely identifies the storage system. With the bar code identifier, the index system, and the circuit descriptions, the production system identifies each circuit regardless of where it is stored. 
     In a first preferred embodiment of the present invention, each of the storage tubes  39  associated with indexed circuit storage system  36  may be designed to retain a single circuit element  20  for later delivery during the assembly of the wire harness. Alternate embodiments of the present invention anticipate the utilization of storage tubes  39  capable of retaining a number of like circuit elements  20  for later use and delivering such circuit elements  20  one at a time in a repetitive manner. Therefore, the index circuit storage system (cart/magazine/buffer)  36  may be configured to receive, store, and deliver a full circuit element set appropriate for the manufacture of a single wire harness or, in an alternate embodiment, the same cart  36  may be configured to receive, store, and deliver ten or more sets of circuit elements  20  by repeatedly drawing out a full set for the manufacture of a wire harness followed by second and subsequent full sets all from the same storage cart  36 . 
     Reference is now made to  FIG. 8B  for a detailed description of what is essentially the second half of the wire harness production process. The sub-systems described in  FIG. 8A  above, produce the building block components that are to be assembled into the final wire harness product. These building block components are, as described above, circuit elements  20  comprising lengths of wire with terminal ends attached. These completed wire/terminal circuits are stored, either for a period of time or for as long as it takes to move the storage cart  36  to the wire harness assembly sub-system  50 .  FIG. 8B  shows the same indexed circuit storage system  36  as shown in  FIG. 8A , this time providing stored circuit sets to the wire harness assembly sub-system for the purposes of completing the manufacture of the wire harness. In the view shown in  FIG. 8B , indexed circuit storage cart  36  is moved to a position adjacent the wire harness assembly sub-system  50 . In some embodiments, indexed circuit storage system  36  includes, as indicated above, a computer system  40  that facilitates the automation of the process of indexing, storing, and delivering the circuit elements  20 . In a preferred embodiment, the circuit descriptions and indexes are stored in a computer server system  40 . Also shown in  FIG. 8B  is storage cart output port array  42  similar in structure to the storage cart input port array  38  shown in  FIG. 8A . In one embodiment of the present invention, storage cart output port array  42  may comprise the same array of ports  39  as storage cart input port array  38 , and cart  36  is simply turned around for receipt or delivery of the circuit elements. Alternately, these storage cart port arrays  38  and  42  may comprise opposite ends of the mobile indexed circuit storage systems (cart/magazine)  36 . 
     As with the input of circuit elements  20  into indexed storage circuit system  36 , the output or delivery of the circuit elements  20  is carried out by effectively reversing the indexing process and selectively withdrawing the appropriate circuit element  20  from the storage cart  36  to be delivered to the wire harness assembly sub-system  50 . In at least one embodiment, computer controlled electric motors position storage system  36  so that the tube with the next circuit required in the wire harness is aligned with a pneumatic tube that ejects circuit element  20  onto conveyor belts  202  and  204  to deliver the circuit element  20  to assembly sub-system  50 . This delivery is again carried out by way of pneumatic conduit  46  (shown in  FIG. 13B ) which withdraws a circuit element  20  from storage system  36  and delivers it to wire harness assembly sub-system  50  for use in conjunction with the assembly process. 
     The actual assembly of the wire harness is carried out manually, although this assembly process is directed, prompted, tested, and verified automatically in conjunction with the elements of the system of the present invention as described in more detail below. While assembly personnel manually receive circuit elements from the circuit indexing sub-system  44  by way of the pneumatic conduit  46  as described above, the process of placing the circuit element  20  onto the assembly table  52  and making the appropriate connections is automatically guided and confirmed by the systems and methods of the present invention. 
     The assembly table of the present invention is generally comprised of assembly table support frame  52  which positions and supports one or more assembly table programmable modules represented by  54   a  &amp;  54   b  in  FIG. 8B . In the preferred embodiment of the present invention, a versatile system might incorporate as many as twelve assembly table programmable modules, with four layout boards per module, that may be used individually or collectively depending upon the size and complexity of the wire harness being constructed. These table modules are interconnectable and may be used separately or collectively according to the requirements of the system and the personnel handling the wire harness assembly. 
     Reference is now made to  FIG. 8C  for a more detailed description of a preferred embodiment of the circuit transfer system of the system and method of the present invention.  FIG. 8C  is a perspective view of a computer-controlled X-Y indexing platform  85  for moving each of three storage buffers  312   a ,  312   b ,  312   c  to direct each individual circuit element  20  from the crimp center  12  into a unique corresponding tube  39  located in the buffers  312   a - 312   c . A such, X-Y indexing platform  85  serves as one of the two circuit indexing sub-systems utilized to deliver completed circuit elements into and out from the mobile storage system  36  (cart/magazine) of the present invention. It is understood that, as discussed above, such an indexing sub-system would preferably be positioned in conjunction with both the circuit manufacture sub-system (the C&amp;C centers) and the harness assembly sub-system (the soft-tool assembly tables) and would provide the manner of directing completed circuit elements  20  into the mobile indexing storage cart  36  as well as providing delivery of the same from the mobile cart  36  to the harness assembly table  52 . 
     Those skilled in the art will recognize that the system may preferably include two such circuit indexing sub-systems, one for delivery of the manufactured circuit elements  20  into the storage cart  36 , as shown in  FIG. 8A , and one for delivery of the indexed circuit elements  20  from the storage cart  36  to the assembly table  52 , as partially shown in  FIG. 8B . Alternately, the storage cart might retain a single array of ports that serve as both the input and output ports for reception and delivery of the various circuit elements  20  stored within the mobile cart  36 . In other words, the circuit indexing sub-system  85  shown in  FIG. 8C  could also serve as the circuit indexing sub-system  24  described above for receiving manufactured circuit elements  20  into the cart  36 . It would be a simple matter of connecting and disconnecting the pneumatic hoses associated with each of the stations discussed above and appropriately programming the X-Y indexing and sorting system to either direct (pneumatically) a just completed circuit element  20  into the storage cart  36  or to withdraw a previously indexed circuit element  20  from the cart  36 . 
       FIG. 8C  shows one embodiment of the present invention and depicts storage systems  312   a ,  312   b , and  312   c  that are positioned by circuit indexing system  85 . System  85  uses commercially available means such as computer controlled electric motors operating lift and side-to-side conveyor mechanisms to move the storage systems  312   a - 312   c . Preferably, electric motor screw jacks at the base of each of the four vertical frame members  99   a - 99   d  control the coordinated vertical movement of forward and rear support beams  94   a  &amp;  94   b  in the (vertical) Y axis (arrows  811   a ,  811   c ), which in turn support the three buffers  312   a ,  312   b , and  312   c . Simultaneously, coordinated forward and rear chain link belt drives (not shown but understood by those of skill in the art) within the forward and rear beams  94   a  &amp;  94   b  preferably control movement in the (horizontal) X axis (arrows  811   b ,  811   d ). 
     The respective motions are controlled and recorded so that the individual tube number and location is recorded in a storage system data structure as previously described. For example, when a circuit element  20  is prepared by automated C&amp;C center  12  and ready for transfer into a storage system tube such as  39   a , computer-controlled circuit indexing system  85  positions tube  39   a  to receive the circuit. If the next circuit is to be stored in tube  39   b , circuit indexing system  85  moves the platform vertically to prepare tube  39   b  to receive the next circuit element  20 . Those skilled in the art will be able to appreciate other means that could be used to position individual tubes to receive a completed circuit element  20  from the automated C&amp;C center  12  or to transfer a circuit element  20  to assembly system  50 . 
     In addition, the circuit indexing system  85  preferably and automatically creates an offset in the height of the forward and rear beams  99   a  and  99   b  in order to take advantage of gravity in moving circuits relative to tubes  39 , thereby creating a slight tilt in the slope of the buffers  312   a - 312   c  in order to minimize hang-ups in circuit conveyance. When used in the preferred embodiment, the buffer tilt (subtly illustrated in  FIG. 8A ) is at least four degrees when viewed from the side. Ideal buffer tilt angles for a given pneumatic conveyance system can be determined by experimenting to find the angle that most closely matches the natural trajectory of a typical circuit  20  exiting end  22   b  of tube  22 , and the computer control system is adapted to automatically introduce that determined tilt to favor the direction of conveyance. 
     Reference is now made to  FIG. 9  for an overview of the flow of the production process associated with the system and method of the present invention.  FIG. 9  is a schematic block diagram of the circuit manufacturing and wire harness assembly sub-systems of the present invention. While  FIGS. 8A, 8B , &amp;  8 C provide a better overview of the structural hardware requirements of the system,  FIG. 9  characterizes the procedural or process flow operable in conjunction with the sub-systems in a more concise view. In  FIG. 9 , automatic C&amp;C center  12  is provided with wire supply reels  14  and wire supply cartridges  16  as described above. The manufacturing process flows from the C&amp;C center to circuit indexing sub-system  24 . This sub-system  24  provides automatic prepared wire indexing, sorting, and delivery by way of the combination of pneumatic ejector tube  22  and the X-Y indexing frame/track for buffer  36  (described in detail below). 
     The indexing, sorting, and delivery system, either  24  or  85 , delivers the prepared circuit elements to indexed circuit storage system (cart/magazine/buffer)  36 . Again, as discussed above, this potentially large number of circuit elements  20  produced and stored may represent all of the necessary circuit elements for the construction of a single wire harness or may represent multiple circuit element sets appropriate for the manufacture of multiple wire harnesses. In any event, these circuit elements  20  are delivered to the programmable, automated, prepared wire index storage system (cart/magazine/buffer)  36  that, in the preferred embodiment, is a mobile cart capable of being moved from an initial location adjacent the C&amp;C center sub-systems  12 ,  22  to a location adjacent the assembly table sub-system  50 . This movement is represented in  FIG. 9  by the line connecting the solid outline circuit storage cart  36  to dashed outline circuit storage cart  36 . Essentially, the top part of  FIG. 9  represents the C&amp;C center sub-system(s)  12 ,  22  whereas the bottom part of  FIG. 9  represents the wire harness assembly sub-system  50 . 
     Once the prepared and indexed circuit elements  20  are stored in indexed circuit storage system  36 , they are moved to the assembly location where they are delivered to the wire harness assembly table  52  by way of circuit indexing sub-system  44 . In a manner essentially the reverse of the action associated with circuit indexing sub-system  24  or  85 , indexing sub-system  44  provides the automatic, indexed, prepared circuit wire delivery, by way of X-Y extraction (not shown in  FIG. 9 ) to the assembly table components of the system of the present invention. Indexing sub-system  44  is discussed below, but as noted above, essentially the reverse action of circuit index system  24  or  85  may be used to retrieve circuits in order from storage system  36  for presentation to the assembly person via conveyor belts  202  and  204 . When the retrieval system, whether using system  44 , system  85 , or a variant, delivers a circuit to the assembler, the delivered circuit element is handled by the assembly personnel and is placed on the assembly table  52  by connection to block tools (connector jigs)  62 , which in the preferred embodiment are sequentially illuminated (as described below) and electrically connected for easy identification and for subsequent electrical testing. Also as mentioned above, programmable assembly table modules  54  incorporate programmable electrical connector arrays and LED (fiber optic) indicator arrays for the purpose of facilitating and guiding the wire harness assembly. 
     Wire harness  64  is therefore assembled by placement of the individual circuit elements  20  between the connector jigs  62 . The method of progressing step by step through the process of assembling the circuit elements  20  into the wire harness  64  is assisted by at least one of the following: 1) augmented reality glasses  560  providing augmented reality display  500 ; or the programmable image projection system or harness assembly sequence projectors  56  (shown in  FIGS. 13 b    and  14 ). Once the wire harness  64  has been completely assembled (and tested and bundled), the finished wire harness product  64  is removed from the table  52  and is now ready for packaging and delivery. 
     Reference is now made to  FIG. 10A  for a more detailed description of the elements of the system of the present invention that facilitate the actual connection between a completed circuit element as described above and a connector block making up a terminal end of a portion of a wire harness assembly. As discussed above, wire harnesses are generally made of bundles of wire that are collectively gathered into a variety of different standard sized connectors which, when installed in the electronic or electrical devices associated with the wire harness, serve to appropriately connect the various components within the larger electrical or electronic device. As indicated, these connectors may be considered standard in configuration, although just as often there are unique or customized connector structures that must be utilized in a given wire harness configuration. In any event, it is an object of the present invention to provide an adaptor tooling base that allows a particular wire harness connector to be positioned on and connected to the programmable assembly table modules described above. 
     In the preferred embodiment, the assembly table modules  54  are constructed of large scale arrays of electrical and optical connections. These “breadboard” type platforms provide a programmable array of electrical connectors and fiber optic light conduits between a source (electrical or light) into the variously placed block tools positioned on the assembly table programmable modules  54 . Every different type of wire harness connector  92  (into which a bundle of completed circuit elements may be positioned) will have a specific block tool or connector jig that interfaces between the connector  92  and the assembly table programmable module  54 . In the example shown in  FIG. 10A , block tool (connector jig)  62  is configured to serve as an adaptor between the assembly table (not shown) and the wire harness connector  92  (typical). The connector interface  90  provides the specific connection between wire harness connector  92  and the standardized configuration of tool base and table interface  88 . In the preferred embodiment, this specific tool base and table interface  88  provides on one side the appropriate connections through connector interface  90  to receive and retain the specific type of connectors shown, in this case wire harness connector  92 . Connector  92  in the example shown has a connector wire circuit port array  96  positioned on a distal face so as to receive a number of individual wire/terminal circuits  48  that have been delivered to the wire harness assembly table. The assembly personnel take each of the wire/terminal circuits and insert a terminal end of the same into the appropriate connector wire circuit port positioned in port array  96 . 
     Initially, block tool  62  is connected to the assembly table programmable module  54  by way of an array of block tool connection pins  98 . As indicated above, these connections may comprise both electrical connections and optical or light connections for the transmission of not only electrical current (primarily for testing the established wire harness circuitry) but also for prompting of locations for assembly personnel placement of the individual wire/terminal circuits  48 . 
       FIGS. 10B &amp;10C  show alternate embodiments for the internal structure of the block tools (connector jigs) and therefore imply alternate embodiments for the structure of the assembly tables. It is understood that the use of visual light prompts to assist with the proper placement of each of the wire/terminal circuits  48  can be achieved either by positioning lights (such as LEDs) within interface connector  90 , as shown in FIG.  10 B, which LED lights  89  shine by way of optical wave guides  87  through electrical test probe/light prompt source  86 , and then through connector  92  to the appropriate port opening for reception of a given manufactured circuit  48 . Alternately, as shown in  FIG. 10C , block tool  62  may simply connect by way of fiber optic light guides  95  to the appropriate insertion port with a programmed LED illumination from within assembly table programmable module  54 . In other words, the light sources appropriate for prompting the proper insertion of a circuit into the connector, may originate either in the block tool itself (in which case, controller  93  positioned on microcontroller PC board  91  may serve to turn the light sources  89  on or off) or may originate within the assembly table itself, in which case fiber optic wave guides  95  in  FIG. 10C  would be required to carry such prompting light indicators to the appropriate port opening in the connector port array. 
     As indicated above, it is anticipated that the various standard sized connectors would each have a standard block tool or connector jig for use in connection with the assembly of a particular wire harness. It is anticipated that many such block tools or connector jigs would be pre-built and available for use with as many different types of connectors as would be typically constructed within the wire harnesses as assembled. In addition, generic block tools might be created to receive and retain circuits that are not directed through standard sized connector assemblies. 
     It will be understood by those skilled in the art that the various functions intended to be carried out by the block tools of the present invention may be carried out with a large number of connections (electrical and optical) between the block tool and the assembly table module (as shown in  FIG. 10C ) or may be effectively multiplexed through a small number of digital signal connections between the block tool and the assembly table (as shown in  FIG. 10B ). In other words, the block tool utilized in the present invention may be a simple (“dumb”) connector for relaying the electrical and optical circuits originating from the assembly table module to the connector to facilitate its assembly and testing, or the block tools themselves may involve “smart” devices capable of receiving a digital signal from the assembly table module and translating that signal into the appropriate testing electrical currents or the appropriate optical prompts for directing the manufacture and assembly of the wire harness in association with the various connectors. 
     The present invention anticipates a range of structural components that place more or less complexity into the structure of block tool  62  varying from simple optical and electrical connections to complex digital devices capable of receiving coded signals from the assembly table and providing (or not providing) the appropriate or inappropriate optical prompts and electrical test currents. The advantages of a “smart” block tool include the ability to repair a faulty connection by simply replacing the block tool being utilized, as well as greatly simplifying the electrical and optical structures associated with the harness assembly table module configuration. With a smart block tool, communication between the block tool and the assembly table module may require little more than a single pair of electrical wires (or the two pairs shown in  FIG. 10B ). On the opposite end of the spectrum, a simple block tool that is little more than an array of electrical and optical conductors would require a much more complex array of similar conductors and connectors between the block tool and the programmable assembly table modules. In the latter embodiment, the assembly table modules would be much more complex with each individual electrical and optical connection being carried between the table and the block tools. While this simplifies the construction of the block tool itself (making the block tools much less subject to error), the structure significantly complicates the assembly table configuration and therefore makes it more difficult to troubleshoot and solve errors and problems in the electrical and optical connections. Various installations of the systems and methods of the present invention may dictate a preference for smart block tools and much simpler construction for the assembly table modules, while other environments may dictate the use of “dumb” block tools and “smart” configurations within the assembly table modules themselves. 
     Reference is now made to  FIG. 11  for a broad overview of the entire system and associated methods of the present invention.  FIG. 11  is a mixed view hardware/software method flowchart of the overall system and method of the present invention, showing the functional relationship between the various components within the system, the data flow within the system, and the time-based sequence of production method steps involved. In general, the elements shown in  FIG. 11  may be identified according to the configuration provided for each component. The hardware sub-systems of the present invention are presented in bold rectangles (comprising the circuit manufacture sub-system and the harness assembly sub-system, as well as the harness itself). Functional operations are provided in non-bold rectangular blocks with directional arrows representing method flow. Oval shaped blocks in  FIG. 11  generally reflect data, either assembled or programmed, utilized to carry out the manufacturing methodology of the present invention. 
     As indicated above, the fundamental hardware sub-systems of the present invention comprise circuit manufacturing sub-system  122  and wire harness assembly sub-system  134 . The final goal of the overall system is the production of harnesses  136 . The process carried out may generally be considered to start with the electronic schematic  102  which is an initial (generated) schematic of the final wire harness desired to be produced. A commercially available CAD software system  104  provides a variety of functions to the operation of the overall system and the production method, as augmented by novel custom software  140 ,  112 , and  130  that produces machine readable scripts to dynamically propagate data throughout the production system. Initially, the CAD software  104  takes the electronic schematic  102  and produces a mechanical drawing  106  suitable for the prototype harness build  108 . This prototype harness then goes through harness verification  110  with a resultant output that may modify, by way of CAD software  104  and automated production script generation process  140 , the production harness instructions. This occurs generally at the creation of harness script  112  and C&amp;C center cut list  118 , both of which basic script generation  140  derives from CAD software  104 . 
     In addition to the feedback loop provided by the prototype manufacturing process, CAD software  104  integrates the data associated with the electronic schematic  102  with the automated quality control and standard catalog information functionality  114  (again, software driven). This centralized quality control software component receives data from standard catalog  116 , which in the preferred embodiment is a database of standard catalog information related to all of the various components that end up being assembled into the final manufactured wire harness. These components include wire gauge standards, terminal configurations, connector configurations, and so on. All of this information is provided by way of automated quality control and standard catalog reconciliation process  114  which provides the same through CAD software  104  to assist with the creation of harness script  112 . A further confirmatory feedback loop is provided between harness script  112  and quality control and standard catalog  114 . 
     CAD software  104 , through the mechanisms described above, generates C&amp;C center cut list  118  which directs circuit production software  120  to carry out the circuit manufacture  122 . Circuit manufacture is, as discussed above with regard to the prior figures, the manner of assembling the building block components of the wire harness, namely the circuits comprising lengths of wire with associated wire terminals. This circuit manufacture  122  is carried out with elements from component stock  128  which has been established by way of a bill of materials  124  generated by sourcing and quotes  126 , all of which derive from the automated quality control and standard catalog reconciliation software system  114 . 
     In addition to generating the C&amp;C center instructions as described above, CAD software  104  generates data files that include descriptions of individual circuits and the harness, but CAD software  104  does not singlehandedly create harness script  112  as it is used in the present invention. Rather, automated production script generation process  140  receives data files from CAD software  104  and uses novel custom software to generate harness script  112 . Harness script  112  contains circuit mechanical descriptions, circuit electrical descriptions, and wire harness manufacturing commands that are sent to assembly system  134 , and are quality checked and reconciled with standard catalog  116  by automated quality control and standard catalog reconciliation process  114 . In a preferred embodiment, harness script  112  is provided to assembly system  134  in machine-readable format and automatically directs the functional assembly of the wire harness at assembly system  134 . 
     After automated quality control and standard catalog reconciliation process  114  processes harness script  112  and develops the requisite information for tooling script  132 , tooling script automated generation  130  occurs so as to create tooling script  132 . Tooling script  132  includes a graphical driver script for assembly system  134 . In some embodiments, under the direction of tooling script  132 , assembly system  134 &#39;s projectors  512   a  and  512   b  (shown in  FIGS. 13B and 14 ) project text and graphics on layout boards and modules that direct the assembly person as to which connector blocks and turn posts to install, where to place them, and how to orient them. Tooling script  132  also directs assembly system  134  to display text and graphics, with accompanying aural information, as well as LED light points for connector blocks to indicate the proper insertion points. Further, tooling script  132  includes a series of automatically generated test vectors to verify proper configuration and operation of module configuration. 
     Tooling script  132 , in conjunction with harness script  112 , a further source of component stock  128 , and through the resultant circuit components manufactured  122 , all come together in assembly system  134  to create wire harnesses  136 . As with the prototype build system, there is a feedback loop provided from the wire harnesses  136  through harness verification process  138  back to a manner of modifying tooling script  132  to again facilitate the most efficient operation of assembly system  134 . 
     Reference is made to  FIGS. 12A-12C  which collectively provide a continuous flowchart of the production process steps for circuit manufacturing, circuit indexing and storage, and guided wire harness assembly.  FIG. 12A  provides the initiation of the production process at Step  150  where programming directed to wire harness individual prepared wire requirements (wire gauge AWG, terminal types, etc.) is carried out. The system then proceeds at Step  152  to supply wire reels and terminal cartridges (bandolier rolls) to cutting, stripping, and crimping machines. At Step  154  the system then proceeds to load programming into the cutting, stripping, and crimping machines, followed by Step  156  wherein the system generates a batch of individual prepared wires (circuits) with terminal ends. The necessary automated programming is loaded at Step  158  into the automated indexing storage cart as described above. The appropriate programming is loaded at Step  160  into wire harness assembly table and projection assembly guide as described above. Step  162  involves the sorting, indexing, and delivery of prepared circuits (as each is prepared) into the automated indexed storage cart by way of the pneumatic tube interface system. 
       FIG. 12B  continues the process wherein Step  164  involves loading the programming into wire harness assembly table and projection assembly guide. This is followed at Step  166  where the projection assembly guides operate to prompt for the selection and placement of connector jigs and cable turn posts on the assembly table module. At Step  168  the accuracy of the placement of the jigs and turn posts with electrical and light position verification is confirmed. The process then proceeds at Step  170  to move programmed indexed storage cart to the assembly area adjacent the wire harness assembly table. The system then connects the indexed storage cart to the assembly table for data communication and movement of the circuits at Step  172 . The system then, at Step  174 , delivers individual prepared wires (circuits) to the assembly table from the automated indexed storage cart with the pneumatic tube delivery interface system. 
     In the wire harness assembly step shown in  FIG. 12C , Step  176  comprises the process of running a projection assembly guide to prompt for the placement of individual delivered prepared wires (circuits) onto wire harness assembly table and into the appropriate connectors positioned on the connector jigs. This is followed at Step  178  by confirming the accuracy of the placement of the individual delivered prepared circuits by way of electrical testing and light illumination indicators. The process is repeated at Step  180  wherein additional prepared wires from the automated indexed storage cart, by way of pneumatic tube delivery system interface, are delivered to the assembly personnel for placement in association with the assembly table. At Step  182  the system confirms the complete placement of all prepared wires (circuits) onto the wire harness assembly along with the associated real time electrical testing and light illumination indicators. The system then, at Step  184 , runs the projection assembly guide to prompt for the placement of cable ties and bindings on the completed wire harness assembly. Finally, the assembly personnel, at Step  186 , remove the completed wire harness assembly from the assembly table and package it for delivery, having already been tested and verified in the manufacturing process. 
     Reference is made first to  FIGS. 13A &amp; 13B  for an overview of the various sub-systems that collectively are engaged in the overall process for the production of wire harnesses according to the present invention.  FIG. 13A  is a partial schematic view of the circuit manufacturing sub-system (C&amp;C centers) of the present invention involving the manufacture of the individual wire/terminal circuits that collectively go together to make up a wire harness. In general, reference herein to a circuit refers to the manufactured combination of a length or lengths of wire provide with (where applicable) terminal ends, that are collectively gathered into and make up the components within a wire harness. The terminal ends are variable in configuration and may simply involve a wire end stripped and tinned (with solder) for purposes of later attachment to a terminal block or circuit board. In most instances, however, a circuit comprises a length of wire that terminates at each end with a crimp-on metal terminal, typically of a pin or spade type. The crimp-on terminals may be either male or female. These metal terminals are most frequently designed to be collectively integrated into what will herein generally be referred to as a connector, which forms the end of a bundle of wires within a wire harness. 
       FIG. 13A  shows the circuit manufacturing sub-system  10  as incorporating automated C&amp;C center  12  as well as manual C&amp;C center  26 . Each of these C&amp;C centers are in turn associated with indexed circuit storage system (cart/magazine/buffer)  36 . These basic sub-systems collectively serve to manufacture the circuit elements  20  utilized in the production of the wire harness. Automated C&amp;C center  12  may be one of a number of different commercially available automated crimping machines that include an array of wire supply reels (auto feed)  14  and an associated array of wire terminal supply cartridges (rolled bands)  16 . Automated C&amp;C center  12  will typically have at least one means for programming the device. The device may be programmed by operator commands entered into C&amp;C center programming terminal  18 . In another embodiment, automated C&amp;C center  12  may be programmed from a remote data input terminal device. In yet another embodiment, automated C&amp;C center  12  may be programmed by importing files from CAD software  104 . 
     Automated C&amp;C center  12  produces a completed wire/terminal circuit  20  of a length, gauge, and terminal type, as specified by the programming provided to automated C&amp;C center  12 . Such programming is versatile and can direct automated C&amp;C center  12  to produce a large number of a single type of circuit  20  or a long list of entirely distinct circuits that together might be eventually bundled to form a wire harness. In the present invention, a very efficient operation of automated C&amp;C center  12  would be to produce a long list of individual circuits required to construct one particular type of wire harness. The C&amp;C center may produce a number of circuit sets that are indexed and stored (as described in more detail below) and then later utilized to produce a number of the same type of wire harness. 
     Functioning in parallel with automated C&amp;C center  12  is manual C&amp;C center  26 . A manual C&amp;C center  26  may be required where one or more custom circuits  32  might be anticipated in the manufacture and construction of a given wire harness. This may result from specialized terminal ends or from a non-typical wire gauge or type. In such instances, an individual circuit  32  may be manufactured at manual C&amp;C center  26  which, like automated C&amp;C center  12 , includes an array of wire supply reels  28  and an array of wire terminals supply containers (typically bulk containers)  30 . Manual mechanisms for feeding wire and hand selecting terminals to be crimped onto the wire are as known in the art for such manual C&amp;C center configurations. 
     Automated C&amp;C center  12  and manual C&amp;C center  26  each provide a completed wire/terminal circuit  20  or  32  which is delivered into an indexed circuit storage system (cart/magazine/buffer)  36  by way of an associated pneumatic conduit  22  or  34  and a circuit indexing sub-system  24 . Indexed circuit storage system  36  includes a mobile cart configured with a large array  38  of linear tubes  39 , each of which may hold one or more completed wire/terminal circuits. This array  38  of storage tubes  39  operates in conjunction with circuit indexing sub-system  24  such that every tube  39  within the array  38  of the cart/magazine/buffer  36  is identified and indexed to contain a known type of circuit element  20  or  32 . In this manner, indexed circuit storage system  36  may be programmed and loaded with a full circuit element set appropriate for the manufacture of a particular type of wire harness. Wire harnesses may of course come in a variety of configurations having less than ten circuit elements to hundreds of circuit elements. Indexed circuit storage system  36  is designed to accommodate simple or complex wire harness circuit sets. 
     The combination of circuit indexing sub-system  24  and pneumatic conduits  22  and  34  serve to deliver completed wire/terminal circuits  20  and  32  from the respective C&amp;C centers into a properly indexed storage tube within indexed circuit storage system  36 . As described in more detail below, circuit indexing sub-system  24  is in one embodiment a mechanism for moving one end of pneumatic conduit  22  and/or  34  to a position adjacent the storage cart input port array  38  on indexed circuit storage system  36 . As mentioned above, the entire indexing system may be programmed and may in the preferred embodiment be controlled by way of computer system  40 . In this manner, each completed wire/terminal circuit from the respective C&amp;C center may be directed into a known and indexed storage tube  39  where it may be held until such time as the manufacturing of that particular wire harness assembly is carried out. The basic structure of the circuit indexing sub-system  24  is an X-Y coordinate variable position frame and track system that allows for the directed movement of the end of the pneumatic delivery tube into contact with the appropriate indexed storage tube. 
     In one embodiment of the present invention, each of the storage tubes  39  associated with indexed circuit storage system  36  may be designed to retain a single circuit element  20  for later delivering during the assembly of the wire harness. Alternate embodiments of the present invention anticipate the utilization of storage tubes  39  capable of retaining a number of like circuit elements for later use and delivering such circuit elements one at a time in a repetitive manner. Therefore, the index circuit storage system (cart/magazine/buffer)  36  may be configured to receive, store and deliver a full circuit element set appropriate for the manufacture of a single wire harness or, in an alternate embodiment, the same cart may be configured to receive, store, and deliver ten or more sets of circuit elements by repeatedly drawing out a full set for the manufacture of a wire harness followed by second and subsequent full sets all from the same storage vehicle. 
     Reference is now made to  FIG. 13B . The features with the same numbers in  FIGS. 8B and 13B  are identical. Therefore, the textual descriptions that are the same for  FIG. 13B  as for  FIG. 8B  are not repeated here. In the view shown in  FIG. 13B , indexed circuit storage cart  36  is moved to a position adjacent the wire harness assembly sub-system  50 . Indexed circuit storage system  36  may include, or may be controlled by, a computer system  40  that facilitates the automation of the process of indexing, storing, and delivering the circuit elements. Although computer system  40  is shown on top of storage system  36 , in a preferred embodiment computer system  40  is a computer server system that stores information about storage system  36 &#39;s contents but is not physically attached to storage system  36 . Also shown in  FIG. 13B  is storage cart output port array  42  similar in structure to the storage cart input port array  38  shown in  FIG. 13A . In one embodiment of the present invention, storage cart output port array  42  may comprise the same array of ports as storage cart input port array  38  and cart  36  is simply turned around for receipt or delivery of the circuit elements. Alternately, these storage cart port arrays may comprise opposite ends of the mobile indexed circuit storage systems (cart/magazine)  36 . 
     As with the input of circuit elements into indexed storage circuit system  36 , the output or delivery of the circuits is carried out, in one embodiment, by way of circuit indexing sub-system  44  which effectively reverses the indexing process and selectively withdraws the appropriate circuit element from the storage cart to be delivered to the wire harness assembly sub-system  50 . This delivery is again carried out by way of pneumatic conduit  46  which withdraws a circuit element from storage system  36  and delivers it to wire harness assembly sub-system  50  for use in conjunction with the assembly process. 
     While assembly personnel manually receive circuit elements from the circuit indexing sub-system  44  by way of the pneumatic conduit  46  as described above, or from circuit indexing sub-system  85  and conveyor belts  202  and  204  as described above, the process of placing the circuit element onto the assembly table and making the appropriate connections is automatically guided and confirmed by the systems and methods of the present invention. 
     Reference is now made to  FIG. 13C  for a more detailed description of two of the more critical components within the system and method of the present invention.  FIG. 13C  is a detailed side plan view of one embodiment of a circuit indexing sub-system  44  utilized to deliver completed circuit elements into and out from the mobile storage system (cart/magazine/buffer)  36  of the present invention. It is understood that, as discussed above, such an indexing sub-system would preferably be positioned in conjunction with both the circuit manufacture sub-system  12 ,  26  (the C&amp;C centers) and the harness assembly sub-system  50  (the assembly table) and would provide the manner of directing completed circuit elements into the mobile indexing storage cart as well as providing delivery of the same from the mobile cart to the harness assembly table. Those skilled in the art will recognize that the system may preferably include two circuit indexing sub-systems, one for delivery of the manufactured circuit elements into the storage cart and one for delivery of the indexed circuit elements from the storage cart to the assembly table. Alternately, the storage cart might retain a single array of ports that serve as both the input and output ports for reception and delivery of the various circuit elements stored within the mobile cart. In other words, the circuit indexing sub-system  44  shown in  FIG. 13C  could also serve as the circuit indexing sub-system  24  described above for receiving manufactured circuit elements into the cart. It would be a simple matter of connecting and disconnecting the pneumatic hoses associated with each of the stations discussed above and appropriately programming the X-Y indexing and sorting system to either direct (pneumatically) a just completed circuit element into the storage cart or to withdraw a previously indexed circuit element from the cart. 
     In one embodiment, circuit indexing sub-system  44  is connected to pneumatic conduit  46  by way of conduit indexing shuttle ring bracket  81 . Circuit indexing sub-system  44  is generally comprised of indexing system X-Y frame  70  as well as X-Y frame controller bracket  72 . Positioned on controller bracket  72  are X-Y position DC stepping motors  74 . Each set of DC stepping motors  74  is connected to and controlled by at least one X-Y frame microcontroller  76 . DC stepping motors  74  are connected to conduit indexing shuttle ring bracket  81  by way of X-Y positioning tension cables  72   a - 78   d . These cables extend from cable drive/take-up reels  84 , each positioned on one of X-Y position DC stepping motors  74  and each terminating on conduit indexing shuttle ring bracket  81  after passing over cable corner pulleys  82 . In an alternative embodiment, shuttle ring bracket  81  may be positioned using electric screw drives rather than an arrangement of pulleys as described herein. 
     The microcontrollers  76  of the present invention therefore direct the appropriate signals to DC stepping motors  74  which turn cable drive/take-up reels  84  and by tension provided in X-Y position tension cables  72   a - 78   d  position and hold bracket  81  and its associated pneumatic conduit end  46  over any X-Y position within the X-Y frame  70 . It is understood that the array of input ports to the storage cabinet are positioned behind or adjacent to the circuit indexing sub-system  44  and are thereby accessible at any particular position that conduit indexing shuttle ring bracket  81  is placed. Depending therefore upon which storage tube within the storage cabinet a particular completed circuit element is intended to be stored, the DC stepping motors  74  direct the movement of conduit indexing shuttle ring bracket  81  (and therefore of the pneumatic conduit  46 ) to a particular location on an X-Y plane defined by the ends of the various input ports associated with the storage cabinet (not shown). Maintaining tension on each of the X-Y position tension cables  72   a - 78   d  allows for any location within the X-Y frame  70  to be moved to and maintained. 
     Once an X-Y position has been established, the system may activate the pneumatic components associated with the pneumatic conduit and direct the circuit element contained within the pneumatic conduit out from the conduit through the conduit indexing shuttle ring bracket  81  and into the appropriate input port on the portable storage cart. Those skilled in the art will recognize various mechanisms for directing air flow through the pneumatic components of the system as described above. These pneumatic components are configured to direct a flow of air through the appropriate tubing components, both for receiving circuit elements into inlet tubing components (such as by directing a negative pressure on such components) and/or to direct a flow of air out from a delivery tube component (such as by providing a positive pressure on such a delivery component). It is anticipated that the air flow movement may be directed from components within the storage cart itself creating the negative pressure necessary to draw a properly positioned circuit element into the storage cart by way of the indexed pneumatic tubing, and likewise to deliver a positive pressure flow of air from the storage cart (by way of the appropriate indexed storage tube) to the delivery pneumatic tube that has been properly positioned to carry the circuit element from the cart to the wire harness assembly table. Various other pneumatic controls, seals, valves, and control elements appropriate for implementing these two basic functions within the pneumatic system should be apparent to those skilled in the art. 
     Reference is now made to  FIG. 14  for a description of an improvement and alternate embodiment of the second half of the wire harness production process. The sub-systems described in  FIGS. 8A &amp; 8B  and other figures are generally the same and perform the same functions in the improvement described in  FIG. 14 . However, the invention in  FIG. 14  includes certain features that greatly improve upon the earlier invention. The invention in  FIG. 14  includes two conveyor belts  202  arranged so that one is parallel above the other. The distance between the two conveyor belts  202  is adjusted to the optimum distance so that each conveyor belt  202  comes in contact with the appropriate circuit element from the storage cart to be delivered to the wire harness assembly sub-system  50 . The advantage of the two conveyor belts  202  arranged in this manner is efficient and consistent delivery of the circuit element  20  from the storage cart  36  to the wire harness assembly sub-system  50 . 
     The next improvement of the invention depicted in  FIG. 14  is the addition of the double buffer assembly  300 . The double buffer assembly  300  comprises the circuit element sensor  301 , the cover assembly  302 , the circuit element buffer tray  303 , circuit element buffer  304 , and the air knife  305 . The circuit element sensor  301  senses the presence or absence of a circuit element in the circuit element buffer tray  303 . The circuit element sensor  301  may be any sensor whether optical or otherwise that can detect the presence of absence of a circuit element in the circuit element buffer tray  303 . The circuit element sensor  301  transmits the presence or absence of a circuit element in the circuit element buffer tray  303  to a computer system  40 . Upon sensing the absence of a circuit element in the circuit element buffer tray  303  the computer system  40  automatically directs the air knife  305  to deposit the buffered circuit element into the circuit element buffer tray  303  and for the delivery of the next circuit element to the circuit element buffer  304 . The air knife  305  may be any device appropriate to quickly move the circuit element from the circuit element buffer  304  to the circuit element buffer tray  303 . In the present embodiment this consists of an air knife as is known in the art. The circuit element buffer  304  is protected by the cover assembly  302 , which prevents the assembly personnel from taking the wrong circuit assembly. 
     The double buffer assembly  300  allows the assembly personnel to nearly always have the next circuit element waiting for assembly in the circuit element buffer tray  303 . The double buffer assembly  300  greatly speeds up the assembly process as the assembly personnel no longer have to wait for the delivery of the next circuit element from the indexed circuit storage cart  36 , but rather only has to wait for the nearly instantaneous delivery of the next circuit element into the circuit element buffer tray  303 . 
     The figures and descriptions in this application depict specific examples to teach those skilled in the art how to make and use the best mode of the invention. These examples are not given to limit the scope of the invention, but rather to teach inventive principles. To concisely teach inventive principles, some conventional aspects of the invention have been simplified or omitted. Those skilled in the art will appreciate many of the configurations, combinations, subcombinations, and variations on these examples that fall within the scope of the invention. For example, certain features of the invention described in separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments—separately or in any suitable subcombination. The invention is not limited to the specific illustrative examples described herein, but by all embodiments and methods within the scope and spirit of the invention as in the current, amended, or added claims and their equivalents. In any case, all substantially equivalent systems, articles, and methods should be considered within the scope of the invention.