Patent Description:
Publications <CIT>, <CIT>, <CIT> and <CIT> are considered to be relevant to the present application.

The problem underlying the present application is solved by an apparatus having the features of claim <NUM>, a method of forming a wiring harness assembly having the features of claim <NUM> and a non-transitory computer readable storage medium having the features of claim <NUM>. Preferred embodiments are the subject matter of the dependent claims.

Presented herein is an assembly that includes a number of conductors that a separated from one another and are encased or embedded within a substrate. The substrate defines a location feature. The substrate also defines an opening that has a predetermined size and shape. A section of the plurality of separated conductors is exposed within the opening. The opening is precisely located relative to the location feature. The assembly, particularly a portion of the substrate that defines the location feature and the opening, may be advantageously formed by an automated additive manufacturing process, e.g. 3D printing, stereolithography, digital light processing, fused deposition modeling, fused filament fabrication, selective laser sintering, selecting heat sintering, multi-jet modeling, multi-jet fusion, electronic beam melting, and/or laminated object manufacturing.

The examples presented herein are directed to assemblies in which the conductors are wire electrical conductors. However, other embodiments of the assembly may be envisioned wherein the conductors are fiber optic, pneumatic, hydraulic conductors, or a hybrid assembly having combination of any of these conductors.

<FIG> illustrates an example of an automotive wiring harness assembly according to an embodiment of this invention, hereinafter referred to as the assembly <NUM>. The assembly <NUM> includes a plurality of wires <NUM> that are formed of an electrically conductive material, e.g. a metallic alloy, carbon nanostructures, and/or electrically conductive polymers. These wires <NUM> are separated from one another and are enclosed within, i.e. surrounded by, a substrate <NUM> that is integrally formed of an electrically insulative material, e.g. a dielectric polymer. As shown in <FIG>, the substrate <NUM> also defines an aperture <NUM> that extends through the substrate <NUM> and in which a section of the wires <NUM> are exposed. Referring again to <FIG>, the substrate <NUM> defines a location feature <NUM>, e.g. a fiducial mark, an edge, a corner, a notch, a slot, or a hole on/in the substrate <NUM>, that can be used by a human operator or preferably an automated assembly robot (not shown) to determine the location of the aperture <NUM>. The aperture <NUM> is precisely located relative to the location feature <NUM>. As used herein, "precisely located" means that the position tolerance of the opening relative to the location feature datum is <NUM> millimeter or less. The position tolerance of the opening may be determined by the capability of the manufacturing technology and/or the capability of the automated assembly robot. This locational relationship between the location feature <NUM> and the aperture <NUM> provides the benefit of adding connectors or electronic modules to the assembly <NUM> using robots rather than requiring human assembly operators. The wires <NUM> are also precisely located relative to one another and relative to the edges of the aperture <NUM>. As shown in <FIG>, the substrate <NUM> surrounds the aperture <NUM>. The exposed section of the wires <NUM> within the aperture <NUM> in this example have an electrically conductive surface that is not covered by an insulative jacket. The wires <NUM> are arranged and maintained by the substrate <NUM> in a predetermined order. In alternative embodiments, the exposed section of the wires <NUM> within the aperture <NUM> may be covered by an insulative jacket. As shown in <FIG>, the assembly <NUM> includes several apertures <NUM> in which several subsets of the wires <NUM> are exposed. As further shown in <FIG>, different sections of the same wires may be exposed in more than one aperture. This provides the benefit of allowing multiple connectors to be attached to the same wires. This may provide easy access to power or signal busses that are connected to more than one connector or electronic module.

This assembly <NUM> lends itself to being manufactured using an automated additive manufacturing process, such as 3D printing, stereolithography, digital light processing, fused deposition modeling, fused filament fabrication, selective laser sintering, selecting heat sintering, multi-jet modeling, multi-jet fusion, electronic beam melting, and/or laminated object manufacturing. The assembly <NUM> may be produced by the automated additive manufacturing process having a shape that is preformed to be placed within the packaging accommodation for the wiring harness within a vehicle. The assembly <NUM> is also well suited for robotic placement of the assembly <NUM> within the vehicle.

As illustrated in <FIG>, the wires <NUM> may have different diameters depending on the current carrying capabilities required by circuits formed by the wires <NUM>.

As illustrated in <FIG>, the assembly <NUM> further includes a connector <NUM> having a lower support segment <NUM> disposed within the aperture <NUM> that is secured to the substrate <NUM> by a lower locking feature <NUM>. The lower support segment <NUM> defines cradle features <NUM>, shown in <FIG> and <FIG>, having a plurality of concave arcuate surfaces that contact a lower portion of the each of the wires <NUM>, thereby supporting the wires <NUM> within the aperture <NUM>. In alternative embodiments, the lower support segment <NUM> may be integrally formed with the substrate <NUM>.

Returning to <FIG>, the connector <NUM> further includes an upper connector segment <NUM> that is received within the lower support segment <NUM> and is secured to the lower support segment <NUM> by an upper locking feature <NUM>. The upper connector segment <NUM> includes a plurality of terminals <NUM>. The terminals <NUM> have a first end <NUM> that is in mechanical and electrical contact with the wires <NUM> and a second end <NUM> that is configured to mate with a corresponding mating terminal (not shown) to form an electrical connection with a separate electrical device (not shown), e.g. an electronic control module, a lighting module, an electronic sensor, and/or another electrical wiring harness. In alternative embodiments, the upper connector segment <NUM> may be integrally formed with the substrate <NUM> and connected to the substrate <NUM> by a living hinge. As illustrated in <FIG>, the assembly <NUM> includes several connectors. The terminals <NUM> in one of these connectors may be connected to wires <NUM> common with the terminals <NUM> in another connector <NUM>. Alternatively, one of these connectors may not include terminals <NUM> that are connected to wires <NUM> common to any of the other connectors.

As illustrated in <FIG>, the first end <NUM> of each terminal <NUM> defines a forked end <NUM> that has two tines <NUM>. A wire <NUM> is received between the two tines <NUM>. The walls of the two tines <NUM> are angled so that the two tines <NUM> are in compressive contact with the wire <NUM> when the upper connector segment <NUM> is fully seated within the lower support segment <NUM>. In alternative embodiments in which the exposed section of the wires <NUM> within the aperture <NUM> is covered by an insulative jacket, the two tines <NUM> are also configured to cut through and displace the insulative jacket so that the terminal <NUM> can make compressive electrical contact with the wire <NUM> within. As shown in <FIG>, the lower support segment <NUM> defines a plurality of recesses in which the ends of the two tines <NUM> of the plurality of terminals <NUM> are received. The cradle features <NUM> of the lower support segment <NUM> support the wires <NUM> to inhibit bending of the wire <NUM> as the wire <NUM> is received within the two tines <NUM> of the terminal <NUM> and the two tines <NUM> come into compressive contact with the wires <NUM>.

In an alternative embodiment of the assembly <NUM>, the wires <NUM> have a coating that is formed of an electrically conductive material (e.g. pure tin or a tin-based solder) that has a lower melting point than the conductive material forming the wires <NUM>. The terminals <NUM> are metallurgically bonded to the wires <NUM> by a soldering or welding process due to localized heating of a portion of the coating. This heating may be performed using a laser, resistive heating of the terminal <NUM> and the wire <NUM>, application of a soldering iron, or other means.

In alternative embodiments of the assembly <NUM>, the upper connector segment <NUM> may be replaced by an upper modular segment that itself contains a relay, an electronic controller, an electronic sensor, a lighting device, and/or other electronic devices. The upper modular segment includes terminals <NUM> that have the first end <NUM> that is in mechanical and electrical contact with the wires <NUM> but the second end of the terminal is directly connected to circuitry or electrical or electronic devices within the upper modular segment rather than corresponding mating terminals.

As shown in <FIG> and <FIG>, the lower support segment <NUM> defines a lower lip <NUM> that extends laterally from the lower support segment <NUM> and engages a lower surface of the substrate <NUM> around a perimeter of the aperture <NUM>. The upper connector segment <NUM> likewise defines an upper lip <NUM> engaging an upper surface of the substrate <NUM> around the perimeter of the opening. The lower and upper lips <NUM>, <NUM> sandwich the substrate <NUM> therebetween to further secure the lower support segment <NUM> within the aperture <NUM>. This provides the benefit of limiting longitudinal movement of the connector <NUM> within the aperture <NUM>.

The lower lip <NUM> defines a lower groove <NUM> that contains a lower seal <NUM> that is formed of a compliant material (e.g. a silicone rubber). The lower seal <NUM> engages the lower surface of the substrate <NUM> around the perimeter of the aperture <NUM> and seals the interface between the lower support segment <NUM> and the substrate <NUM> to inhibit intrusion of contaminants, such as dust and fluids, into the aperture <NUM>, thereby protecting the terminals <NUM> and the wires <NUM> within the aperture <NUM>. The upper lip <NUM> similarly defines an upper groove <NUM> that contains an upper seal <NUM> that is also formed of a compliant material, such as silicone rubber, that engages the upper surface of the substrate <NUM> around the perimeter of the aperture <NUM> and seals the interface between the upper connector segment <NUM> and the substrate <NUM> to inhibit intrusion of contaminants into the aperture <NUM>, thereby protecting the terminals <NUM> and the wires <NUM> within the aperture <NUM>. A single seal design and construction may be used for the lower seal <NUM> and the upper seal <NUM> in order to provide the benefit of reduced number of unique parts in the assembly <NUM>.

In alternative embodiments of the assembly <NUM>, the assembly <NUM> may further include a first inner seal <NUM> that is located intermediate the lower support segment <NUM> and an inner surface of the aperture <NUM> that engages both the lower support segment <NUM> and the substrate <NUM>. The assembly <NUM> may also include a lower seal <NUM> that is formed of a compliant material and sealingly engages a lower inner surface of the substrate <NUM> within the aperture <NUM> to inhibit intrusion of contaminants, such as dust and fluids, into the aperture <NUM>. The first inner seal <NUM> may be used in addition to, or instead of, the lower seal <NUM>. In this or other alternative embodiments, the assembly <NUM> may additionally include a second inner seal <NUM> that is formed of a compliant material located intermediate the upper connector segment <NUM> and the lower support segment <NUM> to further inhibit intrusion of contaminants into the aperture <NUM>.

As shown in <FIG>, a first region <NUM> of the substrate <NUM> surrounding the opening is thicker than a second region <NUM> of the substrate <NUM> remote from the opening. This greater thickness of the substrate <NUM> in the first region <NUM> than the second region <NUM> provides increased stiffness in the first region <NUM> relative to the second region <NUM>. The increased stiffness in the first region <NUM> around the aperture <NUM> provides the benefit of a secure connection between the connector <NUM> and the substrate <NUM> while the decreased stiffness in areas remote from the aperture <NUM> allow the assembly <NUM> to flex in order to be installed within a vehicle. There may also be other regions of varying stiffness in the harness. These variations may provide benefits of providing mounting features or reducing the probability of the assembly <NUM> rattling when installed in the vehicle.

In alternative embodiments of the assembly <NUM>, the increased stiffness in the first region <NUM> relative to the second region <NUM> may be provided by the substrate <NUM> being formed in a particular shape, e.g. including a stiffening rib or beam. The stiffness may also vary due to differences in the structure of the material, e.g. a lattice structure vs. a solid structure, differences in thickness of the material, or use of different polymer materials having different stiffness properties e.g. polyamide and polypropylene.

In alternative embodiments of the assembly <NUM>, the substrate <NUM> is a structural portion of a motor vehicle <NUM>, such as a headliner, trim panel, body panel, floor liner, or hood liner as shown in <FIG>.

As shown in <FIG>, the assembly <NUM> also includes attachment features <NUM> that are incorporated into the substrate <NUM>. These attachment features <NUM> may be used to secure the assembly <NUM> to the structural portion of a motor vehicle <NUM>. The attachment features <NUM> may be integrally formed by the substrate <NUM> or they may be discrete parts that are incorporated into the substrate <NUM> during the forming of the substrate <NUM> by forming the substrate <NUM> around a portion of the attachment feature <NUM>. The attachment features <NUM> shown in <FIG> are eyelets that receive a stud, bolt, push pin or other attachment device having a shaft and a head. In alternative embodiments, the attachment features <NUM> may be smooth studs, treaded studs, barbed pins, "fir trees" or other attachment features <NUM> known to those skilled in the art.

Also presented herein is an apparatus that can be used to manufacture the assembly <NUM> described above. <FIG> illustrates an 3D printing apparatus according to an embodiment of the invention, hereinafter referred to as the apparatus <NUM>. The apparatus <NUM> includes an extruding device <NUM> with a dispensing head <NUM> that selectively dispenses a dielectric thermoplastic material through an orifice <NUM> in the dispensing head <NUM>. The thermoplastic material may be provided to the dispensing head <NUM> in the form of a thermoplastic filament, as used in filament deposition modeling, thermoplastic pellets, and/or a thermoplastic powder.

The apparatus <NUM> also includes a wire feed device <NUM> that selectively feeds an electrically conductive wire, hereinafter referred to as the wire <NUM>, through the orifice <NUM>. A cutting device <NUM> that is configured to selectively sever the wire <NUM> after it passes through the orifice <NUM> is also included in the apparatus <NUM>. The wire <NUM> may already be surrounded by an insulative jacket prior to passing through the orifice <NUM>.

This apparatus <NUM> further comprises an electromechanical device <NUM>, such as a robotic arm, that holds the extruding device <NUM>, the wire feed device <NUM>, and the cutting device <NUM> and is configured to move the extruding device <NUM>, the wire feed device <NUM>, and the cutting device <NUM> within a 3D space.

The apparatus <NUM> additionally encompasses an electronic controller <NUM> that is in communication with the extruding device <NUM>, the wire feed device <NUM>, the cutting device <NUM>, and the electromechanical device <NUM>. The electronic controller <NUM> has one or more processors and memory. The processors may be a microprocessors, application specific integrated circuits (ASIC), or built from discrete logic and timing circuits (not shown). Software instructions that program the processors may be stored in a non-volatile (NV) memory device (not shown). The NV memory device may be contained within the microprocessor or ASIC or it may be a separate device. Non-limiting examples of the types of NV memory that may be used include electrically erasable programmable read only memory (EEPROM), masked read only memory (ROM), and flash memory. The memory device contains instructions that cause the electronic controller <NUM> to send commands to the electromechanical device <NUM> that direct the electromechanical device <NUM> to move the extruding device <NUM>, the wire feed device <NUM>, and the cutting device <NUM> within the 3D space. The memory device also contains instructions that cause the electronic controller <NUM> to send commands to the extruding device <NUM> to directing it to selectively dispense the dielectric material through the orifice <NUM>. The memory device furhter contains instructions that cause the electronic controller <NUM> to send commands to wire feed device <NUM> to instruct it to selectively feed the wire <NUM> through the orifice <NUM> and cause the cutting device <NUM> to selectively sever the wire <NUM>.

The memory device may further contain contains instructions that cause the electronic controller <NUM> to send commands to the extruding device <NUM>, the wire feed device <NUM> the cutting device <NUM> that direct the extruding device <NUM> to selectively dispense the dielectric material through the orifice <NUM> as the electromechanically device moves the extruding device <NUM> in the 3D space to form the substrate <NUM>, cause the wire feed device <NUM> to selectively feed the wire <NUM> through the orifice <NUM>, and the cutting device <NUM> to selectively sever the wire <NUM> as the electromechanically device moves the wire feed device <NUM> and the cutting device <NUM> in the 3D space to form a plurality of wires <NUM> formed of the wire <NUM> that are subsequently encased within the substrate <NUM> by the extruding device <NUM>. The memory device may further contain contains instructions that cause the electronic controller <NUM> to send commands to the electrotechnical device and the extruding device <NUM> to define a location feature <NUM> in the substrate <NUM> and define an aperture <NUM> in the substrate <NUM> which has a predetermined size and shape in which a portion of the wires <NUM> is exposed. This aperture <NUM> is precisely located relative to the location feature <NUM>.

According to an alternative embodiment of the apparatus <NUM>, the apparatus <NUM> further includes a 3D curved surface <NUM> upon which the extruding device <NUM> selectively dispenses the dielectric material and the wire feed device <NUM> to selectively deposits the conductive wire. This 3D curved surface <NUM> provides the benefit of forming the assembly <NUM> with a predetermined shape.

This alterative embodiment may also include a heating device <NUM> in communication with the electronic controller <NUM> and is configured to heat a portion of the 3D curved surface <NUM>. The memory device may further contain contains instructions that cause the electronic controller <NUM> to send commands to the heating device <NUM> to selectively heat the portion of the curved surface <NUM>. This feature provides the benefit of heating the thermoplastic material while forming the substrate <NUM> in order to produce a desired shape or material properties.

This alterative embodiment may additionally or alternatively include a cooling device <NUM> that is also in communication with the electronic controller <NUM> and is configured to cool a portion of the 3D curved surface <NUM>. heating device <NUM> the cooling device <NUM> to selectively cool the portion of the curved surface <NUM>. This feature provides the benefit of cooling the thermoplastic material while forming the substrate <NUM> in order to produce a desired shape or material properties. The heating device <NUM> and the cooling device <NUM> may be the same device, e.g. a thermoelectric device.

Additionally, a method <NUM> of operating the apparatus <NUM>, as described above, to manufacture the assembly <NUM>, also as described above is presented herein. <FIG> illustrates an example of a method <NUM> of forming a wiring harness assembly <NUM> using an apparatus <NUM> comprising an extruding device <NUM> having a dispensing head <NUM>, a wire feed device <NUM>, a cutting device <NUM>, an electromechanical device <NUM>, and an electronic controller <NUM> in communication with the extruding device <NUM>, the wire feed device <NUM>, the cutting device <NUM>, and the electromechanical device <NUM>.

The steps of the method <NUM> of operating the apparatus <NUM> are described below:.

STEP <NUM>, DISPENSE A DIELECTRIC MATERIAL USING AN extruding device <NUM>, includes selectively dispensing a dielectric material through an orifice <NUM> in the dispensing head <NUM> by operating the extruding device <NUM> in accordance with a command from the electronic controller <NUM>;.

STEP <NUM>, FEED A CONDUCTIVE WIRE USING A WIRE FEED DEVICE, includes selectively feeding a wire <NUM> through the orifice <NUM> by operating the wire feed device <NUM> in accordance with a command from the electronic controller <NUM>;.

STEP <NUM>, SEVER THE CONDUCTIVE WIRE USING A CUTTING DEVICE, includes selectively severing the wire <NUM> by operating the cutting device <NUM> in accordance with a command from the electronic controller <NUM>;.

STEP <NUM>, MOVE THE EXTRUDING DEVICE, THE WIRE FEED DEVICE, AND THE CUTTING DEVICE WITHIN A 3D SPACE BY OPERATING AN ELECTROMECHANICAL DEVICE, includes moving the extruding device <NUM>, the wire feed device <NUM>, and the cutting device <NUM> within a 3D space by operating the electromechanical device <NUM> in accordance with a command from the electronic controller <NUM>;.

STEP <NUM>, FORM A PLURALITY OF ELECTRICALLY CONDUCTIVE WIRES, includes forming a plurality of wires <NUM> by operating the wire feed device <NUM>, the cutting device <NUM>, and the electromechanical device <NUM> in accordance with a command from the electronic controller <NUM>;.

STEP <NUM>, FORM A SUBSTRATE, includes forming a substrate <NUM> made of the dielectric material that encases the plurality of wires <NUM> by operating the extruding device <NUM> and the electromechanical device <NUM> in accordance with a command from the electronic controller <NUM>;.

STEP <NUM>, FORM A LOCATION FEATURE, includes forming a location feature <NUM> in the substrate <NUM> by operating the extruding device <NUM> and the electromechanical device <NUM> in accordance with a command from the electronic controller <NUM>; and.

STEP <NUM>, FORM AN OPENING IN THE SUBSTRATE, includes forming an opening or an aperture <NUM> in the substrate <NUM> having a predetermined size and shape in which a portion of plurality of wires <NUM> is exposed by operating the extruding device <NUM> and the electromechanical device <NUM> in accordance with a command from the electronic controller <NUM>, wherein the opening or aperture <NUM> is precisely located relative to the location feature <NUM>.

In an alternative embodiment of the method <NUM>, the apparatus <NUM> further includes a 3D curved surface <NUM> and the method <NUM> further includes a step of selectively dispensing the dielectric material onto the curved surface <NUM> by operating the extruding device <NUM> and the electromechanical device <NUM> in accordance with a command from the electronic controller <NUM>. This embodiment may further include a cooling device <NUM> in communication with the electronic controller <NUM> and configured to cool a portion of the curved surface <NUM> and the method <NUM> further comprises the step of cooling the portion of the curved surface <NUM> by operating the cooling device <NUM> in accordance with a command from the electronic controller <NUM>. This embodiment may alternatively or additionally include a heating device <NUM> in communication with the electronic controller <NUM> and configured to heat a portion of the curved surface <NUM> and the method <NUM> further comprises the step of heating the portion of the curved surface <NUM> by operating the heating device <NUM> in accordance with a command from the electronic controller <NUM>.

Accordingly, a wiring harness assembly <NUM>, an apparatus <NUM> configured to form the wiring harness assembly <NUM>, and a method <NUM> of operating the apparatus <NUM> is provided. The wiring harness provides the benefits of allowing robotic assembly of the wiring harness and robotic installation of the wiring harness into a vehicle or any other subassembly.

While this invention has been described in terms of the preferred embodiments thereof, it is not intended to be so limited, but rather only to the extent set forth in the claims that follow. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to configure a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments, and are by no means limiting and are merely prototypical embodiments.

Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the following claims, along with the full scope of equivalents to which such claims are entitled.

As used herein, 'One or more' includes a function being performed by one element, a function being performed by more than one element, e.g., in a distributed fashion, several functions being performed by one element, several functions being performed by several elements, or any combination of the above.

The terminology used in the description of the various described embodiments herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term "and/or" as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms "includes," "including," "comprises," and/or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

While terms of ordinance or orientation may be used herein, these elements should not be limited by these terms. All terms of ordinance or orientation, unless stated otherwise, are used for purposes distinguishing one element from another, and do not denote any particular order, order of operations, direction or orientation unless stated otherwise.

Although the present disclosure is not so limited, the following numbered examples demonstrate one or more aspects of the disclosure.

Example <NUM>. An apparatus (<NUM>), comprising: an electronic controller (<NUM>) having a memory device; an extruding device (<NUM>) in communication with the electronic controller (<NUM>), said extruding device (<NUM>) having a dispensing head (<NUM>) configured to selectively dispense a dielectric material though an orifice (<NUM>) in the dispensing head (<NUM>) in accordance with a command from the electronic controller (<NUM>); a wire feed device (<NUM>) in communication with the electronic controller (<NUM>), said wire feed device (<NUM>) connected to the extruding device (<NUM>) and configured to selectively feed a conductive wire (<NUM>) through the orifice (<NUM>) in accordance with a command from the electronic controller (<NUM>); a cutting device (<NUM>) in communication with the electronic controller (<NUM>), said cutting device (<NUM>) connected to the extruding device (<NUM>) and configured to selectively sever the conductive wire (<NUM>) after it is fed through the orifice (<NUM>) in accordance with a command from the electronic controller (<NUM>); and an electromechanical device (<NUM>) in communication with the electronic controller (<NUM>), said electromechanical device (<NUM>) connected to the extruding device (<NUM>) and configured to move the extruding device (<NUM>), the wire feed device (<NUM>), and the cutting device (<NUM>) within a 3D space in accordance with a command from the electronic controller (<NUM>).

Example <NUM>. The apparatus (<NUM>) according to example <NUM>, wherein the memory device contains instructions that cause the electronic controller (<NUM>) to transmit the command to the electromechanical device (<NUM>) to move the extruding device (<NUM>), the wire feed device (<NUM>), and the cutting device (<NUM>) within the 3D space, wherein the memory device contains instructions that cause the electronic controller (<NUM>) to transmit the command to the extruding device (<NUM>) to selectively dispense the dielectric material though the orifice (<NUM>), wherein the memory device contains instructions that cause the electronic controller (<NUM>) to transmit the command to the wire feed device (<NUM>) to selectively feed the conductive wire (<NUM>) through the orifice (<NUM>), and wherein the memory device contains instructions that cause the electronic controller (<NUM>) to transmit the command to the cutting device (<NUM>) to selectively sever the conductive wire (<NUM>).

Example <NUM>. The apparatus (<NUM>) according to example <NUM>, wherein the wherein the memory device contains instructions that cause the electronic controller (<NUM>) to transmit commands to the electromechanical device (<NUM>), the extruding device (<NUM>), the cutting device (<NUM>), and the wire feed device (<NUM>) to move the extruding device (<NUM>), the wire feed device (<NUM>), and the cutting device (<NUM>) within a 3D space, while the extruding device (<NUM>) simultaneously selectively dispenses the dielectric material though the orifice (<NUM>), while the wire feed device (<NUM>) simultaneously selectively feeds the conductive wire (<NUM>) through the orifice (<NUM>), and while the cutting device (<NUM>) simultaneously selectively severs the conductive wire (<NUM>) to form a plurality of electrically conductive wires (<NUM>) formed of the conductive wire (<NUM>), a substrate (<NUM>) formed of the dielectric material encasing the plurality of electrically conductive wires (<NUM>), a location feature (<NUM>) defined in the substrate (<NUM>), and an opening defined in the substrate (<NUM>) having a predetermined size and shape in which a portion of plurality of electrically conductive wires (<NUM>) is exposed, wherein the opening is precisely located relative to the location feature (<NUM>).

Example <NUM>. The apparatus (<NUM>) according to any one of examples <NUM> to <NUM>, further comprising: a curved surface (<NUM>) upon which the extruding device (<NUM>) selectively dispenses the dielectric material.

Example <NUM>. The apparatus (<NUM>) according to example <NUM>, further comprising: a cooling device (<NUM>) in communication with the electronic controller (<NUM>) and configured to cool a portion of the curved surface (<NUM>) in accordance with a command from the electronic controller (<NUM>), wherein the memory device contains instructions that cause the electronic controller (<NUM>) to transmit the command to the cooling device (<NUM>) to selectively cool the portion of the curved surface (<NUM>).

Example <NUM>. The apparatus (<NUM>) according to example <NUM>, further comprising: a heating device (<NUM>) in communication with the electronic controller (<NUM>) and configured to heat a portion of the curved surface (<NUM>) in accordance with a command from the electronic controller (<NUM>), wherein the memory device contains instructions that cause the electronic controller (<NUM>) to transmit the command to the heating device (<NUM>) to selectively heat the portion of the curved surface (<NUM>).

Example <NUM>. A method (<NUM>) of forming a wiring harness assembly (<NUM>) using an apparatus (<NUM>) comprising an extruding device (<NUM>) having a dispensing head (<NUM>), a wire feed device (<NUM>), a cutting device (<NUM>), an electromechanical device (<NUM>), and an electronic controller (<NUM>) in communication with the extruding device (<NUM>), the wire feed device (<NUM>), the cutting device (<NUM>), and the electromechanical device (<NUM>), the steps of the method (<NUM>) comprising: selectively dispensing (<NUM>) a dielectric material though an orifice (<NUM>) in the dispensing head (<NUM>) by operating the extruding device (<NUM>) in accordance with a command from the electronic controller (<NUM>); selectively feeding (<NUM>) a conductive wire (<NUM>) through the orifice (<NUM>) by operating the wire feed device (<NUM>) in accordance with a command from the electronic controller (<NUM>); selectively severing (<NUM>) the conductive wire (<NUM>) by operating the cutting device (<NUM>) in accordance with a command from the electronic controller (<NUM>); and moving (<NUM>) the extruding device (<NUM>), the wire feed device (<NUM>), and the cutting device (<NUM>) within a 3D space by operating the electromechanical device (<NUM>) in accordance with a command from the electronic controller (<NUM>).

Example <NUM>. The method (<NUM>) according to example <NUM>, further comprising the steps of: forming (<NUM>) a plurality of electrically conductive wires (<NUM>) by operating the wire feed device (<NUM>), the cutting device (<NUM>), and the electromechanical device (<NUM>) in accordance with a command from the electronic controller (<NUM>); forming (<NUM>) a substrate (<NUM>) of the dielectric material encasing the plurality of electrically conductive wires (<NUM>) by operating the extruding device (<NUM>) and the electromechanical device (<NUM>) in accordance with a command from the electronic controller (<NUM>); forming (<NUM>) a location feature (<NUM>) in the substrate (<NUM>) by operating the extruding device (<NUM>) and the electromechanical device (<NUM>) in accordance with a command from the electronic controller (<NUM>); and forming (<NUM>) an opening in the substrate (<NUM>) having a predetermined size and shape in which a portion of plurality of electrically conductive wires (<NUM>) is exposed by operating the extruding device (<NUM>) and the electromechanical device (<NUM>) in accordance with a command from the electronic controller (<NUM>), wherein the opening is located relative to the location feature (<NUM>).

Example <NUM>. The method (<NUM>) according to example <NUM> or <NUM>, wherein the apparatus (<NUM>) further comprises a curved surface (<NUM>) and the method (<NUM>) further comprises the step (<NUM>) of selectively dispensing the dielectric material onto the curved surface (<NUM>) by operating the extruding device (<NUM>) and the electromechanical device (<NUM>) in accordance with a command from the electronic controller (<NUM>).

Example <NUM>. The method (<NUM>) according to example <NUM>, wherein the apparatus (<NUM>) further comprises a cooling device (<NUM>) in communication with the electronic controller (<NUM>) and configured to cool a portion of the curved surface (<NUM>) and the method (<NUM>) further comprises the step (<NUM>) of cooling the portion of the curved surface (<NUM>) by operating the cooling device (<NUM>) in accordance with a command from the electronic controller (<NUM>).

Claim 1:
An apparatus (<NUM>), comprising;
an extruding device (<NUM>) configured to selectively dispense a dielectric material through an orifice (<NUM>);
a wire feed device (<NUM>) configured to selectively feed a conductive wire (<NUM>) through the orifice (<NUM>);
a cutting device (<NUM>) configured to selectively sever the conductive wire (<NUM>) after it is fed through the orifice (<NUM>); and
an electronic controller (<NUM>) configured to control the extruding device (<NUM>), the wire feed device (<NUM>), and the cutting device (<NUM>), wherein the electronic controller (<NUM>) commands the extruding device (<NUM>) to selectively dispense the dielectric material through the orifice (<NUM>), the wire feed device (<NUM>) to selectively feed the conductive wire (<NUM>) through the orifice (<NUM>), and the cutting device (<NUM>) to selectively sever the conductive wire (<NUM>), thereby forming a dielectric substrate (<NUM>) encasing a plurality of conductive wires (<NUM>), characterized in that the electronic controller (<NUM>) is further configured to command the extruding device (<NUM>) to form an opening defined in the substrate (<NUM>) in which the plurality of electrically conductive wires (<NUM>) is exposed and a fiducial mark (<NUM>) that is usable by an automated assembly robot to determine the location of the opening, wherein a position tolerance of the opening relative to the fiducial mark (<NUM>) is <NUM> millimeter or less.