A system for forming, in a plane, a wiring harness having a plurality of conductors each of which must follow a predetermined path, of the type which has: (a) a flat support; (b) a unit for representing each of the paths on the support; and (c) a unit for provisionally holding the conductors in position along their path. The representation unit is a coherent light beam generator, for which the flat support plays the role of screen, and which is capable of scanning the flat support so as to display thereon the light trace of the path of a given conductor of the harness. The system further has a unit for storing the information relative to the paths of the different conductors of the wiring harness, which unit is connected both to a unit for identifying a given conductor and to a unit for controlling the beam generator for displaying, on the support, the path specific to the given conductor.

A conductor tester including two contour-identical parts of a main unit and a remote unit is used to test and indicate present condition of conductors. Both the main and the remote units are formed at two ends with high and low raised portions that are provided with fastening means for the two units to detachably connect to each other to form a compact unit. The high and low raised portions are provided at side walls with notches that are electrically connected to internal circuits of the main and the remote units, and at inner walls between the high and low raised portions with light-emitting diodes. By connecting the main and/or the remote unit at two notches thereof to two ends of one or more conductors, internal circuits of the main and/or the remote unit are brought to contact with the conductor or conductors, causing one or more of the light-emitting diodes to light to indicate present conditions of the conductor or conductors, such as short circuit, open circuit, reverse connection, wrong connection, etc.

A production system (1) has workstations (2), each having a bench (3) with a movable service rail (4). Each service rail (4) is movable to allow very quick configuration of the system (1). Each rail (4) also has an electrical power duct (15) and a pneumatic supply (14) having outlets for production and test apparatus on the bench (3). There is a single switch (17) for each duct 15 and this allows interconnection to an overhead duct system (5). The production apparatus includes tools for stripping cable jackets, for unravelling individual wires (61), for stripping insulation by heating (71) and for applying connectors (104) and for applying a protective sleeve (111). A test system (130) has a controller (132) and a modular test fixture (135) with components which are easily removed and replaced.

A method for inspecting a wireharness is disclosed that enables reduced inspection time. The method comprises inspecting a wireharness, including a plurality of wires and connectors for receiving terminals attached to ends of the wires, to judge wireharness quality.

A current flowing through the automotive battery and the battery voltage are measured by the battery current measuring means and the battery voltage measuring means. The battery is connected to a plurality of wiring harnesses which in turn connect to a plurality of loads. Data on normal resistance values between the battery and the wiring harnesses as produced by each of the loads being activated are stored and held in the load current data holding means. When the resistance value comparison means determines that the resistance value between the battery and the wiring harnesses calculated by the resistance value calculating means does not agree with the data of normal resistance values between the battery and the wiring harnesses held by the load resistance data holding means and produced by each of the loads being activated, it is decided that abnormal currents are flowing through the wiring harnesses.