Method and device for producing an at least partly wrapped wiring harness for an onboard electrical system of a vehicle

Abstract

The invention relates to a method for producing an at least partly wrapped wiring harness for an onboard electrical system of a vehicle, having the steps of: - providing a support layer (4) with a receiving surface (5) for a wiring harness (7), - positioning the wiring harness (7) on the receiving surface (5) of the support layer (4), which has support layer overlapping regions (8, 9) that project beyond the wiring harness (7), - providing a cover layer (14), which has cover layer overlapping regions (16, 17) that project beyond the wiring harness (7), and - actuating a device (11) that generates a pulling force and pulls and / or presses a cover layer enclosing region (20) into contact with the wiring harness (7) so as to enclose same, thereby adapting the shape and / or contour of the enclosing region, wherein the cover layer overlapping regions (16, 17) rest against a correspondingly paired support layer overlapping region (8, 9) and are connected to same such that the composite consisting of the cover layer (14) and the support layer (4) wraps the wiring harness (7). The support layer (4) and / or the cover layer (14) are assembled such that specified regions and / or components of the wiring harness (7) are exposed and are not coated by the support layer (4) and / or cover layer (14). The invention additionally relates to a device for carrying out such a method.

Description

[0001] Method and device for producing a cable harness for a vehicle electrical system that is at least partially bandaged

[0002] Technical area

[0003] The present invention relates to a method and a device for producing a wiring harness for an on-board network of a vehicle that is at least partially bandaged.

[0004] State of the art

[0005] It is generally known to electrically connect electrical or electronic components of a vehicle, such as electrical power sources, switching elements, electrical consumers, and control units, using a function-based or customer-specific configured electrical wiring harness to form an on-board network in which information is exchanged between the various on-board network components or these are supplied with electrical energy. Such a wiring harness, also known as a wiring harness, is formed by a plurality of electrical conductors or electrical lines (hereinafter referred to simply as electrical conductors) combined to form a conductor bundle, to the ends of which, for example, electrical connectors or similar connection elements can be attached.In addition to cable ties, bandages are primarily used to bundle electrical conductors into a conductor bundle. These are usually adhesive tapes that are wrapped around the electrical conductors to be bundled at predetermined intervals. An automated solution for bandaging with adhesive tape is difficult or very complex to implement because the rotating movement requires the adhesive tape to penetrate the cable harness level twice with each winding revolution, with the cable harness representing an interfering contour each time. Automation is therefore not only technically demanding but also very complex to achieve, so that the bandaging of the cable harnesses is still largely carried out manually and not automatically.

[0006] Description of the invention

[0007] The object of the invention is therefore to provide a method and a device for producing a wiring harness for an on-board network of a vehicle that is at least partially bandaged, with which the bandaging of a wiring harness can be carried out in a technically simple manner with a high degree of automation.

[0008] This object is achieved by the features of the independent claims. Advantageous developments of the invention are specified in the subclaims, the following description, and the figures.

[0009] The method according to the invention for producing a cable harness for a vehicle's electrical system that is at least partially bandaged in relation to the longitudinal direction of the cable harness comprises at least the following steps: providing a carrier layer with a receiving surface for a cable harness that is formed by a plurality of electrical conductors combined to form a conductor bundle,

[0010] - Arranging the cable harness on the receiving surface of the carrier layer, wherein the carrier layer projects beyond the cable harness at least transversely to its longitudinal direction with carrier layer overlapping areas,

[0011] - Providing a cover layer on the side of the cable harness facing away from the carrier layer and thus in the area above the cable harness, wherein the cover layer projects beyond the cable harness at least transversely to its longitudinal direction with cover layer overlap areas assigned to the carrier layer overlap areas,

[0012] - Actuating a device which generates an attractive force, the device acting on the cover layer in such a way that a cover layer enveloping region of the cover layer which lies between the cover layer overlap regions, at least in relation to the transverse direction, is pulled and / or pressed into a shape- and / or contour-adapted contact with the cable set which envelops the cable set, preferably up to the carrier layer, wherein the cover layer overlap regions also bear against a correspondingly assigned carrier layer overlap region and are connected to it, so that the composite of cover layer and carrier layer bandages the cable set in the circumferential direction.

[0013] Such an inventive solution enables simple automation of the bandaging of cable harnesses, since the bandaging is performed by simply layering the elements required for bandaging (carrier layer, cable harness, cover layer), thus eliminating the need for any rotational movement around the cable harness. With the inventive solution, the positioning of the carrier layer, the placement of the cable harness on the carrier layer, the application of the cover layer, as well as any necessary cutting and / or removal of the finished bandaged cable harness can be fully automated, resulting in a significant reduction in cycle times, so that not only the production effort but also the production time for bandaging cable harnesses can be significantly reduced.The method according to the invention is also characterized by the fact that process monitoring can be significantly simplified and also automated.

[0014] The method according to the invention also enables flexible design options for the bandaging of cable harnesses, as, for example, add-on components can be easily integrated and / or different materials can be used. For example, the carrier layer can be made of a different material than the cover layer, which offers the possibility of integrating additional functions, such as soundproofing measures in conjunction with a carrier layer made of a sound-absorbing material, to name just one example.

[0015] However, the later exposure of covered connection elements such as plugs and / or attachments can be problematic because these, such as plugs and the contacts formed there, often have very fine contours and cavities which have a springy and tolerance-compensating function. If these are exposed to adhesive residue while covered, for example, this can lead to unacceptable functional restrictions. In addition, adhesive residue on connection elements such as cable lugs can increase the electrical resistance when installed in the vehicle. Finally, subsequent removal of the covering, for example by trimming the covering, where the cut is made close to and perpendicular to the cable insulation, carries a high risk of damaging the cable insulation or even severing the conductors.For this reason, it is further provided according to the invention that the carrier layer and / or the cover layer are or will be prepared in such a way that predetermined areas and / or components of the cable harness, in particular connection elements and / or attachments of the cable harness, are exposed and are not bandaged, wrapped and / or coated with the carrier layer and / or cover layer after carrying out the method according to the invention.

[0016] The assembly of the carrier layer and / or cover layer preferably takes place prior to the provision of the respective layer, e.g., in a process stage preceding the actual process, but can also be integrated into the process, e.g., by cutting the carrier layer and / or cover layer after its provision in a dedicated device. Therefore, it is essential and important that assembly takes place before the device generating an attractive force is activated to ensure that the desired parts and / or areas of the cable harness are exposed.

[0017] Accordingly, according to a particularly preferred specific embodiment, it is provided that the cover layer and / or the carrier layer extend over the entire length of the cable harness up to the conductor ends of the electrical conductors and / or connection elements attached to the conductor ends, in particular plug connectors, preferably in such a way that the conductor ends and / or connection elements are not bandaged by the composite of cover layer and carrier layer.

[0018] Alternatively or additionally, in particular for a further reduction of rework or material consumption, it can be provided that the cover layer and / or the carrier layer have a shape that corresponds to that of the wiring harness.

[0019] According to a further particularly preferred embodiment, at least the carrier layer overlap regions of the carrier layer and / or at least the cover layer overlap regions of the cover layer are provided with an adhesion promoter, at least in some regions, so that the carrier layer overlap regions and cover layer overlap regions, which are brought into contact with one another and assigned to one another, are firmly bonded to one another. This ensures a functionally reliable sheathing of the cable harness over its entire circumference. It is understood, however, that not only the carrier layer overlap regions or the cover layer overlap regions can be provided with such an adhesion promoter, but the entire carrier layer or the entire cover layer can be provided with such an adhesion promoter.For example, according to a particularly preferred embodiment, the entire cover layer can be provided with an adhesion promoter, so that not only can the cover layer overlap areas be firmly bonded to the carrier layer overlap areas, but the cover layer can also be firmly bonded to the covered wiring harness. Accordingly, according to a particularly preferred embodiment, the cover layer sheathing area is provided at least partially with an adhesion promoter, so that the cover layer sheathing area, which envelops the wiring harness in a form-fitting and / or contour-adapted manner, is at least partially firmly bonded to the wiring harness. This then results in the desired tight-fitting bandaging of the finished, bandaged wiring harness that conforms to the wiring harness after the application of the attractive force.

[0020] In principle, any material suitable for creating a material-to-material bond between two components can be used as an adhesion promoter. Adhesives are particularly suitable as adhesion promoters for joining different components or materials, as they can be easily applied to at least one of the surfaces to be joined. In principle, it is possible to apply such an adhesive, for example, to the cover layer and then heat it together with the cover layer, which may be in the form of a film, in order to activate the adhesive. However, this is relatively complex, so the use of an adhesive as an adhesion promoter that enables the bond to form at room temperature is preferred. Such "cold adhesives" thus enable rapid bonding without the use of heat.Examples of such cold adhesives include cyanoacrylate adhesives or polyurethane adhesives, to name just a few.

[0021] In conjunction with the carrier layer, a complete coating of the carrier layer with an adhesion promoter can serve to fix the wiring harness in a desired position after application, so that the wiring harness arranged on the carrier layer is reliably held throughout the entire process. This can, of course, also be achieved in other ways than just using an adhesion promoter, for example, using other fixing elements or fastening elements. Therefore, according to a particularly preferred embodiment of the present invention, it is advantageous for the wiring harness to be fixed on and / or to the carrier layer using at least one fastening element.

[0022] The carrier layer can, in principle, have any suitable shape, for example, even be rectangular. However, in conjunction with a material-saving design, it is advantageous if the carrier layer has a shape that corresponds, at least in sections, to that of the wiring harness.

[0023] To ensure the desired covering of the cable harness by means of the cover layer, it is advantageous for the cover layer to be flexible, preferably so flexible that the cover layer is suitable for enclosing the cable harness in a preferably essentially gap-free, form- and / or contour-adapted manner. This is achieved, for example, by a cover layer film, for example, made of a plastic material. The material thickness or the thickness of the cover layer film is preferably 10 μm to 2 mm.

[0024] For the automation and / or the functionally reliable sheathing of the cable harness, it is also particularly advantageous if the cover layer, preferably before actuation of the device generating an attractive force, is lowered onto the composite of cable harness and carrier layer in such a way that at least the cover layer sheathing region of the cover layer is arranged with a preferably small gap directly above the cable harness or alternatively the cover layer sheathing region rests on the cable harness.As a result, the cover layer can then be pulled and / or pressed in a particularly simple and process-reliable manner by the attractive force of the device generating an attractive force with its cover layer enveloping area into the shape and / or contour-adapted system on the cable harness, preferably up to the carrier layer, and with its cover layer overlapping areas into a system on the respectively assigned carrier layer overlapping areas.

[0025] The device for generating an attractive force can also be designed in principle in different ways. For example, the attractive force could theoretically also be generated electromagnetically, although this is relatively complex. According to a particularly preferred and practical embodiment, the device for generating an attractive force is formed by a vacuum device, the actuation of which creates a negative pressure as an attractive force. Vacuum technology makes it easy to reduce the pressure in a defined space and thus create a vacuum. With a vacuum device, the attractive force can therefore be generated in a technically high-quality and functionally reliable manner. Alternatively or in addition to the embodiment variant specifically described above with a suppression orIn the case of a vacuum device, the device for generating an attractive force could also be formed by an overpressure device, the actuation of which generates an overpressure as an attractive force. The overpressure technology makes it easy to increase the pressure in a defined space and thus exert the desired pressure on the carrier layer. With an overpressure device, the attractive force can be generated in a technically high-quality and functionally reliable manner. According to a particularly preferred specific embodiment in this regard, it is provided that the vacuum device has a preferably air-permeable positioning table which has a support surface for the carrier layer, and a vacuum-generating device, preferably a vacuum pump, by means of which the air is drawn from the area to be evacuated above the positioning table, preferably through the air-permeable positioning table.In conjunction with such a concrete structure, the desired attraction force can be implemented in a technically simple manner with a reduced component expenditure and a small space requirement.

[0026] In connection with the vacuum device, there are fundamentally different ways in which the attractive force generated by the vacuum can specifically affect the covering layer surrounding the cable set, which is explained in more detail below:

[0027] Thus, according to a first embodiment, the carrier layer can be designed to be air-permeable at least in some regions, preferably at least in a region associated with the cover layer. The vacuum device then sucks the air present between the air-permeable upper layer and the carrier layer through the carrier layer, creating a negative pressure as an attractive force acting directly on the cover layer. This force draws the cover layer enveloping region into a shape- and / or contour-adapted contact with the cable harness, preferably up to the carrier layer. Preferably, this also draws the cover layer overlap regions to the associated carrier layer overlap regions.The latter is preferably carried out by means of a material-to-material bond between the cover layer overlapping regions and the associated carrier layer overlapping regions, for example by means of an adhesion promoter, and / or preferably in such a way that the associated cover layer overlapping regions and carrier layer overlapping regions abut one another in a substantially gas-tight manner, so that no air can flow between the adjacent cover layer overlapping regions and carrier layer overlapping regions. The latter, in turn, contributes significantly to ensuring a functionally reliable attraction or suction of the cover layer onto the cable harness in the desired shape and / or contour-adapted manner. With such a process, the cover layer is preferably formed over a large area and held in a frame of an upper tool, with which the cover layer is then lowered onto the carrier layer accommodating the cable harness.To ensure a gas-tight process and create a vacuum beneath the cover layer, the cover layer preferably covers the entire cable harness over a large area. This design may require the removal of a relatively large amount of excess material to ensure a bandage that conforms to the course and extent of the cable harness. Furthermore, heating the cover layer is advantageous for a reliable process with a relatively large cover layer.

[0028] According to an alternative and particularly preferred method, an air-impermeable process cover is provided which is arranged in the vertical axis direction above the cover layer and interacts with the cover layer and which, during operation of the vacuum device, seals off the area of ​​the cable harness to be bandaged, including the cover layer and carrier layer areas required for this, in a gas-tight manner to the outside. This can be implemented, for example, in such a way that the process cover is placed in a gas-tight manner on an area of ​​the carrier layer adjoining the carrier layer overlap areas in the direction away from the cable harness and / or on the positioning table of the vacuum device during operation of the vacuum device, which counteracts any subsequent flow of air into the area below the process cover.In this embodiment, the vacuum device thus sucks out the air present beneath the process cover and a negative pressure is generated as an attractive force acting directly on the process cover, which pulls the process cover downwards towards the carrier layer, whereby the process cover presses the cover layer enveloping area into the form and / or contour-adapted system on the cable set, preferably up to the carrier layer, and the process cover further presses the cover layer overlap area onto the associated carrier layer overlap areas, preferably with a material-to-material connection of the cover layer overlap areas to the associated carrier layer overlap areas.A process control with such a process cover has the advantage that not only the carrier layer but also the cover layer can have a shape that corresponds at least partially, preferably completely, to that of the cable harness, since the vacuum is generated not under the cover layer but under the process cover. This allows both the carrier layer and the cover layer to be prefabricated in a material-saving manner, and the cycle time and production effort can be further reduced, since cutting the bandaged cable harness following the bandaging process can essentially be dispensed with entirely or only requires minimal effort.

[0029] In addition, in this design variant with a process cover, it is particularly easy to avoid covering the entire cable harness including its conductor ends or connection elements with the cover layer, since, as already explained, the vacuum is not generated under the cover layer, but under the process cover.

[0030] For particularly reliable process control, it is advantageous if the process cover, which is preferably formed by a film and thus forms a process film, is designed to be flexible in such a way that it is suitable for pressing the cover layer into a system that envelops the cable set, preferably in a substantially gap-free manner and adapted to its shape and / or contour. The process cover can be formed, for example, from a plastic film or the like. A further advantage of such a process cover is that it can be reused at any time, which is particularly advantageous in conjunction with an automated process. There are basically several ways to arrange the cover layer in the desired manner beneath the process cover. For example, it can be provided that the cover layer is detachably connected to the process cover.This ensures, on the one hand, that the cover layer and the process cover can be moved together, for example, using a correspondingly assigned tool. Furthermore, in this context, it is preferred if the detachable connection is designed such that the process cover can be detached from the cover film after it has adhered to the cable harness. This can be achieved, for example, by ensuring that the adhesive force of the cover film to the cable harness is greater than the adhesive force of the cover film to the process cover, to name just one example.

[0031] Alternatively, according to a particularly advantageous embodiment, it can also be provided that the cover layer, in particular independently of the process cover, is positioned on the cable set in advance or before the process cover is lowered, for example using a separate tool or the same tool to which the process cover is held. In this case, the process cover itself can be held in a frame, for example, which is lowered downwards, for example shortly before the vacuum device is activated, so that the process cover presses the cover layer onto the cable set and the carrier layer with the aid of the negative pressure in the manner already described. The process cover can then be lifted upwards again with the frame.

[0032] Even though it is fundamentally possible to heat the cover layer even in the variant with a process cover (including adhesive activation), the particular advantage of conducting the process with a process cover is that this is not necessary, which significantly simplifies both the process control and the construction of a corresponding device for carrying out the process. As already explained above, the cover layer, or the cover layer and the process cover, can be held and moved reliably and precisely on an upper tool arranged above the carrier layer and thus above the cable harness in relation to the vertical axis and lowerable downwards towards the carrier layer.

[0033] The carrier layer and the cover layer can, in principle, be formed from the same material, for example, a film, in particular a plastic film. As already explained above, however, the process according to the invention also allows for the carrier layer to be formed from a different material than the cover layer. Accordingly, the carrier layer can generally preferably be formed from a film and / or a fabric. Alternatively or additionally, the carrier layer can also be formed from a synthetic material, preferably plastic, or from a natural material, for example, based on natural fibers, to name just a few examples.

[0034] According to a further additional and particularly advantageous embodiment, it can be provided that the carrier layer is arranged on a support surface of a positioning table, wherein the support surface has at least one cavity forming a channel-like depression in the support surface, which cavity is suitable and / or designed to at least partially accommodate at least one conductor of the cable harness in the cavity, wherein the extension direction of the at least one cavity corresponds to the extension direction of the at least one conductor to be arranged therein. The carrier layer comprises a carrier layer cavity section that lines the at least one cavity, wherein the at least one conductor is arranged in the cavity after the at least one cavity has been lined with a carrier layer cavity section.

[0035] The embodiment allows the conductor(s) of a cable harness to be positioned in a functionally reliable manner in a desired manner, so that the bandaging of the cable harness can be carried out precisely and reliably by subsequently applying a cover layer. The introduction of one or more conductors into the cavity after the lining of the at least one cavity with a carrier layer cavity section thus enables precise fixing and arrangement of the conductors in a cavity. Improved fixing of the conductors and thus greater process reliability are achieved in particular with a further optional embodiment, according to which it is provided that the side of the carrier layer facing the at least one conductor is provided at least regionally or at least sectionally with an adhesion promoter, for example with an adhesive layer.

[0036] In principle, it is possible to provide a single cavity capable of accommodating a single conductor, a bundle of conductors, or even an entire cable assembly. This makes the process versatile, as it can be adapted to various cable configurations. It is further understood that the at least one conductor does not have to be completely accommodated within the cavity, although this can of course be the case. However, the conductor(s) can also protrude upwards above the opening plane formed by the support surface, which facilitates application for conductors of different thicknesses or irregular shapes.

[0037] The fact that the extension direction of the at least one cavity is aligned with the extension direction of the at least one conductor accommodated therein results in a high degree of flexibility in adapting to a wide variety of conductor or conductor set configurations. The cavities can, for example, be straight, curved, or wave-shaped, thus precisely replicating the configuration of the conductors. Intersecting conductors and correspondingly intersecting cavities are also possible, making the device even more versatile.

[0038] At this point, it should be expressly noted that the conductors of a wiring harness can be not only electrical conductors, but can alternatively or additionally be formed by any other type of conductor that can be part of a wiring harness. This includes, for example, optical conductors, such as fiber optic cables or fiber optic cables, pneumatic or hydraulic lines for the transport of liquids or gases, as well as data lines or communication lines for the transmission of signals. Mechanical conductors, such as pull or push rods, as well as conductors for heat transfer, such as thermal lines or refrigerant lines, also fall under this term. The term "conductor" or "electrical conductor" is therefore expressly used throughout this description as a synonym for any type of conductor and not just for electrical conductors alone.

[0039] Even if the formation of a single cavity is fundamentally possible, according to a particularly preferred embodiment, the support surface, based on a cross-section of the positioning table, has a plurality of cavities spaced apart from one another in the transverse direction and forming channel-like depressions in the support surface, which cavities are suitable and / or designed to at least partially accommodate at least one conductor of the cable harness in the cavity, wherein the extension direction of the cavities corresponds to the extension direction of the at least one conductor to be arranged therein. In this embodiment, the carrier layer comprises a plurality of carrier layer cavity sections that line the cavities, wherein the at least one conductor is arranged in the cavity assigned to it after the cavities have been lined with a carrier layer cavity section.This design allows multiple conductors of a cable harness to be positioned precisely and reliably in multiple cavities. This allows for faster and more efficient processing of complex cable configurations.

[0040] In principle, the lining of the at least one cavity can be achieved by means of the carrier layer cavity section in any desired and arbitrary manner. This can be done, for example, with an at least partial gap from the cavity wall or, preferably, such that the at least one carrier layer cavity section lines the at least one cavity at least partially, preferably completely, in a shape- and / or contour-adapted manner. The shape- and contour-adapted lining of the cavity maximizes the available space for the conductor(s) and protects the carrier layer in the region of its cavity sections from damage, thus resulting in efficient use of the cavity space and high material durability.

[0041] According to another particularly preferred embodiment, a device generating an attractive force is provided, by means of which a defined carrier layer region is pulled and / or pressed into the at least one cavity to form one or more carrier layer cavity sections. Such a device generating an attractive force can be designed in different ways, as will be explained in more detail below. Within the scope of the present invention, the term "attractive force" or "attractive force-generating device" is thus to be understood in a comprehensive and broad sense.It includes not only an attractive force in the classic sense, such as that generated by a vacuum or magnetic forces, but also any other form of force suitable for bringing the cover layer into a shape and / or contour-adapted contact with the wiring harness and / or suitable for acting on the carrier layer area required to form a carrier layer cavity section. This expressly includes a contact force, pressing force or similar effects, such as those that can be generated by an overpressure device or other mechanical, pneumatic or hydraulic devices. The term “attractive force” is therefore intended to generally cover any device or device that generates an attractive force.include any force that is suitable for pulling and / or pushing the cover layer in a form-fitting and / or contour-adapted manner to the wiring harness and that is suitable for pulling, pushing and / or shaping the carrier layer regions into the cavities.

[0042] In this context, it is particularly advantageous if the device generating an attractive force is formed in a dual function by the device acting on the cover layer for applying an attractive force, or at least is used and employed together with this, thereby ensuring more efficient process control. In principle, however, the device generating an attractive force can also be formed by a separate unit independent of the device acting on the cover layer. In principle, the device generating an attractive force can be controlled in such a way that, in the case of the formation of several carrier layer cavity sections, carrier layer regions assigned to the cavities are pulled and / or pressed together or in groups into the respectively assigned cavities. However, this can bewith certain materials, have the disadvantage that an uneven material flow occurs, which can create tensions in the carrier layer, making precise and form-fitting adjustment of the carrier layer cavity sections difficult. Furthermore, there may be a risk that an excess or shortage of material occurs in certain cavities, which could lead to faulty bandaging. Therefore, according to a particularly preferred embodiment, it is particularly advantageous if the device generating an attractive force for forming a plurality of carrier layer cavity sections is controlled such that defined carrier layer regions assigned to the cavities are pulled and / or pressed one after the other into the assigned cavities.

[0043] The advantage of this process lies in the fact that the material flow can be controlled and precisely regulated, enabling uniform deformation of the carrier layer. This minimizes stresses in the material and ensures precise and form-fitting adaptation of the carrier layer in each cavity, resulting in greater process reliability and improved quality of the final product.

[0044] According to another particularly preferred embodiment, the carrier layer is fixed to the support surface only in regions or sections, and a carrier layer region associated with the at least one cavity, which forms a carrier layer cavity section, rests freely and unfixed on the support surface and can be pulled and / or pressed into the associated cavity by means of the device generating an attractive force. The fixing can be achieved by any suitable fixing device, for example, by a hold-down device or similar holding device. However, the fixing device, with a dual function, is particularly preferably also formed by the device generating an attractive force.

[0045] By fixing the carrier layer section by section to the support surface, not only is a controlled material flow enabled, but the material is also specifically "guided." This means that the unfixed carrier layer areas can be precisely pulled or pushed into the cavities, while the fixed areas remain stable and unwanted flow or displacement of the material is prevented. This controlled material flow ensures that the material is evenly distributed and optimally adapts to the cavities. This results in a clean and form-fitting formation of the carrier layer cavity sections, which significantly improves the quality of the deformation. This approach also prevents the occurrence of stresses or deformation defects, as the material always flows exactly where it is needed. At the same time, this leads to greater process stability, as the material flow is not disrupted by external influences.Thus, the controlled movement of the material contributes significantly to increasing the precision and efficiency of the entire process and significantly improving the production of the carrier layer cavity sections.

[0046] These advantages are achieved in particular with a particularly preferred development, according to which it is provided, for example, that the support surface, based on a cross-section through the positioning table, forms a support surface support area on both sides of the at least one cavity, on which the carrier layer rests before the actuation of the device generating the attractive force, overlapping the at least one cavity with a carrier layer support area.The device generating an attractive force is controlled in such a way that it generates an attractive force in the cavity and on at least one support surface support region simultaneously or with a time delay in order to fix a carrier layer support region to the at least one support surface support region and to pull or push a carrier layer region intended for forming a carrier layer cavity section and adjacent to the carrier layer support region into the cavity, so that the carrier layer cavity section is formed.

[0047] In principle, when the device generating the attractive force is activated, both support surface support areas, together with the cavity located between them or assigned to them, could be subjected to an attractive force in such a way that both carrier layer support areas resting on the support surface support areas are fixed and only the adjacent, unfixed carrier layer area covering the cavity is pulled and / or pushed into the cavity, forming the carrier layer cavity section. However, this may have the disadvantage that simultaneous application of force to both support surface support areas can create stresses in the carrier layer, leading to undesirable deformations. There is also a risk that the material flow into the cavities is uneven or insufficient, which can result in inadequate formation of the carrier layer cavity sections.Accordingly, according to a particularly preferred embodiment, it is provided that the device generating the attractive force is controlled such that it generates an attractive force in the cavity and on a support surface support area simultaneously or with a time delay in order to fix the carrier layer support area resting on the support surface support area and to pull and / or push the adjacent carrier layer area covering the cavity into the cavity to form the carrier layer cavity section, wherein carrier layer material flows from the unfixed carrier layer support area.

[0048] By applying pressure to only one support surface area and one cavity (either simultaneously or sequentially), the material flow can be better controlled while simultaneously minimizing stresses, enabling uniform, controlled deformation of the carrier layer. The subsequent flow of material from the unfixed second support surface area ensures that the carrier layer fits neatly into the cavity without wrinkles, resulting in precise and form-fitting formation of the carrier layer cavity sections.

[0049] Preferably, the method is carried out such that, after the formation of the at least one carrier layer cavity section and based on a cross-section through the carrier layer and / or the positioning table, the carrier layer has opposing edge regions that rest on the support surface and form the carrier layer overlap regions. This allows the cover layer to be bonded to the carrier layer in a simple and functionally reliable manner.

[0050] The carrier layer can be specifically heated before forming the at least one carrier layer cavity section to increase its flexibility and enable precise deformation into the cavities. Alternatively, the carrier layer can also be designed in such a way that it has sufficient flexibility even in the cold state to be deformed into the cavities without stress and without heating. This ensures precise formation of the carrier layer cavity sections.

[0051] Basically, as already explained, there are various ways to generate an attractive force to pull or push the carrier layer into the cavity. One possibility is the use of mechanical devices, such as molds or punches, which physically press the defined area of ​​the carrier layer into the cavity. Pneumatic or hydraulic systems could also be used as attractive force generating devices to exert pressure on the carrier layer and thus ensure precise deformation. Furthermore, electromagnetic forces could also be conceivable as attractive forces to move the carrier layer into the cavity by means of a suitable device. However, an embodiment in which the attractive force generating device is formed by a vacuum device and / or an overpressure device is particularly preferred.The use of a vacuum device enables the carrier layer to be drawn into the cavities in a controlled and precise manner using negative pressure. This is particularly advantageous when it comes to gently forming thin or delicate materials, as the negative pressure acts evenly across the entire surface and reduces the risk of forming errors. A positive pressure device, on the other hand, offers the advantage of being able to force the material into the cavities in a targeted manner. This is particularly useful when using thicker or stiffer materials that require more force to be formed into the cavities. A combination of vacuum and positive pressure device, on the other hand, offers the advantage that the forming process can be flexibly adapted to different material properties and geometries.

[0052] According to a specific embodiment, it can be provided, for example, that the device generating an attractive force is formed by a vacuum device, the actuation of which generates a negative pressure as an attractive force. The support surface is provided with openings at least in some regions, preferably at least in the region of the at least one cavity, most preferably in the region of the at least one cavity and in the support surface support regions, through which a negative pressure can act as an attractive force on the carrier layer. This allows a defined carrier layer region to be drawn into the cavity or onto the support surface and the cavity in a simple and functionally reliable manner.

[0053] According to a particularly preferred embodiment, a cavity and / or at least one associated support surface area forms or forms a section that can be individually controlled by the vacuum device and subjected to negative pressure. This embodiment offers several possibilities for technical implementation. Each cavity or each support surface area can be controlled separately by the vacuum device and subjected to negative pressure. Alternatively, a cavity together with at least one associated support surface area can form a section and be controlled by the vacuum device and subjected to negative pressure. This opens up the possibility of specifically suctioning and fixing or deforming certain areas of the carrier layer.This modular design allows the different sections to be controlled independently of each other, allowing flexible adaptation of the process to different line configurations with high process reliability.

[0054] Optionally, the individual sections can be sealed against each other. Sealing the sections prevents the generated negative pressure from escaping between the sections. This ensures that the pressure is applied precisely and effectively to the desired areas of the carrier layer without unintentionally affecting other sections.

[0055] According to a further embodiment, it can be provided alternatively or additionally that the device generating an attractive force is formed by an overpressure device, upon actuation of which an overpressure is generated as an attractive force, wherein the overpressure device interacts with a tool, for example an upper tool, or is a component of a tool, for example an upper tool, which is provided with openings at least in some regions, preferably at least in the region of the at least one cavity, most preferably in the region of the at least one cavity and in the support surface support regions, so that when the tool is resting on or lowered onto the support surface of the positioning table, which forms a lower tool, for example, an overpressure can act on the carrier layer arranged on the support surface.This allows a defined carrier layer area to be pressed into the cavity or onto the support surface and the cavity in a simple and reliable manner.

[0056] At this point, it should be expressly noted that the terms "upper" and "lower," for example, in connection with the term "tool," as well as the term "lower," throughout this description and the claims, always refer only to a simplified representation chosen for reasons of clarity, in which the orientation occurs along a vertical axis. However, these terms are not to be understood as restrictive with regard to a specific spatial direction. They are merely intended to illustrate the relative position of the tools to one another by way of example. It is expressly pointed out that the terms are reversible in any way and do not imply a commitment to a specific spatial direction.For example, the "upper" tool can be arranged in a different spatial direction, such as horizontally or laterally, while the "lower" tool is positioned at a correspondingly different location. Likewise, the term "lowering" can describe a movement in any direction, be it vertically, horizontally, or in another direction of movement, and it also includes movements in which the two tools are moved toward each other simultaneously. This applies equally to all terms used in the context of spatial direction or movement. Any reference to spatial directions or directions of movement is therefore for clarity only and does not limit the scope of the invention.

[0057] According to a particularly preferred embodiment, it is provided that a first tool area of ​​the tool assigned to a cavity and / or at least one second tool area assigned to a carrier layer support area forms or form a section that can be individually controlled by the overpressure device and subjected to overpressure. This embodiment variant offers several possibilities for technical implementation. Each cavity or each support surface support area can be separately controlled by the overpressure device and subjected to overpressure. Alternatively, a cavity together with at least one assigned support surface support area can form a section and be controlled by the overpressure device and subjected to overpressure. This opens up the possibility of specifically fixing or deforming certain areas of the carrier layer.This modular design allows different sections to be controlled independently, allowing flexible adaptation of the process to different line configurations and ensuring high process reliability. Optionally, the individual sections can be sealed against each other. Sealing the sections prevents the generated overpressure from escaping between the sections. This ensures that the pressure is applied precisely and effectively to the desired areas of the carrier layer without unintentionally affecting other sections.

[0058] The object of the invention is further achieved by a device for producing a cable harness for a vehicle electrical system that is bandaged at least in sections with respect to the longitudinal direction of the cable harness, which device has at least the following features:

[0059] - a positioning table, preferably permeable to air, as the lower tool, which is suitable and designed to form a support surface for a carrier layer, on the receiving surface of which a cable set formed by a plurality of electrical conductors combined to form a conductor bundle can be arranged in such a way that the carrier layer projects beyond the cable set at least transversely to its longitudinal direction with carrier layer overlapping areas,

[0060] - at least one upper tool arranged above the positioning table with respect to the vertical axis and lowerable towards the positioning table, to which a cover layer or a cover layer and / or a process cover can be releasably secured, wherein the cover layer is suitable and designed to project beyond the cable set, preferably when the cover layer is resting on the cable set and / or in the lowered state of the positioning table, at least transversely to its longitudinal direction of extension with cover layer overlap regions assigned to the carrier layer overlap regions, an attractive force generating device which is suitable and designed to act on the cover layer when the upper tool is lowered and thus when the cover layer is lowered in such a way that a cover layer enveloping region of the cover layer lying between the cover layer overlap regions is formed into a cover layer enveloping region of the cable set, preferably up to the carrier layer,enveloping, shape- and / or contour-adapted system is pulled and / or pressed, wherein each of the cover layer overlap areas rests against a correspondingly assigned carrier layer overlap area and is connected to it, so that the composite of cover layer and carrier layer bandages the cable harness in the circumferential direction, and wherein the carrier layer and / or the cover layer are manufactured in such a way that predetermined areas and / or components of the cable harness, in particular connecting parts and / or attachments of the cable harness, are exposed and are not bandaged, wrapped and / or coated with the carrier layer and / or cover layer.

[0061] The advantages resulting from the device according to the invention are identical to those of the inventive method described in detail above. Therefore, to avoid repetition, reference is made to the above explanations.

[0062] This applies analogously to the preferred and optional embodiments of the device, according to which the support surface has at least one cavity forming a channel-like depression in the support surface, which cavity is suitable and / or designed to at least partially accommodate at least one conductor of the cable harness in the cavity, wherein the extension direction of the at least one cavity corresponds to the extension direction of the at least one conductor to be arranged therein, and wherein the at least one cavity is suitable and / or designed to be lined with a carrier layer cavity section of a carrier layer arranged on the support surface.

[0063] In addition, for the following optional embodiment, according to which it is provided that the support surface, based on a cross section of the positioning table, has a plurality of cavities spaced apart from one another in the transverse direction and forming channel-like depressions in the support surface, which cavities are suitable and / or designed to accommodate at least one conductor of the cable harness at least partially in the cavity, wherein the extension direction of the cavities of the

[0064] direction of extension of the at least one conductor to be arranged therein.

[0065] Furthermore, for the following optional embodiment, according to which it is provided that the cavities are suitable and / or designed to be lined with carrier layer cavity sections of a carrier layer arranged on the support surface.

[0066] Furthermore, for the following optional embodiment, according to which it is provided that a device generating an attractive force is provided, by means of which a defined carrier layer region can be pulled and / or pressed into the at least one cavity to form one or the at least one carrier layer cavity section.

[0067] Furthermore, for the following optional embodiment, according to which it is provided that the device generating an attractive force for forming a plurality of carrier layer cavity sections is controllable such that defined carrier layer regions assigned to the cavities can be pulled and / or pressed individually one after the other into the assigned cavities.

[0068] Furthermore, for the following optional embodiment, according to which it is provided that a fixing device, preferably the device generating an attractive force as the fixing device, is provided, which is suitable and / or designed to fix the carrier layer only in regions or sections on the support surface, so that a carrier layer region assigned to the at least one cavity, which forms a carrier layer cavity section, rests freely and unfixed on the support surface and can be pulled and / or pressed into the assigned cavity.

[0069] Furthermore, for the following optional embodiment, according to which it is provided that the support surface, based on a cross-section through the positioning table, forms a first support surface support region and a second support surface support region on both sides of the at least one cavity, which are suitable and / or designed to support a carrier layer support region of a carrier layer. In addition, the device generating an attractive force is suitable and / or designed to generate an attractive force in the cavity and on at least one support surface support region simultaneously or with a time delay in order to fix a carrier layer support region to the at least one support surface support region and to pull or push a carrier layer region intended for forming a carrier layer cavity section and adjacent to the carrier layer support region into the cavity to form a carrier layer cavity section.

[0070] Furthermore, for the following optional embodiment, according to which it is provided that the device generating the attractive force is suitable and / or designed to generate an attractive force in the cavity and on a support surface support area simultaneously or with a time delay in order to fix the carrier layer support area resting on the support surface support area and to pull and / or push the adjacent carrier layer area covering the cavity into the cavity to form the carrier layer cavity section, wherein carrier layer material flows from the unfixed carrier layer support area.

[0071] In addition, for the following optional embodiment, according to which it is provided that the device generating an attractive force is formed by a vacuum device and / or by an overpressure device.

[0072] Furthermore, for the following optional embodiment, according to which it is provided that the device generating an attractive force is formed by a vacuum device, upon actuation of which a negative pressure can be generated as an attractive force, wherein the support surface is provided at least in some regions, preferably at least in the region of the at least one cavity, most preferably in the region of the at least one cavity and in the support surface support regions, with openings through which a negative pressure can act as an attractive force on the carrier layer. Furthermore, for the following optional embodiment, according to which it is provided that a cavity and / or at least one associated support surface support region forms or form a section that can be individually controlled by the vacuum device and subjected to negative pressure.

[0073] Furthermore, for the following optional embodiment, according to which it is provided that the device generating an attractive force is formed by an overpressure device, upon actuation of which an overpressure can be generated as an attractive force, wherein the overpressure device interacts with an upper tool or is a component of an upper tool that is provided with openings at least in some regions, preferably at least in the region of the at least one cavity, most preferably in the region of the at least one cavity and in the support surface support regions. As a result, when the upper tool rests on or is lowered onto the support surface of the positioning table as the lower tool, an overpressure can act on the carrier layer arranged on the support surface.

[0074] Furthermore, for the following optional embodiment, according to which it is provided that a first tool area of ​​the tool assigned to a cavity and / or at least one second tool area assigned to a carrier layer support area of ​​the support surface forms or form a section that can be individually controlled by the overpressure device and subjected to overpressure.

[0075] And finally, also for the following optional design, according to which the individual sections are sealed against each other.

[0076] All advantages resulting from the optional device configurations are thus identical to those of the optional process configurations already described in detail above. To avoid repetition, reference is made to the above explanations regarding the optional process configurations. The bandaged wiring harness produced using the method or device according to the invention can, in principle, be used in any type of on-board electrical system, such as the on-board electrical systems of aircraft, ships, railways, commercial vehicles (trucks, buses, etc.), and especially in automotive engineering.

[0077] Character description

[0078] Advantageous embodiments of the invention are explained in more detail below with reference to the accompanying figures. They show:

[0079] Fig. 1 is a schematic diagram of a first embodiment with a positioning table including a carrier layer and a cable set arranged thereon in cross section,

[0080] Fig. 2 shows a schematic diagram corresponding to Figure 1 with an integrated attachment,

[0081] Fig. 3 is a schematic diagram corresponding to Figure 1 with an upper tool and a cover layer in an exploded view,

[0082] Fig. 4 is a schematic diagram corresponding to Figure 3 with the upper tool lowered before the vacuum device is activated,

[0083] Fig. 5 is a view corresponding to Figure 4 after the vacuum device has been activated and the upper tool has been lifted,

[0084] Fig. 6 shows a cross-section through the finished bandaged cable harness which is cut by means of a cutting device (not shown), Fig. 7 shows a schematic diagram of a second embodiment with a carrier layer arranged on a positioning table together with the cable harness,

[0085] Fig. 8 shows a schematic diagram corresponding to Figure 7 with integrated attachment,

[0086] Fig. 9 is a schematic diagram corresponding to Figure 7 with a process cover, a cover layer and an upper tool in an exploded view,

[0087] Fig. 10 is a schematic diagram corresponding to Figure 9 during the lowering of the upper tool, during which the covering layer is adhered to the cable set,

[0088] Fig. 11 is a schematic diagram corresponding to Figure 9 and Figure 10 with the upper tool lowered after the vacuum device has been activated,

[0089] Fig. 12 a schematic diagram corresponding to Figure 11 with the finished cable set with the upper tool lifted,

[0090] Fig. 13 is a schematic diagram of a positioning table with a support surface having cavities on which a carrier layer is arranged in the ground state,

[0091] Fig. 14 shows the representation corresponding to Figure 13 with a first carrier layer cavity section drawn into a first cavity,

[0092] Fig. 15 is a representation corresponding to Figure 14, in which a second carrier layer cavity section is additionally drawn into a second cavity, Fig. 16 is a schematic representation corresponding to Figures 13 to 15, in which all carrier layer cavity sections are formed so that conductors of a cable set can be inserted into the cavities lined with the carrier layer cavity sections,

[0093] Fig. 17 shows an alternative embodiment to the embodiment of Figures 13 to 16 with an upper tool and an overpressure device,

[0094] Fig. 18 is a representation corresponding to Figure 17, with formed carrier layer cavity sections.

[0095] Figure 1 shows a schematic diagram of part of a device 1 for producing a wiring harness for a vehicle's electrical system that is bandaged at least in sections, namely a positioning table 2, which is designed here as an example to be air-permeable, as the lower tool, which forms a support surface 3 for a carrier layer 4, on the receiving surface 5 of which a wiring harness 7 formed by a plurality of electrical conductors 6 combined to form a conductor bundle is arranged such that the carrier layer 4 projects beyond the wiring harness 7, as shown in the image plane of Figure 1, transversely to its longitudinal direction of extension with carrier layer overlapping regions 8, 9.

[0096] As shown only in dashed lines and schematically in Figure 1, the carrier layer 4 is coated with an adhesive layer 10 on its upper side facing away from the positioning table 2.

[0097] The positioning table 2 is here part of a vacuum device 11, which further comprises a vacuum pump 12, by means of which, in the example shown here, the air can be drawn through the air-permeable positioning table 2 from the area to be evacuated above the positioning table 2, as will be explained in more detail below.

[0098] Figure 2 shows a representation corresponding to Figure 1, but with the difference that an add-on part 13 is also integrated into the carrier layer 4. The further process is explained in more detail below on the basis of the schematic diagram in Figure 1, although this further process could of course also be carried out in conjunction with Figure 2.

[0099] Figure 3 shows, purely schematically and by way of example, an upper tool 15 arranged above the positioning table 2 or above the cable harness 7 and lowerable towards the positioning table 2. A cover layer 14, which in Figure 3 is also arranged above the cable harness 7, can be detachably arranged on this upper tool 15, wherein the cover layer projects beyond the cable harness 7, relative to the image plane of Figure 3 and thus transversely to the longitudinal direction of the cable harness 7, with the cover layer overlap regions 16, 17 assigned to the carrier layer overlap regions 8, 9.

[0100] The cover layer 14 is preferably formed here by a plastic film. The carrier layer 4 can also be formed by a plastic film, for example, made of the same material as the cover layer 14, but can alternatively also be formed by a different material, for example, a fabric.

[0101] As shown only schematically and in dashed lines in Figure 3, the cover layer 14 is provided with an adhesive layer 18 on its underside facing the cable set 7.

[0102] In the example shown here, the cover layer 14 is designed to be airtight and, as schematically indicated by arrow 19 in Figure 4, is lowered downwards by means of the upper tool 15 until the cover layer overlap areas 16, 17 come into contact with the associated carrier layer overlap areas 8, 9, which are then firmly bonded to one another by means of the adhesive layers 10, 18. Furthermore, due to its adhesive layer 18, the cover layer 14 also preferably adheres to the upper side of the cable harness 7.

[0103] Furthermore, only the cover layer 14 can be provided with the adhesive layer 18, but not the carrier layer 4 with the adhesive layer 10. This variant still enables the cover layer 14 to adhere to the upper side of the cable harness 7 or the cover layer overlap regions 16, 17 to the carrier layer overlap regions 8, 9.

[0104] In this embodiment, the carrier layer 4, like the positioning table 2, is designed to be permeable to air, so that when the vacuum device 11 or the vacuum pump 12 is actuated, the air between the air-impermeable cover layer 14 and the carrier layer 4 is sucked out above the positioning table 2 and the carrier layer 4, thus generating a negative pressure as an attractive force.This has the effect that the attractive force draws a cover layer enveloping region 20 lying between the cover layer overlap regions 16, 17, as shown in Figure 5, into a shape and / or contour-adapted contact with the cable harness 7, enveloping the cable harness up to the carrier layer 4, and preferably also draws the cover layer overlap regions 16, 17 to the associated carrier layer overlap regions 8, 9, specifically, as the comparison of Figures 4 and 5 shows, with further material-locking connection of the cover layer overlap regions 16, 17 to the associated carrier layer overlap regions 8, 9. As a result, the mutually associated cover layer overlap regions 16, 17 and carrier layer overlap regions 8, 9 lie against one another in a gas-tight manner, so that no air can flow through them into the region between the cover layer 14 and the carrier layer 4.

[0105] The upper tool 15, shown only schematically here, can, for example, have or be formed with a rectangular frame, which, like the cover layer 14 held on it, then completely encloses or surrounds the entire cable harness 7 at its edges, which is not shown in detail here. This ensures that the area beneath the air-impermeable cover layer 14 can be reliably evacuated and that the cover layer adheres or clings to the cable harness 7 in the desired manner.

[0106] As shown in Figure 5, the cable harness 7 is now tightly bandaged in the desired manner by the composite of carrier layer 4 and cover layer 14, so that the upper tool 15 can be lifted from the positioning table 2 as the lower tool according to arrow 21 and the bandaged cable harness 7 can be removed from the device 1. As shown only very schematically in Figure 6 by the arrows 22, 23, a cutting can then be carried out at the end of the bandaging process, for example by means of a cutting device not shown here.

[0107] Figures 7 to 12 show a further alternative embodiment of the device 1 according to the invention and the method according to the invention, which are described in more detail only to the extent that they differ from the first embodiment of Figures 1 to 6:

[0108] The schematic diagrams in Figures 7 and 8 are identical to those in Figures 1 and 2, so that reference is made to the previous explanations in this regard.

[0109] Figure 9 now shows the upper tool 15 together with the cover layer 14 and a process cover 24. The process cover 24 is formed, for example, by a flexible process film made of a plastic material, so that it is suitable for pressing the cover layer 14, in a manner described below, into a system that encloses the cable set 7, preferably in a substantially gap-free manner and in a shape and / or contour-adapted manner. As can be seen only schematically from Figure 10, the cover layer 14 together with the process cover 24 can be displaced downwards towards the positioning table 2 by means of the upper tool 15. For this purpose, the cover layer 14 can, for example, be detachably connected to the process cover 24. Alternatively, the cover layer 14 can also be held independently of the process cover 24, for example, on a separate tool (not shown) or likewise held on the upper tool 15.In this case, the cover layer 14 is then positioned in advance, ie before the process cover 24 is lowered onto the cable set 7.

[0110] The upper tool 15 is then, in each of the cases, as schematically shown in Figure 11, preferably moved downwards so far that the air-impermeable process cover 24, during operation of the vacuum device 11, seals off the area of ​​the cable set 7 to be bandaged, including the cover layer and carrier layer areas required for this, in a gas-tight manner to the outside, so that as little air as possible can flow into the area below the process cover.

[0111] If the vacuum device 11 or the vacuum pump 12 is now actuated, it sucks out the air present beneath the process cover 24 and thus creates a negative pressure as an attractive force acting directly on the process cover 24, which pulls the process cover 24 downwards in the direction of the carrier layer 4, wherein the process cover 24 presses the cover layer enveloping region 20 into the shape and / or contour-adapted contact with the cable set 7, enveloping the cable set 7 up to the carrier layer 4, and the process cover 24 further presses the cover layer overlap regions 16, 17 onto the associated carrier layer overlap regions 8, 9, again preferably with a material-to-material connection of the cover layer overlap regions 16, 17 to the associated carrier layer overlap regions 8, 9, as is schematically shown in Figure 11.In this embodiment with a process cover 24, the cover layer 14 can be designed to be either air-permeable or air-impermeable. The same applies to the carrier layer 4, which can also be air-permeable or air-impermeable. In the latter case, i.e., with an air-impermeable carrier layer 4, it is only necessary to ensure that a free space 25 remains between the process cover 24 and the carrier layer 4, which allows the air to be extracted from beneath the process cover 24. This is shown only schematically and in principle in Figure 11.

[0112] Thus, the cable harness is now tightly bandaged in the circumferential direction by the composite of cover layer 14 and carrier layer 4 and the upper tool 15 can be lifted off the positioning table 2 together with the process cover 24 according to the arrow 26 in Figure 12.

[0113] In particular in this second embodiment, both the cover layer 14 and the carrier layer 4 can have a shape that corresponds to that of the cable harness 7, wherein the cover layer 14 and the carrier layer 4 extend over the entire length of the cable harness 7 and only up to the conductor ends (not shown here) of the electrical conductors 6 or connection elements (not shown) attached to the conductor ends, so that the conductor ends or connection elements are not bandaged by the composite of cover layer 14 and carrier layer 4.

[0114] Figure 13 now shows schematically and by way of example an alternative embodiment of a positioning table 2 of the device 1, in which the support surface 3, based on the cross-section through the positioning table 2 shown here, has a plurality of cavities 27 which are spaced apart from one another in the transverse direction and form channel-like depressions in the support surface 3. These cavities 27 are dimensioned such that, for example, one or more conductors ß of a cable set 7 can be at least partially received and arranged therein. The cavities 27 extend into and out of the image plane of Figure 13, wherein the direction of extension of the cavities 27 corresponds to the direction of extension of the at least one conductor 6 to be arranged in the cavity 27.

[0115] As can be further seen from Figure 13, the support surface 3, based on the cross section through the positioning table 2 shown in Figure 13, forms a support surface support area 29 on both sides of each cavity 27, on which the carrier layer 4 rests before the actuation of a device generating an attractive force, which is formed here by way of example by the vacuum device 11, while covering the cavities 27 with a carrier layer support area 31.

[0116] As further schematically shown in Figure 13, in the embodiment shown here, a cavity 27 and an associated support surface support area 29 together form a single section 33, 34, 35 and 36 that can be controlled by the vacuum device 11 and subjected to negative pressure. In principle, however, the cavities 27 and the support surface support areas 29 could also be controlled independently of one another.

[0117] If a negative pressure is now generated as an attractive force by means of the vacuum device 11, which only acts on the first section 33, as is shown schematically and by way of example in Figure 14 by the arrows 32, then the carrier layer support region 31 assigned to the first section 33, relative to the image plane of Figure 14, to the left of the cavity 27, which rests on the support surface support region 29 assigned to the first section 33, is fixed, while the adjacent carrier layer region covering the cavity 27 is pulled into the cavity 27 to form a carrier layer cavity section 4a. In this case, carrier layer material flows from the unfixed carrier layer support area 31 located to the right of the cavity 27, with respect to the image plane of Figure 14, which rests on the support surface support area 29 assigned to the second section 34, which is indicated schematically by the arrow 30.The same process is then repeated, as schematically shown in Figure 15, for the second section 34 to form the carrier layer cavity section 4b, and continues until, in the example shown here, all of the intended carrier layer cavity sections 4a, 4b, 4c, 4d have been formed. For this purpose, the sections 34, 35, 36 are controlled sequentially by the vacuum device 11.

[0118] As can be seen in particular from Figure 16, the individual carrier layer cavity sections 4a, 4b, 4c, 4d of the carrier layer line the respectively assigned cavities 27 preferably in a shape and / or contour-adapted manner.

[0119] As can be clearly seen from Figure 16, the carrier layer 4 is preferably dimensioned such that the carrier layer 4, after the formation of the carrier layer cavity sections 4a to 4d and based on the cross section through the carrier layer 4, has opposite edge regions which rest on the support surface 3 and form the carrier layer overlap regions 8, 9.

[0120] In order to allow a negative pressure to act as an attractive force on the carrier layer 4, the support surface 3 is provided at least in some areas with openings 37, which is shown only schematically and by way of example for the section 33 in Figure 13.

[0121] After the formation of the carrier layer cavity sections 4a to 4d, conductors 6 can then be arranged in the cavities 27 and thus positioned on the carrier layer 4, as indicated only very schematically and by way of example in Figure 16. For this purpose, the upper side of the carrier layer 4 can again be provided with an adhesive layer 10.

[0122] The dimensions and design of the cavities 27, the carrier layer cavity sections 4a to 4d, and the conductors 6 are shown in the embodiment of Figures 13 to 16 merely by way of example and schematically. It is understood that, of course, several conductors 6 with different dimensions can also be arranged per cavity or per carrier layer cavity section, for example, conductors 6 that project upwards above the support surface 3, relative to the image plane shown here.

[0123] After the conductors have been positioned and arranged on the carrier layer 4 or in the cavities 27, a cover layer 14 is then applied, as described above in connection with Figures 1 to 12, and connected to the carrier layer by bandaging the conductors 6 of a cable harness 7. To avoid repetition, reference is made to the above explanations.

[0124] Figures 17 and 18 further show an alternative embodiment to the embodiment of Figures 13 to 16, in which the carrier layer cavity sections 27 are formed not by means of a vacuum device 11, but alternatively with the aid of an overpressure device 28. The overpressure device 28 is here a component of an upper tool 38 or interacts with an upper tool 38.

[0125] The tool 38 is, as shown only schematically and by way of example in Figure 17, provided with openings 37 on its side associated with the carrier layer 4 or the positioning table 2, so that when the tool 38 is resting on the support surface 3 of the positioning table 2 (see Figure 18), an overpressure (see arrows 32) can act on the carrier layer 4 resting on the support surface 3.

[0126] In the embodiment shown here in Figures 17 and 18, a first tool area 39 of the tool 38, which is assigned to a cavity 27, as well as a second tool area 40, which is assigned to a carrier layer support area 31, each form sections 41 to 49 which can be individually controlled by the overpressure device 28 and subjected to overpressure, wherein the individual sections can be sealed against one another by means of a seal 50. Here too, to form the carrier layer cavity sections 4a to 4d, the individual sections 41 to 49 are individually controlled, for example in such a way that first, simultaneously or with a time delay, the two sections 41 and 42 are controlled in order to, on the one hand, press the carrier layer support area 31 onto the assigned

[0127] support surface area 29 of the support surface 3 (see Figure 18) and on the other hand the adjacent cavity 27 covering

[0128] Carrier layer area to be pressed into the associated cavity 27, forming the carrier layer cavity section 4a. Here, too, carrier layer material flows from the unfixed carrier layer support area 31 resting on the opposite support surface support area 29, as has already been explained in more detail in connection with the design of Figures 13 to 16.

[0129] As shown schematically and in dashed lines in Figure 18, in addition to the overpressure device 28, a vacuum device 11 can also optionally be provided in a further alternative embodiment, so that the formation of the carrier layer cavity sections 4a to 4d can then take place with overpressure and with negative pressure.

[0130] LIST OF REFERENCE SYMBOLS

[0131] 1 device

[0132] 2 positioning table

[0133] 3 Support surface

[0134] 4 Carrier layer

[0135] 4a Carrier layer cavity section

[0136] 4b Carrier layer cavity section

[0137] 4c Carrier layer cavity section

[0138] 4d carrier layer cavity section

[0139] 5 Recording area

[0140] 6 electrical conductors

[0141] 7 Wiring harness

[0142] 8 Carrier layer overlap area

[0143] 9 Carrier layer overlap area

[0144] 10 adhesive layer

[0145] 11 Vacuum device

[0146] 12 Vacuum pump

[0147] 13 Attachment

[0148] 14 Top layer

[0149] 15 upper tool

[0150] 16 Top layer overlap area

[0151] 17 Top layer overlap area

[0152] 18 adhesive layer

[0153] 19 Arrow

[0154] 20 Top layer enveloping area

[0155] 21 Arrow

[0156] 22 Arrow

[0157] 23 Arrow

[0158] 24 Process coverage

[0159] 25 Free space 26 Arrow

[0160] 27 Cavity

[0161] 28 Overpressure device

[0162] 29 Support surface support area

[0163] 30 Arrow

[0164] 31 Carrier layer support area

[0165] 32 Arrow

[0166] Section 33

[0167] 34 Section

[0168] Section 35

[0169] 36 Section

[0170] 37 Opening

[0171] 38 tools

[0172] 39 first tool area

[0173] 40 second tool area

[0174] Section 41

[0175] 42 Section

[0176] Section 43

[0177] Section 44

[0178] Section 45

[0179] 46 Section

[0180] Section 47

[0181] Section 48

[0182] Section 49

[0183] 50 Seal

Claims

CLAIMS 1. A method for producing a wiring harness for a vehicle electrical system that is at least partially bandaged, comprising: - Providing a carrier layer (4) with a receiving surface (5) for a cable set (7), - arranging the cable harness (7) on the receiving surface (5), wherein the carrier layer (4) projects beyond the cable harness (7) at least transversely to its longitudinal direction with carrier layer overlapping regions (8, 9), - providing a cover layer (14) on the side of the cable harness (7) facing away from the carrier layer (4), which projects beyond the cable harness (7) at least transversely to its longitudinal direction with cover layer overlapping regions (16, 17), - actuating a device (11) generating an attractive force, which acts on the cover layer (14) in such a way that a cover layer enveloping region (20) located, at least in the transverse direction, between the cover layer overlap regions (16, 17) is pulled and / or pressed into a shape- and / or contour-adapted contact with the cable set (7) enveloping the cable set (7), wherein, in addition, the cover layer overlap regions (16, 17) bear against an associated carrier layer overlap region (8, 9) and are connected thereto, so that the composite of cover layer (14) and carrier layer (4) bandages the cable set (7), wherein the carrier layer (4) and / or the cover layer (14) are or will be manufactured in such a way that predetermined regions and / or components of the cable set (7) are exposed and are not in contact with the carrier layer (4) and / or cover layer (14) are coated.

2. Method according to claim 1, characterized in that the cover layer (14) and / or the carrier layer (4) extends over the entire length of the cable set up to the conductor ends of the electrical conductors and / or at the connecting elements, in particular plug connectors, attached to the conductor ends and / or that the cover layer (14) and / or the carrier layer (4) have a shape which corresponds to that of the cable set (7).

3. Method according to claim 1 or 2, characterized in that at least the carrier layer overlap regions (8, 9) of the carrier layer (4) and / or at least the cover layer overlap regions (16, 17) of the cover layer (14) are provided at least in regions with an adhesion promoter, so that the carrier layer overlap regions (8, 9) and cover layer overlap regions (16, 17) brought into contact with one another and assigned to one another are joined to one another in a materially bonded manner.

4. Method according to one of the preceding claims, characterized in that the cover layer sheathing region (20) is provided at least in regions with an adhesion promoter, so that the cover layer sheathing region (20) enclosing the cable set (7) in a form-fitting and / or contour-adapted manner is at least in regions connected in a materially bonded manner to the cable set (7).

5. Method according to one of the preceding claims, characterized in that the cover layer (14) is lowered onto the composite of the cable harness (7) and the carrier layer (4) in such a way that at least the cover layer enveloping region (20) of the cover layer (14) is arranged with a gap directly above the cable harness (7) or rests on the cable harness (7), and that the cover layer (14) is subsequently pressed onto the carrier layer by the attractive force of the device (11) generating an attractive force. Enveloping area (20) into which the cable harness (7), preferably up to the carrier layer (4), is or are pulled and / or pressed into a shape and / or contour-adapted attachment to the cable harness (7) and / or with its cover layer overlapping areas (16, 17) into an attachment to the respectively assigned carrier layer overlapping areas.

6. Method according to one of the preceding claims, characterized in that the device (11) for generating an attractive force is formed by a vacuum device, upon actuation of which a negative pressure is generated as an attractive force which draws the cover layer (14) into a shape- and / or contour-adapted contact with the line set (7), and / or is formed by an overpressure device, upon actuation of which an overpressure is generated as an attractive force which presses the cover layer (14) into a shape- and / or contour-adapted contact with the line set (7).

7. Method according to claim 6, characterized in that the carrier layer (4) is designed to be air-permeable at least in some regions, that the vacuum device (11) sucks the air present between the air-impermeable cover layer (14) and the carrier layer (4) through the carrier layer (4) and a negative pressure is generated as an attractive force acting on the cover layer (14), which attracts the cover layer enveloping region (20) into the form and / or contour-adapted contact with the cable set (7), preferably up to the carrier layer (4).

8. Method according to claim 6, characterized in that that an air-impermeable process cover (24) is provided which is arranged in the vertical axis direction above the cover layer (14) and interacts with the cover layer (14), and which, during operation of the vacuum device (11), seals off the area of the cable set (7) to be bandaged, together with the cover layer and carrier layer areas required for this, in a gas-tight manner to the outside, that the vacuum device (11) sucks out the air present beneath the process cover (24) and a negative pressure is generated as an attractive force acting on the process cover (24), which pulls the process cover (24) downwards towards the carrier layer (4), wherein the process cover (24) presses the cover layer enveloping area (20) into the shape and / or contour-adapted contact with the cable set (7) and the process cover (24) further also presses the cover layer overlap areas (16, 17) to the associated carrier layer overlap areas (8, 9).

9. Method according to one of the preceding claims, characterized in that the carrier layer (4) is arranged on a support surface (3) of a positioning table (2), wherein the support surface (3) has at least one cavity (27) forming a channel-like depression in the support surface (3), which cavity is suitable and / or designed to receive at least one conductor (6) of the cable harness (7) at least partially in the cavity (27), wherein the extension direction of the at least one cavity (27) corresponds to the extension direction of the at least one conductor (6) to be arranged therein, that the carrier layer (4) comprises a carrier layer cavity section (4a, 4b, 4c, 4d) which lines the at least one cavity (27), wherein the at least one conductor (6) is, after a lining of the at least one Cavity (27) with a carrier layer cavity section (4a, 4b, 4c, 4d) is arranged in the cavity (27).

10. The method according to claim 9, characterized in that a device (11, 28) generating an attractive force is provided, by means of which a defined carrier layer region is pulled and / or pressed into the at least one cavity (27) to form a carrier layer cavity section (4a, 4b, 4c, 4d).

11. Method according to claim 10, characterized in that the device (11, 28) generating an attractive force for forming a plurality of carrier layer cavity sections (4a, 4b, 4c, 4d) is controlled such that defined carrier layer regions assigned to the cavities (27) are pulled and / or pressed individually one after the other into the assigned cavities (27).

12. Method according to claim 10 or 11, characterized in that the carrier layer (4) is fixed only in regions or sections on the support surface (3) and a carrier layer region assigned to the at least one cavity (27), which forms a carrier layer cavity section (4a, 4b, 4c, 4d), rests freely and unfixed on the support surface (3) and can be pulled and / or pressed into the assigned cavity (27) by means of the device (11, 28) generating an attractive force.

13. Device for producing a cable harness for an on-board network of a vehicle, which is at least partially bandaged, in particular for carrying out a method according to one of the preceding claims, comprising: - a positioning table (2) as a lower tool, which is suitable and designed to have a support surface (3) for a carrier layer (4) to form, on whose receiving surface (5) a cable set (7) can be arranged in such a way that the carrier layer (4) projects beyond the cable set (7) at least transversely to its longitudinal direction with carrier layer overlapping areas (8, 9), - at least one upper tool (15) arranged above the positioning table (2) relative to the vertical axis direction and lowerable in the direction of the positioning table (2), to which a cover layer (14) or a cover layer (14) and / or a process cover (24) can be releasably secured, wherein the cover layer (14) is suitable and designed to project beyond the cable set (7) at least transversely to its longitudinal direction with cover layer overlap regions (16, 17) assigned to the carrier layer overlap regions (8, 9), - an attractive force generating device (11) which is suitable and designed to act on the cover layer (14) when the upper tool (15) and thus when the cover layer (14) is lowered in such a way that a cover layer enveloping region (20) of the cover layer (14) located between the cover layer overlap regions (16, 17) is pulled and / or pressed into a shape- and / or contour-adapted contact region enveloping the cable set (7), wherein, in addition, the cover layer overlap regions (16, 17) bear against an associated carrier layer overlap region (8, 9) and are connected to it, so that the composite of cover layer (14) and carrier layer (4) bandages the cable set (7), and wherein the carrier layer (4) and / or the cover layer (14) are manufactured in such a way that predetermined regions and / or components of the cable set (7) exposed and not coated with the carrier layer (4) and / or cover layer (14).

14. Device according to claim 13, characterized in that that the support surface (3) has at least one cavity (27) forming a channel-like depression in the support surface (3), which is suitable and / or designed to receive at least one conductor (6) of the cable set (7) at least partially in the cavity (27), wherein the extension direction of the at least one cavity (27) corresponds to the extension direction of the at least one conductor (6) to be arranged therein, that the at least one cavity (27) is suitable and / or designed to be provided with a carrier layer cavity section (4a, 4b, 4c, 4d) of a to be lined with a carrier layer (4) arranged on the support surface (3).

15. Device according to claim 13 or 14, characterized in that an attractive force generating device (11, 28) is provided, by means of which a defined carrier layer area for forming the at least one carrier layer cavity section (4a, 4b, 4c, 4d) can be pulled and / or pressed into the cavity (27).

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