Installing a twisted pair of wires into a target structure

Abstract

The present disclosure relates to a method of installing a twisted pair of wires into a target structure, the method comprising: laying the twisted pair of wires into the target structure, the twisted pair of wires comprising a first wire and a second wire, wherein the laying of the twisted pair of wires is performed by feeding the first wire through a first opening in a head towards the target structure and feeding the second wire through a second opening in the head towards the target structure while rotating the head, and wherein the first opening and the second opening are distinct from one another, or the first opening and the second opening are each a sub-portion of a common opening.

Description

[0001] INSTALLING A TWISTED PAIR OF WIRES INTO A TARGET STRUCTURE

[0002] TECHNICAL FIELD

[0003] The disclosure relates to: a method of installing a twisted pair of wires into a target structure; a product obtained using the method; a computer program comprising instructions, which, when executed, cause a computer to control a system to perform the method; a wire deposition apparatus configured to perform the method; and an apparatus configured to install a twisted pair of wires into a target structure.

[0004] BACKGROUND

[0005] A wiring harness is an assembly of wires or cables which can transmit signals and / or electrical power. The wires may be bound together in the wiring harness by a durable material, such as a polymer.

[0006] Currently, wiring harnesses are largely made by hand. Robotics can cut wire to length and add crimp terminations, but the laying of the cables and / or wires in the harness is almost exclusively done on a pin-board by skilled workers.

[0007] A typical process for manufacturing a wiring harness involves a series of steps. First, the wires are cut, stripped and crimped. Next, a 1 : 1 scale pin-board is used to organize wires into bundles which are held together with ties or sleeves. Then termination connectors (or plugs) are added. The wires or wire bundles are labelled and there is a quality control check. The harness is then packaged and shipped to the OEM. At the OEM the harness is installed into the system. Often further stand-offs and mounts and ties are needed to hold the wires in place. This is a complex, labour intensive and costly process that can result in manufacturing errors that require expensive product recalls.

[0008] Wires may be installed into a wiring harness as a twisted pair. A twisted pair comprises a first conductive member (i.e. a first wire) and a second conductive member (i.e. a second wire) which are twisted together. The two conductive members may be part of the same circuit. The twisting of the conductive members may lead to reduced noise (i.e. electromagnetic interference) entering and / or exiting the circuit, relative to a single wire or an untwisted pair of wires.

[0009] When installing a twisted pair into a target structure (i.e. a system in which the twisted pair will be used), it is necessary for the orientation of the first wire and the second wire to be known, so that the first wire and the second wire can be connected to the correct terminations. When a twisted pair is installed by hand, the worker may be able to distinguish the first wire from the second wire based on a visual indicator, such as the colour of the first wire and the second wire.

[0010] Considering the complexity, labour intensity and cost associated with the manual installation of wires into wiring harnesses, it may be advantageous for such processes to be automated. However, currently-available methods for the automated installation of twisted pairs are limited in that they do not provide effective means for determining the orientation of the first wire and the second wire of the twisted pair. Thus, there is a risk that, in automated installation processes, the first wire and the second wire are connected to incorrect terminations. Methods which do attempt to provide means for determining the orientation of the first wire and the second wire of the twisted pair in automated installation processes are complex, so the apparatus required to perform the method are expensive and unreliable.

[0011] Whilst the above background has focused on the installation of twisted pairs into wiring harnesses, the problems identified are applicable to the installation of twisted pairs generally.

[0012] SUMMARY

[0013] It is an object of the disclosure to provide an efficient and reliable method for installing twisted pairs of wires into target structures.

[0014] According to a first aspect of the invention, there is provided a method of installing a twisted pair of wires into a target structure, the method comprising: laying the twisted pair of wires into the target structure, the twisted pair of wires comprising a first wire and a second wire, wherein the laying of the twisted pair of wires is performed by feeding the first wire through a first opening in a head towards the target structure and feeding the second wire through a second opening in the head towards the target structure while rotating the head wherein the first opening and the second opening are distinct from one another, or the first opening and the second opening are each a sub-portion of a common opening.

[0015] In the method described above, the first wire and the second wire are each fed through their own respective opening in the head (i.e. the first opening and the second opening). Consequently, if the orientation of the head is known (i.e. the orientation of the first opening and the second opening), the orientation of the first wire and the second wire is known. Thus, the first wire and the second wire can be indexed. As a result of this, it is possible to reliably connect the first wire and the second wire to the correct terminations, and the method of installing the twisted pair of wires into the target structure is more efficient and reliable.

[0016] In some embodiments, the feeding the first wire through the first opening and feeding the second wire through the second opening while rotating the head is such that the first wire and the second wire are twisted together as they laid into the target structure. In this case, it is not necessary to supply the first wire and the second wire to the apparatus as a twisted pair, because the twisted pair is formed (i.e. the first wire and the second wire are twisted together) as part of the method of installing the twisted pair. This may simplify and / or reduce the cost of the procurement of the first wire and the second wire.

[0017] In some embodiments, the method further comprises, after the head has reached the end of a predetermined path, rotating the head so that a target orientation of the first wire and the second wire is obtained. For example, the head can be rotated so that a first opening (and therefore the first wire) is aligned with a termination which the first wire is to be connected to, and the second opening (and therefore the second wire) is aligned with a termination which the second wire is to be connected to. Consequently, the ease and reliability of connecting the first and second wires to the correct terminations can be further improved.

[0018] In some embodiments, the method further comprises rotating the head relative to a housing. By only rotating the head and not the housing, the mass (and therefore moment of inertia) of the rotating part of the apparatus which performs the method is reduced. This means that the rotating part of the apparatus can be accelerated and decelerated more quickly, and the top speed of the rotation of the first and second opening can be increased. Thus, takt time can be improved. Further, the lower mass of the rotating part of the apparatus means that the energy required to rotationally accelerate and decelerate the rotating part of the apparatus is reduced, and the apparatus is safer.

[0019] In some embodiments, rotating the head may cause a twist rate of the first wire and the second wire to increase in the housing (e.g. between first and second wire guides and third and fourth wire guides). Consequently, the method may further comprise, after the first wire and the second wire have been cut, counter-rotating the head such that the twist rate of the first wire and the second wire decreases between the first and second wire guides and the third and fourth wire guides. This means that the method can be performed again (i.e. repeated) without any intervention from an operator.

[0020] In some embodiments, the first wire and the second wire may be twisted together before being fed through the first opening and the second opening. That is, the apparatus which performs the method may be provided with a pre-formed twisted pair. This may avoid the need for a counter-rotation step after the first wire and the second wire have been cut.

[0021] In some embodiments, the head may be coupled to a housing such that the housing and the head rotate together, and a first feedstock portion (which supplies the first wire) and a second feedstock portion (which supplies the second wire) may be coupled to the housing such that the first feedstock portion and the second feedstock portion rotate with the housing. This may avoid the need for a counter-rotation step after the first wire and the second wire have been cut, even when the first wire and the second wire are not provided to the apparatus as a pre-formed twisted pair.

[0022] In some embodiments, the head may be configured to rotate freely, and the feeding the first and second wires through the first and second openings causes the rotation of the head. This may mean that it is not necessary to provide driving means (e.g. a motor and transmission) to the head, thus simplifying the component.

[0023] In some embodiments, wire guides (which are used to feed the first wire and the second wire through the first opening and the second opening) comprise pairs of traction belts. Such traction belts may be particularly effective at feeding the wires through the first opening and the second opening in the method of the present disclosure.

[0024] According to a second aspect of the invention, there is provided an apparatus configured to install a twisted pair of wires into a target structure, wherein: the twisted pair of wires comprises a first wire and a second wire; the apparatus comprises a head having a first opening and a second opening; and the apparatus is configured to feed the first wire through the first opening towards the target structure and feed the second wire through the second opening towards the target structure while the head is rotated wherein the first opening and the second opening are distinct from one another, or the first opening and the second opening are each a sub-portion of a common opening.

[0025] In the apparatus described above, the first wire and the second wire are each fed through their own respective opening in the head (i.e. the first opening and the second opening). Consequently, if the orientation of the head is known (i.e. the orientation of the first opening and the second opening), the orientation of the first wire and the second wire is known. Thus, the first wire and the second wire can be indexed. As a result of this, it is possible to reliably connect the first wire and the second wire to the correct terminations, and the method of installing the twisted pair of wires into the target structure is more efficient and reliable. In accordance with a third aspect of the present invention, there is provided a method of installing a twisted pair of wires into a target structure, the method comprising: laying the twisted pair of wires into the target structure, the twisted pair of wires comprising a first wire and a second wire, wherein the laying of the twisted pair of wires is performed by feeding the first wire through an opening in a head towards the target structure and feeding the second wire through the opening in the head towards the target structure while rotating the head, and wherein the opening is configured such that the orientation of the first wire and the second wire within the opening is fixed.

[0026] In accordance with a fourth aspect of the present invention, there is provided an apparatus configured to install a twisted pair of wires into a target structure, wherein: the twisted pair of wires comprises a first wire and a second wire; the apparatus comprises a head having an opening; and the apparatus is configured to feed the first wire through the opening towards the target structure and feed the second wire through the opening towards the target structure while the head is rotated, wherein the opening is configured such that the orientation of the first wire and the second wire within the opening is fixed.

[0027] BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Embodiments of the disclosure will now be described, by way of example only, with reference to the accompanying drawings in which corresponding reference symbols indicate corresponding parts.

[0029] Figure 1 A depicts an apparatus according to the first embodiment after the first ends of the first wire and the second wire have been fed through the first opening and the second opening.

[0030] Figure IB depicts an apparatus according to the first embodiment, after the first end of the first wire has been connected to the first fixation point and the first end of the second wire has been connected to the second fixation point.

[0031] Figure 1C depicts an apparatus according to the first embodiment, after the first wire has been fed through the first opening towards the target structure and second wire has been fed through the second opening towards the target structure while rotating the head.

[0032] Figure ID depicts an apparatus according to the first embodiment, after the first wire and the second wire have been cut. Figure IE depicts an apparatus according to the first embodiment, after the second end of the first wire has been connected to the third fixation point and the second end of the second wire has been connected to the fourth fixation point.

[0033] Figure IF depicts an apparatus according to the first embodiment, after the first and second wires have been untwisted in the housing.

[0034] Figure 2 depicts a flowchart showing steps involved in the installation of a twisted pair into a target structure, in accordance with embodiments of the present disclosure.

[0035] Figure 3 depicts an apparatus according to a second embodiment.

[0036] Figures 4A-4D depict variants of the apparatus according to the second embodiment.

[0037] Figure 5 depicts an apparatus according to a third embodiment.

[0038] Figure 6 depicts a variant of the apparatus according to the third embodiment.

[0039] Figure 7A and 7B depict a schematic representation of the shape of a common opening through which the first wire and the second wire are fed.

[0040] Figure 8 schematically depicts a machine comprising the apparatus according to embodiments of the present disclosure.

[0041] Figure 9 depicts perspective view of a machine comprising the apparatus according to embodiments of the present disclosure.

[0042] DETAILED DESCRIPTION

[0043] The present disclosure is directed to a method of installing a twisted pair of wires into a target structure. The term “target structure” means the structure in which the twisted pair of wires are to be installed. The target structure may be the ultimate destination of the wires. In some embodiments, the target structure is the system in which the twisted pair of wires are to be used. For example, the target structure may be a system in which the wires distribute power and / or transmit signals. The target structure may be a wiring harness which is, at a later stage, assembled into the system in which the wires distribute power and / or transmit signals. The system may be, for example, a vehicle (e.g. a car), or an appliance (e.g. a washing machine).

[0044] The twisted pair of wires may comprise a first wire and a second wire. The first wire and the second wire may be twisted around one other. The first wire and the second wire may each extend helically. The direction in which the twisted pair extends may be referred to as an axial direction. Directions perpendicular to the axial direction may be referred to as radial directions. Figures 1 A to IF depict an apparatus 100 according to a first embodiment, which may be used to perform the method of the present disclosure. The apparatus 100 comprises a head 150 having a first opening 154a and a second opening 154b. The apparatus 100 is configured to feed the first wire Wa through the first opening 154a towards the target structure 10 and feed the second wire Wb through the second opening 154b towards the target structure 10 while the head 150 is rotated.

[0045] The first opening 154a and the second opening 154b may be distinct. For instance, the first opening 154a and the second opening 154b may be non-overlapping. That is, the first opening 154a may be separate from the second opening 154b.

[0046] The apparatus 100 may be configured such that the head 150 can be moved (translationally) relative to the target structure 10 along a path corresponding to the target path. The target path may be a path along which the first wire and the second wire are to be laid. The path along which the head 150 is moved may be parallel to the target path. The apparatus 100 may be configured to lay the twisted pair onto a surface of the target structure 10. In an example, the surface extends in a horizontal plane (i.e. an X / Y plane).

[0047] The apparatus 100 may be configured such that, while moving along the path corresponding to the target path, the head is moved relative to the target structure in a direction that is substantially parallel to the surface. To provide this movement, the apparatus 100 may be mounted on a motorised X / Y stage.

[0048] The apparatus 100 may be configured such that a distance between the head 150 and the target structure 10 can be increased and / or decreased. That is, the head 150 may be movable in a direction that is perpendicular to the target structure 10 (or, more specifically, the surface of the target structure 10). This direction may be a vertical direction.

[0049] The apparatus 100 may be configured such that the head 150 can be rotated. In accordance with the present disclosure, the head 150 is configured to be rotated around an axis which is substantially parallel to a direction in which the first wire Wa is fed through the first opening 154a and / or a direction in which the second wire Wb is fed through the second opening 154b. This axis may be referred to as the primary axis. The primary axis may be substantially perpendicular to the target structure 10, or more specifically, to the surface of the target structure 10 onto which the twisted pair is to be installed. This primary axis may be a vertical (Z) axis. The head 150 may also be configured to rotate around one or more horizontal axes (e.g. around an X-axis and a Y-axis).

[0050] In the head 150, the first opening 154a may be defined by a first nozzle 153a and the second opening 154b may be defined by a second nozzle 153b. For the present purposes, the term “nozzle” is used to mean a component with a cylindrical passageway extending therethrough. The term “nozzle” does not imply that the component is configured for the control of fluids. The first opening 154a may be defined by a first cylindrical passageway which extends through the first nozzle 153a. The first opening 154a may be defined at an end of the first nozzle that is closest to the target structure 10 and / or furthest away from other components of the apparatus 100, such as a housing 110. The second opening 154b may be defined by a second cylindrical passageway which extends through the second nozzle 153b. The second opening 154b may be defined at an end of the second nozzle 153b that is closest to the target structure 10 and / or furthest away from other components of the apparatus 100, such as the housing 110.

[0051] The second cylindrical passageway may be distinct from the first cylindrical passageway. The first cylindrical passageway may be substantially parallel to the second cylindrical passageway. The first cylindrical passageway and the second cylindrical passageway may each be parallel to the direction in which the first and second wires Wa, Wb are fed through the first and second opening 154a, 154b. The first cylindrical passageway and the second cylindrical passageway may each be parallel to the primary axis.

[0052] The first nozzle 153a and the second nozzle 153b may be different components. Alternatively, the first nozzle 153a and the second nozzle 153b may be defined in the same component. In this case, the first cylindrical passageway and the second cylindrical passageway would each extend through the same component to define the first nozzle 153a and the second nozzle 153b.

[0053] The first nozzle 153a and the second nozzle 153b may be arranged such that the first opening 154a and the second opening 154b are in the same horizontal plane. That is, a distance between the first opening 154a and the target structure 10 may be substantially the same as the distance between the second opening 154b and the target structure 10. The first opening 154a and the second opening 154b may be separated from each other in a horizontal direction.

[0054] A distance between the first opening 154a and the second opening 154b in a horizontal direction may be small so that the separation of the first wire Wa and the second wire Wb in the twisted pair is small (i.e. so that the first wire Wa and the second wire Wb are tightly wound together). For instance, a distance between the centre of the first opening 154a and the centre of the second opening 154b may be less than the diameter of the first wire Wa or the second wire Wb multiplied by 5, preferably less than the diameter of the first wire Wa or the second wire Wb multiplied by 2, and further preferably less than the diameter of the first wire Wa or the second wire Wb multiplied by 1.5. In the case that the first opening 154a and the second opening 154b are separate and / or distinct, the distance between the centre of the first opening 154a and the centre of the second opening 154b may be greater than the diameter of the first wire Wa or the diameter of the second wire Wb.

[0055] As described above, the head 150 is configured to be rotated around an axis which is substantially parallel to a direction in which the first wire Wa is fed through the first opening 154a and / or a direction in which the second wire Wb is fed through the second opening 154b. This axis may be referred to as the primary axis. The primary axis may pass through a position interposed between the first opening 154a and the second opening 154b. A distance in a horizontal direction between the first opening 154a and the primary axis may be substantially the same as a distance in a horizontal direction between the second opening 154b and the primary axis. The primary axis may pass through the centre of the head 150.

[0056] In the apparatus 100 depicted in Figure 1 A, the first opening 154a is on the lefthand side and the second opening 154b is on the right-hand side. If the head 150 were to be rotated through 180° around the primary axis, the first opening 154a would be on the right-hand side and the second opening 154b would be on the left-hand side. Rotation through a further 180° would bring the head back to the original position, with the first opening 154a on the left-hand side and the second opening 154b on the right-hand side, as depicted in Figure 1 A.

[0057] In some embodiments, the head 150 further comprises means for cutting the first wire Wa and the second wire Wb. The type of cutting means is not particularly limited. The cutting means may comprise one or more shear blades. For example, in some embodiments, the cutting means comprises a single shear blade configured to cut the first wire Wa and the second wire Wb. In other embodiments, the cutting means may comprise a first blade 152a, a second blade 152b and a central portion 152c. The first blade 152a may be moveable in a horizontal direction towards and away from the central portion 152c. To cut the first wire Wa, the first blade 152a may move towards the central portion 152c to apply pressure to the first wire Wa between the first blade 152a and the central portion 152c. In some embodiments, the first blade 152a is a V-shaped blade and the central portion is a shear surface. In some embodiments, a surface of the central portion 152c facing the first blade 152a may comprise a bladed edge. The second blade 152b may be moveable in a horizontal direction towards and away from the central portion 152c. To cut the second wire Wb, the second blade 152b may move towards the central portion 152c to apply pressure to the second wire Wb between the second blade 152b and the central portion 152c. A surface of the central portion 152c facing the second blade 152b may comprise a bladed edge.

[0058] In some embodiments, the apparatus 100 may comprise cutting means 152, where the cutting means are not comprised in the head 150. In such embodiments, the cutting means 152 may not rotate with the head 150. For example, the cutting means may remain stationary while the head rotates. That is, the head 150 may rotate relative to the cutting means.

[0059] The first wire Wa may be supplied to the first opening 154a from a first feedstock portion (not shown). The first feedstock portion may be a spool around which the first wire Wa is wound. The second wire Wb may be supplied to the second opening 154b from a second feedstock portion. The second feedstock portion may be a spool around which the second wire Wb is wound.

[0060] In some embodiments, the apparatus 100 further comprises a housing 110. The housing may surround a portion of the first wire Wa and the second wire Wb between the head 150 and the first and second feedstock portions. The first and second feedstock portions may be rigidly coupled to the housing. The housing may be rigidly coupled to the system responsible for the translational movement of the apparatus 100, e.g. the X / Y stage described above.

[0061] In some embodiments, the shape of the housing 110 may comprise one or more curves. This may allow the apparatus 100 to operate within situations in which there are constraints on the areas which the apparatus can occupy.

[0062] Additionally or alternatively, the housing 110 may be flexible, i.e. the shape of the housing 110 may be able to change upon the application of an external force. A first wire guide 131a and a second wire guide 131b may be disposed within the housing 110. The first wire guide 131a and the second wire guide 131b may be rigidly coupled to the housing 110. That is, the first wire guide 131a and the second wire guide 131b may not be able to rotate relative to the housing 110 around a vertical axis (e.g. the vertical axis around which the head 150 rotates relative to the target structure 10). The first wire guide 131a may comprise a first pair of opposing rollers. The first wire Wa may be fed between the first pair of opposing rollers. The first pair of opposing rollers may be driven to pull the first wire Wa from the first feedstock portion, thus aiding the apparatus 100 in the feeding of the first wire Wa through the first opening 154a. The second wire guide 13 lb may comprise a second pair of opposing rollers. The second wire Wb may be fed between the second pair of opposing rollers. The second pair of opposing rollers may be driven to pull the second wire Wb from the second feedstock portion, thus aiding the apparatus 100 in the feeding of the second wire Wb through the second opening 154b. Thus, the first wire Wa may be provided to the first opening 154a from the first feedstock portion via the first wire guide 131a, and the second wire Wb may be provided to the second opening 154b from the second feedstock portion via the second wire guide 131b.

[0063] In some embodiments, the head 150 further comprises a third wire guide 151a and a fourth wire guide 151b. The third wire guide 151a and the fourth wire guide 151b may be rigidly coupled to the head 150. That is, the third wire guide 151a and the fourth wire guide 151b may not be able to rotate relative to the head 150 around a vertical axis (e.g. the vertical axis around which the head 150 rotates relative to the target structure 10). The third wire guide 151a may comprise a third pair of opposing rollers. The first wire Wa may be fed between the third pair of opposing rollers. The third pair of opposing rollers may be driven to feed the first wire Wa through the first opening 154a. The fourth wire guide 151b may comprise a fourth pair of opposing rollers. The second wire Wb may be fed between the fourth pair of opposing rollers. The fourth pair of opposing rollers may be driven to feed the second wire Wb through the second opening 154b. Thus, the first wire Wa may be provided to the first opening 154a from the first feedstock portion via the third wire guide 151a and the second wire Wb may be provided to the second opening 154b from the second feedstock portion via the fourth wire guide 151b.

[0064] In some embodiments, the third wire guide 151a and the fourth wire guide 151b may not be disposed in the head 150. For example, the third wire guide 151a and the fourth wire guide 151b may be rigidly coupled to a rotation stage 120 in the housing.

[0065] The orientation of the first wire Wa and the second wire Wb may be constrained in the housing 110 by the first wire guide 131a and the second wire guide 131b. The orientation of the first wire Wa and the second wire Wb may be constrained in the head 150 by the third wire guide 151a and the fourth wire guide 151b. In this context, the orientation of the first wire Wa and the second wire Wb relates to the relative positioning of the first wire Wa and the second wire Wb. For example, if the first wire guide 13 la is leftward of the second wire guide 131b (as shown in Fig. 1 A), the first wire Wa will be leftward of the second wire Wb at the point where the first wire Wa passes through the first wire guide 151a. If the third wire guide 151a is leftward of the fourth wire guide 151b (as shown in Fig. 1 A), the first wire Wa will be leftward of the second wire Wb at the point where the first wire Wa passes through the third wire guide 151a. The term “arrangement” may be used as an alternative to “orientation”.

[0066] In the apparatus 100 depicted in Figures 1A to IF, the head 150 may be rotated relative to the housing 110. This relative rotation may be facilitated by the rotation stage 120. The rotation stage 120 may be rigidly coupled to the head 150 (i.e. coupled such that the head 150 cannot rotate around the primary axis relative to the rotation stage 120). The rotation stage 120 may be rotatably coupled to the housing 110 (i.e. coupled such that the rotation stage 120 can rotate around the primary axis relative to the housing 110).

[0067] The apparatus 100 may further comprise drive means (not shown) configured to rotate the head 150 around the primary axis. The drive means may comprise, for example, a motor. The motor may directly cause rotation of the head 150, e.g. through a physical coupling to the head. Alternatively, the motor may directly cause rotation of the rotation stage 120, e.g. through a physical coupling to the rotation stage 120. Rotation of the rotation stage 120 may then cause rotation of the head 150.

[0068] The apparatus 100 may further comprise a secondary head. The secondary head may be configured to control the separation between the first wire Wa and the second wire Wb. The secondary head may be disposed between the head 150 and the target structure 10. Thus, after being fed through the first opening 154a and the second opening 154b, the first wire Wa and the second wire Wb may arrive at the secondary head. The secondary head may be configured to control the separation between the first wire Wa and the second wire Wb such that the separation between the first wire Wa and the second wire Wb corresponds to (e.g., is the same as) a spacing between fixation points at an electrical connection (e.g. between the first fixation point I la and the second fixation point 1 lb, or between the third fixation point 12a and the fourth fixation point 12b). That is, the controlling the separation between the first wire Wa and the second wire Wb comprises may comprise setting a distance between the first opening 154a and the second opening 154b. This may allow the first and second wires Wa, Wb to be easily connected to the fixation points of the electrical connection.

[0069] The secondary head may have a similar structure to the head 150 described above. For instance, the secondary head may comprise two openings. The apparatus 100 may be configured such that one of the wires Wa passes through one of the openings in the secondary head and the other of the wires Wb passes through the other of the openings in the secondary head. The spacing between the two openings of the secondary head may determine the spacing between the first wire Wa and the second wire Wb as the first wire Wa and the second wire Wb are placed into the target structure 10.

[0070] The secondary head may be configured such that a spacing between the two openings in the secondary head can be changed. Additionally or alternatively, the secondary head may be an interchangeable component, and, in different versions of the secondary head, the spacing between the two openings may be different. This may allow the secondary head to control the separation of the first wire Wa and the second wire Wb such that the first wire Wa and the second wire Wb can be easily connected to different types of electrical connections (which may have different spacings between the fixation points).

[0071] A distance between the two openings of the secondary head may be greater than 0.5 mm. A distance between the two openings may be less than 100 mm. Larger separations between the wires Wa, Wb (and therefore the two openings of the secondary head) may be required in high power applications. For many standard applications, a distance between the two openings may be greater than 1 mm and less than 10 mm, preferably less than 6 mm.

[0072] In some embodiments, the head 150 may be configured to perform the functionality of the secondary head. That is, the head 150 may be configured to control the separation between the first wire Wa and the second wire Wb such that the separation between the first wire Wa and the second wire Wb corresponds to (e.g., is the same as) a spacing between fixation points at an electrical connection (e.g. between the first fixation point I la and the second fixation point 1 lb, or between the third fixation point 12a and the fourth fixation point 12b). In such embodiments, the head 150 may have the same or similar features to the features of the secondary head described above.

[0073] The apparatus 100 described above is one example of an apparatus which may be used to perform the method of the present disclosure. The method comprises laying the twisted pair of wires into the target structure. This is performed by feeding the first wire Wa through the first opening 154a toward the target structure and feeding the second wire Wb through the second opening 154b towards the target structure. While the first and second wires Wa, Wb are fed through the first and second openings 154a, 154b, the head is rotated. Figure 2 depicts a flowchart showing steps involved in the installation of a twisted pair into a target structure, in accordance with embodiments of the present disclosure. The steps outlined in Figure 2 may be performed by any of the apparatuses 100, 200, 300 disclosed herein (with modifications where appropriate). As will be appreciated, in some cases, various steps may be added or omitted from the method without affecting the overall effect achieved by the method.

[0074] The method may comprise a step SI of securing a first end of the first wire Wa at a first fixation point I la and securing a second end of the second wire Wb at a second fixation point 1 lb. The first and second fixation points I la, 1 lb may be electrical terminations. A first connection / connector, may be provided on the target structure 10, and the first and second fixation points I la, 11b may be a part of the first connection / connector. The first connection / connector may be an electrical connection / connector. Thus, the first electrical connection / connector may therefore allow the first and second wires Wa, Wb to be electrically connected to other components and / or other systems. For the rest of the description, the first connection / connector shall be referred to as the first electrical connection / connector. However, it is not essential that the first connection / connector is an electrical connection / connector. In some embodiments, the first connection / connector may not be an electrical connection / connector (e.g. the first connection / connector may be electrically isolated). For example, the first connection may be any feature, or combination of features (e.g. hole(s), hook(s) or groove(s)) which provide(s) a fixation point for the first wire Wa (i.e. the first fixation point I la) and a fixation point for the second wire Wb (i.e. the second fixation point Wb). Figure IB depicts the apparatus 100 and the target structure 10 after the first end of the first wire Wa has been secured at the first fixation point I la and the first end of the second wire Wb has been secured to the second fixation point 1 lb.

[0075] Before the step SI of securing the first ends of the first and second wires Wa, Wb, it may be necessary to feed the first ends of the first and second wires Wa, Wb through the first and second openings 154a, 154b. This may be necessary if it is the first time that the apparatus 100 is being used, or if the feedstock has been replaced. Figure 1 A depicts the apparatus 100 and the target structure 10 after the first ends of the first wire Wa and the second wire Wb have been fed through the first opening 154a and the second opening 154b. Before the step SI of securing the first ends of the first and second wires Wa, Wb, it may be necessary to feed the first and second wires Wa, Wb through the first and second openings 154a, 154b to the extent that there exists sufficient lengths of the first and second wires Wa, Wb downstream of the first and second openings 154a, 154b for the first and second wires Wa, Wb to reach the first and second fixation points 1 la, 1 lb.

[0076] The method may further comprise, before the step SI of securing the first ends of the first and second wires Wa, Wb, rotating the head 150 so that a first target orientation of the first wire Wa and the second wire Wb is obtained. The first target orientation of the first wire Wa and the second wire Wb may be an orientation in which the first wire Wa can be connected to the first fixation point I la and the second wire Wb can be connected to the second fixation point 1 lb. To achieve the first target orientation of the first wire Wa and the second wire Wb, the head 150 may be rotated so that the first opening 154a is aligned with the first fixation point I la and the second opening 154b is aligned with the second fixation point 1 lb. That is, the head 150 may be rotated such that the orientation of the first and second openings 154a, 154b (i.e. the relative positioning of the first and second openings 154a, 154b) corresponds to the orientation of the first and second fixation points I la, 11b (i.e. the relative positioning of the first and second fixation points 1 la, 1 lb). The orientation of the first and second fixation points I la, 11b may be known to the apparatus 100. For example, the orientation of the first and second fixation points I la, 1 lb may be input to the apparatus 100 by a user. Alternatively, the orientation of the first and second fixation points I la, 11b may be detected by one or more sensors on the apparatus 100.

[0077] The method further comprises a step S2 of feeding the first wire Wa through the first opening 154a in the head 150 towards the target structure 10 and feeding the second wire Wb through the second opening 154b in the head 150 towards the target structure 10 while rotating the head 150. In the step S2 of feeding the first and second wires Wa, Wb through the first and second openings 154a, 154b and rotating the head 150, the head may be rotated in a first direction around the primary axis. The feeding of the first wire Wa through the first opening 154a and the feeding of the second wire Wb through the second opening 154b while rotating the head 150 may cause the first wire Wa and the second wire Wb to become twisted together as they laid into the target structure 10. The step S2 of feeding the first and second wires Wa, Wb through the first and second openings 154a, 154b and rotating the head 150 is performed after the step SI of securing the first ends of the first and second wires Wa, Wb.

[0078] During the step S2 of feeding the first and second wires Wa, Wb through the first and second openings 154a, 154b and rotating the head 150, (i.e. during the laying of the twisted pair of wires Wa, Wb), the head 150 may be moved relative to the target structure 10 along a path corresponding to a target path. As explained above, the target path may be a path along which the first wire and the second wire are to be placed. Figure 1C depicts the apparatus 100 and the target structure 10 after the step S2 of feeding the first and second wires Wa, Wb through the first and second openings 154a, 154b and rotating the head 150 has been performed for some time, and the head 150 has moved some way along the path corresponding to the target path.

[0079] After the step SI of securing the first ends of the first and second wires Wa, Wb, but before rotation of the head 150 is initiated, the first and second wires Wa, Wb may be fed through the first and second openings 154a, 154b while the head 150 is moved relative to the target structure along the target path. This may result in the laying of portions of the first and second wires Wa, Wb which are straight (i.e. untwisted) adjacent to the first and second fixation points I la, 1 lb.

[0080] During the step S2 of feeding the first and second wires Wa, Wb through the first and second openings 154a, 154b and rotating the head 150, the head 150 may move in a direction that is substantially parallel to a surface of the target structure 10 onto which the wires Wa, Wb are to be placed. This is because the target path runs along the surface of the target structure 150, so to move along a path corresponding to the target path, the head must move in a direction that is substantially parallel to the surface of the target structure 10. The head 150 may move in other directions. For instance, the head 150 may be moved towards the target structure 10 or away from the target structure 10. In this case, the direction of the movement of the head 150 may not be substantially parallel to the target structure 10, but the movement of the head 150 will have a component in a direction that is substantially parallel to the target structure 10 while the first and second wires Wa, Wb are being laid. While the first and second wires Wa, Wb are not being laid, the head 150 may or may not move. While the first and second wires Wa, Wb are not being laid, if the head 150 does move, the movement of the head may not have a component that is parallel to the surface of the target structure 10. For example, the head 150 may be moved in a direction that is perpendicular to the surface of the target structure 10.

[0081] The step S2 of feeding the first and second wires Wa, Wb through the first and second openings 154a, 154b and rotating the head 150 may continue until the head 150 has moved along a path corresponding to all, or substantially all of the target path. At this point, the head 150 may be in the proximity of (e.g. aligned with and above) a second connection / connector. The second connect! on / connector may define a third fixation point 12a, to which the first wire Wa is to be connected, and a fourth fixation point 12b, to which the second wire Wb is to be connected. The second connection / connector may be an electrical connection. The second connect! on / connector may have similar features to the first connection / connector.

[0082] In some embodiments, the method further comprises, after the head has reached the end of the path corresponding to the target path (i.e. the end of a predetermined path), rotating the head 150 so that a second target orientation of the first wire Wa and the second wire Wb is obtained. The second target orientation of the first wire Wa and the second wire Wb may be an orientation in which the first wire Wa can be connected to the third fixation point 12a and the second wire Wb can be connected to the fourth fixation point 12b. To achieve the target orientation of the first wire Wa and the second wire Wb, the head 150 may be rotated so that the first opening 154a is aligned with the third fixation point 12a and the second opening 154b is aligned with the fourth fixation point 12b. That is, the head 150 may be rotated such that the orientation of the first and second openings 154a, 154b (i.e. the relative positioning of the first and second openings 154a, 154b) corresponds to the orientation of the third and fourth fixation points 12a, 12b (i.e. the relative positioning of the third and fourth fixation points 12a, 12b). The orientation of the third and fourth fixation points 12a, 12b may be known to the apparatus 100. For example, the orientation of the third and fourth fixation points 12a, 12b may be input to the apparatus 100 by a user. Alternatively, the orientation of the third and fourth fixation points 12a, 12b may be detected by one or more sensors on the apparatus 100.

[0083] The method may further comprise a step S3 of cutting the first wire Wa and the second wire Wb. Figure ID depicts the apparatus 100 and the target structure 10 after the first wire Wa and the second wire Wb have been cut. The step S3 of cutting the first wire Wa and the second wire Wb may be performed after the head 150 has moved along a path corresponding to all, or substantially all of the target path, and the head 150 is close to (e.g. aligned with and above) the second connection / connector, and after the head 150 has been rotated to achieve the second target orientation of the first and second wires Wa, Wb. The first and second wires Wa, Wb may be cut by the cutting means 152, as described above. The cutting of the first wire Wa may define (i.e. form) a second end of the first wire Wa, which is opposite to the first end of the first wire Wa. The cutting of the second wire Wb may define (i.e. form) a second end of the first wire Wb, which is connected to the first end of the second wire Wb. The method further may further comprise a step S4 of securing the second end of the first wire Wa at the third fixation point 12a and securing the second end of the second wire Wb at the fourth fixation point 12b. Figure IE depicts the apparatus 100 and the target structure 10 after the second end of the first wire Wa has been secured to the third fixation point 12a and the second end of the second wire Wb has been secured to the fourth fixation point 12b. This step may be similar to the step SI of securing the first end of the first wire Wa to the first fixation point and securing the first end of the second wire Wb to the second fixation point. The step S4 of securing the second end of the first wire Wa at the third fixation point 12a and securing the second end of the second wire Wb at the fourth fixation point 12b may be performed after the step S3 of cutting the first wire Wa and the second wire Wb.

[0084] At the fixation points (i.e. the first fixation point I la, the second fixation point 1 lb, the third fixation point 12a and the fourth fixation point 12b), the means by which the ends of the wires Wa, Wb are secured is not particularly limited. In some embodiments, the ends of the wires Wa, Wb are soldered to the fixation points I la, 1 lb, 12a, 12b. A solder-type connection may allow for a strong, solid mechanical and electrical connection. The solder may be applied with a soldering iron. The soldering iron may be automated. In other embodiments, the wires Wa, Wb may be secured to the fixation points 1 la, 1 lb, 12a, 12b at a crimped connection. The crimped connection may be formed by the application of mechanical force. In other embodiments, the wires Wa, Wb may be secured to the fixation points 1 la, 1 lb, 12a, 12b by an insulation displacement connector (TDC). In other embodiments, the fixation points 1 la, 1 lb, 12a, 12b may be defined by connector blocks or junction blocks into which the wires Wa, Wb can be fed to be secured. In some embodiments, the fixation points may provide anchoring points (e.g. holes, hooks or grooves) for the ends of the wires Wa, Wb to be secured to.

[0085] After the step S2 of feeding the first and second wires Wa, Wb through the first and second openings 154a, 154b and rotating the head 150, rotation of the head 150 may be stopped (i.e. discontinued), and the translational movement of the head may be continued. This may result in the laying of portions of the first and second wires Wa, Wb which are straight (i.e. untwisted) adjacent to the third and fourth fixation points 12a, 12b.

[0086] During the step S2 of feeding the first and second wires Wa, Wb through the first and second openings 154a, 154b and rotating the head 150, there may be periods in which the rotation of the head 150 is paused, the translational movement of the head 150 is continued, and the feeding of the first and second wires Wa, Wb through the head 150 is continued. Additionally or alternatively, during the step S2 of feeding the first and second wires Wa, Wb through the first and second openings 154a, 154b and rotating the head 150, there may be periods in which the rotation of the head 150 and the translational movement of the head is paused and the feeding of the first and second wires Wa, Wb through the head 150 is continued. This may result in the laying of portions of the first and second wires Wa, Wb which are straight (i.e. untwisted) between portions of the first and second wires Wa, Wb which are twisted together.

[0087] During the step SI of securing the first end of the first wire Wa at the first fixation point I la and securing the first end of the second wire Wb at the second fixation point 1 lb (i.e. before the step S2 of feeding the first and second wires Wa, Wb through the first and second openings 154a, 154b and rotating the head 150), the first and second wires Wa, Wb may be in an untwisted state between the first and second wire guides 131a, 131b and the third and fourth wire guides 151a, 151b. In the apparatus 100 depicted in Figures 1A to IF, the head 150 is rotated relative to the housing during the step S2 of feeding the first and second wires Wa, Wb through the first and second openings 154a, 154b and rotating the head 150. Thus, the third and fourth wire guides 151a, 151b are rotated relative to the first and second wire guides 131a, 131b. Because the orientation of the first wire Wa and the second wire Wb in the housing 110 is constrained by the first wire guide 131a and the second wire guide 131b, and the orientation of the first wire Wa and the second wire Wb in the head 150 is constrained by the third wire guide 151a and the fourth wire guide 151b, the rotation of the head (and the third wire guide 151a and the fourth wire guide 151b) relative to the housing (and the first wire guide 131a and the second wire guide 131b) may cause the first and second wires Wa, Wb to become twisted between the third and fourth wire guides 151a, 151b and the first and second wire guides 131a, 131b. In other words, rotating the head 150 relative to the housing 110 may cause a twist rate of the first wire Wa and the second wire Wb to increase between the first and second wire guides 131a, 131b and the third and fourth wire guides 151a, 151b. The twist rate is measure of the number of twists in a given length.

[0088] A distance between the first wire guide 131a and the third wire guide 151a may be sufficiently large to accommodate twisting of the first and second wires Wa, Wb between the third and fourth wire guides 151a, and the first and second wire guides 131a, 131b during the step S2 of feeding the first and second wires Wa, Wb through the first and second openings 154a, 154b and rotating the head 150. The distance between the first wire guide 131a and the third wire guide 151a may be greater than 0.5 m, preferably greater than 1 m and further preferably greater than 3 m, and further preferably greater than 5 m. The distance between the first wire guide 131a and the third wire guide 151a may be less than 10 m.

[0089] The distance between the first wire guide 131a and the third wire guide 151a may be similar to the length of the target path. Thus, the distance between the first wire guide 131a and the third wire guide 151a may be determined from the length of the target path. The distance between the second wire guide 131b and the fourth wire guide 151b may be substantially the same as the distance between the first wire guide 131a and the third wire guide 151a.

[0090] To provide a sufficient distance between the first wire guide 131a and the third wire guide 151a without excessively increasing the length of the housing 110, the housing 110 may be curved. For example, the housing 110 may be curved back on itself once, twice, three times or more times to increase the distance between the first wire guide 131a and the third wire guide 151a without increasing the length of the housing 110. In such a configuration, further wire guides may be provided to aid the first and second wires Wa, Wb in navigating the curves.

[0091] Also in consideration of the twisting of the first and second wires Wa, Wb between the third and fourth wire guides 151a, and the first and second wire guides 131a, 131b during the step S2 of feeding the first and second wires Wa, Wb through the first and second openings 154a, 154b and rotating the head 150, the method may further comprise a step S5 of untwisting the first and second wires Wa, Wb between the third and fourth wire guides 151a, and the first and second wire guides 131a, 131b. The step S5 of untwisting the first and second wires Wa, Wb may comprise, after the first and second wires Wa, Wb have been cut, rotating the head 150 around the primary axis in a second direction. The second direction is opposite to the first direction. For example, if the first direction is clockwise, the second direction is anticlockwise.

[0092] The rotation of the head 150 in the second direction may cause the twist rate of the first wire and the second wire to decrease between the first and second wire guides and the third and fourth wire guides. To fully un-twist the first wire Wa and the second Wa, the number of rotations of the head 150 in the second direction during the step S5 of untwisting the first and second wires Wa, Wb may be approximately equal to the number of rotations of the head in the first direction in the step S2 of feeding the first and second wires Wa, Wb through the first and second openings 154a, 154b and rotating the head 150. Figure IF depicts the apparatus 100 and the target structure 10 after the step S5 of untwisting the first and second wires Wa, Wb between the third and fourth wire guides 151a, 151b, and the first and second wire guides 131a, 131b has been performed. Performing the step S5 of untwisting the first and second wires Wa, Wb between the third and fourth wire guides 151a, 151b and the first and second wire guides 131a, 131b means that the apparatus 100 can be returned to its initial state (i.e. as depicted in Figure 1 A). Consequently, the method can be repeated (i.e. to install another twisted pair) without intervention from an operator.

[0093] During the step S5 of untwisting the first and second wires Wa, Wb between the third and fourth wire guides 151a, 151b and the first and second wire guides 131a, 131b (i.e. while the head is rotated in the second direction), the first wire guide 131a and the second wire guide 131b may be moved away from the third wire guide 151a and the fourth guide 151b (i.e. upwards as shown in Figure IF). This may be done so that the first wire Wa remains in tension between the first wire guide 131a and the third wire guide 151a and the second wire Wb remains in tension between the second wire guide 131b and the fourth wire guide 151b. Additionally or alternatively, during the step S5 of untwisting the first and second wires Wa, Wb between the third and fourth wire guides 151a, 151b, and the first and second wire guides 131a, 131b (i.e. while the head is rotated in the second direction), the first wire Wa may be retracted from between the first wire guide 131a and the third wire guide 151a, and the second wire Wb may be retracted from between the second wire guide 131b and the fourth wire guide 151b. This retraction may be towards the feedstock portions (i.e. upwards as shown in Figure IF). This may be done so that the first wire Wa remains in tension between the first wire guide 131a and the third wire guide 151a and the second wire Wb remains in tension between the second wire guide 131b and the fourth wire guide 151b.

[0094] Figure 3 depicts an apparatus 200 according to a second embodiment. The apparatus 200 may be similar to the apparatus 100 depicted in Figures 1 A-1F, except as described below.

[0095] In the apparatus 200, the housing 210 is rigidly coupled to the head 250. That is, the head 250 may be coupled to the housing 210 such that the housing 210 and the head 250 rotate together. Consequently, the apparatus 200 may not comprise a rotation stage, like the rotation stage 120 of the apparatus 100. Further, in the apparatus 200, the first feedstock portion 260a and the second feedstock portion 260b may be rigidly coupled to the housing 210. That is, the first feedstock portion 260a and the second feedstock portion 260b may be coupled to the housing 210 such that the first feedstock portion 260a and the second feedstock portion 260b rotate with the housing 210.

[0096] Thus, in the step S2 of feeding the first and second wires Wa, Wb through the first and second openings 254a, 254b and rotating the head 250, the housing 210, the first and second feedstock portion 260a, 260b, and any wire guides coupled to the housing 210 may be rotated (i.e. around the primary axis). This means that the first and second wires Wa, Wb do not become twisted in the housing 210 during the step S2 of feeding the first and second wires Wa, Wb through the first and second openings 254a, 254b and rotating the head 250.

[0097] Because there is no requirement for the head 250 to be rotatable relative to the housing 210 in the apparatus 200, the head 250 and the housing 210 may be integrally formed.

[0098] The arrangement of the wire guides in the apparatus 200 may differ from the arrangement of the wire guides in the apparatus 100. Figure 3 depicts one possible arrangement of wire guides within the apparatus 200. Variations in the configurations of the wire guides are depicted in Figures 4A-4D.

[0099] In the embodiment depicted in Figure 3, the apparatus 200 comprises a fifth wire guide 255a, 256a and a sixth wire guide 255b, 256b, a seventh wire guide 257a, 258a and an eighth wire guide 257b, 258b. The fifth to eight wire guides 255a, 256a, 255b, 256b, 257a, 258a, 257b, 258b may be instead of the first to fourth wire guides 131a, 131b, 151a, 151b. The fifth to eight wire guides 255a, 256a, 255b, 256b, 257a, 258a, 257b, 258b may be similar in functionality to the first to fourth wire guides 131a, 131b, 151a, 151b. In some cases, the fifth to eight wire guides 255a, 256a, 255b, 256b, 257a, 258a, 257b, 258b may alternatively be referred to as first to fourth wire guides 131a, 131b, 151a, 151b. The fifth wire guide 255a, 256a is configured to guide (e.g. feed) the first wire Wa. The sixth wire guide 255b, 256b is configured to guide (e.g. feed) the second wire Wb. The seventh wire guide 257a, 258a is configured to guide (e.g. feed) the first wire Wa. The eighth wire guide 257b, 258b is configured to guide (e.g. feed) the second wire Wb.

[0100] Each of the wire guides may be configured to feed the wires through the apparatus 200. Where a wire guide is configured to feed a wire through the apparatus 200, the wire guide may be driven (e.g. by a motor). The fifth wire guide and the seventh wire guide may form a feed mechanism for the first wire Wa. The sixth wire guide and the eighth wire guide may form a feed mechanism for the second wire Wb. The feed mechanism for the first wire Wa may be independent of (i.e. separate to) the feed mechanism for the second wire Wb.

[0101] The seventh and eighth wire guides may be disposed above (i.e. further from the target structure 10 and closer to the feedstock portions 260a, 260b) than the fifth and sixth wire guides. The seventh and eighth wire guides may be disposed within the housing 210. The fifth and sixth wire guides may be disposed in (or be part of) the head 250.

[0102] The fifth and sixth wire guides may be coupled to the head 250. The fifth and sixth wire guides may be fixedly coupled to the head 250 such that the fifth and sixth wire guides cannot rotate relative to the head 250 around the primary axis. The seventh and eight wire guides may be coupled to the housing 210. In the case that the apparatus is configured such that the head 250, the housing 210 and the feedstock portions 260a, 260b rotate together, the seventh and eight wire guides may be fixedly coupled to the housing 210.

[0103] The fifth wire guide, the sixth wire guide, the seventh wire guide and / or the eighth wire guide may each comprise a pair of drive members. For example, the fifth wire guide comprises a first drive member 255a and a second drive member 256a. Each drive member 255a, 256a may comprise a pair of rollers and a traction belt. Within a drive member, the traction belt may be disposed around the pair of rollers, such that rotation of the pair of rollers causes the traction belt to be fed around the pair of rollers. Within a wire guide (e.g. within the fifth wire guide), the pair of drive members (e.g. the first and second drive members 255a, 256a) may be arranged to oppose one another. The wire guides (e.g. the fifth wire guide) may be configured to feed a wire (e.g. the first wire Wa) through the apparatus (i.e. from the first feedstock portion 260a towards the first opening 254a). The wires (e.g the first wire Wa) may be provided between the drive members (e.g. between traction belts of the opposing drive members), such that rotation of the rollers of that wire guide cause the wire to be fed through the apparatus 200.

[0104] In some embodiments, the apparatus comprises the fifth wire guide and the sixth wire guide only (see Figures 4C and 4D). In other words, the apparatus 200 may not comprise the seventh wire guide and the eighth wire guide.

[0105] In some embodiments, one or more of the fifth wire guide, the sixth wire guide, the seventh wire guide and the eight wire guide comprise a one or more pairs of opposing rollers, but not a traction belt (see Figures 4A, 4B and 4C). In the apparatus 200, the motor may cause rotation of the housing (around the primary axis), e.g. through a physical coupling between the motor and the housing 210. The rotation of the housing 210 (around the primary axis) may cause the required rotation of the head 250 (around the primary axis). When the feedstock portions 260a, 260b and the seventh and eighth wire guides are fixedly coupled to the housing 210, the rotation of the housing 210 (around the primary axis) also causes the rotation of feedstock portions 260a, 260b and the seventh and eighth wire guides (around the primary axis).

[0106] The apparatus 200 depicted in Figure 3 may perform the same method as described above in relation to the apparatus 100 depicted in Figures 1 A to IF. However, the step S5 of untwisting the first and second wires Wa, Wb between the third and fourth wire guides 151a, 151b and the first and second wire guides 131a, 131b may not be performed. Such a step may not be of technical benefit in the apparatus 200, because with the apparatus 200, the first and second wires Wa, Wb do not become twisted in the housing 210 during the step S2 of feeding the first and second wires Wa, Wb through the first and second openings 254a, 254b and rotating the head 250.

[0107] In a variant of the apparatus 200 depicted in Figure 3, the apparatus 200 may be configured such that the feedstock portions 260a, 260b and the wire guides in the housing (e.g. the seventh wire guide and the eighth wire guide) rotate in accordance with the head 250 around the primary axis, but the housing 210 may remain rotationally fixed (i.e. does not rotate around the same axis as the head 250). That is, the feedstock portions 260a, 260b and the wire guides in the housing (e.g. the seventh wire guide and the eighth wire guide) may rotate around the primary axis relative to the housing 210. In such an embodiment, the first and second wires Wa, Wb do not become twisted in the housing 210 during the step S2 of feeding the first and second wires Wa, Wb through the first and second openings 254a, 254b and rotating the head 250. By not rotating the housing 210, the mass of the rotating portion of the apparatus 200 is reduced. The advantages of this have been discussed above. However, in some cases, it may be more complex to rotatably couple the feedstock portions 260a, 260b to the housing 210.

[0108] In the variant of the apparatus 200 in which the feedstock portions 260a, 260b and the wire guides in the housing 210 (e.g. the seventh wire guide and the eighth wire guide) rotate relative to the housing 210, the feedstock portions 260a, 260b may be rotatably coupled to the housing 210, and seventh wire guide and the eighth wire guide may be rotatably coupled to the housing 210. Figure 5 depicts an apparatus 300 according to a third embodiment. The apparatus 300 may be similar to the apparatus 100 depicted in Figures 1 A-1F, except as described below.

[0109] The apparatus 300 depicted in Figure 5 may be configured to install a pre-formed twisted pair of wires Wa, Wb. Thus, in a method comprising use of the apparatus 300, the the first wire Wa and the second wire Wb are twisted together before being fed through the first opening 354a and the second opening 354b. That is, the method comprises providing a pre-formed twisted pair to the apparatus 300, where the apparatus comprises the head 350, the housing 310, and a single feedstock portion (not shown).

[0110] Like the apparatus 100 and the apparatus 200 discussed above, the apparatus 300 comprises a first opening 354a through which the first wire Wa is fed and a second opening 354b. As such, the orientation of the first and second wires Wa, Wb of the twisted pair in the apparatus can be known from the orientation of the first and second openings 354a, 354b.

[0111] The apparatus 300 may comprise a similar wire guide configuration to that described above. A key difference may be that each wire guide may be configured to act on the twisted pair as a whole (i.e. the first wire Wa and the second wire Wb), as opposed to just one of the first wire Wa and the second wire Wb. The apparatus 300 may comprise a ninth wire guide 355 and a tenth wire guide 356, each comprising a pair of opposing rollers 3551, 3552, 3561, 3562. The twisted pair of wires Wa, Wb may be fed between the pairs of opposing rollers 3551, 3552, 3561, 3562 of the ninth wire guide 355 and the tenth wire guide 356. The ninth wire guide 355 and a tenth wire guide 356 may be driven so as to feed the twisted pair of wires Wa, Wb from a single twisted pair feedstock portion and through the first and second openings 354a, 354b. The configuration depicted in Figure 5 is one way of feeding the twisted pair of wires Wa, Wb from the first and second feedstock portions and through the first and second openings 354a, 354b. However, any configuration of wire guides that are suitable for feeding the twisted pair of wires through the apparatus 300 in this way may be employed.

[0112] In the apparatus 300, the head 350 may rotate (Rl) relative to the housing 310, as in the apparatus 100. This relative rotation may be facilitated by the rotation stage 320. Because the first and second wires Wa, Wb are provided to the apparatus 300 as a twisted pair, the relative rotation of the head 350 and the housing 310 may not result in a change in the twist rate of the first wire Wa and the second wire Wb within the housing. To ensure that this is the case, the head 350 may be rotated in accordance with the lay length of the twisted pair. The lay length may alternatively be referred to as the twist rate. That is, if the twist rate of the twisted pair (of the first and second wires Wa, Wb) provided to the apparatus is X per metre, the head 350 may be rotated X times for every metre of the first and second wires that is fed through the first and second openings 354a, 354b.

[0113] As a result of the twisted nature of the first and second wires Wa, Wb in the twisted pair, the orientation of the first and second wires Wa, Wb in the twisted pair may vary as a function of the axial position along the twisted pair. Thus, as the twisted pair is fed through the apparatus 300, the orientation of the first and second wires Wa, Wb at the head 350 may vary. The head may rotate in accordance with the lay length of the twisted pair such that the arrangement of the first and second openings 354a, 354b corresponds to the arrangement of the first and second wires Wa, Wb as the twisted pair is fed through the head 350.

[0114] In some embodiments, the head 350 is configured to rotate freely relative to the housing 310. That is, a frictional force that opposes the rotation of the head 350 relative to the housing 310 may be relatively low, and the rotation of the head may not be driven by an external motor. Rather, the rotation of the head may be induced by the feeding the first and second wires Wa, Wb through the first and second openings 354a, 354b. In other embodiments, the head may be driven (e.g. by an external motor), with the speed of the motor controlled in accordance with the twist rate of the twisted pair.

[0115] In some embodiments, the apparatus 100 may further comprise a rotary encoder. The head 150 may comprise the rotary encoder. The rotary encoder may be configured to determine the angular position of the head 150. By determining the angular position of the head 150, the orientation of the wires Wa, Wb can be determined. The angular position of the head 150 may be used at various points throughout the method described above. For example, the angular position of the head 150 may be used during the step of rotating the head such that the orientation of the first and second openings 154a, 154b (i.e. the relative positioning of the first and second openings 154a, 154b) corresponds to the orientation of the first and second fixation points I la, 1 lb (i.e. the relative positioning of the first and second fixation points 1 la, 1 lb).

[0116] Figure 6 depicts a variant of the apparatus 300. In the variant of the apparatus 300 depicted in Figure 6, a first traction belt 3591 may be disposed around one of the rollers 3551 of the ninth wire guide 355 and one of the rollers 3561 of the tenth wire guide 356, and a second traction belt 3592 may be disposed around the other of the rollers 3552 of the ninth wire guide 355 and the other of the rollers 3562 of the tenth wire guide 356. The first wire Wa and the second wire Wb may then pass between the first traction belt and the second traction belt. Providing traction belts 3591, 3592 in this way may allow the first and second wires Wa, Wb to be drawn through the apparatus more reliably.

[0117] Where traction belts are disposed around one or more rollers (e.g. where the first traction belt 3591 is disposed around one of the rollers 3551 of the ninth wire guide 355 and one of the rollers 3561 of the tenth wire guide 356), the rollers may be timing pulleys. Use of timing pulleys in such circumstances may prevent slip between the traction belt and the rollers. Use of timing pulleys may also allow the different rollers to be indexed together.

[0118] The above description has referred to embodiments in which the head comprises two openings (the first opening and the second opening). The purpose of the two openings is to fix the orientation of the first wire and the second wire relative to the head. Thus, if the orientation of the head is known, the orientation of the first wire and the second wire is known. In this way, the first wire and the second wire can be indexed, and easily connected to the requisite terminations.

[0119] As will now be described, in some embodiments, the head 150 comprises a single common opening 154 through which both the first wire Wa and the second wire Wb are fed.

[0120] The common opening 154 may be configured such that the orientation of the first wire and the second wire within the common opening is fixed. In this way, if the orientation of the head 150 is known, the orientation of the first wire Wa and the second wire Wb is known, as in the case that the head comprises two distinct openings.

[0121] Figures 7A and 7B depict schematic representations of the geometry of a common opening 154 which is configured such that the orientation of the first wire and the second wire within the common opening is fixed. A portion of the common opening 154 through which the first wire Wa passes may be referred to as a first sub-portion 154a of the common opening 154, and a portion of the common opening 154 through which the second wire passes may be a second sub-portion 154b of the common opening 154.

[0122] The common opening 154 is configured such that, once the wires Wa, Wb are passing through the common opening 154 (and, specifically, once the first wire Wa is passing through the first sub-portion 154a of the common opening 154 and the second wire Wb is passing through the second sub-portion of the common opening 154), the wires Wa, Wb cannot move within the common opening 154 to change places (i.e. such that the first wire Wa passes through the second sub-portion 154b of the common opening 154 and the second wire Wb passes through the first sub-portion 154a of the common opening). That is, each of the wires Wa, Wb are confined to their own sub-portion of the common opening.

[0123] In the example of the common opening 154 depicted in Figure 7A, the common opening 154 has a figure-8 shape. That is, the shape of the common opening 154 is formed of two circles (which form the sub-portions 154a, 154b of the common opening 154), and relief portions (e.g. fillets) therebetween. The first sub-portion 154a of the common opening 154 is separated from the second sub-portion 154b of the common opening by a constriction, wherein the constriction has a width that is less than the diameters of the first wire Wa and the second wire Wb. Consequently, the first wire Wa is prevented from moving to the second sub-portion 154b of the common opening 154 and the second wire Wb is prevented from moving to the first sub-portion 154b of the common opening 154.

[0124] In the example of the common opening 154 depicted in Figure 7B, the common opening 154 has a rounded rectangle shape. The common opening 154 depicted in Figure 7B does not comprise a constriction, like the constriction depicted in the common opening of Figure 7A. The first sub-portion 154a of the common opening 154 is aligned with the second-sub-portion 154b of the common opening in a first direction. A width of the common opening 154 (i.e. a dimension of the common opening in a dimension that is perpendicular to the first direction) is less than the sum of the diameters of the first and second wires Wa, Wb. Consequently, the wires Wa, Wb are unable to move past each other within the common opening. That is, the first wire Wa is prevented from moving to the second sub-portion 154b of the common opening 154 and the second wire Wb is prevented from moving to the first sub-portion 154a of the common opening 154.

[0125] In the examples of the common opening 154 depicted in Figures 7A and 7B, the first sub-portion 154a of the common opening 154 and the second sub-portion 154b of the common opening 154 are tangential. The point at which the first sub-portion 154a of the common opening 154 and the second sub-portion 154b of the common opening 15 contact one another tangentially is labelled T. However, this is not essential, and the sub-portions of the common opening 154 may, for example, be separated from one another.

[0126] In the examples of the common opening 154 depicted in Figures 7A and 7B, the first sub-portion 154a of the common opening 154 and the second sub-portion 154b each have a diameter that is substantially the same as the diameter of the first wire Wa and the second wire. Specifically, the first sub-portion 154a of the common opening 154 has a diameter that is substantially the same as the first wire Wa, and the second sub-portion 154b has a diameter that is substantially the same as the second wire Wb. In practice, diameter of the first sub-portion 154a of the common opening 154 may be slightly larger than the diameter of the first wire Wa and the diameter of the second sub-portion 154b of the common opening 154 may be slightly larger than the diameter of the second wire Wb. This may be to ensure that the wires Wa,Wb can pass smoothly through the common opening 154 (i.e. with relatively low friction). The fit between the wires Wa, Wb and the sub-portions of the common opening 154a, 154b may be a clearance fit.

[0127] By providing a common opening as described above, it is possible to reduce the distance between the first wire Wa and the second wire Wb as the first wire Wa and the second wire Wb are twisted together. Consequently, it is possible for the two wires of the resulting twisted pair to be more tightly wound together. Further, a head with a common opening may be easier to manufacture than a head with two distinct openings.

[0128] As will be appreciated, a head with a common opening may be implemented in any of the embodiments of the wire deposition apparatus described herein. For example, a head with a common opening may be implemented in the apparatus 100 depicted in Figures 1 A-1F, the apparatus 200 depicted in Figures 3-4D, and the apparatus 300 depicted in Figure 5. When implemented in such embodiments, the first and second sub-portions of the common opening take the place (and perform the functionality) of the first and second openings.

[0129] A product obtained by the method of the present disclosure may comprise the target structure and the installed twisted pair of wires Wa, Wb.

[0130] The apparatus 100, 200, 300 may perform the method of the present disclosure.

[0131] Figures 8 and 9 depict a machine 500. The machine 500 may be used to install a twisted pair of wires (not shown) into a target structure 10. The machine 500 may comprise an apparatus, such as the apparatus 100, 200, 300 described above.

[0132] The machine 500 may comprise a spatial manipulation system. The spatial manipulation system may be configured to provide for the various movements of the apparatus 100, 200, 300 (or the head 150, 250, 350 thereof) described above. The spatial manipulation system may be configured to allow relative movement between a holder 538 for holding the target structure 10 and at least a portion of the apparatus 100, 200, 300. The relative movement may include translation relative to three mutually non-parallel (e.g. orthogonal) translation axes and rotation about two mutually non-parallel (e.g. orthogonal) rotation axes. The relative movement may be during the laying of the twisted pair of wires Wa, Wb into the target structure 10 by the apparatus 100, 200, 300. Generally, the machine 500 may allow for relative movement between the apparatus 100, 200, 300 and the holder 538 in at least three degrees of freedom, and preferably at least in the five degrees of freedom (three translational and two rotational) described above. In some embodiments, the machine 500 may allow for relative movement between the apparatus 100, 200, 300 and the holder 538 in six degrees of freedom.

[0133] The spatial manipulation system may comprise a first subsystem configured to provide the translation relative to the three mutually non-parallel translation axes and rotation about the two mutually non-parallel rotation axes, and a second subsystem configured to provide relative translational movement between the first subsystem and the structure being formed.

[0134] In the example of Figures 8 and 9, the apparatus 100, 200, 300 is mounted (e.g. removably mounted) on an arm 534 which is connected to an x-y translation stage 536. The x-y translation stage 536 allows the arm 534, and thus the apparatus 100, 200, 300 attached thereto, to be moved in an x-direction illustrated by arrow 544 and in a y-direction illustrated by arrow 546, thereby providing two orthogonal translation axes.

[0135] The holder 538, which supports the target structure 10, may be arranged on a first rotational stage 540 which is operatively connected to a z-height, i.e. vertical height, translation stage 542. As depicted by the arrow 548, the z-height translation stage 542 allows the holder 538 to be moved vertically up and down in the z-direction, thereby providing a third orthogonal translation axis.

[0136] The first rotational stage 540 may be configured to allow the holder 538 to rotate relative to the apparatus 100, 200, 300. In the embodiment depicted, the first rotational stage 540 permits rotation in a plane orthogonal to the z-axis and parallel to the x- and y- axis. The rotation is illustrated by the arrow 552.

[0137] A second rotational stage 554 be arranged between the apparatus 100, 200, 300 and the arm 534. The second rotational stage 554 may allow for rotation of the apparatus 100, 200, 300 in a plane parallel to the z-axis and orthogonal to the x- and y- axis. In the embodiment depicted, the second rotational stage 554 allows the apparatus 100, 200, 300 to rotate in the direction illustrated by the arrow 550. The second rotational stage 554 therefore permits rotation of the apparatus 100, 200, 300 relative to the holder 538.

[0138] In a variant of the machine 500, a first rotational stage may be configured to rotate the apparatus 100, 200, 300 rotation in a plane orthogonal to the z-axis and parallel to the x- and y-axis. Such a first rotational stage may be interposed between the second rotational stage 554 and the apparatus 100, 200, 300, for example. Such a first rotational stage may be instead of, or in addition to, the first rotational stage 540 configured to rotate the holder 538 in a plane orthogonal to the z-axis and parallel to the x- and y-axis.

[0139] In a variant of the machine 500, the apparatus 100, 200, 300 may be operatively connected to a z-height, i.e. vertical height, translation stage, such that the apparatus 100, 200, 300 can be moved in the z-direction. This may be instead of, or in addition to, the z- height, i.e. vertical height, translation stage 542 configured to raise and lower the holder 538. In a variant, the holder may not be operatively coupled to any rotation / translation stages (e.g. may be spatially fixed), and all of the translation / rotational relative movement between the apparatus 100 / 200 / 300 and the holder 538 may be provided by rotation / translation stages operably coupled to the apparatus 100 / 200 / 300.

[0140] In the embodiment shown in Figures 8 and 9, the spatial manipulation system comprises the x-y translation stage 536, the z-height translation stage 542, the first rotational stage 540 and the second rotational stage 554. Together, all of these stages provide the three orthogonal translation axes and rotation about two orthogonal rotation axes.

[0141] In the case where first and second subsystems are provided, all of these stages could form part of the first subsystem and the second subsystem could comprise a gantry configured to move all of the stages as unit along a further translation axis (which may be referred to as a major axis). The various translation stages need not necessarily have the specific arrangement described above and instead may be arranged in any other suitable manner to achieve the three mutually non-parallel (e.g. orthogonal) translation axes and two mutually non-parallel (e.g. orthogonal) rotation axes, and, where applicable, the further movement along the major axis.

[0142] Thus, the machine 500 is able to install a twisted pair of wires Wa, Wb into a target structure 10 without direct control / intervention by a human operator. This is a significant improvement over prior art alternatives for manufacturing devices such as wiring harnesses, where wires need to be cut to length, stripped, terminated and then assembled together to form the harnesses. Such prior art wiring harnesses are largely manufactured by hand. Some complicated wiring harnesses can take days or even weeks to manufacture. The machine 500 provides significant improvements over such prior art techniques by allowing increased automation, thereby reducing manufacturing time, reducing quality variability and / or reducing and cost, as well as producing superior devices for all of the reasons described above. These advantages may be particularly beneficial in aircraft and electric vehicles, where downtime for fault finding and repairs is notoriously expensive. The apparatus 100, 200, 300 may be controlled by a computer. The computer may run a computer program comprising instructions which, when executed, cause the computer to control the apparatus 100, 200, 300 to perform the method of the present disclosure. In the computer, the computer program may be stored on a computer-readable medium.

[0143] As used herein, terms such as “first”, “second” and “third” are used to provide distinct labels for different features. These terms are not intended to carry their own meaning, or impart structural or functional limitations to the components / features with which they are used. For example, the presence of a ninth wire guide does not imply the presence of at least nine wire guides. Similarly, where a first wire guide and a second wire guide are defined, it is not implied that the second wire guide comes after the first wire guide.

[0144] Aspects of the invention are described in the following numbered clauses.

[0145] 1. A method of installing a twisted pair of wires into a target structure, the method comprising: laying the twisted pair of wires into the target structure, the twisted pair of wires comprising a first wire and a second wire, wherein the laying of the twisted pair of wires is performed by feeding the first wire through a first opening in a head towards the target structure and feeding the second wire through a second opening in the head towards the target structure while rotating the head, and wherein the first opening and the second opening are distinct from one another, or the first opening and the second opening are each a sub-portion of a common opening.

[0146] 2. The method according to clause 1, wherein, during the laying of the twisted pair of wires, the head is moved relative to the target structure along a path corresponding to a target path, wherein the target path is a path along which the first wire and the second wire are to be placed.

[0147] 3. The method according to clause 1 or 2, wherein the feeding the first wire through the first opening and feeding the second wire through the second opening while rotating the head is such that the first wire and the second wire are twisted together as they laid into the target structure.

[0148] 4. The method according to any of the preceding clauses, further comprising, before laying the twisted pair of wires into the target structure, securing a first end of the first wire at a first fixation point, and securing a first end of the second wire at a second fixation point.

[0149] 5. The method according to any of the preceding clauses, further comprising, after laying the twisted pair of wires into the target structure, securing a second end of the first wire at a third fixation point and securing a second end of the second wire at a fourth fixation point.

[0150] 6. The method according to clause 4 or 5, wherein a first electrical connection comprises the first fixation point and the second fixation point, and / or a second electrical connection comprises the third fixation point and the fourth fixation point.

[0151] 7. The method according to clause 5 or 6, further comprising cutting the first wire and the second wire, wherein the second end of the first wire and the second end of the second wire are formed where the first wire and the second wire are cut.

[0152] 8. The method according to clause 7, wherein the cutting the first wire and the second wire is performed before the second end of the first wire is secured at the third fixation point and the second end of the second wire is secured at the fourth fixation point.

[0153] 9. The method according to any of the preceding clauses, wherein the first wire and the second wire are configured in the target structure to distribute power and / or transmit signals.

[0154] 10. The method according to any of the preceding clauses, wherein the twisted pair is laid on a surface, and the head is moved relative to the target structure in a direction that is substantially parallel to the surface.

[0155] 11. The method according to any of the preceding clauses, wherein the head is rotated around an axis which passes through a position interposed between the first opening and the second opening.

[0156] 12. The method according to any of the preceding clauses, wherein the head is rotated around an axis which is substantially parallel to a direction in which the first wire is fed through the first opening and / or a direction in which the second wire is fed through the second opening.

[0157] 13. The method according to any of the preceding clauses, wherein the method further comprises rotating the head relative to a housing.

[0158] 14. The method according to clause 13, wherein the first wire is provided to the first opening from a first feedstock portion via a first wire guide, and the second wire is provided to the second opening from the second feedstock portion via a second wire guide, wherein the first wire guide and the second wire guide are rigidly coupled to the housing.

[0159] 15. The method according to clause 14, wherein the first wire is provided to the first opening from a first feedstock portion via a third wire guide and the second wire is provided to the second opening from a second feedstock portion via a fourth wire guide, and the third wire guide and the fourth wire guide are rigidly coupled to the head.

[0160] 16. The method according to any of clause 15, wherein, during the step of securing the first end of the first wire at the first fixation point and securing the first end of the second wire at a second fixation point, the first and second wires are in an untwisted state between the first and second wire guides and the third and fourth wire guides.

[0161] 17. The method according to clause 13 to 16, wherein rotating the head causes a twist rate of the first wire and the second wire to increase between the first and second wire guides and the third and fourth wire guides.

[0162] 18. The method according to clause 13 to 17, wherein the head is rotated in a first direction while the first wire is fed through the first opening and the second wire is fed through the second opening, and the method further comprises, after the first wire and the second wire have been cut, rotating the head in a second direction, wherein the second direction is opposite to the first direction.

[0163] 19. The method according to clause 18, wherein the rotation of the head in the second direction causes the twist rate of the first wire and the second wire to decrease between the first and second wire guides and the third and fourth wire guides.

[0164] 20. The method according to clause 18 or 19, wherein a number of rotations of the head in the second direction is approximately equal to a number of rotations of the head in the first direction.

[0165] 21. The method according to clause 19 or 20, further comprising, while the head is rotated in the second direction, moving the first wire guide and the second wire guide away from the third wire guide and the fourth guide such that the first wire remains in tension between the first wire guide and the third wire guide and the second wire remains in tension between the second wire guide and the fourth wire guide. 22. The method according to clause 19 or 20, further comprising, while the head is rotated in the second direction, retracting the first wire from between the first wire guide and the third wire guide, and retracting the second wire from between the second wire guide and the fourth wire guide, such that the first wire remains in tension between the first wire guide and the third wire guide and the second wire remains in tension between the second wire guide and the fourth wire guide.

[0166] 23. The method according to any of clauses 1 to 12, wherein the head is coupled to a housing such that the housing and the head rotate together.

[0167] 24. The method according to clause 23, wherein a first feedstock portion and a second feedstock portion are coupled to the housing such that the first feedstock portion and the second feedstock portion rotate with the housing.

[0168] 25. The method according to any of clauses 1 to 13, wherein the first wire and the second wire are twisted together before being fed through the first opening and the second opening.

[0169] 26. The method according to clause 25, wherein the method comprises providing a pre-formed twisted pair to a wire deposition apparatus comprising the head, the housing, and a feedstock portion.

[0170] 27. The method according to clause 26, wherein the head is rotated in accordance with the lay length of the twisted pair.

[0171] 28. The method according to clause 27, wherein the head is rotated in accordance with the lay length of the twisted pair such that the arrangement of the first and second openings corresponds to the arrangement of the first and second wires as the twisted pair is fed through the head.

[0172] 29. The method according to any of clauses 27 to 30, wherein the rotation of the head is driven.

[0173] 30. The method according to any of clauses 27 to 30, wherein the head is configured to rotate freely, and the feeding the first and second wires through the first and second openings causes the rotation of the head.

[0174] 31. The method according to any of clauses 27 to 30, wherein the preformed twisted pair is provided to the first opening and the second opening via a ninth wire guide.

[0175] 32. The method according to clauses 27-30, wherein the preformed twisted pair is provided to the first opening and the second opening via a tenth wire guide. 33. The method according to any of clauses 27 to 32, further comprising, after the head has reached the end of a predetermined path, rotating the head so that a target orientation of the first wire and the second wire is obtained.

[0176] 34. The method according to clause 33 wherein the target orientation of the first wire and the second wire is an orientation in which the first wire can be connected to the third fixation point and the second wire can be connected to the fourth fixation point.

[0177] 35. The method according to any of the preceding clauses, wherein the shape of the housing comprises one or more curves.

[0178] 36. The method according to any of the preceding clauses, wherein the first opening is a first sub-portion of the common opening and the second opening is a second sub-portion of the common opening, and the geometry of the common opening is configured to confine the first wire to the first sub-portion of the common opening and to confine the second wire to the second sub-portion of the common opening.

[0179] 37. The method according to clause 36, wherein the first sub-portion of the common opening is substantially tangential to the second sub-portion of the common opening.

[0180] 38. The method according to any of clauses 4 to 35, wherein the first opening and the second opening are distinct from one another, and the method further comprises controlling the separation between the first wire and the second wire to correspond to a spacing between: (i) the first fixation point and the second fixation point; and (ii) the third fixation point and the fourth fixation point, optionally wherein the controlling the separation between the first wire and the second wire comprises setting a distance between the first opening and the second opening.

[0181] 39. The method according to any of clauses 4 to 37, wherein the method further comprises, using a secondary head, controlling the separation between the first wire and the second wire to correspond to a spacing between: (i) the first fixation point and the second fixation point; and (ii) the third fixation point and the fourth fixation point, optionally wherein the controlling the separation between the first wire and the second wire comprises setting a distance between two openings in the secondary head.

[0182] 40. The method according to any of the preceding clauses, wherein one or more of the openings are defined by a nozzle. 41. The method according to any of the preceding clauses, wherein one or more of the first wire guide, the second wire guide, the third wire guide and the fourth wire guide, the ninth wire guide and the tenth wire guide comprise rollers.

[0183] 42. The method according to any of the preceding clauses, wherein one or more of the first wire guide, the second wire guide, the third wire guide and the fourth wire guide, the ninth wire guide and the tenth wire guide comprise a pair of rollers.

[0184] 43. The method according to any of the preceding clauses, wherein one or more of the first wire guide, the second wire guide, the third wire guide and the fourth wire guide, the ninth wire guide and the tenth wire guide comprise traction belts.

[0185] 44. The method according to any of the preceding clauses, wherein one or more of the first wire guide, the second wire guide, the third wire guide and the fourth wire guide, the ninth wire guide and the tenth wire guide comprise a pair of traction belts.

[0186] 45. The method according to any of the preceding clauses, wherein one or more of the first wire guide, the second wire guide, the third wire guide and the fourth wire guide, the ninth wire guide and the tenth wire guide are driven such that the first wire is fed towards the first opening and / or the second wire is fed towards the second opening.

[0187] 46. The method according to any of the preceding clauses, wherein the target structure is a wiring harness.

[0188] 47. A product obtained using the method according to any of the preceding clauses.

[0189] 48. A computer program comprising instructions which, when executed, cause a computer to control a wire deposition apparatus to perform the method of any of clauses 1 to 40.

[0190] 49. A computer-readable medium storing the computer program of clause 43.

[0191] 50. A wire deposition apparatus configured to perform the method according to any of clauses 1 to 46.

[0192] 51. An apparatus configured to install a twisted pair of wires into a target structure, wherein: the twisted pair of wires comprises a first wire and a second wire; the apparatus comprises a head having a first opening and a second opening; and the apparatus is configured to feed the first wire through the first opening towards the target structure and feed the second wire through the second opening towards the target structure while the head is rotated, wherein the first opening and the second opening are distinct from one another, or the first opening and the second opening are each a sub-portion of a common opening.

[0193] 52. A method of installing a twisted pair of wires into a target structure, the method comprising: laying the twisted pair of wires into the target structure, the twisted pair of wires comprising a first wire and a second wire, wherein the laying of the twisted pair of wires is performed by feeding the first wire through an opening in a head towards the target structure and feeding the second wire through the opening in the head towards the target structure while rotating the head, and wherein the opening is configured such that the orientation of the first wire and the second wire within the opening is fixed.

[0194] 53. An apparatus configured to install a twisted pair of wires into a target structure, wherein: the twisted pair of wires comprises a first wire and a second wire; the apparatus comprises a head having an opening; and the apparatus is configured to feed the first wire through the opening towards the target structure and feed the second wire through the opening towards the target structure while the head is rotated, wherein the opening is configured such that the orientation of the first wire and the second wire within the opening is fixed.

[0195] 54. The method of clause 52 or the apparatus of clause 53, wherein the orientation of the first wire and the second wire is the relative positioning of the first wire and the second wire relative to the opening.

[0196] While specific embodiments of the invention have been described above, it will be appreciated that the invention may be practiced otherwise than as described. The descriptions above are intended to be illustrative, not limiting. Thus it will be apparent to one skilled in the art that modifications may be made to the invention as described without departing from the scope of the claims set out below.

Claims

CLAIMS1. A method of installing a twisted pair of wires into a target structure, the method comprising: laying the twisted pair of wires into the target structure, the twisted pair of wires comprising a first wire and a second wire, wherein the laying of the twisted pair of wires is performed by feeding the first wire through a first opening in a head towards the target structure and feeding the second wire through a second opening in the head towards the target structure while rotating the head, and wherein the first opening and the second opening are distinct from one another, or the first opening and the second opening are each a sub-portion of a common opening.

2. The method according to claim 1, wherein, during the laying of the twisted pair of wires, the head is moved relative to the target structure along a path corresponding to a target path, wherein the target path is a path along which the first wire and the second wire are to be placed.

3. The method according to claim 1 or 2, wherein the feeding the first wire through the first opening and feeding the second wire through the second opening while rotating the head is such that the first wire and the second wire are twisted together as they laid into the target structure.

4. The method according to any of the preceding claims, further comprising, before laying the twisted pair of wires into the target structure, securing a first end of the first wire at a first fixation point, and securing a first end of the second wire at a second fixation point.

5. The method according to any of the preceding claims, further comprising, after laying the twisted pair of wires into the target structure, securing a second end of the first wire at a third fixation point and securing a second end of the second wire at a fourth fixation point.

6. The method according to claim 4 or 5, wherein a first electrical connection comprises the first fixation point and the second fixation point, and / or a second electrical connection comprises the third fixation point and the fourth fixation point.

7. The method according to claim 5 or 6, further comprising cutting the first wire and the second wire, wherein the second end of the first wire and the second end of the second wire are formed where the first wire and the second wire are cut, optionally wherein the cutting the first wire and the second wire is performed before the second end of the first wire is secured at the third fixation point and the second end of the second wire is secured at the fourth fixation point8. The method according to any of the preceding claims, wherein the head is rotated around an axis which passes through a position interposed between the first opening and the second opening, and / or wherein the head is rotated around an axis which is substantially parallel to a direction in which the first wire is fed through the first opening and / or a direction in which the second wire is fed through the second opening.

9. The method according to any of the preceding claims, wherein the method comprises rotating the head relative to a housing.

10. The method according to claim 9, wherein the head is rotated in a first direction while the first wire is fed through the first opening and the second wire is fed through the second opening, and the method further comprises, after the first wire and the second wire have been cut, rotating the head in a second direction, wherein the second direction is opposite to the first direction, optionally wherein the rotation of the head in the second direction causes the twist rate of the first wire and the second wire to decrease between the first and second wire guides and the third and fourth wire guides, further optionally wherein a number of rotations of the head in the second direction is approximately equal to a number of rotations of the head in the first direction.

11. The method according to claim 10, further comprising, while the head is rotated in the second direction:moving the first wire guide and the second wire guide away from the third wire guide and the fourth guide such that the first wire remains in tension between the first wire guide and the third wire guide and the second wire remains in tension between the second wire guide and the fourth wire guide, and / or retracting the first wire from between the first wire guide and the third wire guide, and retracting the second wire from between the second wire guide and the fourth wire guide, such that the first wire remains in tension between the first wire guide and the third wire guide and the second wire remains in tension between the second wire guide and the fourth wire guide.

12. The method according to any of claims 1 to 8, wherein the head is coupled to a housing such that the housing and the head rotate together.

13. The method according to claim 12, wherein a first feedstock portion and a second feedstock portion are coupled to the housing such that the first feedstock portion and the second feedstock portion rotate with the housing.

14. The method according to any of claims 1 to 9, wherein the first wire and the second wire are twisted together before being fed through the first opening and the second opening, optionally wherein the method comprises providing a pre-formed twisted pair to a wire deposition apparatus comprising the head, the housing, and a feedstock portion.

15. The method according to claim 14, wherein the head is rotated in accordance with the lay length of the twisted pair, optionally wherein the head is rotated in accordance with the lay length of the twisted pair such that the arrangement of the first and second openings corresponds to the arrangement of the first and second wires as the twisted pair is fed through the head.

16. The method according to any of the preceding claims, wherein the rotation of the head is driven.

17. The method according to claim 14 or 15, wherein the head is configured to rotate freely, and the feeding the first and second wires through the first and second openings causes the rotation of the head.

18. The method according to any of the preceding claims, further comprising, after the head has reached the end of a predetermined path, rotating the head so that a target orientation of the first wire and the second wire is obtained, optionally wherein the target orientation of the first wire and the second wire is an orientation in which the first wire can be connected to the third fixation point and the second wire can be connected to the fourth fixation point.

19. The method according to any of the preceding claims, wherein the first opening is a first sub-portion of the common opening and the second opening is a second sub-portion of the common opening, and the geometry of the common opening is configured to confine the first wire to the first sub-portion of the common opening and to confine the second wire to the second sub-portion of the common opening.

20. The method according to any of claims 4 to 18, wherein the first opening and the second opening are distinct from one another, and the method further comprises controlling the separation between the first wire and the second wire to correspond to a spacing between: (i) the first fixation point and the second fixation point; and (ii) the third fixation point and the fourth fixation point, optionally wherein the controlling the separation between the first wire and the second wire comprises setting a distance between the first opening and the second opening.

21. The method according to any of claims 4 to 19, wherein the method further comprises, using a secondary head, controlling the separation between the first wire and the second wire to correspond to a spacing between: (i) the first fixation point and the second fixation point; and (ii) the third fixation point and the fourth fixation point, optionally wherein the controlling the separation between the first wire and the second wire comprises setting a distance between two openings in the secondary head.

22. The method according to any of the preceding claims, wherein the first wire and the second wire are configured in the target structure to distributepower and / or transmit signals, optionally wherein the target structure is a wiring harness.

23. A computer program comprising instructions which, when executed, cause a computer to control a wire deposition apparatus to perform the method of any of claims 1 to 22.

24. A computer-readable medium storing the computer program of claim 23.

25. A wire deposition apparatus configured to perform the method according to any of claims 1 to 22.

26. An apparatus configured to install a twisted pair of wires into a target structure, wherein: the twisted pair of wires comprises a first wire and a second wire; the apparatus comprises a head having a first opening and a second opening; and the apparatus is configured to feed the first wire through the first opening towards the target structure and feed the second wire through the second opening towards the target structure while the head is rotated, wherein the first opening and the second opening are distinct from one another, or the first opening and the second opening are each a subportion of a common opening.

27. A method of installing a twisted pair of wires into a target structure, the method comprising: laying the twisted pair of wires into the target structure, the twisted pair of wires comprising a first wire and a second wire, wherein the laying of the twisted pair of wires is performed by feeding the first wire through an opening in a head towards the target structure and feeding the second wire through the opening in the head towards the target structure while rotating the head, and wherein the opening is configured such that the orientation of the first wire and the second wire within the opening is fixed.

28. An apparatus configured to install a twisted pair of wires into a target structure, wherein: the twisted pair of wires comprises a first wire and a second wire;the apparatus comprises a head having an opening; and the apparatus is configured to feed the first wire through the opening towards the target structure and feed the second wire through the opening towards the target structure while the head is rotated, wherein the opening is configured such that the orientation of the first wire and the second wire within the opening is fixed.

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