Manufacturing process for a power distribution assembly of an electrical system

In an electrical system comprising an elongate power distribution assembly PDA having an elongate casing with a plurality of electrical conductor PDA wires therein, said casing having groups of openings providing access to said wires, and one or more electrical components adapted to plug into said openings for electrical connection to said PDA wires, a manufacturing process for a power distribution assembly comprising the steps of:

• extruding a longitudinal length of an extrusion profile which is configured to define a PDA casing, said extrusion profile configured to define a plurality of elongate bores extending through said PDA casing;
• cutting said extrusion profile to a length which defines the length of said PDA casing;
• forming patterns of openings in said extrusion profile to define said groups of openings in said PDA casing;
• providing a wire insertion machine which includes a stock of wire material provided on one or more wire spools;
• positioning said PDA casing with open ends of said bores being disposed adjacent to a free end of a longitudinal length of feed wiring extending from said spool;
• operating said wire insertion machine to drive said feed wiring into said respective bore of said PDA casing;
• and
• cutting said wiring to define said PDA wire in said bore.

In an electrical system comprising an elongate power distribution assembly PDA having an elongate casing with a plurality of electrical conductor wires therein, said casing having groups of openings providing access to said wires, and one or more electrical components adapted to plug into said openings for electrical connection to said wires, a manufacturing process for a power distribution assembly comprising the steps of:

• forming said PDA casing from a longitudinal length of an extrusion profile which has bores extending therethrough and said wires dispose therein, said extrusion profile being defined by an extruded material;
• cutting said extrusion profile to predetermined lengths which each define a desired length of said PDA casing;
• forming patterns of said openings in said extrusion profile prior to positioning of said wires within said bores to define said groups of openings in said PDA casing;
• positioning said wires within said bores so as to be accessible through said openings, said wires being cut to a length which corresponds to a length of said extrusion profile so as to extend substantially along the length of said PDA casing;
• and
• selectively repeating said cutting step on said extrusion profile to define different lengths for said PDA casing, and performing said step of forming said openings depending upon the selected length of said PDA casing, said wires having a uniform longitudinal shape which is independent of the patterns of said openings.