AC/DC Charging Gun Cable Harness Automated Production Line Solution

　　一. Overview

　　This solution provides a fully automated production line for AC and DC charging gun cable harnesses. The system achieves complete automation from raw cable feeding to finished product output, integrating cutting, stripping, laser foil cutting, braiding handling, terminal crimping, sheath assembly, quality inspection, and automatic NG (defective) separation.

　　Production Target: 200–600 pcs/hour (depending on harness complexity and terminal count)

　　Applicable Products: AC/DC charging gun cable harnesses with multicore cables, aluminum foil shielding, braided shielding, protective sheaths, and terminal connectors.

　　Automated New Energy Wiring Harness Production Line

　　二. Process Flow

　　1. Automatic Wire Feeding

　　Multireel feeding racks with tension and encoder length control. Automatic reel change and material shortage alarm ensure uninterrupted operation.

　　2. Wire Measuring and Cutting

　　Servodriven feeding and highprecision rotary or guillotine cutting. Length tolerance within ±1mm. Smooth cut edges without wire distortion.

　　3. Outer Jacket Stripping

　　CNCcontrolled stripping unit removes the outer insulation layer precisely, with automatic waste collection.

　　4. Laser Foil Cutting

　　Noncontact fiber laser cutting precisely removes or sections aluminum foil shielding. The system ensures clean edges with minimal heat effect and includes fume extraction and laser safety shielding.

　　5. Braiding Cutting and Folding

　　Mechanical or pneumatic braiding cutters trim the braided shield. An automated folding station flips and positions the braid evenly over the sheath for grounding or shielding continuity.

　　6. Inner Jacket Stripping

　　Precision stripping of the inner insulation without damaging the conductors, using multistage adjustable blades.

　　7. Shielding Ring Crimping

　　Forming and crimping of aluminum foil or braided shielding rings. Equipped with servo or hydraulic press and force sensors for consistent pressure and crimp quality.

　　8. Terminal Crimping

　　Automatic terminal feeding and positioning system. Servo or hydraulic crimping press with realtime crimp force monitoring. Each crimp is logged and traceable. Optional CCD vision alignment ensures accuracy.

　　9. Sheath Assembly (A/B Ends)

　　Automatic loading and positioning of protective sheaths at both cable ends. Options include heatshrink, coldfit, or overmolded sleeves with localized heating tunnels or infrared modules.

　　10. Online Inspection (Visual & Electrical)

　　Multiangle CCD vision checks for alignment, braiding fold, and sheath positioning. Electrical tests verify continuity, insulation resistance, and shortcircuit detection per harness.

　　11. Automatic NG Sorting and Labeling

　　Defective harnesses are automatically sorted and labeled by reason (visual, electrical, mechanical), logged in the MES system for traceability.

　　12. Automatic Product Unloading

　　Qualified products are counted and sent to the packaging station. Barcodes or QR codes are printed automatically for traceable product identification.

　　三. Key Equipment Summary

　　Multireel wire feeding racks with automatic tension control

　　Servodriven wire feeding & cutting modules

　　CNC stripping machines (outer and inner jackets)

　　Fiber laser cutting system (20–50W with fume extraction and safety enclosure)

　　Braiding cutting & folding mechanism with CCD alignment

　　Shield ring forming & crimping press (servo/hydraulic)

　　Terminal feeding & servo crimping presses

　　Heatshrink or overmolding assembly station

　　CCD visual inspection and lighting control systems

　　Electrical test unit (continuity, insulation, high voltage as required)

　　Industrial PLC (Siemens, Omron, or Mitsubishi) + HMI touchscreen control

　　Robots or manipulators for NG sorting, labeling, and sheath handling

　　MES system integration with barcode traceability

　　四. Control System and Communication

　　PLC + IPC Architecture:

　　PLC handles motion and I/O control, while the IPC manages MES and data processing. EtherCAT or PROFINET bus communication ensures fast servo and I/O response.

　　Servo Motion Control:

　　Highspeed servo motors control feeding, cutting, folding, and crimping with realtime feedback.

　　Data Traceability:

　　Each cable is assigned a unique barcode/QR code. Process data (crimp force, electrical test results, CCD images) are logged for every product.

　　Remote Monitoring:

　　Supports OPC UA / MQTT communication for data reporting, production tracking, and remote diagnostics.

　　五. Quality Control and NG Management

　　Inline Inspection:

　　CCD cameras at key stations (stripping, folding, crimping) ensure visual quality. Final inspection checks electrical continuity, insulation resistance, and tensile strength.

　　Automatic NG Sorting:

　　Products failing inspection are automatically separated by defect type (visual, crimp, electrical, dimension).

　　Traceability & Rework:

　　MES records all NG events with timestamp, station ID, and operator info. Reworkable items are flagged automatically; nonreworkable ones go to material recovery or scrap.

　　SPC (Statistical Process Control):

　　Key process parameters like crimp force and insulation resistance are monitored statistically for predictive maintenance.

　　六. Estimated Throughput Example

　　Typical process timing (per harness):

　　Feeding + Cutting + Outer Strip: 3–5 s

　　Laser Foil Cutting: 1–2 s

　　Braiding Folding + Inner Strip: 3–4 s

　　Shield Ring Crimp: 2–3 s

　　Terminal Crimp (per end): 2–3 s (parallel possible)

　　Testing + Vision Check: 1–2 s

　　With parallel workstations and buffering, average cycle time can be reduced to 6–18 seconds per harness, achieving 200–600 pcs/hour depending on design complexity.

　　七. Layout and Ergonomics

　　Linear or Ushaped flow layout for minimal cable transfer.

　　Enclosed safety zones for laser, crimping, and inspection stations.

　　Buffer zones between inspection/testing to prevent process bottlenecks.

　　Clear separation of OK and NG product flow for easy collection and counting.

　　八. Implementation Timeline

　　1. Technical Review & Specification Confirmation: 1 week

　　2. 3D Layout & Design Approval: 2–3 weeks

　　3. Equipment Manufacturing & Procurement: 8–12 weeks

　　4. Onsite Installation: 1–2 weeks

　　5. System Debugging & Pilot Run: 2 weeks

　　6. Mass Production Handover: 1–2 weeks

　　(Typical schedule; subject to project complexity and client requirements.)

　　九. Maintenance and Safety

　　Routine Maintenance:

　　Regular lubrication and replacement of blades, sensors, and servo drives. Periodic laser head cleaning and fume system check.

　　Safety:

　　Laser enclosures with interlocks, forcesensing protection on presses, emergencystop circuits across the line.

　　Operator Training:

　　Includes system operation, safety procedures, fault diagnosis, and quickchange tooling.

　　This system provides a highefficiency, datadriven, and fully traceable manufacturing solution for modern EV charging cable harness production. It minimizes manual labor, enhances product consistency, and ensures full compliance with international quality standards.