HighVoltage Wiring Harness Automated Production Line Solution | Smart Manufacturing for the EV Era
Automated New Energy Wiring Harness Production Line
一. Overview
With the rapid growth of electric vehicles, energy storage systems, and highvoltage power equipment, the demand for precision, reliability, and safety in highvoltage wiring harnesses has never been higher. Traditional manual assembly methods are inefficient and prone to human error.
To address these challenges, we have developed a fully automated highvoltage wiring harness production line, integrating intelligent feeding, cutting, stripping, crimping, and assembly — ensuring consistent quality, higher productivity, and traceable manufacturing.
二. System Functions and Workflow
This automated production line integrates multiple advanced functions to handle various wire lengths and diameters. The key processes include:
1. Automatic Wire Feeding
The system automatically feeds wire from reels with tension control to ensure smooth and stable delivery.
2. Precision Wire Cutting
Highspeed servo blades cut wires to the programmed length with accuracy within ±0.5 mm.
3. Outer Jacket Stripping
Automatic removal of the outer insulation layer without damaging the braided shield or conductor.
4. Laser Foil Cutting
Laser technology precisely cuts aluminum foil shielding, delivering clean, burrfree edges.
5. Braiding Cutting and Flipping
Robotic tools cut and neatly flip the braided shield for consistent preparation of the next step.
6. Inner Insulation Stripping
Controlled stripping depth prevents conductor damage and ensures uniform exposure.
7. Shield Ring Crimping
Servocontrolled crimping units provide accurate shield ring compression for optimal grounding.
8. Terminal Crimping
Closedloop terminal crimping with pressure curve monitoring automatically detects and rejects faulty crimps.
9. Protective Sheath Assembly (A/B Ends)
Automatic installation and positioning of protective sheaths on both ends of the harness.
10. Automatic NG Product Sorting
The vision and pressure detection system automatically identifies and separates defective products.
11. Automatic Product Unloading
Qualified harnesses are automatically discharged and sorted, ready for packaging or further processing.
三. Key Advantages
Fully Automated Process – Reduces manual labor and increases productivity by 40–60%.
High Accuracy and Stability – Servo motors and vision systems guarantee repeatability and precision.
Customizable Configuration – Supports different wire sizes, lengths, and terminal types.
Integrated Quality Monitoring – Realtime vision and pressure monitoring ensure zerodefect output.
Data Traceability – Compatible with MES/ERP systems for full production tracking and analytics.
四. Application Fields
This automated line is ideal for manufacturing:
Electric vehicle (EV) highvoltage cable harnesses
Energy storage system (ESS) power connections
Industrial robotics power cables
Marine and rail electrical systems
