HSD Wiring Harness Automated Production Line Solution
HSD (High Speed Data) wiring harnesses require extremely high precision in stripping, shield processing, crimping, and overall consistency due to their multilayer shielding and highfrequency transmission characteristics. An automated production line ensures stable quality, high repeatability, and significantly improved efficiency.
This document outlines a complete automated manufacturing solution for HSD cable assemblies.
1. Automated Production Process
1) Automatic Wire Feeding & Cutting
Supports HSD coaxial and twistedpair structures
Cutting tolerance ±0.5 mm
Automatic cable alignment to prevent jacket rotation errors
2) Automatic Outer Jacket Stripping
Thermal or rotary blade stripping
Zero damage to the braided shield
Clean, round stripping edge with no burrs
3) Automatic Braiding Processing
Option A: Automatic Braiding Unfolding
Option B: Automatic Braiding Cutting
Detects braid density automatically
Protects inner insulation from mechanical damage
4) Automatic Foil Shield Processing
Precise foil cutting or automated peeling
Maintains shield integrity without stretching or damaging the conductor
5) Automatic Inner Insulation Stripping
Tolerance ±0.1 mm
No damage to the copper conductor
Supports singlepair, dualpair, and quad HSD structures
6) Automatic Shield Ring Crimping
Servocontrolled crimping for consistent height
Smooth, uniform appearance
Compatible with HSD, FAKRA, and MiniFAKRA shield rings
7) Automatic Terminal Crimping
Supports TE, Rosenberger, Molex and other HSD terminals
Stable crimp height & pullforce performance
Optional MES data recording for crimp parameters
8) Automatic Connector Housing Assembly
Automated latch opening, terminal insertion, and locking
CCD verification of terminal positions (TPA check)
9) Automatic NG Sorting
Detects appearance, crimp height, shield integrity, and terminal locking
Rejects faulty harnesses automatically
10) Automatic Output & Bundling (Optional)
Automatic cable bundling
Label printing & application
Automated tray or box arrangement
2. Core Equipment in the Production Line
| Process | Equipment |
| Wire Feeding | Auto Feeder |
| Cutting & Stripping | Fully Automatic Cutting & Stripping Machine |
| Braiding Handling | Braiding Cutting/Unbraiding Module |
| Foil Shield Processing | Foil Shield Processing Unit |
| Precision Inner Strip | Inner Insulation Precision Stripper |
| Shield Ring Crimping | Shield Ring Crimping Machine |
| Terminal Crimping | Terminal Crimping Press |
| Connector Assembly | Automatic Connector Assembling Machine |
| Optical Inspection | CCD Vision Inspection System |
| NG Sorting | Automatic Reject System |
3. Advantages of the Automated Solution
✓ Excellent consistency for highfrequency, highspeed cables
Precise strip length
Reliable shielding and crimping
Supports impedancecontrolled cable assembly
✓ Reduces labor by 70%–90%
Minimizes manual tasks such as:
Braid unfolding
Shield ring crimping
Terminal insertion
✓ MES System Integration
Full traceability for each cable
Records crimp height, strip length, inspection data
✓ Compatible with multiple highspeed cable types
HSD
FAKRA / MiniFAKRA
LVDS
Automotive USB/HDMI
Automotive Ethernet (100/1000BASET1)
4. Standard Production Line Layout
Feeding → Cutting → Outer Jacket Stripping → Braid Processing → Foil Cutting → Inner Stripping → Shield Ring Crimping → Terminal Crimping → Connector Assembly → CCD Inspection → NG Sorting → Output
Available in:
Linear production line
Ushaped production line
Modular island layout
