HSD wire harness automated production line

Time:2025-11-26Viewed:()

HSD wire harness automated production line

　　1) Overview

　　A fully automated wire harness production line integrates cutting, stripping, crimping, assembly, testing, and final packaging into one coordinated system. It replaces multiple manual stations with a unified, highefficiency automated workflow, ideal for automotive, EV, consumer electronics, and telecom harness production.

　　2) Full Process Flow (Recommended Sequence)

　　1. Import CAD/BOM → Autogenerate process and production parameters.

　　2. Automated material feeding (wires, terminals, connectors, sleeves).

　　3. Automatic cutting & laser/inkjet marking for traceability.

　　4. Programmable wire stripping (singlecore, multicore, shielded cables).

　　5. Servo crimping with CFM (Crimp Force Monitoring) and optional crosssection analysis.

　　6. Robotic assembly: connector insertion, routing, taping, cable board assembly.

　　7. Electrical testing: continuity, hipot, insulation; plus vision inspection and pullforce testing.

　　8. Heat shrink, sleeving, overmolding or protective treatments.

　　9. Final inspection → labeling → packing → warehouse/outbound.

　　3) Core Equipment Modules

　　Automatic cutting and marking machine.

　　Programmable stripping station compatible with multicore and shielded wires.

　　Multistation servo crimping machine with CFM monitoring.

　　Vision inspection (CVM) for terminal shape, copper exposure, connector seating.

　　Robots/cobots + flexible feeding systems for highmix assembly.

　　Automated pullforce tester, electrical test bench, crosssection analyzer.

　　Heatshrink/overmold units and integrated conveyor system.

　　4) Quality Control & Traceability

　　CFM for realtime crimp force monitoring and defect detection.

　　CVM vision system for identifying shape defects, misinsertion, or contamination.

　　100% electrical testing tied to MES with barcode and batch tracking.

　　Compliance with IPC/WHMAA620, DIN standards, and customerspecific specs.

　　5) Production Line Layout Recommendations

　　Central conveyor line linking key stations: cutting → stripping → crimping → assembly → testing.

　　Buffer stations to prevent bottlenecks.

　　Robotic cells placed near highprecision or repetitive tasks.

　　Smart material racks with barcode/vision confirmation for errorproof feeding.

　　6) Key Performance Indicators (KPIs)

　　FTQ (First Time Quality) ≥ 99% depending on product complexity.

　　Cycle time and output (pcs/hour) based on harness type.

　　Manual touchtime < 10% of total cycle time for highlevel automation.

　　7) Implementation Steps (For Turnkey Projects)

　　1. Define product family (wire types, connectors, monthly volume, variability).

　　2. Invite 2–3 system integrators capable of turnkey delivery with MES integration.

　　3. Conduct FAT (Factory Acceptance Test) and SAT (Site Acceptance Test).

　　4. Standardize process files and adopt automationfriendly harness design rules.

　　8) Risk & Mitigation

　　High product variation → modular fixtures + quick program switching.

　　Small batches / high mix → combine flexible robots with semiautomatic modules.

　　Data isolation → enforce full MES integration for CFM/CVM/test data.