New process enables automated production of cable belts, Technologie-License-Büro (TLB) der Baden-Württembergische Hochschulen GmbH, press release

Wire harnesses are one of the few parts that still have to be manufactured or processed by hand, especially in the production of automobiles and consumer goods. Given the bottleneck in connecting wire harnesses, the process developed by researchers at Karlsruhe University of Applied Sciences could now become attractive. With this method, it is possible to produce or automatically assemble cable belts as industrial robots can be used flexibly and economically to produce cable belts.

Whereas the set of wires used consisted of a small number of wires that had to be connected, for example, from the battery to the starter, today it is about very complex wiring harnesses weighing up to 60 kg and with a total length of several wires. kilometres. Wire harnesses are installed not only in cars, but also in control cabinets and the so-called white and brown goods, that is, for household appliances and consumer electronics.

In these devices in particular, but also in cars, more and more electronic devices are being accommodated in the smallest of spaces. As a result, cables, connections and sockets are smaller than ever and manual handling is more difficult. Demands for electric vehicles or future developments in autonomous systems will reinforce this issue of having to accommodate more and more electronics in the smallest possible space and with minimal weight.

Smaller cable cross-sections and very small switch sizes make it increasingly difficult to manually produce cable wiring. Until now, individual cables were laid on a cable board and bent in certain directions or connected together. Automation is difficult because previous gripping systems were not able to grip cables that were not precisely laid or plug sockets.

The pressure for production automation has become more important for various reasons: On the one hand, cable belts can be individually adapted to special requirements by means of an on-site robot system. On the other hand, the cross-sections of cable, sockets and connections have become so small that manual processing is difficult and time-consuming. Even quality control, so far done visually or by cable pulling, is hardly possible using very small components.

Prof. Dr. Eng. Bernd Langer and Prof. Dr. Eng. Martin Kipfmüller has developed a process for automated production and assembly of cable belts at Karlsruhe University of Applied Sciences. This process will make it possible to flexibly and economically use industrial robots to manufacture cable belts.

The relationship between force and deformation is clearly defined and linear in the rigid state. After the cables reach their annealed state by freezing, they are shaped by industrial robots and clamped to laying arrangements, which feature adjustable, movable, temperature-controlled pins. Cooling can be done in a cooling zone or by cooling the bread – any microclimate. So it is conceivable that the heating and cooling elements are present in the industrial robot clutch.

The cables are heated locally at the point of bending so that the insulation is not irreversibly damaged during deformation. Then the cable is immediately cooled again to stabilize the bend. The robotic arms can then use a predetermined force to align the next section of cable. It is particularly interesting that cables can now also be inserted through the walls of the connector during assembly without twisting.

The foundations for the implementation of the prototype have been laid, and now it comes to industrial use cases.

Through cooling, the process enables automation in cable harness production with a high degree of variability and flexibility for the customer. The wire pigtail can be pre-produced in the desired version in a short time and then ready for installation on time. It is no longer necessary, as it was before, to plan for a delivery date lasting weeks.

This means that the method can also be incorporated into manufacturing processes that will be optimized for lean production. The advantages of this process are significant reduction in production times as well as better planning and shorter supply chain, as production can be moved to industrialized countries due to cost optimization through automation. This in turn has a positive effect on quality assurance. In addition, the transfer time can be reduced since the required cable wiring does not have to be pre-ordered.

If the wire harness can be manufactured within the production process through automation, the so-called one-piece flow becomes possible as well, which in turn increases flexibility.

Patents were granted for the invention in Germany and various European countries. Technologie-License-Büro (TLB) GmbH supports the Karlsruhe University of Applied Sciences in patenting and commercializing innovation. On behalf of the university, the TLB is responsible for the global commercial implementation of this future-oriented technology and offers companies the opportunity to license or purchase patents.

For more information: Dipl.-Ing. Eric Perez Boruto Ferrer ([email protected])