What is a complete wire harness production?

A concept for a complete wire harness production includes the production steps wire cutting, stripping and crimping realized by one crimping machine as well as placement of connector housings on the mounting board, wire routing, contact insertion, wrapping and harness removal executed by four different robots .

Are high-voltage wire harnesses a new technology?

Today’s manufacturing processes of high-voltage wire harnesses are part of the new technology and determined by a high level of manual work reaching up to 85% of the added value in manufacturing. The rationalization potential exhibited by the automation of manufacturing has not been fully exploited.

Why is a wire harness necessary for Electromobility?

It is essential for electromobility to have a physical automotive wire harness that has been developed to meet the new required functions . Electric vehicles cannot operate efficiently with a standard low-voltage power supply. It is necessary to have a multi-voltage power supply with a direct current electrical energy storage system .

What is a wire harness in automotive engineering?

Keywords: automotive engineering; vehicle electrical system; assembly systems; manufacturing automation; design for manufacture 1. Introduction A wire harness is an assembly of electrical cables which is used in automobiles to connect electronic components, control units, sensors and actuators.

What is the most time consuming process in wire harness production?

Automation Requirements and Current Challenges The most time-consuming processes in wire harness production are wire preparation (up to 38% of standard time), wire routing (up to 50%), and wire bundling (up to 30%) as studies from the 1980’s and 1990’s indicate [14, 15]. Unfortunately, no current data is publicly available .

What influences the production process of automotive wire harnesses?

Especially autonomous driving, electrification as well as additional trends like miniaturization, higher data rates and high-voltage harnesses will have a great influence on the production process of automotive wire harnesses [9, 11].