Fraunhofer Institute for Machine Tools and Forming Technology
Fraunhofer Institute for Machine Tools and Forming Technology

AuCA - Automated Cable Assembly

From grip to print: automated cable laying rethought

Handling and automated assembly of a wiring harness consisting of multiple cables with different lengths, cross-sections, and end contacts is extremely difficult for a robotic system to manage. For this reason, solutions typically involve a significant amount of cameras, software, and processing. In the AuCA system, cable laying has been completely rethought and combined with 3D printing technology, so that the flexible cables no longer need to be "gripped" but are laid from an endless reservoir

How does the AuCA system work?

The AuCA system consists of two tools (cable placement and contacting) that can be guided by collaborative robots. The end effector "Cable Deposition" enables cable feeding from an endless roll, automatic assembly, positioning, and mechanical attachment (thermoplastic extrusion) on the component. Up to 4 cables can be laid simultaneously. The end effector "Contacting" allows for independent gripping, stripping, crimping, and plugging of the laid cable ends into connector housings. The system has an automatic change option for crimp applicators, allowing different crimp elements from an endless roll to be attached according to DIN standards. This technology enables the flexible, fully automatic production of various wiring harnesses on the workpiece.

Wire deposition

  • 185 x 136 x 290;  5kg deposition toolhead for use with Cobots
  • Simultaneous depositing of 4 wires with 0,35mm² (customization possible)
  • Wires are placed in defined lines to achieve a deterministic identification
  • Individual attaching points for each wire with a spot of thermoplastic Material like PA6 (material can be choosen according to needs)
  • Cheap raw materials (FLRY cables from spool and standard polymers)
  • 15 mm/s tcp speed while extruding a attaching spot, up to 50mm/s while placing cables
  • All path planning can be done within the robot via teaching the significant points, attachment spots and feed rates are automatically calculated

Contacting

  • 450 x 500 x 660 mm; 18 kg, work at stationary points
  • Crimping tool head with certified standard crimping tools
  • Stripped wires are picked up from the part at the last fastening point and processed in the tool head
  • Crimping is force-controlled with an electric stroke cylinder
  • Crimped contacts can be inserted into connector housings in various orientations
  • Several connector housings for different connections are stored in the tool head
  • Crimping tools can be changed automatically on a ramp within a workpiece
  • Finished connector housings are placed on the workpiece

Range of services

  • Production of sample parts or small series with the AuCA system
  • Development of integration concepts according to your application and requirements
  • Testing of concepts or production layouts in the laboratory
  • Development of special AuCA tool heads and process steps for your application
  • Technology transfer/implementation of AuCA technology
  • Consulting or optimization of your process chain towards fully automated application or integration of electrical functions on or in your components