TE Connectivity , a world leader in connectors and sensors, was a key player in the now completed Next2OEM project funded by the German Federal Ministry for Economic Affairs and Energy (BMWE). As an innovation partner, TE contributed significantly to the further development of automated processes in wiring harness production. The project addressed the end-to-end automation of wiring systems along the entire value chain – from wiring harness production to installation in the vehicle. TE’s input was particularly important in the early design of the components and mechanical interfaces – a key requirement for stable, automated handling and integration into the overall process flow.
TE as a technical pioneer of automated process chains
TE contributed its expertise in connectivity to the development of automation-compatible cable harness components. Together with an OEM, a technical manufacturer, plant engineers, robotics specialists, a specialist in product data management, and a producer of testing equipment were defined to ensure their reliable integration into automated manufacturing and assembly processes. The project demonstrated that even flexible components such as cable harnesses can be handled and assembled automatically using innovative design and process approaches. At the same time, it became clear that robust automation can only be achieved through the coordinated design of components, processes and systems engineering – via clearly defined mechanical interfaces.
“In the Next2OEM project, we have consistently developed our connection technology from the perspective of the automated process chain – not only in terms of electrical performance, but with a clear focus on industrial robotic processing,’ says Stefan Glaser, TE product management director. “The great interest from the market shows that automation-compatible wiring harness components are a decisive lever for future series processes. They are thus becoming a strategic driver for future vehicle platforms – and are now also technically feasible”
Cooperation as the key to success
The successful development of automated processes in cable harness production and installation in vehicles requires close cooperation between all experts involved in the process to ensure a reliable and trouble-free workflow. The fact that 10 companies along the entire process chain collaborated on the project is not only extraordinary, but also a prerequisite for achieving the goals stated – and a key success factor for putting the project into practice and later series production.
Transferring project results to series production processes and future vehicle platforms
The results obtained in the Next2OEM project will be specifically transferred to series production processes for future vehicle platforms at TE. The findings will be incorporated into the further development of wiring harness components such as contacts and connectors to develop new products designed for automatic processing right from the start.
At the same time, the project has shown that numerous technical and procedural challenges remain, particularly with complex wiring harnesses. Additional automation solutions will need to be developed for these applications in the coming years. TE is therefore working closely with OEMs and technology partners beyond Next2OEM to further develop existing solutions as well as new approaches for automated wiring harness production.
For more information, visit www.te.com.
