Cables, cord sets and wire harnesses are invariably assembled with at least some amount of manual labor—even when high volumes are needed. Sure, the process of cutting, stripping and terminating individual wires can be fully automatic. But at some point, those wires must be touched by human hands, whether it’s for assembly, testing, packaging or other process.

A fully automated system that produces wire assemblies from start to finish—raw materials go in, finished products come out—is rare, indeed. Systems integrator Clear Automation of Southington, CT, recently designed and built just that: a fully automatic robotic assembly system for electrical cords.