Wiring harnesses for complex assemblies, such as cars or airplanes, can contain hundreds or even thousands of wires. Routing all those wires from connector to connector is fraught with opportunities for error.
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.
Every electrically-powered machine is filled with wires, connectors and delicate electronics, such as circuit boards and sensors. These parts are subjected to stress from constant vibration, physical strain, abrasion and impacts. These stresses can damage parts and leave them useless without some level of protection.
With standards for wire harnesses getting tighter, harness assemblers are increasingly using crimp force monitors to ensure quality connections. However, that technology can only tell you how well the crimping process is working. It can't make the process better.
Like every niche assembly process, manufacturing cables for industrial equipment presents numerous challenges. One of the most common is being able to consistently print clear markings on each cable.
Based in Gutersloh, Germany, the Miele Group is one of the world's leading manufacturers of commercial and residential appliances. However, it didn't start out that way. Founded in 1899 by Carl Miele and Reinhard Zinkann, the company initially made cream separators for the dairy industry. Over the years, the company has manufactured butter churns, hand carts, bicycles and even automobiles.
The need for high-quality medical devices by doctors, patients and medical facilities is great. Because the need is also global, makers of such products are able to contract with the best wire-harness and cable-assembly manufacturers regardless of where they're located.
The Industrial Internet of Things (IIoT) is more than just the latest manufacturing fad. It promises to transform the way that many types of products are designed, assembled and serviced.
A typical Porsche sports car contains more than 2,000 individual wires. If laid end to end, the wiring would stretch 2 to 3 kilometers. Designing such a complex wiring system would be challenge enough, but at Porsche, almost no harness design in series production matches another one.