One-stop, fully automated production of automotive wire harnesses—covering all process steps: wire cutting, stripping, terminal crimping, waterproof plug insertion, connector assembly, in-line testing, and material collection—replaces multiple standalone machines and manual handling and manual connector assembly, making it a standardized wire‑harness production line for new‑energy vehicle and complete‑vehicle manufacturers.

I. Process Integration (Integrated Machine for Closed-Loop Continuous Production)
One piece of equipment integrates wire feeding, wire cutting, double‑layer wire stripping, terminal numbering‑tube printing, pre‑assembly of waterproof plugs, precision terminal crimping, CCD visual positioning, simultaneous insertion of multiple wires into connector housings, and in‑line tensile‑strength, continuity, and appearance inspections—covering the entire front‑end processing workflow. Raw materials enter the line and directly yield semi‑finished wire harnesses with protective jackets already installed, with automated intra‑process material flow and no segmented handling or transfer.
II. Core Advantages
Eliminate transit and transshipment.
Eliminates manual handling, stacking, and loading/unloading among multiple split‑type machines; eliminates the need for a semi‑finished‑goods buffer zone, thereby reducing damage from impacts and minimizing idle time.
Compact footprint, energy-efficient, and labor-saving.
The integrated rack is compact, eliminating the need for multiple equipment operating stations; it shares servo, cooling, and control systems, with no‑load losses apportioned across the system; a single operator can manage the entire line, removing the requirement for dedicated personnel at each machine.
Multi-line synchronous parallel operation ensures stable production capacity.
Multi‑specification wire processing is performed in sync, with unified servo‑controlled coordination; processing length, crimping, and housing insertion all adhere to consistent standards. Visual error‑proofing significantly reduces defect rates associated with missed insertions and insufficient crimping.
End-to-end quality control online
Crimping pressure monitoring, insertion force detection, wire‑order visual verification, and continuity self‑diagnosis are all performed simultaneously; data is automatically stored, enabling production traceability.
Integrated Digital Management and Control
The entire machine is equipped with a unified control system that integrates with the MES, enabling one-click parameter switching for model changes and delivering significantly higher efficiency compared to multiple standalone units requiring individual debugging.
III. Limitations
It is suitable only for high‑volume, continuous full‑production conditions; during low‑volume, intermittent operation, the energy consumption of the entire unit under no‑load is higher than that of a single split‑type machine; and when shut down for extended periods, it cannot be disassembled for individual storage, making the rust‑prevention, draining, and maintenance procedures more complex.
IV. Applicable Scenarios
Mass production of low-voltage wiring harnesses for passenger vehicles, as well as body, seat, and sunroof wiring harnesses for new-energy vehicles.