Page 25 - 2021 Connectivity Components: Everything but the Connectors eBook

7. Termination
Inner conductors are either crimped or ultrasonically welded to the terminals. Automation systems can integrate suitable crimping presses with crimp force monitoring systems. Ultrasonic welding systems typically have integrated monitoring to ensure a proper weld.
Automation systems that can integrate third-party systems are very convenient. These systems can minimize the validation process for presses and welding systems that have already gone through lengthy approval processes.
8. Multiconductor connector loading
For multiconductor cables that will be terminated and loaded into a connector, it is critical that the wire ends and terminal positioning are very consistent. This will ensure that the terminals will load and lock into the connectors properly.
Subsequent housings or components can be applied automatically and locked into position if volumes justify it. However, steps 1 through 4 and 6 listed above are the most common process steps for the widest variety of applications. Automating these process steps will likely have the best return on investment since they are the most commonly applied. These steps are also the most critical to ensure proper connector performance.
New visual inspection systems inspect 360° around the cable. Artificial intelligence is utilized to identify the different layers of the cable assembly to perform a thorough analysis. Numerous quality characteristics can be programmed for each assembly.
When inquiring about an automatic HV cable connectorization system, be prepared with the following information for all potential applications:
• Cable specifications and stripping requirements
• Connector specifications and the necessary process steps • Quality assurance requirements
• Production requirements and required cycle times
With this information, the automation supplier will be able to provide recommendations on the most cost-effective system for the specified production requirements along with the expected performance, be it a semi-automatic or a fully automatic system.
Considering how fast EV technology is evolving, automation systems should be flexible and adaptable in the field and at the facility, without major interruptions in production. For instance, moving semi-automatic stations onto a fully automatic platform should be possible. Similarly, the fully automatic platform should be expandable, as volumes increase over time, to provide the most flexibility and maximize the investment moving forward.
Visit Schleuniger Inc. to learn more.
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