ZY-CBL-301 Automatic Automotive Wire Harness Processing Machine

Samples produced by the equipment

The ZY-CBL-301 is a configurable automatic automotive wire harness processing machine designed for multi-wire harness assemblies. It coordinates cable supply, waterproof-seal feeding, terminal crimping, connector housing handling, and positioned terminal insertion within one production platform.

Depending on the approved project configuration, the machine can accommodate up to 24 cable reels, four waterproof-seal feeding sets, 12 crimping tools, and 20 housing types. A 3D positioning system supports terminal insertion into the assigned connector cavities.

Servo-driven motion, robotic handling, CCD-assisted control, and PC-based data collection are integrated to coordinate the processing sequence. Production records can be retained for traceability and connected with a compatible manufacturing execution system.

The stated processing efficiency is at least 1,200 pieces per hour, with an equipment utilization rate of at least 90% under the specified production conditions. Actual output depends on the harness design, wire lengths, component combinations, inspection scope, material quality, and changeover requirements.

Multi-Component Wire Harness Processing

Automotive harness groups may contain multiple wire colors, cross-sections, terminals, seals, and connector housings. The ZY-CBL-301 is engineered around the customer’s approved wire harness bill of materials and process sequence.

The machine configuration can coordinate:

• Multiple cable reels

• Waterproof wire seals or plugs

• Reel-fed terminals

• Crimping applicators

• Connector housing feeders

• Robotic material transfer

• Positioned terminal insertion

• CCD-assisted process checks

• Production data collection

• MES data exchange

The exact process is defined for the target harness rather than assuming that every wire, terminal, seal, and housing can use the same tooling.

Before machine engineering begins, the component drawings and physical samples should be reviewed together. Wire insulation diameter, terminal geometry, seal dimensions, connector cavity structure, locking features, and material presentation all affect the final design.

Cable and Material Feeding

Multi-Reel Cable Supply

The ZY-CBL-301 can be configured with up to 24 cable reels. This supports harness assemblies containing multiple circuits, wire colors, or wire specifications within the approved production scope.

The reel layout should be planned according to:

• Wire part number

• Conductor cross-section

• Insulation diameter

• Wire color

• Required length

• Reel dimensions

• Payoff direction

• Minimum bending radius

• Production consumption rate

Stable feeding depends on correct reel loading, wire tension, straightening, and material identification. Wire condition should be checked before production because damaged insulation, irregular winding, or inconsistent outside diameter can affect downstream processing.

Component Presentation

Terminals, waterproof seals, and connector housings must be supplied to the processing stations in a repeatable orientation.

The feeding method is selected according to whether the component is supplied on a reel, in bulk, in a tray, or in another approved packaging format. Component presentation should be included in the project evaluation because it affects feeder design, refill frequency, cycle time, and changeover procedures.

Material Identification

Where traceability is required, wire reels and component batches can be associated with the corresponding production order through the control and data-collection system.

The required identification method—such as barcode, batch number, operator entry, or MES-issued production order—should be defined during project engineering.

Seal and Terminal Processing

Waterproof-Seal Feeding

The machine can be configured with four sets of waterproof-seal or waterproof-plug feeding equipment. These stations present and position the specified sealing components for the approved wire and terminal combinations.

Seal compatibility depends on:

• Seal outside diameter

• Seal length

• Wire insulation diameter

• Seal hardness

• Seal orientation

• Terminal rear-seal geometry

• Component cleanliness

• Lubrication condition

A seal should be tested with the actual wire and terminal. A component that appears dimensionally similar may still behave differently during feeding or assembly because of material hardness, surface condition, or molding variation.

Terminal Crimping

Up to 12 sets of crimping tools can be included in the machine configuration. Each tool must match the terminal, applicator interface, wire range, and required crimp specification.

The crimping process should be approved using measurable acceptance criteria such as:

• Conductor crimp height

• Insulation crimp condition

• Crimp width

• Bellmouth condition

• Conductor brush position

• Terminal deformation

• Pull-force result

• Cross-section analysis where required

The presence of an automatic crimping station does not remove the need for tooling setup, scheduled inspection, applicator maintenance, and periodic sample testing.

If crimp-force monitoring, automatic crimp-height measurement, or defective-crimp handling is required, these functions should be defined as part of the project configuration.

Connector Housing Insertion

Multiple Housing Types

The ZY-CBL-301 can be engineered to handle up to 20 connector housing types within the specified configuration.

Housing compatibility depends on:

• Housing dimensions

• Number of cavities

• Cavity pitch

• Terminal orientation

• Connector keying

• Locking structure

• Material stiffness

• Feeding orientation

• Required insertion path

Housing feeders, fixtures, and grippers are designed around approved samples. Connector dimensional consistency is important because variation can affect feeding, positioning, and terminal insertion.

3D-Positioned Insertion

The 3D positioning system moves the terminal and connector housing into the programmed insertion relationship. This supports assemblies with different cavity positions or connector orientations.

The insertion recipe should define:

1. Connector housing identification

2. Housing orientation

3. Target cavity

4. Terminal orientation

5. Approach position

6. Insertion path

7. Final insertion position

8. Completion or inspection signal

The system should be validated using the customer’s cavity map and production samples. Terminal retention and locking engagement must meet the connector manufacturer’s requirements.

Cavity Assignment

For harnesses with multiple wires and connector cavities, the production recipe should link each wire circuit to the correct terminal, seal, housing, and cavity.

Recipe control helps reduce manual assignment, but the approved BOM, cavity map, and revision information must remain accurate. Engineering changes should be introduced through a controlled revision process.

CCD Vision Control

The ZY-CBL-301 combines CCD cameras with robotic handling and machine control. The vision system can be configured to support component positioning and selected process inspections.

Depending on the camera arrangement, lighting, lens, software, and approved inspection criteria, CCD checks may be used for:

• Component presence

• Component orientation

• Housing position

• Terminal position

• Seal presence

• Selected dimensional features

• Insertion position

• Component-type comparison

The inspection scope must be defined for each project. A CCD camera does not automatically verify hidden crimp geometry, electrical continuity, terminal retention force, or every internal connector feature.

For stable inspection, the acceptance window should be established using verified good and defective samples. Lighting, component color, surface reflection, molding variation, and contamination should be considered during validation.

Production Traceability and MES

PC-Based Data Collection

The machine uses an industrial computer or upper-level control system to collect and evaluate production data. This creates a basis for reviewing operating status, production quantity, alarms, and selected inspection results.

Available records can be configured around the approved project and may include:

• Production order

• Harness part number

• Recipe version

• Component batch

• Production time

• Machine cycle status

• CCD inspection result

• Alarm history

• Output quantity

• Reject quantity

• Operator information

The data fields should be selected according to the customer’s traceability requirements.

MES Connectivity

Production information can be connected with a compatible MES. The interface may be used to receive production orders, select recipes, record material information, and return production results.

Before integration, both parties should define:

• Communication protocol

• Network architecture

• Data fields

• Order-download format

• Result-upload format

• Product identification method

• Error and timeout handling

• Data storage period

• User access permissions

• Cybersecurity requirements

MES connectivity should be tested with the customer’s actual data structure before final acceptance.

Product Revision Control

Automotive harness specifications may change during a project. Recipe names, BOM revisions, cavity maps, terminal assignments, and inspection limits should therefore be managed as controlled production data.

Only approved revisions should be released for production. Changes to terminals, seals, housings, wire suppliers, or dimensions may require new sample validation.

Modular Automation Design

Modular Machine Architecture

The machine mechanism uses a modular and standardized design approach. Feeding, crimping, robotic handling, vision, housing insertion, and data functions can be arranged around the required harness process.

A modular layout supports project-specific engineering and allows individual stations to be accessed for adjustment, maintenance, or future evaluation.

The configuration should still be finalized before manufacture because adding a new component or process later may require more than a software change.

Servo-Driven Motion

Servo transmission is used for controlled movement in applicable machine stations. Motion parameters can be coordinated with the processing sequence, component handling, and insertion path.

Servo control supports programmable positioning, but final accuracy also depends on tooling, fixtures, component tolerances, calibration, and mechanical condition.

Guarded Access

The machine cover incorporates controlled access for operation and maintenance. Guard doors and access points should remain closed during automatic operation except where the approved operating procedure permits access.

The final safety design should consider:

• Guard-door interlocks

• Emergency-stop locations

• Maintenance access

• Stored pneumatic or electrical energy

• Operator loading positions

• Manual and setup modes

• Local machinery requirements

Operators should be trained before using, adjusting, or maintaining the equipment.

Automotive Harness Applications

The ZY-CBL-301 is intended for compatible multi-wire automotive harness assemblies that require coordinated cable supply, sealing, crimping, housing handling, and terminal insertion.

Potential applications include:

• Automotive body harness subassemblies

• Door and window harnesses

• Lighting harness assemblies

• Instrument-panel harness sections

• Seat and interior electrical harnesses

• Sensor and actuator connection harnesses

• Small connector harness groups

• Custom multi-circuit wire assemblies

Suitability depends on the actual wire, terminal, seal, housing, and quality requirements.

High-voltage electric-vehicle cables, shielded data cables, coaxial cables, airbag circuits, and safety-critical connector systems should not be assumed compatible without a separate process and equipment assessment.

Project Configuration

Required Project Information

To prepare a machine proposal, provide:

• Wire harness drawings

• Bill of materials

• Wire specifications

• Wire lengths and tolerances

• Terminal drawings and samples

• Waterproof-seal drawings and samples

• Connector housing drawings and samples

• Housing cavity maps

• Terminal insertion requirements

• Production volume

• Target cycle time

• Shift arrangement

• Inspection requirements

• Traceability requirements

• MES interface information

• Available power and compressed air

• Factory layout constraints

Complete data reduces the risk of designing around components that differ from the actual production materials.

Sample Evaluation

Physical samples are recommended even when drawings are available. Samples allow the engineering team to evaluate feeding behavior, dimensional variation, terminal presentation, seal handling, connector positioning, and insertion conditions.

Component lots used during validation should represent the planned production materials.

Process Development

A project-specific process can be developed through the following stages:

1. Review the harness BOM and drawings.

2. Evaluate wire, terminal, seal, and housing samples.

3. Define the automatic process boundary.

4. Confirm the required stations and tooling.

5. Establish cycle-time assumptions.

6. Define CCD inspection items.

7. Define traceability and MES data.

8. Manufacture and assemble the equipment.

9. Run sample trials.

10. Complete the agreed acceptance tests.

Acceptance Planning

The acceptance document should specify the harness part number, component revision, sample quantity, output target, quality criteria, permitted stoppages, inspection method, and production time used for the test.

This provides a clearer basis for evaluating the machine than a nominal speed figure alone.

Technical Specifications

The final machine specification is determined by the approved wire harness, component samples, process scope, inspection requirements, and system interface.

Engineering and Manufacturing Support

CO-SHINING is operated by Dongguan Zhongyao Automation Equipment Co., Ltd., an automation equipment manufacturer founded in 2009.

The company’s published manufacturing information includes:

• An approximately 8,000 m² production workshop

• More than 60 processing machines

• A team of more than 200 R&D and production personnel

• Experience developing and producing more than 6,000 sets of equipment

• Wire harness processing and connector assembly equipment

• Project-specific automation engineering

• Equipment testing before shipment

Engineering support can cover component evaluation, machine layout, process development, tooling design, CCD inspection planning, MES interface definition, sample testing, installation, and operator training.

CO-SHINING publishes a one-year warranty from machine arrival and online technical support. The project quotation should define the final warranty scope, installation arrangement, training, spare parts, and on-site service requirements.

FAQs

Can the ZY-CBL-301 process any automotive wire harness?

No. Compatibility depends on the wire, terminal, seal, connector housing, circuit arrangement, and required process. Drawings and physical samples should be evaluated before the machine configuration is approved.

Is the output always at least 1,200 finished harnesses per hour?

The published efficiency is at least 1,200 pieces per hour under the specified configuration and production conditions. Actual output depends on how a “piece” is defined, the number of circuits, wire lengths, insertion steps, inspections, material refilling, and permitted stoppages.

Are cutting and stripping included as standard functions?

The available product information focuses on cable supply, waterproof-seal feeding, crimping, housing handling, 3D insertion, CCD control, and data collection. Cutting and stripping requirements should be explicitly included in the process specification if they are required.

Can existing terminal applicators be installed on the machine?

Potential compatibility depends on applicator dimensions, press interface, shut height, feed direction, terminal reel, crimp force, and control requirements. Existing applicators should be identified and evaluated before the tooling layout is finalized.

How is crimp quality verified?

Crimp approval should use the terminal supplier’s specification and measurable checks such as crimp height, crimp width, conductor position, insulation support, pull force, and cross-section analysis where required. Built-in monitoring functions must be defined in the machine configuration.

What is the difference between CCD inspection and electrical testing?

CCD inspection evaluates visible component features and positions. Electrical testing checks circuit continuity, resistance, short circuits, or other electrical characteristics. A camera does not replace an electrical tester unless the project includes a separate validated test process.

Can the machine connect to our existing MES?

The equipment supports production-data collection and MES connectivity. Integration depends on the customer’s protocol, data structure, network, order format, traceability fields, and security requirements. An interface specification should be exchanged before programming.

How are product changeovers managed?

Changeover requirements depend on which wires, terminals, seals, crimping tools, feeders, housings, fixtures, and recipes must be changed. The expected product mix and changeover frequency should be provided during machine design.

Can the ZY-CBL-301 process high-voltage EV harnesses?

High-voltage harnesses should not be assumed compatible based only on the automotive application. Cable size, shielding, terminals, seals, connectors, crimp force, electrical tests, and safety requirements require a separate engineering review.

What maintenance does the machine require?

Routine work may include cleaning feeders and vision components, inspecting crimping tools, lubricating approved mechanisms, checking grippers and fixtures, backing up recipes, reviewing alarms, and replacing wear parts. The maintenance schedule should follow the final machine manual and component operating hours.

What should be included in the factory acceptance test?

The FAT should use approved production materials and define sample quantity, test duration, output, quality criteria, allowed stoppages, inspection results, traceability records, alarm tests, and MES communication checks where applicable.