EFFICIENT CABLE ASSEMBLY FOR PASSIVE AND ACTIVE SAFETY SYSTEMS

Modern cars are data centers on wheels - networked and packed with sensors, intelligent software, and electronics. Sometimes more than 100 control units in upper / mid-range vehicles process a vast amount of data, which ensures that drivers benefit from a wide range of functions relating to safety, comfort, and multimedia. These include assistance functions such as distance or emergency brake assist, but also lifesavers such as airbags and belt tensioners. For this to work, cables are needed to transport energy, signals, and information quickly and reliably.

Many kilometers of cables are installed in modern vehicles. Their efficient production is a decisive competitive factor for suppliers. PIA has developed a solution based on a basic cable machine (KGM) that produces cables fully automatically. The special feature: The modular and expandable KGM not only assembles pure single or multi-core cables, but also integrates the assembly of connections and components requested by the customer. The KGM can be customized and consists of various stations: PIA can integrate all the necessary processes, for example cutting to length and stripping, or even complex soldering and welding processes. This provides customers with an efficient and reliable solution for high-volume production. Previously time-consuming manual processes are automated - with consistently high quality.  

No compromise on safety

Wired signal transmission between assemblies and connected components plays a particularly important role in passive safety systems in vehicles. Actuators are used to trigger airbags or the "active hood": they raise the hood by a few centimetres within milliseconds - in the event of a collision with a pedestrian, for example. This becomes an additional crumple zone to cushion the impact.

Passive safety systems protect lives. In this respect, the requirements of PIA customers for the automated production of cable components are particularly high. This was also the case for a customer from the supplier industry, who requested PIA manufacture an assembly consisting of cables and actuators. Previously, this process had been carried out mainly by hand.

"Among other specifications, the customer required consistently excellent quality, inspection processes integrated into the process, and a high cycle time," explains Herbert Knorr, Team Coordinator Sales at PIA. The experts at PIA designed a system based on the KGM that automates all process steps: after being fed into the machine, the cables are first labeled, cut to length, then stripped and untwisted. This is followed by further process steps such as crimping, which joins individual components together by means of plastic deformation. In a second part of the system, KGM finally processes the other side of the cable using similar process steps. A particular challenge in this project was the welding of different materials. PIA worked closely with the customer and a university to develop an innovative process in which two components are reliably welded together.

Quality check during the ongoing process

The system checks the quality of the assembly during the ongoing process, using cameras among other things. As soon as all sub-steps have been completed, the line outputs the finished assembly into a small load carrier for further processing. Each cable is fully traceable after completion and all relevant data during the process is documented. This was not only a requirement of the customer but is particularly important for components for vehicle safety systems. PIA was also able to meet the required cycle time: A new assembly falls into the small load carrier every 3.5 seconds. 

Conclusion: Keep running and running

In the meantime, the system is running reliably at the customer's premises - 24 hours a day, five days a week. The customer is very satisfied with the cable assembly system from PIA. "Our concept has also proven itself with this customer," says Knorr. "The line produces cables with highly complex connections reliably and economically." The employees, who previously had to produce the assembly with a lot of manual work, are relieved, and the quality remains consistently high. Whether such cables are ultimately used in electric vehicles or combustion engines is irrelevant for the assembly process. "Our strength is that we can adapt to the different requirements of our customers. Thanks to KGM's modular concept, we can quickly offer a tailor-made solution," says Knorr. The possible applications for the modular basic machine therefore extend far beyond the automotive industry.