FAKRA Wiring Harness Solutions

FAKRA Wiring Harness Solutions

The Fakra production line equipment is specifically designed for automated processing of Fakra connectors. Fakra connectors are high-frequency, high-speed, impedance-matched signal connectors widely used in the automotive industry, primarily in automotive antennas, in-vehicle entertainment systems, navigation, and wireless communication devices. It typically includes multiple workstation modules, each capable of independent operation, supporting non-standard customization and flexible expansion with additional functions. The entire production line employs a modular design and precision servo drive mechanisms, equipped with a CNC human-machine interface system. Furthermore, the Fakra production line equipment enables fully automated production, including wire cutting, stripping, crimping center terminals, braiding, crimping outer conductors, CCD full inspection, O/S electrical testing, and insulation/withstand voltage testing, thereby significantly improving production efficiency, reducing labor costs, and ensuring product consistency and quality.

Industry Challenges

Poor Inconsistency in Wire Feeding Length Error of Belt-Pulley Wire Feeding Mechanism:
The front-end automatic wire feeding station uses a synchronous pulley clamping and dragging method for wire feeding. Belt aging or slippage can lead to significant deviations in wire feeding length, resulting in a high defect rate.

Intermittent Fluctuations in PLC Communication Interface Cause Communication Drops, Leading to Low Yield:
Modular control of production line workstations involves data interaction with multiple PLCs. Intermittent communication drops require restarting all PLCs and re-establishing communication connections, leading to secondary processing of semi-finished products or scrapping, increasing costs.

Short Production Line Delivery Cycles, Multiple Workstation Combinations, and the Need for Multi-User Collaboration:
Automotive wiring harness terminals are large-scale, have diverse process requirements, require significant program maintenance, and face heavy production line delivery pressure.

Solution Features

Automatic Reconnection After Wire Disconnection:** Employs an intelligent communication handshake mechanism, supporting… Automatic reconnection after disconnection ensures stable production line communication.

Saves configuration time: A customized master-slave communication network saves configuration time.

Modular production line workstations: Each workstation is controlled by an individual PLC. Through the PLC's built-in EtherNet/IP interface, a distributed topology communication network enables data exchange between upstream and downstream workstations.

Precise positioning: The Leadshine system accurately positions and photographs workstations, with a positioning error of <0.01%.

Value realization:

Production line quality traceability: The production line system intelligently tracks product quality data such as the length, stripping, and terminal crimping of each wire harness, enabling product quality traceability and improving production quality standards.

High-efficiency production: Using Leadshine's complete solution, it can produce various new energy vehicle Fakra wire harnesses with a production cycle of up to 6 seconds per harness.

Flexible manufacturing: This system supports arbitrary combinations of workstations; only IP configuration is required to meet customers' flexible production needs.

Efficient delivery: Utilizing Leadshine's standardized program templates, it supports multi-person collaborative program development, shortening the development cycle.