With electromobility booming and the trend moving toward autonomous driving, demand for high-voltage cables is growing enormously. In just a few years, up to 30 percent of new cars worldwide will be electrically powered. A vehicle’s high-voltage electrical system also integrates units such as air conditioning, power steering, brake assist and heating.

Demand for a sophisticated automation concept

Today, most manufacturers still largely produce complex HV cables manually. However, it is now barely possible to serially produce the required quantities by hand – and certainly not with the required levels of precision and within the specified time frames. As a result, manufacturers are asking themselves: “Is there a platform I can use to economically automate the entire process of HV cable processing? Can it also take into account varying wire harnesses and achieve production volumes at the required quality?”

Modular platform for HV processing at short cycle times

Komax has created the best conditions for automating the HV cable processing chain flexibly and with high productivity levels. With Lambda 440, Komax meets the need for a modular platform. Komax’s broad process expertise is reflected in various process modules, which can be arranged according to requirements all the way to full automation. On this basis, Komax develops targeted solutions for different types of high-voltage cables and connectors. Stations connected in parallel can now process different cables simultaneously. When a cable has gone through the first steps and is being prepared for crimping, the first tool is already removing the jacket and foil of the next cable. This saves time and increases productivity.

Optimally designed for characteristics of high-voltage cables 

The active conveyor belt option ensures that the heavy and bulky HV cables can be handled quickly and easily. Each cable is placed on a conveyor belt, which ensures that the shuttles and tools can perform their tasks at top speed without strain. While a cable is moved from module to module by shuttle, its other ends remain on a conveyor belt, so that their comparatively heavy weight does not put any strain on the tools or on the conveyor system. The belts follow the movements of the shuttles, which allows the cable to be carefully processed in less than 20 seconds.

Integrated monitoring ensures high quality standards 

The quality requirements in this sector are extremely high - and rightly so. The processing machines use integrated tools to meet these high standards. They control the individual processing steps and log the results. 

One of the critical processes for example is shortening the braided shield in shielded high-voltage cables. The braid cut off in the process must be reliably removed from the cable. The most effective way to do this is to suction away the cables in a shielded environment. This meets the strict requirements for technical cleanliness.