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Ready for take-off: automated Electrical Wire Interconnection Systems (EWIS) assembly

The way we transport people and goods by air in the future and the way we maintain systems and buildings are facing a major upheaval. Minimized CO2 emissions and aircraft noise are just two aspects that require rethinking in modern aerospace.  

The growing and more diverse use of aircraft means that OEMs and their suppliers will face an increased demand for electrical wiring systems. Until now, the relatively small quantities of cable and wire harnesses are readily produced manually. However, green air traffic requires significantly higher productivity and thus at least a gradual increase in the automation of conductor assembly, not least in order to meet the high quality specifications. E-mobility technologies are considered to be a valid blueprint for this. 

The advantage of new digital technologies drives modern production platforms to be flexibly scalable and meeting requirements such as traceability, data analysis for process optimization and quality assurance.

Platforms for compliant automated conductor assembly

For more than 10 years, Komax Aerospace has been developing production platforms for semi-automated and fully automated EWIS production together with the OEMs of aircraft, helicopters, electric vertical and take off and landing aircraft (eVTOL). 

With increasing automation, from digitally provided assembly data to machine-supported sub-processes and fully automated conductor assembly, the error rate and material waste decrease. With a very high cycle rate, connectors are created with consistently high, logged quality. The resulting wire harnesses fully comply with the particularly high safety standards of the aerospace industry. They are lightweight, space-saving and robust to withstand their harsh operating environment, which exposes them to high temperatures and air pressure fluctuations as well as strong vibrations. 

Traceability thanks to sustainable marking of cables and conductors

Requirements such as low weight and imperviousness to harsh environmental influences represent a particular challenge for the cable sheath material. Applied by laser, the individually configured ID code is up-to-date and complies with industry standards and regulations. 

Automated conductor assembly with integrated inline or end-of-line quality assurance via industrial image processing ensures digital traceability since it logs the visual inspection.