Automation of the

Initial situation and motivation

State-of-the-art inline process monitoring is possible in upstream sub-processes, such as cutting and crimping. The quality data determined here is usually documented in relation to batch sizes. However, any existing quality features, such as the assembly alignment and positioning of components, are checked again in the end-of-line test.

Increasing miniaturization is a major challenge for workers, both physically and mentally. Complex reworking caused by possible subsequent errors requires manual removal and reapplication at the end-of-line test, which puts mechanical strain on the Wire Harness .

By shifting 100% consistently documented, automated inspection steps towards corresponding production steps, the technical basis can be created for quality assurance in the intermediate steps of the ongoing production process.

Current focus of work

Based on the current EOL test, the aim of the sub-project is to identify options for integrating test steps into the wire harness production process. This involves analyzing the requirements that must be met by the production process and equipment in order to relocate the test steps.

This analysis was carried out for the manufacture of cable harnesses for low-voltage applications and is supplemented by the scope of high-voltage applications.

Outlook

The next steps of SP 5 include the basic development of information models relating to the aspects of quality that are to be included in the Asset Administration Shell . The Asset Administration Shell describes the entire life cycle of a product and creates cross-manufacturer interoperability. Specifically, a complete vehicle electrical system is to be mapped as a digital twin and its quality characteristics are also to be taken into account.