Difficulties in the automated wiring harness assembly process:
Handling is difficult because the wires that are part of the harness are very flexible elements and are of great length;
Various components that make up the final wiring harness: wires of different lengths and diameters, terminals, seals, connectors, protectors, connectors, fasteners, etc.;
Multiple operations required to ensure continuity: simple crimping (manual or automatic), two-wire crimping (manual or automatic), ultrasonic welding, twisting, threading terminal wire assemblies into connectors, applying protection, etc.;
The variety of harnesses produced in a project, with many references requiring different assembly plates (trays);
Changes to the wiring architecture that occur during the project development phase, involving rapid modifications/adjustments to the sequence of operations and assembly systems;
The changes brought about by after-sales quality events, although smaller than the development stage, also involve the rapid adaptation of the wiring system.