High-Voltage Solutions

HV-CAM/HV-RAM - High-Voltage Cobot/Robot Assembly Machine

The HV-CAM (or HV-RAM), High-Voltage Cobot (Robot) Assembly Machine, is a solution for assembling HV cable components, using Cobots or 6 axis-robots.

It can be used in pre-processing (before cutting, stripping, etc) or in post-processing (for connector assembly).

It uses linear bowl feeders to supply each of the components in a fast and autonomous way. In the example of this datasheet’s application, it supplies: rear holder; seal; connector housing, shield crimp and stress relief;

The cobot picks up the individual components and puts them into poke-yoke jigs. It then picks up the cables from a rack that holds them after being cut and performs the complete assembly and vision inspection. Finally, it feeds the assembly to the stripping machine.

The entire process has a tacktime of 30 seconds. If the cables are handled by the operator (utilizing the cobot only for components’ handling), the tacktime is below 17 seconds.

The disposition of the assembly cell and jigs is fully customizable in order to integrate easily into the current process (to work on a line or in standalone).

HV-CAM - Cables Handled by Cobot - German Version

HV-CAM - Cables Handled by Cobot - English Version

HV-RAM - Cables Handled by Operator

HV-TM - High-Voltage Taping Machine

The HV-TM, High-Voltage Taping Machine, is a spot taping machine designed to perform a precise spot tape that ties and protects the wire shield of HV cables.

The position where the spot tape is made is highly precise, with a tolerance of +/- 0.5 mm. This position is ensured using sensors to detect the cable’s position.

The machine is able to operate with different cross sections, by changing two side clamps. The clamp setup is very quick, since it uses plungers to secure them.

The machine recognizes the clamps installed and automatically adjusts the taping parameters.

The change of tape is done in a very fast and easy way, in less than 50 seconds.

The machine is designed as standalone, but also can be modified to be integrated with other machines or to work inline, since the cable is fixed and its the taping head that goes to the wire.

SACA - Semi-Automatic Component Assembly

The SACA, Semi-Automatic Component Assembly, is a machine designed to assemble, in a controlled way, the flaps' modules of EVs' charging ports.

It can process 4 different variants of flap modules. The variant is selected using a barcode reader.

The operator places each component in poke-yoke jigs, which upon detection, automatically performs the assembly.

After the assembly process, the machine measures the spring constant modulus of each flap independently.

The result of the assembly and the spring constant value is printed into a dedicated label.

A touchscreen displays every step of the assembly process.

HV-OI - High-Voltage - O-Ring Inserter

The HV-OI, High-Voltage - O-Ring Inserter, is a machine designed to insert O-Rings into HV cables’ terminals in an automatic way.

Each cable type/O-ring type, has a dedicated inserter. The number of inserters is unlimited, only influencing the machine size.

The operator selects which type is to be processed using a barcode reader. Once selected, the machine lights a LED to inform where the operator should put the cable and shows the information on the touchscreen.

The operator places the cable on the selected inserter (only this one activates) and the machine locks the terminal, verifying if its the correct and if so, the O-Ring is inserted by pressing a button.

Each inserter has it’s own O-Ring feeder with an average capacity of 40 units.

HV-IAT - High-Voltage - Interactive Assembly Table

The HV-IAT, High-Voltage - Interactive Assembly Table, is a machine designed to guide and assist operators during the assembly of HV cables’ harnesses.

Each assembly table has 3 different assembly panels, arranged in a triangle configuration, which allows the simultaneous usage of 2 different panels. The rotation of the panels is done manually, but the machine recognizes which variation is selected.

Each assembly panel is made by fixtures, where the operator places the different components. During this process, indicative LEDs guide the operators to ensure all steps are made correctly and a general touchscreen shows the progress and reference being produced.

Other processes, like tightning and straps application are also monitored. All data is stored for traceability.

When the assembly is finished correctly, the harness is released and a label is printed.