The automotive industry in particular has especially stringent requirements regarding the size and weight of wire harnesses. The demand for even shorter and thinner wires in large quantities is constantly increasing. These are typically used in the steering wheel or vehicle interior.

The fully automatic Omega 740 is very popular among our customers because it is purposefully designed for the production of particularly compact wire harnesses with terminal housings on one or both sides. The minimum workable length of wires with jumper connections on both sides was previously 300 mm.

Today, however, even shorter wires are required. What can be done? A return to manual insertion? Produce individual wires using a machine and then load them manually into the housing? With such small housings, the error rate would be much too high with both these methods.

3.6 seconds for a wire loaded on both sides

We were looking for and developed a convincing solution: a new application for the Omega 740, with two insertion heads working in parallel instead of just one. This drastically reduces the minimum possible wire length for processing to 200 mm. This brings enormous advantages for wire manufacturers – in view of the shortage of skilled workers and price pressure. The fully automatic machine can achieve loading on both sides in just 3.6 seconds.

Guaranteed, traceable quality

And that’s just one benefit. Progress has also been made in terms of quality. The Omega 740 not only assembles wire harnesses from A to Z in a single process step, it also continuously checks their compliance with the quality requirements, for example using force sensors, incision monitoring, optical inspections of stripping and seal position, and an optical measuring system for terminals. To sum it up: Quality control takes place during the manufacturing process and no longer needs to be carried out on the finished wire harness. Of course, the machine stores the quality data from the production process for each wire harness, ensuring complete traceability.

Secure investment thanks to an extremely wide range of applications

The high flexibility of the Omega 740 also significantly contributes to ensuring a safe investment. The standard machine can be quickly and individually converted and is suitable for an unlimited number of applications. The new fully automatic block loaders with the enlarged holding pallets provide even more flexibility for specific production across the entire range of applications. Therefore: If one product is no longer in demand on the market, the machine can be converted for another.

Comprehensive consulting for function-oriented application

With every new project, the question for you as a wire manufacturer is how production can be automated to the greatest possible extent. You can fully rely on our expert knowledge here. Specialists assess the design of the wire harnesses and components with regard to automated processing. They provide design proposals and support you in the optimal integration into your production process. For more information, please get in touch with your contact person. The author will also be happy to answer your questions and looks forward to hearing your opinions, wishes and suggestions.