Fully Automatic RT-Version Ethernet Cable Assembly & Inspection Line
Designed for next-generation vehicle networks, this system delivers an ultra-high-speed automotive Ethernet cable assembly line process that automatically crimps connectors onto standardized single-pair twisted cables. As an advanced Ethernet cable assembly equipment solution, it unifies complex wire processing tasks with comprehensive wire harness inspection to ensure zero-defect, factory-gate quality. This line achieves full automation of assembly processes, including winding wire, binding wire, loading wire, twisting off the cable sheath, crimping the crimp ferrule, turning the braided sleeve inside out, punching the braided sleeve out, wrapping copper foil, cutting aluminum foil via laser, separating twisted wires, stripping wires, crimping the double-ended terminal, assembling the outer conductor, laser spot welding the outer conductor, and AOI.
Product Specifications
Item |
Parameter |
| Dimensions | L 23,000 × W 1,200 × H 1,950 mm |
| CT | < 8 s |
| OEE | ≥ 85% |
| Yield | FPY (First Pass Yield) ≥ 99% |
| Capacity | UPH up to 900 pcs (single end) |
| Processing Length | 100-3,000 mm |
| Crimping Monitoring | Pressure curve monitoring/prevention of poor crimping/missing wire/missing core |
| Vision Inspection | Wire stripping length, exposed inner conductor, proper assembly, and color |
| Electrical Testing | Continuity, short circuit, open circuit, and insulation resistance |
Core Strengths
Guaranteed Exceptional Electrical Performance
By precisely controlling the twist pitch of twisted pair, we can achieve 360° full-coverage shielding layer processing and ultra-high precision crimping. This ensures each cable possesses exceptional and highly consistent electrical performance from the process source, laying a solid foundation for stable signal transmission.
Highly Integrated Automation
This line highly integrates complex processes originally dispersed across multiple stations and reliant on technician’s skills into this line for fully automated operation, effectively reducing the dependence on skilled technicians and enhancing process stability and standardization level.
High-Efficiency Continuous Production Capacity
With a rapid cycle time of within 12 s/pcs and the support for 24/7 uninterrupted operation, the output of a single equipment significantly surpasses that of traditional manual teams, effectively ensuring peak capacity and order delivery and solving production efficiency bottlenecks.
Flexible Production and Full Inspection Traceability
First, this line supports quick changeover of products with different lengths or single/double ends and their simultaneous production in the same line. Second, it possesses processes including wire length & dimension measurement, aluminum foil laser cutting, and outer conductor laser spot welding and introduces AIDI deep learning technology for 360° no-dead-angle detection of filaments of braided sleeves. Besides, it also integrates crimping pressure monitoring and displacement sensor-based assembly compensation to achieve 100% full inspection and full-process data upload for traceability.
Core Process — Laser Rotary Aluminum Foil Cutting
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360° circumferential precision cutting, removes only the shielding layer without damaging core insulation, smooth and burr-free cut.
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It can automatically vacuum fragments of aluminum foil away to prevent dust pollution and potential damage to the core wires.
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It is synchronously controlled with the entire line; quick parameter recall for changeovers; compatible with Cat5e/6/6A/7 shielded network cables.
Application Scenarios
Industry Focus: Network cable manufacturing, wire harness processing, and low-voltage communication industries.
Applicable Products: Tailor-made for the assembly and inspection of CAT5e/CAT6 Ethernet cables.
Line Compatibility: Compatible with manual/semi-automatic/fully automatic assembly lines.
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Contact Information
Service Commitment
- 24-hour quote response
- Free technical solution design
- On-site demonstration and training
- One-year warranty, lifetime maintenance
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