From Automation to Intelligence: How Can Cable Harness Manufacturers Lead the Market

The productronica China, a crucial platform for showcasing and exchanging ideas in the electronic intelligent manufacturing industry, will grandly resume from March 26 to 28, 2025, in Halls E1-E5 & W1-W3 of the Shanghai New International Expo Centre (SNIEC). This exhibition will be extensive, covering nearly 100,000 square meters. It is expected to attract nearly 1,000 quality enterprises from the electronics manufacturing industry. They will showcase products and technologies spanning the entire electronic manufacturing supply chain, including electronic and chemical materials, dispensing and gluing technologies, electronic assembly automation, testing, measurement, and quality assurance, electronic manufacturing services, surface mount technology (SMT), harness processing and connector manufacturing, component and part manufacturing, motion control and drive technology, industrial sensors, robotics, and intelligent warehousing, among others.

As the automobile, electronics, and communications sectors rapidly develop, the demand for cable harnesses—essential components that connect internal parts—continues to rise. They are crucial not only for ensuring the proper functioning of products but also for maintaining quality, safety, and reliability. However, as market demands become increasingly complex and the need for environmentally friendly production grows, the cable harness processing industry faces new challenges. Enhancing production efficiency, reducing costs, and ensuring product quality while minimizing environmental impact have become urgent issues for cable harness manufacturers. Automation and intelligence are undoubtedly two key trends for addressing these challenges.

The automation as the engine continues to gain momentum, accelerating innovation in cable harness equipment.

Typically, the cable harness manufacturing process consists of four main stages: cutting, crimping, pre-assembly, and final assembly. The first two stages, cutting and crimping, are highly automated, while the later stages, pre-assembly and final assembly, primarily rely on manual labor. Consequently, the cable harness processing industry has been regarded as labor-intensive for a long time, especially in later stages like pre-assembly and final assembly, where low automation leads to high costs and challenges in maintaining quality. To tackle these challenges, more and more companies are developing advanced automatic processing equipment, such as automatic wire strippers and terminal crimping machines. This significantly increases production efficiency while also improving product quality and consistency.

Reliable and high-quality terminal crimping technology is essential to the entire cable harness value chain. The Komax Alpha series, which is highly regarded by customers, sets a strong standard for crimping technology. The Alpha 550 G2 is designed specifically for efficient automotive batch production. It features a fully automatic and deeply integrated quality control system that ensures excellent results and minimal reject rates thanks to significantly reduced operator influence, a dual blade holder, and the optional fast sampling function that ensures precise and high-quality processing. It covers a wide range of applications, communicates with all commercially available MES systems, and can be continuously adapted to individual production requirements thanks to freely selectable process and quality modules.

Schleuniger's five new B series wire strippers for traditional wires and coaxial cables excel in the precision stripping field thanks to their efficiency, reliability, high precision, flexibility, and user-friendly design. Whether it's the B340 for various stranded wire applications or the B540 for coaxial cables, nearly all movable axes are programmable. The cutting head can be fully configured through the user interface, accommodating a wide range of diameters. Additionally, the choice of blade materials and cutting angles ensures the reliable processing of challenging materials and insulation layers. With different models available, the B series machines provide a wider range of applications and greatly simplify programming.

JAM has built a strong reputation for its fully automatic terminal crimping machines, gaining broad support and recognition from users. To meet the demands of the Fakra market, JAM has introduced a comprehensive solution that spans from connector production to the automatic production line for Fakra cable harnesses. The high-speed dual-end crimping machine CPR-F-ZERO stands out as an innovative choice in the industry for its remarkable emphasis on compact design, high speed, and workability. This model is equipped with a 10-inch panel that makes operation more intuitive and convenient. The pre-feed wire device is positioned on the side of the machine, which saves space and lessens the operator's workload. It accommodates wire sizes from 0.03 to 2.0 square millimeters and offers a crimping speed of up to 0.7 seconds per wire, showcasing its exceptional processing capability.

ShinMaywa Industries, Ltd. specializes in fully automatic wire processing machines that are essential for cable harness manufacturing. Recognizing the demands for weight reduction and cost optimization in automotive cable harnesses, ShinMaywa has developed high-performance models that offer exceptional processing capabilities and consistent machining precision. This has been made possible through their unique linear drive system, more advanced high-speed control technology, and a robust drive mechanism design. For ease of operation, a computer-controlled system has been developed, providing a more user-friendly interface. All models come with a standard digital crimping mechanism. The high-rigidity structure incorporates a unique linkage design that improves consistency in crimping height and shortens preparation time.


Hacint Intelligence Technology Co., Ltd. provides a complete end-to-end solution for conventional crimping, testing, high voltage, high speed, intelligent connectors, ultrasonic processes, and MES software. It has launched a fully servo-driven semi-automatic crimping machine and inspection workstation in the area of conventional crimping equipment. The testing equipment includes high and low voltage testing platforms, as well as Fakra coaxiality testing devices. The high voltage automatic cable features a highly flexible design, with each module serving as an independent functional unit, allowing for flexible combinations and direct connections, minimizing losses during equipment changeovers. For high-speed cable equipment, the Fakra automatic cable and semi-automatic and fully automatic devices compatible with 100M, 1G, and 10G Ethernet have been successfully implemented.

Wuxi Airstorm Intelligence Equipment Co., Ltd. has introduced several innovative products in the research, development, and manufacturing of high-voltage cable harness processing equipment. Notably, the 4th generation small square high-voltage cable harness processing platform, also known as the 600 processing platform, integrates and optimizes key processes such as cutting, stripping, turning, and crimping, and is expected to set a new standard in the small square high-voltage cable harness production industry. Compared to the previous generation, the 4th generation platform nearly doubles the production speed, achieving an efficient level of 6 to 7 seconds per terminal. It also offers exceptional flexibility and cost-effectiveness, supporting rapid changeovers for various shielding rings and terminals, enabling customers to expand its functionality according to their needs. Additionally, Airstorm has launched the new generation 5-station integrated machine, known as the 800 processing platform. This machine is designed for processing high-voltage thick cables and can pre-feed plastic sheaths, enabling simultaneous processing of two cables. It boasts a fast time of 10 to 12 seconds per cable and covers a wide range of applications (accommodating cable sizes from 2.5 to 120 square millimeters), addressing needs for shielding ring crimping and customized requirements.

To meet the demands of the AI era, KM Digitech Co., Ltd. will launch the most advanced LIMS-P3 fully automatic crimping machine in 2025. This technology includes a digital tension regulator that automatically regulates pressure based on wire size, effectively eliminating the need to reset pressure values when changing wires and reducing the chance of errors. Additionally, the crimping head can automatically adapt to different terminal styles, significantly enhancing operational efficiency. The standard configuration still includes the auto height adjustment device and laser stripping sensor, but the new equipment will feature a lower terminal rack for easier loading and unloading of terminals. In addition, the vibration values of the waterproof plug insertion device can be programmed for adjustment, automatically completing this when the LOT is selected. All of these features are designed to maximize user convenience and work efficiency.

The HPC-5020NC fully automatic terminal crimping and twisting machine from Xiamen Hiprecise Technology Co., Ltd. is a mature product that performs various processes, including wire length cutting, stripping, inserting waterproof plugs and   crimping at both ends, and twisting. With fully automatic production, it saves turnaround time for semi-finished products in the workflow, enhancing production efficiency for enterprises. It is widely used in industries such as automobile and power. The machine supports long wire twisting (4, 6, 8, and 10 meters) and same-side long and short opening twisting, utilizing a well-known servo crimping system that allows automatic adjustment of crimping height and other parameters based on the work order. Featuring a stable and reliable flexible operating system, it ensures continuous operation without downtime, achieving a maximum processing efficiency of up to 1,000 PCS/h. Additionally, the HPC-5020NC includes a built-in pressure management system that monitors crimping quality in real-time, along with an innovative twisting mechanism that ensures the high quality of the final product, helping enterprises reduce costs and increase efficiency.

Jiangsu Bozhiwang Automation Equipment Co, Ltd. was established in 2001, marking 23 years of development. As a leader in R&D and production of cable harness processing equipment, Bozhiwang specializes in intelligent production solutions for high-speed communication harnesses (FAKRA, HSD, Ethernet) of the automobile sector and new energy high-voltage cable harnesses. With strong technological capabilities and ongoing innovation, Bozhiwang has become a benchmark enterprise in this field. Since its launch, the BZW-8.0HM Ethernet fully automatic intelligent processing platform has achieved significant success in the market and is widely used in the production lines of many well-known automotive cable harness manufacturers. Through continuous technological innovation, the BZW-8.0HM platform has addressed various bottlenecks in the automated processing of HMTD, AMEC, METnet, and other fast, Gigabit, and 10 Gigabit Ethernet systems, helping customers achieve fully automated production and greatly enhancing their competitiveness. Precision processing station: High-precision processing capabilities ensure that every component is flawless. Online inspection: The integration with multiple online inspection modules monitors product processing accuracy and qualification rates in real time. Data collection and traceability: Each product has a unique identity, and all data during the processing is recorded, enabling intelligent product traceability. Flexible design: The production line layout is adaptable, quickly meeting the production needs of different products and saving investment costs for customers. Applicable wire: Φ3.5-4.5 millimeters (Ethernet cable); Processing length: 150-10,000 millimeters; Production speed: 6s/pcs; Product qualification rate: 98.5%-99%. Create a future of innovation, intelligent manufacturing, and global prosperity. This encapsulates Bozhiwang's vision and goals for future development. Bozhiwang will continue to uphold the philosophy of innovation-driven development, consistently introducing more innovative products and providing better quality services for customers, promoting the progress and development of the cable harness processing industry.

Schunk Sonosystems' ultrasonic welding equipment is mainly used in the automobile industry, cooling technology, power electronics, and battery technology. The Minic-Ⅲ ultrasonic welding machine, known for its efficiency, advanced technology, and ease of use and maintenance, has set the process standards for leading global cable harness manufacturers. It particularly excels in welding strength, welding quality (Cpk), equipment stability (Cmk), and weld point appearance. This equipment supports a welding range from 0.26 to 30 square millimeters, making it suitable for welding copper wires, aluminum wires, and copper-aluminum connections. The integrated ID chip allows for plug-and-play functionality and supports sequential welding.

Powerful digital pulse drives efficient cable harness production.

In addition to advancements and innovations in equipment, intelligent production management has become a key focus in the development of cable harness processing. Connecting production devices not only helps optimize workflows and improve resource utilization but also allows for the timely identification and resolution of issues, thus preventing production accidents. For example, integrating sensors and intelligent control systems allows for real-time monitoring of the production line, automatically adjusting parameters to ensure optimal performance. With big data analytics, companies can gain insights into production data, identify potential bottlenecks, and discover optimization opportunities for more refined management. This intelligent production approach improves efficiency and significantly enhances product quality and consistency, giving cable harness manufacturers a competitive edge.

The 6080-2A secondary line automation intelligent production line launched by Ningbo Hongsheng Intelligent Technology Co., Ltd. has garnered widespread praise from customers for its excellent performance and efficient workflow. This product is mainly used in the electrical set industry for wiring inside distribution cabinets and in the automation control industry for control cabinet wiring. It integrates multiple processes—including wire prefabrication, offline production, stripping, crimping terminals, and sleeves—into a single device, achieving fully automatic production. It supports compatibility with six or more specifications of wires, four specifications of sleeves, and various terminal specifications, automatically switching production based on work orders. This enables a complete production model for single cabinets, significantly saving labor costs and improving material utilization and production efficiency, generating substantial economic benefits for companies. The entire machine features a modular design and assembly line layout, making it easy to operate and maintain while supporting future expansion and upgrades.

Shenzhen Linquan Technology Co., Ltd. has successfully integrated cutting-edge intelligent systems with traditional processing equipment, redefining the production model for automotive cable harnesses. It has introduced a range of industry-leading products in intelligent manufacturing, online testing, and comprehensive smart factory solutions, including fully automatic low-voltage/high-voltage cable harness processing centers and MES systems. These innovations assist customers in building their core competitiveness.

Yijia Technology Co., Ltd. has developed an intelligent management platform that enables companies to achieve production transparency, real-time data monitoring, and paperless operations. This enhances management capabilities, increases production efficiency, and reduces material waste, allowing managers to monitor the production status in real time and drive business development through data analysis. The E7 management system is a deeply customized software product designed specifically for the cable harness industry. Utilizing advanced technologies in automatic process generation, intelligent scheduling, and equipment interoperability, it provides comprehensive control over the entire cable harness production process. The E7 system supports integration with ERP, WMS, and PLM systems, offering a one-stop solution that covers product process design and changes, equipment connectivity, advanced planning and scheduling, machine-platform capacity balancing, on-site material management, equipment and mold control, and complete product quality traceability.

RY-K588 is a combined cable harness shell insertion machine with multi-head terminals developed by Shenzhen Riyan Precision Machinery Co., Ltd. for the automobile industry. It is capable of crimping 12 different types of terminals and accommodating 6 types of waterproof plugs, supporting various plastic shell insertions as well as wire sizes 18 to 26#. With a multi-station open platform and a precision servo drive mechanism, it provides high processing capability and excellent machining accuracy. The machine features a 24-inch touchscreen and a computer numerical control human-machine interface, making production management more convenient. It includes built-in pressure monitoring and can be optionally equipped with a CCD visual inspection system for comprehensive quality control throughout the manufacturing process, ensuring high-quality product output. The flexible plastic insertion tray can accommodate various types of plastic shells, allowing for the efficient production of a wide range of specific cable harnesses. Additionally, it offers flexible expansion options for multiple functionalities, including high flexibility, configurable workstations, short product changeover times, and high machining precision.

Lazpiur, headquartered in Basque, Spain, is a manufacturing company specializing in automation equipment with a history of over a century. The high quality of its products comes from continuous innovation and improvement over the past hundred years, along with a strong commitment to product quality. The company focuses on providing customers with high-quality custom automation equipment (including high-speed pin insertion machines, connector bending machines, and new energy OBC assembly lines for automotive electronics). At this exhibition, Lazpiur showcased its new generation H2 pure servo-driven pin insertion machine, which can meet customers' needs for four different pin types simultaneously, making it highly competitive in the pin insertion field. This product features ergonomic design and intelligent technology, combined with traceability systems and big data analysis, allowing customers to experience faster speeds, greater intelligence, and improved reliability in the equipment.

Looking ahead, cable harness processing will continue to advance along the paths of intelligence, sustainability, and customization. On the one hand, as artificial intelligence and robotics mature, more intelligent equipment will be utilized in the cable harness processing industry, further enhancing automation levels and production efficiency. On the other hand, in response to the challenges posed by global climate change, cable harness manufacturers will increase their investment in R&D to explore new technologies and materials for energy conservation and emission reduction, working together to build a low-carbon and environmentally friendly production system.

As market demand for high-quality and personalized products continues to grow, cable harness manufacturers must continually innovate and provide more diverse and higher value-added products and services to meet the unique needs of their customers. productronica China 2025 will take place from March 26 to 28, 2025, at the Shanghai New International Expo Centre (SNIEC), expanding the display scale of cable harness processing and connector manufacturing sections. Leading companies will showcase a variety of advanced cable harness processing equipment and connector products, including automatic cable harness processing machines, crimping machines, and connector molds. These companies include KOMAX, Schleuniger, JAM, ShinMaywa, Wuxi Airstorm, KM Digitech, Hiprecise, Bozhiwang, Hacint Intelligence, Hongsheng Intelligent, Linquan Technology, Changchun Yijia, Schunk Sonosystems, Riyan Precision, Lazpiur, Haihong Software, Fu Brothers, Xunye, TELSONIC Ultrasonics, Wingud, Da Senlin, ZX Science, Yixin, ZhuoMai, Huaxu Tech, Chaori, Schaefer, Haorituo, Zetai Technology, Hosver, True Soltec, Qingzhi, Elink, Raysun, ZOKO, Junquan, Guanju, Suncota, Defond, NISSEI, CANU, Xya, SBT Ultrasonic, BONNE Ultrasonic, Zhongyao, Ruiling, Huirun Electrical Machinery, Liuxu, Keruixin, Himinsen, Ruixin Automation, Hechang, Keweisi, Yantai, Damptac, Juha, Wenlian Technology, Changsheng Ruiyafeng, Xinyide, Zhenda Automation, HySum, AEG, Zhongli Automation, and maverick. These machines are designed to improve production efficiency and product quality, effectively meeting the needs of various industries.

Secure premium booths! 2025 booths in high demand!

We extend a heartfelt invitation to electronic manufacturing enterprises both domestically and internationally to participate in the exhibition. Here, you will have an unparalleled opportunity to showcase your latest products and technologies. Leveraging the exhibition's strong influence and wide reach, you can precisely reach target customers and swiftly expand your presence in both domestic and international markets. Moreover, a wide range of exchange activities will foster in-depth collaboration among enterprises. Together, we will explore industry trends, uncover potential business opportunities, achieve mutually beneficial outcomes, and collectively compose a remarkable chapter in the history of the electronics manufacturing industry. There are still a few booths available, so book quickly to seize the competitive advantage in the industry! For further information, please contact Ms. Sinsia at +86 21 20205553.