Assembly Solutions
for Smart Mobility
Assembly lines and test systems for
automotive connectors
Applications in cars for traffic and safety-relevant systems, e-mobility and autonomous driving require high-performance, versatile and safe connection technology for signal transmission and power supply. This results in new requirements for design, materials and coatings as well as for testing and product safety.
To meet these requirements, XENON offers production equipment with advanced technology modules to ensure consistent quality throughout the entire product life cycle.
Our key competencies for automotive connectors are:
- Product development support
- Resource-saving automation concepts
- AOI of complex assemblies
- Assumption of responsibility as general contractor
for the automation solution - Integration of third-party systems
- Broad testing expertise for consistently high product quality
- Smart process data management
Application fields in the wiring system
Customer products in operation
A selection of automotive connector and adapter solutions,
which have been assembled and tested by XENON automation systems.
Key processes in assembly
Our wide expertise in technology is the perfect foundation
for your individual automation solution.
Feeding and Separation
Bulk or Strip Material (Pins, Body/Housing, Insulation)
Joining and Positioning
Pick and Place, Cam-Controlled Assembly, Robot Handling
Pre- and Final Assembly
Press-Fit, Crimping, ...
Inspection and Selection IO/NIO
Quality Assurance (Function, Pin Position, Tightness, ...)
Identification and Traceability
Labeling, Lasering, Marking
Packaging and Sealing
Blister Belt, Palletizing, ...
Automation and Assembly Portfolio
Power / High Frequency / Signal & Differential Connectors
Wire-to-Wire/Inline
Cable-to-Cable Solutions for Signal,
Power Connectors and I/O,
and Sealed Applications
Wire-to-Board/PCB-Header
Cable-to-Board Solutions
for microminiature, Power Connector,
Signal and I/O Applications
Device connections
Connector Solutions
for microminiature, Power Connector, Signal and I/O Applications
Key Technologies for Connectors
Feeding
Vibratory Feeder, Bowl Feeder, Centrifugal Feeder, Flex Feeder
Handling
SCARA Robots, 6-Axis Robots, Multi-Axis Gantry Systems, High-Speed Pick and Place
Joining
Assembling, Snapping, Soldering, Gluing, Riveting,
Screwing, Welding
Pressing/Press-Fit
"Force-Displacement" monitored Press-Fitting of Multipin Plug Contacts into Printed Circuit Boards (PCB)
Injection Moulding
Supply and Processing
of Inserts, Contact Assembly
Crimping
Crimp to Crimp, Crimp to Seal, UniCrimp, Sealing
Testing
Optical Inspection (AOI), Quality Control, Leakage Tests, Flow Tests, Electrical Tests, EOL Function Tests
Packaging
Tray, Tube, Tape & Reel Packaging, Blister Tape, Bag Packaging
Customer Products
A selection of automotive connectors for which XENON has developed and built automation systems.
REFERENCE PROJECTS
Automatic Assembly of a Squib Airbag Connector
Customer product
Squib Airbag Connector (Female)
Automation requirements
- Fully automated assembly
- Separation of bulk & tape goods
(Contact, housing/body, ferrite and CPA) - Sensory and optical monitoring and testing of the components
- Sorting of IO/NIO parts
- Laser labelling
- Packaging in Trays
Assembly, Testing and Packaging of DT-XT Connector Systems
Customer product
DT-XT connector family
Automation requirements
- High variety of variants with short cycle times
- Minimal set-up cycles
- Universal feeding of components
- Qualified testing (function and tightness)
- Sorting IO/NIO already in the feeding process
- Fully automated packaging in tubular bags
Contact Assembly Line for Multi-Pin Connectors
Customer product
Multi-pole motor connectors & pin headers
Automation requirements
- Fully automated assembly of contacts into insulating bodies
- Highly flexible assembly line for different connectors
- Separation and Feeding of bulk & strip material
(various insulating bodies, contacts) - Optical and mechanical monitoring and functional
testing of the components - Sorting of IO/NIO parts
- Packing in Trays