Automotive Harness Automation

• Automation-Optimized Design
  

The connector geometry allows for precise robotic gripping, making it scalable for fully automated production lines. 
 

• Future-Proof System Integration

Designed with standardized specifications, the new geometry ensures compatibility across various OEMs and suppliers. 

• Advancing Next-Generation Mobility 

The design marks an important step towards end-to-end automation of wiring systems while empowering fully automated manufacturing processes and strengthening end-to-end automation capabilities in the automotive industry.

Q:   What does “automation-ready” mean for automotive connectors?                

A:   Automation-ready connectors are designed to reliably support automated or semi-automated manufacturing processes. This includes features such as stable geometry for robotic gripping, optimized orientation for automated feeding and error free blockloading, and terminal designs that enable consistent insertion forces and crimping quality.
To achieve this, connector design, tolerances, and materials are aligned with recognized design guidelines for automated harness assembly, such as those described in DIN 72036. The use of automation ready components enables higher throughput, reduces manual handling, and improves production repeatability and overall process reliability.

Q:  Why is automation becoming increasingly important in wiring harness production?

A:  Wiring harnesses are among the most labor intensive assemblies in a vehicle, and their complexity continues to increase with the growth of vehicle electronics, ADAS, EV high voltage systems, and data connectivity. Automation helps manufacturers manage this rising complexity and volume by offsetting labor costs, improving quality, and stabilizing production—especially in the face of workforce shortages. 

At the same time, it enables cost effective manufacturing closer to OEM locations, shortens supply chains, reduces CO₂ emissions, and supports sustainability goals. Automated processes also deliver faster response times to changes and higher, reproducible quality standards, which are essential for advanced functions such as autonomous driving.

Q:  What connector features support higher levels of automation?

A:  Connectivity components optimized for automation typically include the following features: 
 

• Connector and contact designs that are precisely matched to enable reliable and repeatable blockloading (contact assembly).
•  Standardized geometries that help to allow consistent robotic gripping throughout the entire manufacturing process.
• Reduction of separately mounted connector components to reduce handling steps.
• Terminal designs that support in process crimp quality monitoring.
   

Q:  Are automation-ready connectors compatible with existing equipment?

A:  Many automation-ready connectors are engineered to integrate with industry standard crimping, inserting, and testing platforms. TE and other suppliers often provide design guidelines, equipment recommendations, and digital models to support smooth deployment. However, compatibility may vary depending on the specific connector family and production workflow.

Q:  Can automation be introduced gradually into harness manufacturing?

A:  Yes. Most manufacturers introduce automation step-by-step, depending on production volume, complexity, and maturity. 
 

Typical stages include:
 

• Automated cutting, stripping and crimping
• Automated terminal insertion and blockloading
• Automated routing
• Automated taping and application of fixing elements
• Fully automated harness manufacturing, combining steps 1-4

Using automation-ready connectors supports this phased approach and helps ensure scalability as companies move from semi-automated cells to higher levels of automation.

Q:  Which applications are expected to be most relevant for automated wiring harnesses in the coming years?
A:  Key applications include:
 

• Seats
• Bumpers
• Headlamps
• Roof systems
• Doors
• Center consoles
• Tailgates
   

Q:  Are automation-ready connectors relevant for both ICE and electric vehicles?
A:  Automation-ready connectors benefit any vehicle program by improving quality, consistency, and efficiency. They are increasingly relevant across body electronics, infotainment, lighting, chassis, and powertrain systems.

Q:  How involved is TE in industry initiatives supporting automation, digitalization, and data-driven collaboration in the automotive value chain?
A:  TE is part of the Catena-X Automotive Network. This is one of the leading initiatives driving digitalization of the entire automotive value chain in Germany. Harness suppliers increasingly adopt Catena X data spaces for future automated manufacturing data flows. Even though Catena-X does not automate production machinery, it enables automation and standardization by providing shared data infrastructure. 

TE is engaged at ARENA2036, a future automotive production research campus in Germany.  TE is actively involved in the Wire Harness Standardization Initiative (SILS), in which OEMs, assemblers, contact and connector manufacturers, machine builders, software providers and system houses work together to establish DIN 72036 standard.