High-Voltage Solutions

High-Voltage - Robotic Fully Automated Line


The High-Voltage - Robotic Fully Automated Line (HV-RoFAL), is a complete and fully automatic line to cut, pre-assemble components and perform cable processing operations, in HV cables and HV connectors.

It is a technological combination of Komax’s machines Kappa and Lambda 240 with StoneShield’s HV-RAM.

The entire process is fully automatic and without operators’ intervention:

  The machine is fed with the wire’s spools and with the connector’s components in bulk in feeders;

  From here, the cable is cut, fed directly to the HV-RAM, that performs the pre-assembly of components;

  The HV-RAM handles the cable and feeds it directly to the Lambda, to perform the wire processing operations, like cutting, stripping and crimping;

  After the Lambda completes its cycle, the HV-RAM picks up the finished product and stores it into a cable rack for later pickup.

The solution can work both for single core or double core cables, which if it is the case, two dereelers are used and the Kappa cuts both wires simultaneously.

Combined with the full autonomy, an error free process is obtained since the products’ quality is controlled throughout the entire process.

The seamless communication between all machines also ensures the complete traceability of the process.

High-Voltage - Cobot/Robot Assembly Machine


HV-CAM - Cables Handled by Cobot

A robotic system designed to break plastic pins from connectors (punching system) in a fast and automatic way.

It has an integrated vision system to inspect and validate the end results of the punching process.

It has dedicated tools for each vias’ pattern and allows the processing of different connectors, in the same operation.

The standard machine can handle 8 different connectors with 8 different punching tools.

After selecting the pattern with a barcode reader or a network file (KSK server), the operator puts the connectors in the selected nests. The machine will pick the necessary tool and angle and start the punching process.

At the end of the process, the vision system will check each of the connectors to ensure that the punching process is accurate and burr free, identifying OK and NOK parts.

HV-RAM - Cables Handled by Operator

High-Voltage - Final Assembly


The HV-FA – High-Voltage – Final Assembly is a system designed to perform the final assembly of HV connectors, in a controlled and monitored way.

The operator places the components into poke-yoke jigs (in some cases, these components are loaded automatically from feeders), and after detecting the presence of all components, a servo motor performs the insertion.

Some key aspects of the final assembly, for example: the position of the outer conductor is monitored by a vision system, with multiple cameras, that relays the information to the servo motor, in a closed loop control system, in order to achieve the perfect position.

The vision system and laser sensors are also used to ensure the correct final position of the components.

With inbuilt OPC-UA communication, full traceability of the process is ensured and reported to the MES servers.

High-Voltage - Taping Machine


The HV-TM, High-Voltage - Taping Machine, is a spot taping machine designed to perform a precise spot tape that ties and protects the wire shield of HV cables.

The position where the spot tape is made is highly precise, with a tolerance of +/- 0.5 mm. This position is ensured using sensors to detect the cable’s position.

The machine is able to operate with different cross sections, by changing two side clamps. The clamp setup is very quick, since it uses plungers to secure them.

The machine recognizes the clamps installed and automatically adjusts the taping parameters.

The change of tape is done in a very fast and easy way, in less than 50 seconds.

The machine is designed as standalone, but also can be modified to be integrated with other machines or to work inline, since the cable is fixed and its the taping head that goes to the wire.

High Voltage - Semi-Automatic Component Assembly


The HV-SACA, High Voltage - Semi-Automatic Component Assembly, is a machine designed to assemble, in a controlled way, the flaps' modules of EVs' charging ports.

It can process 4 different variants of flap modules. The variant is selected using a barcode reader.

The operator places each component in poke-yoke jigs, which upon detection, automatically performs the assembly.

After the assembly process, the machine measures the spring constant modulus of each flap independently.

The result of the assembly and the spring constant value is printed into a dedicated label.

A touchscreen displays every step of the assembly process.

High-Voltage - O-Ring Inserter


The HV-OI, High-Voltage - O-Ring Inserter, is a machine designed to insert O-Rings into HV cables’ terminals in an automatic way.

Each cable type/O-ring type, has a dedicated inserter. The number of inserters is unlimited, only influencing the machine size.

The operator selects which type is to be processed using a barcode reader. Once selected, the machine lights a LED to inform where the operator should put the cable and shows the information on the touchscreen.

The operator places the cable on the selected inserter (only this one activates) and the machine locks the terminal, verifying if its the correct and if so, the O-Ring is inserted by pressing a button.

Each inserter has it’s own O-Ring feeder with an average capacity of 40 units.

High-Voltage - Interactive Assembly Table


The HV-IAT, High-Voltage - Interactive Assembly Table, is a machine designed to guide and assist operators during the assembly of HV cables’ harnesses.

Each assembly table has 3 different assembly panels, arranged in a triangle configuration, which allows the simultaneous usage of 2 different panels. The rotation of the panels is done manually, but the machine recognizes which variation is selected.

Each assembly panel is made by fixtures, where the operator places the different components. During this process, indicative LEDs guide the operators to ensure all steps are made correctly and a general touchscreen shows the progress and reference being produced.

Other processes, like tightning and straps application are also monitored. All data is stored for traceability.

When the assembly is finished correctly, the harness is released and a label is printed.

High-Voltage - Tube Inserter


The HV-TI – High-Voltage - Tube Inserter is a system designed to insert a braid shield and wires into long HV corrugated power distribution tubes, with more than 5 meters.

It uses jigs to conform the tube into position and a motor to push the braid and wires along the tube, making a complex and laborious manual task, into an automatic and simple process.

© 2018 ELCAB solutions. All Rights Reserved.