Harmontronics

The Harmontronics IPA800 is a new-generation fully automatic pin insertion machine equipped with automatic ejector pin switching and an innovative cam mechanism design that ensures highly efficient pin insertion speed. It supports more flexible insertion head configurations and features advanced force-displacement detection, helping customers achieve flexible and efficient production planning.

Equipment dimensions: 2000*1400*2000mm (single unit); Pin insertion speed: 3~8 pins/s (up to 8 pins/s); Bending speed: 6 pins/s; Changeover time: <20 minutes for a single unit; Air pressure: 0.5~0.7Mpa; Power supply: 3~380V/AC/50Hz; Up to 3 pin insertion heads can be mounted; Modular design for fast changeover; Supports different types of terminal pins; Friendly human-machine interface for easy operation and maintenance.

• Press-Fit terminal press-fitting for automotive connector PCB boards
• Terminal assembly for electronic control units / automotive electronic modules
• Flexible pin insertion production with multiple varieties and small batches

A fully automatic automotive fuse box assembly line for inserting fuses and relays. It integrates feeding, insertion, press-fit in-position detection and electrical performance testing, providing customers with a one-stop assembly and testing solution.

Cycle time CT: 0.9 s/pcs; Yield: ≥99.5%; OEE: ≥85%; Core process: auto fuse/relay insertion; Inspection: CCD press-fit + continuity/withstand-voltage; Traceability: supported

• Automotive central electrical box / fuse box assembly
• Relay insertion and electrical performance testing
• Vehicle harness power distribution module production

It integrates injection molding machines and robots together with precision bending, blanking and injection molds to achieve automated insert molding integration, delivering efficient, flexible mass production and guaranteeing product consistency.

Cycle time CT: 0.9 s/pcs; Yield: ≥99.5%; OEE: ≥85%; Changeover time: ≤15 min; Core process: precision bending/blanking + insert molding; Inspection: post-molding full check

• Insert injection molding for automotive-grade board-end connectors
• Mass production of PCB board-end connectors
• Flexible mixed-model production of multiple connector types

It adopts a carrier circulation conveying form, is compatible with various products, supports digital communication and uses a modular design to achieve automated assembly and testing of board-end connectors with non-injection molding processes.

Cycle time CT: 0.9 s/pcs; Yield: ≥99.5%; OEE: ≥85%; Changeover time: ≤15 min; Conveying: carrier circulation; Inspection: CCD vision + insertion-in-position + electrical

• Non-injection molded board-end connector assembly
• Flexible assembly line compatible with multiple product models
• Production lines requiring full product data traceability

Based on the Harmontronics self-developed HDC platform and equipped with automated standard process modules, it realizes full-line automation of coaxial harness stripping, crimping, assembly and electrical performance testing.

Cycle time CT: 0.9 s/pcs; Yield: ≥99.5%; OEE: ≥85%; Platform: self-developed HDC; Core process: stripping/crimping/assembly/testing; Harness type: FAKRA/Mini-FAKRA

• Automotive coaxial harness (FAKRA / Mini-FAKRA) processing
• High-frequency signal harness assembly and testing
• Smart cockpit and ADAS camera harnesses

Assembly and testing equipment for automotive Ethernet harnesses (100/1000BASE-T1, etc.). The official website states that single-side and double-side semi-automatic as well as fully automatic equipment configurations are available.

Cycle time CT: 0.9 s/pcs; Yield: ≥99.5%; Form: single/double-side semi-auto + fully auto; Core process: stripping/braid/terminal crimp/shield-ring press; Test: continuity + high-frequency

• Automotive Ethernet harness processing and assembly
• Dedicated lines for high-speed data transmission harnesses
• Domain controller / gateway connection harnesses

A fully automated airbag harness production line with full-process assembly and electrical performance testing. It adopts carrier circulation conveying, is compatible with various products, and reinforces the bottom line of automotive safety.

Cycle time CT: 0.9 s/pcs; Yield: ≥99.5%; OEE: ≥85%; Conveying: carrier circulation; Core process: squib terminal crimping + sealing; Test: continuity + high-voltage insulation

• Automotive airbag (SRS) harness production
• Seat belt pretensioner squib harnesses
• High-reliability harnesses for occupant restraint systems

A standard standalone machine for cable end processing, used to strip the outer jacket / insulation layer of coaxial cables and provide pre-processing for the subsequent crimping and insertion operations.

Strip diameter: 1~8 mm; Blade/fixture change: none required; Platform compatible: HDC; Integration: automated lines; Cable type: coaxial

• Coaxial cable outer jacket stripping pre-processing
• Ethernet / high-frequency harness processing
• Trial production and mass production with flexible switching between multiple wire diameters

A standard standalone terminal crimping machine, compatible with common mechanical or pneumatic universal crimping tools, and supporting force and displacement process monitoring.

Crimping force up to 20KN; compatible with common mechanical or pneumatic universal crimping tools; can be integrated with the HDC platform and standard process modules of the complete line (as described on the official website).

• Automotive harness terminal crimping
• High-voltage / large cross-section terminal crimping
• Standard crimping station in harness mass production lines

A standard standalone wire pay-off and feeding machine that provides stable pay-off and tension control for heavy-tonnage wire reels, continuously feeding the entire line.

It can handle wire reels weighing up to 400 kg and cables with a diameter of 1-6 mm; it can be integrated with the HDC platform and automated lines (as described on the official website).

• Wire pay-off feeding before automotive harness production
• Stable tension pay-off of large-tonnage wire reels
• Supporting equipment for coaxial and Ethernet harness lines

Designed for high-volume production of automotive low-voltage harness connectors, it adopts a flexible modular design that integrates component feeding, precision assembly, performance testing and data traceability.

Cycle time CT: 0.9 s/pcs; Yield: ≥99.5%; OEE: ≥85%; Changeover time: ≤15 min; Core process: precision assembly + CCD + continuity/withstand; Traceability: supported

• Mass production of automotive low-voltage harness connectors
• Flexible connector assembly with multiple models on a shared line
• Tier 1 production lines requiring full-process data traceability

A high-precision assembly and signal performance testing solution for automotive-grade high-speed communication connectors, meeting the stringent requirements of high-speed communication transmission.

Changeover time: ≤15 min; Yield: ≥99.5%; Core process: shield/terminal precision assembly; Test: signal integrity SI + full HF check; Design: modular flexible; Applicable: FAKRA/HSD/Ethernet

• Assembly of automotive high-speed data connectors (FAKRA/HSD/Ethernet)
• Mass production of intelligent driving domain controller high-speed interconnect products
• Full high-frequency signal performance inspection lines

A high-precision assembly solution for high-voltage connectors of new energy vehicles, which also carries out dedicated withstand-voltage and insulation testing to ensure the safety and reliability of the complete vehicle high-voltage system.

Detailed technical specifications are not published on the official website; the core processes include high-voltage terminal crimping (crimping force up to 20KN with the standard standalone machine configuration), shielding ring press-fitting, seal assembly, and dedicated withstand-voltage and insulation resistance testing; typical line indicators are yield >=99.5%, OEE >=85%, CT 0.9s/pcs (subject to the project proposal).

• Production of high-voltage connectors for new energy vehicles
• High-voltage interconnection components for battery packs / e-drives
• High-voltage harness assemblies for charging interfaces

For products such as harness-free wheel speed sensors, it performs precision assembly of magnets, housings and other parts, integrating assembly and functional testing in one line to achieve stable batch delivery.

Detailed technical specifications are not published on the official website; the core processes include precision assembly of magnets / coils / housings, welding, dispensing and curing, and functional testing of sensing gap and output signal; typical line indicators are CT 0.9s/pcs, yield >=99.5%, OEE >=85% (subject to the project proposal).

• Mass production of wheel speed (ABS) sensors
• Assembly of harness-free conventional automotive sensors
• Full functional inspection of position / speed sensors

Realises fully automatic assembly, dispensing and screw locking of radar circuit boards, housings and RF components, and covers high/low temperature and RF performance testing to meet the mass-production requirements of intelligent driving sensors.

Detailed technical specifications are not published on the official website; the core processes include radar PCBA loading and assembly, precision housing alignment, dispensing and torque-controlled screw tightening, air-tightness / high-low temperature cycling tests and radio frequency (RF) performance testing; flexible changeover between multiple models is supported (subject to the project proposal).

• Mass production of millimeter-wave radar sensors
• Assembly and testing of intelligent driving perception components
• Production lines for cockpit / parking radar modules

A coil-type automated production line under the comprehensive product line, completing coil winding, component press-fitting, welding and resistance/inductance performance testing.

Detailed technical specifications are not published on the official website; the core processes include automatic winding, press-fitting of the coil with the bobbin and magnet assembly, welding, and full inspection of resistance and inductance performance; it is a one-stop high-speed precision assembly solution (energy consumption / cycle time indicators are subject to the project proposal).

• Production of coils for ABS wheel speed sensors
• Winding and assembly of solenoid valve / actuator coils
• Production lines for automotive-grade inductive components

An integrated assembly and testing solution that realises automatic assembly of automotive fuse parts, fuse-element welding and full inspection of continuity and current-withstand performance.

Detailed technical specifications are not published on the official website; the core processes include loading and assembly of fuse tubes / terminals, automatic fuse-element welding, CCD appearance inspection, and full inspection of continuity and current-withstand performance; full line data traceability is supported (subject to the project proposal).

• Mass production of automotive-grade fuse devices
• Welding and selection testing of fuse components
• Production lines for power distribution protection devices

Completes the press-fitting of sealing rings and locking assembly of fluid pipe fittings, and integrates air-tightness and pressure-resistance testing; suitable for automotive thermal management and fluid pipeline components.

Detailed technical specifications are not published on the official website; the core processes include automatic loading and press-fitting of sealing rings, assembly of locking clips / retaining springs, air-tightness (leakage) testing and pressure-resistance TEST; it is a one-stop high-speed precision assembly solution (subject to the project proposal).

• Production of quick connectors for automotive thermal management pipelines
• Connector assemblies for cooling system water pipes
• Production lines for fluid components with full air-tightness / pressure-resistance inspection