Cellios Developed Automated Wire Harness Assembly System
The new robotic platform combines machine vision and sensors to improve precision in complex cable assembly tasks.
Updated on Sept. 30, 2026 in Robotics
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Cellios GmbH has unveiled a new robotic system designed to automate the assembly of wire harnesses. The platform utilizes advanced machine vision and specialized sensors to manage tasks like crimping and cable routing with high precision.
Why it matters
The system addresses the significant challenge of geometric deviations caused by the flexible nature of cables, which previously made preprogrammed robotic assembly unreliable.
The system integrates Kuka six-axis robots with Omron SCARA units to handle connector singulation and taping. It achieves 0.1-millimeter insertion accuracy by using MVTec MERLIC software for real-time image processing and correction.
The players
Cellios GmbH
This engineering firm specializes in developing robotic automation solutions for industrial assembly applications.
TE Connectivity
This global technology company designs and manufactures connectivity and sensor solutions for various industries.
MVTec Software GmbH
This company provides machine vision software and image processing technology used in automated manufacturing.
Kuka
This major global manufacturer produces industrial robots and systems for various automotive and industrial sectors.
Omron
This multinational electronics company develops and manufactures control equipment, factory automation systems, and electronic components.
The details
By utilizing two 2D cameras and force-torque sensors, the robot can calculate precise crimp positions and adjust for insertion forces during assembly. This technology replaces older methods that relied on rigid, preprogrammed paths that often failed to account for flexible cable geometry.
Timeline
The system is scheduled for a commercial launch in early 2027.
The Tech Race
This development signals a shift in the robotics sector from static, preprogrammed automation to dynamic, sensor-driven assembly lines. It places Cellios alongside major automation providers by solving the fundamental issue of component flexibility in hardware production.
The transition to automated wire harness assembly will likely improve quality control and efficiency for electronics and automotive manufacturers. This could lead to more reliable vehicle and appliance electronics for consumers as assembly errors are reduced.
The takeaway
Automating flexible component assembly is a critical step for manufacturers seeking to reduce human-error-related failures in electronic systems. Companies are increasingly moving toward vision-based corrections to handle complex tasks that were previously too imprecise for standard robots.
Further reading
For more information on the latest industrial developments, visit the Robotics section.
Source note: This article includes information reported by Assembly Magazine.
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