Agile Robots SE is a leading provider of next-generation automation solutions. By combining artificial intelligence and robotics, the company makes industries smarter, more flexible, and more efficient. Founded in 2018 by renowned robotics researchers at the German Aerospace Center (DLR) in Munich, Agile Robots is growing rapidly worldwide. Currently, more than 2.300 highly qualified robot and AI enthusiasts work at locations in Germany, China, and India. The company employs one of the largest research and development teams in the AI ​​and robotics industry. Agile Robots has a unique portfolio. Together with its subsidiaries Franka Robotics, BÄR Automation, and audEERING, as well as idealworks, a joint venture with BMW, the company covers all areas of AI-controlled robotics.

Solution / Demonstrator
The robot demonstrator presented here demonstrates how complex processes in wiring harness assembly can be automated. The core of the system is a generic setup with two Agile Robots Diana7 robots, equipped with parallel grippers, 2D cameras, and force-torque sensors. Central control via AgileCore enables synchronous coordination of the robots and the connection of external devices. Of particular note is the use of AI-based algorithms for precise crimp alignment. Together with the sensors, force-controlled and reliable connector assembly is achieved – a process that was previously difficult to automate. An AGV (Automated Guided Vehicle) allows the setup to be flexibly integrated into existing production lines. The modular architecture allows for easy adaptation and scaling to industrial applications.

Conclusion
As part of the challenge, extensible skills for wiring harness automation were developed, such as for benchtop calibration, cable routing, or inserting crimp contacts in connector systems. These skills can be executed reproducibly via AgileCore and are versatile in their application.

For more information about Agile Robots SE, please visit: www.agile-robots.com

The Chair of Manufacturing Automation and Production Systems (FAPS) at Friedrich-Alexander University Erlangen-Nuremberg is engaged in interdisciplinary research on innovative manufacturing processes. Around 100 academic staff from the fields of mechanical engineering, electrical engineering, and computer science work at the locations in Erlangen and Nuremberg. Research focuses on innovative robotics and automation solutions, novel assembly technologies for electrical energy storage devices, advanced processes in electronics and electrical machine production, technologies for electrified roads, and digitalization and automation solutions for signal and power networking. Modern machine and plant engineering covering approximately 2.500 m² enables the research, efficient implementation, and testing of new manufacturing processes for mechatronic components and systems.

Solution / Demonstrator
The demonstrator from the FAPS Institute showcases a robot-assisted system for automated cable harness assembly that performs all process steps without tool changes. Cables are fed via a linear axis, measured using a laser line scanner, and inserted into connector systems in the correct position. This specifically addresses the challenges of flexible cables with small cross-sections (up to 0,13 mm²). Forming gates for depositing the cables give the cable harness its geometry. Other functions such as closing the secondary locking mechanism, repositioning connectors, and applying cable ties are also automated. The demonstrator is complemented by a connection concept for existing assembly machines and a digital configurator for new cable harnesses.

Conclusion
The demonstrator demonstrates how modern automation technologies can be economically integrated into assembly processes. The solutions developed at FAPS are aimed primarily at the automotive industry and enable the sustainable implementation of complex mechatronic systems.

Further information about the FAPS Chair can be found at: www.faps.fau.de

The Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW) at the University of Stuttgart is one of the world's leading university research institutes in the field of control engineering. The ISW conducts interdisciplinary research into technologies for the production and automation of the future. Its guiding principle is the development and application of control engineering and other computer-aided systems for solving automation tasks. Research is divided into six research areas: drive systems and control, mechatronic systems and processes, virtual production, communications technology, engineering, and control engineering. For over 50 years, the ISW has been an innovative and reliable partner for industry, addressing demanding challenges from the initial idea to the final product.

Solution / Demonstrator
As part of the Robotics Challenge, the ISW developed an AI-supported method for manipulating deformable linear objects. Based on synthetic training data from the MuJoCo simulation environment, a neural network was trained to learn the deformation behavior of a cable. A bidirectional LSTM network is used as the dynamic model. The targeted shape change of the cable is achieved using a Model Predictive Path Integral (MPPI) controller, which extracts the optimal movement from stochastically generated robot trajectories. The method was validated both in simulation and practically with a Franka Emika Panda robot. The current cable geometry is recorded using a depth camera.

Conclusion
The presented solution enables machine-learning-based cable shaping, for example, for placement in cable receptacles. Virtual simulation also offers potential for process planning and stress analysis. Future technology transfer to industry is planned.

For further information about the ISW, please visit: www.isw.uni-stuttgart.de

Leverage Robotics is a spin-off of the German Aerospace Center (DLR). The company emerged from the Factory of the Future research program and is focused on developing flexible automation solutions for the production of the future. The focus is on highly flexible, intelligent plug-and-produce robot cells that enable more efficient production through short setup times in multitasking applications.

The specially developed robot tool technology enables the implementation of complex tasks in areas such as logistics, assembly, quality assurance, and especially in machine loading and start-of-line applications. The solution portfolio is complemented by multi-robot programming software with an integrated AI programming assistant, which enables easy implementation of complex applications even without programming knowledge. The goal is to support regional, flexible production approaches with short delivery routes.

demonstrator
As part of the challenge, Leverage Robotics presented the FactoryCube in combination with the RoboHive software solution as a demonstrator for automating tasks in the field of cable handling and connector assembly.

The FactoryCube is a modular, scalable system that combines various automation tasks into a single compact unit. The solution is designed to respond flexibly to changing production requirements, especially for sensitive components such as cables and connectors.

RoboHive extends the FactoryCube with a software platform featuring time-based, graphical programming via a drag-and-drop interface. This allows for visual planning of robot actions in terms of duration and completion time to avoid collisions and ensure smooth workflows. The software also uses large language models to translate natural language input into robot programs – even for users without in-depth technical knowledge.

Together, FactoryCube and RoboHive offer a flexible and powerful solution for automation tasks in wire processing, characterized by ease of use and adaptability.

Conclusion
FactoryCube and RoboHive impressively demonstrate how modern robotics solutions can simplify production processes while simultaneously optimizing their adaptability. Leverage Robotics offers interested partners from the cable processing industry practical, innovative robot solutions for the factory of the future.

For more information about Leverage Robotics, please visit: www.leverage-robotics.com

The Center for Robotics (CERI) at the University of Applied Sciences Würzburg-Schweinfurt combines teaching and application-oriented research in the field of intelligent robotics. Nine robotics professors, supported by laboratory staff, doctoral students, and master's and bachelor's students, are working on innovative solutions for production automation in interdisciplinary projects. A particular focus is on collaborative industrial robots, AI-supported image processing, and intelligent tool handling. Through close cooperation with industry, CERI enables rapid technology transfer and also serves as a starting point for new company start-ups.

Solution / Demonstrator
The developed demonstrator showcases a fully automated system for cable insertion in cable harness assembly. Using a deep learning algorithm for key point detection, the exact alignment of the cable is analyzed in real time. A vibration motor supports precise insertion into the connector and contributes to a significant reduction in cycle time. Force and torque sensors are also used to provide feedback on assembly success and adaptively adjust the robot's motion strategy.
Another highlight is the automated tool change: After the cable has been inserted, the robot exchanges its gripper for a clip gun and can thus carry out the entire assembly process autonomously – without human intervention or manual retooling.

Conclusion
The system impressively demonstrates how AI-based image processing and intelligent robotic handling can be combined to create a flexible, adaptive solution for wire harness assembly. The developed technologies make an important contribution to the automation of previously manual processes and offer great potential for industrial applications.

For further information about the CERI of the THWS, please visit: www.robotic.thws.de