The consortium aims to establish a fully digital process chain for automating wiring harness manufacturing. The starting point is a standardized KBL file in XML format, containing all geometric and topological information about the wiring harness. This data is processed automatically, converted into suitable data models, and prepared for robotic assembly planning.

This creates a seamless data flow – from product specification to physical execution on the robot. The approach includes, among other things, automated motion planning, kinematic calculations, trajectory optimization, and collision detection in virtual space. Manufacturing-related tolerances of flexible cables are taken into account using advanced image processing. The integrated robot toolbox automatically calculates all motion sequences, enabling variant-specific adjustments without manual reprogramming.

This article demonstrates how digital product data can not only be documented but also used directly for automated process generation. This creates a seamless connection between development, planning, and manufacturing, significantly improving consistency, traceability, and automation.

The Kitzingen Technology Transfer Center of THWS, the Institute of Aircraft Design at the University of Stuttgart, and Ravensburg-Weingarten University of Applied Sciences are involved. Together, the partners are pooling their expertise in robotics, artificial intelligence, model-based development, lightweight construction, and production technology.

For more information, please visit: www.thws.de | www.ifb.uni-stuttgart.de | www.rwu.de