AMWire
Project challenges
Wiring electrically connects everything together and makes it work, it is one of the last parts of the manufacturing process that is still largely done by hand. It is a labour-intensive and costly process that is prone to error.
Business challenge
Product Innovation
Sector
Road & Rail
Technology or capability
Digital Manufacturing
Additive Manufacturing
Automation & Robotics
Project Challenges
Wiring electrically connects everything together and makes it work, it is one of the last parts of the manufacturing process that is still largely done by hand. It is a labour-intensive and costly process that is prone to error. Harnesses are laid up and terminated on pin-boards, by skilled workers, often in low-wage economies. They are then packaged and shipped to the OEM where they are assembled into the product, again by hand.
Q5D have developed an automated solution for these two processes, providing increased productivity and reduced manufacturing costs, making it possible to onshore manufacture of wiring looms, reducing the complexity of the supply chain and improving resilience.
Sophisticated software and interfaces must be developed to operate and integrate the hardware with 3rd party systems and the workflow from design to manufacture requires simplification before they can be released to non-expert customers.
MTC's Solution
- The IUK funded project, AMWire aimed to mature the hardware and software interfaces of Q5D’s CY10 platform.
- MTC provided expertise for integration of the platform with industry standard robotics and manufacturing execution systems in production environments.
- Further guidance was given on integrating metrology and NDT solutions into the equipment for part measurement and post-build validation, cyber security and data interfaces for advanced analytics.
- The MTC leveraged parts of its membership to provide industry steer on topics including part design, machine integration and future applications.
- An industry day was hosted as part of AMWire to raise awareness of structural & printed electronics within UK manufacturing.
Having the CY10 work in a simulated factory environment is a significant milestone for Q5D. It brings us another step closer to our vision of transforming the way products are made by automating wire harness assembly, something no one has previously achieved. Working with the MTC has enabled us to demonstrate our systems are ready to integrate into the latest factory environments.
Simon Baggott, Q5D
The Outcome
- Thanks to MTC, Q5D’s CY10 platform now has enhanced connectivity for seamless integration with industry standard production environments.
- Successful installation of the Q5D CY10 at the MTC facility and integration of robot for part loading and unloading demonstrates the improved functionality of the platform enable by the AMWire project.
- Adoption of robotic wire harness manufacturing could enable improved quality, better process control, lower costs and the ability to onshore manufacture back to the UK for complex wiring assemblies.
- Greater industry awareness of robotic wire harness manufacturing processes and the benefits they can bring for UK industry.
Benefits to the Client
- Improved product offering for integration of the CY10 platform into production environments and with advanced Industry4.0 systems.
- Experience of implementing the CY10 machine into a representative factory production environment, improving future installations and on-going support.
- Valuable industry steer on the development of the CY10,benefitting from The MTC membership and network.
- Industrial showcase day, demonstrating the CY10 with robot integration to a wide range of potential customers interested in robotic assembly of wiring, representing a wide range of industries.
