Cellios Developed Automated Wire Harness Assembly System
The robotic platform addresses geometric cable deviations using machine vision and sensor-monitored precision.
Updated on Sept. 30, 2026 in Robotics
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Cellios GmbH has developed a new robotic system designed to automate complex wire harness assembly tasks, including crimping, routing, and testing. This announcement-stage technology utilizes integrated machine vision to account for the unpredictable physical structure of cables.
Why it matters
The system solves a common manufacturing bottleneck where preprogrammed robot paths fail due to the flexible, non-rigid geometry of cables. By automating this process, the development seeks to improve consistency in tasks that traditionally required manual intervention.
The system achieves 0.1-millimeter insertion accuracy by using 2D cameras paired with MVTec MERLIC software to dynamically calculate crimp positioning. A force-torque sensor continuously monitors insertion levels to adjust movement and ensure components seat correctly.
The players
Cellios GmbH
An engineering firm focused on developing automated manufacturing solutions for electrical harness assembly.
TE Connectivity
A global industrial technology company that designs and manufactures sensors and connectors for harsh environments.
MVTec Software GmbH
A software company specializing in machine vision components and image processing algorithms for industrial automation.
The details
The robotic cell coordinates Kuka six-axis robots and Omron SCARA (Selective Compliance Assembly Robot Arm) robots to perform singulation, taping, and end-of-line testing. Because cable structures naturally deform, the system uses its machine vision software to perform real-time orientation corrections. The force-torque sensor acts as a tactile feedback loop, allowing the system to detect resistance during assembly and adjust pressure to prevent damage during the insertion process.
Timeline
September 2026: The robotic assembly system was announced.
Early 2027: Commercial launch of the robotic system is planned.
The Tech Race
Most current wire harness assembly relies on static, preprogrammed robot movements that often fail to account for the loose, flexible nature of cabling. By integrating vision and force sensing, this platform shifts the field toward autonomous, adaptive assembly lines.
The technology is intended for industrial manufacturing environments, with commercial availability currently slated for early 2027. Once launched, it will likely target manufacturers looking to replace manual assembly workflows in cable routing and end-of-line testing.
The takeaway
This development highlights the industry shift toward using sensor fusion to handle flexible materials that frustrate legacy automation. Interested users should monitor the company's announcements for the planned commercial launch date in early 2027.
What happens next
Cellios GmbH has indicated plans to expand the system functionality to include control cabinet wiring and automated quality inspection by early 2027.
Further reading
For broader trends in adaptive manufacturing, see the Robotics section.
Source note: This article includes information reported by Assembly Magazine.
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