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Wiring Harness Channels

A plastic molder of automotive wiring harness channels had been faced with the task of installing multiple Compression Limiters into irregular shaped components. In total, there were four different components - each containing between two and six SPIROL® Series CL6000 Aluminum Compression Limiters. The irregular shape and thin walls of the wiring harness posed a fixturing and installation challenge for the customer. The wiring harness was not only irregular in shape, but the Compression Limiter installation heights varied within the part. The previous method of assembly was manual with the operator placing and hammering each Compression Limiter into place. The manual process was slow, it was difficult to ensure proper alignment of the Compression Limiter with the hole, and the scrap levels were unacceptable.

SPIROL Engineers reviewed their installation process and recommended the Model CL Compression Limiter Installation Machine. The Model CL was designed with multiple fixture cavities. Each cavity accommodates and securely holds the harness channels at the proper height and orientation for Compression Limiter installation. The operator simply loads the wiring harness assembly into the proper fixture location using the fixture cut-out as a guide. Each installation hole is loaded over a guidepost to ensure proper hole location, alignment and support throughout the installation process. The operator then manually loads a Compression Limiter onto each post. Once all components are loaded, the fixture plate is moved into the work zone and locks in place. The machine is activated and the top platen advances downward simultaneously installing all Compression Limiters. Upon verification that the installation cycle has completed and all Compression Limiters are sensed as installed, the machine retracts, the fixture is unlocked and the completed assemblies removed.

SPIROL delivered the complete assembly solution by providing the Compression Limiters and Installation Machine. The Model CL significantly increased productivity, improved product quality, and eliminated scrap associated with the customers original manual installation process.

Complimentary Applications Engineering Support: SPIROL Engineers will review your application needs and work with your design team to recommend the best solution.