Cable Harnessing Process – How To Improve in Quality and Productivity

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Cabinet CablingIn the Cable Harnessing Process, there are several steps such as Cable Cutting, Stripping, Crimping, Looming and Assembling (Tightening).

Today, most harnessing process are still done manually.

With a manual process, we will need more people, time and quality is also a concern due to human error.

Cable Connections

To improve this process, Phoenix Contact can now offer you solutions in Cutting, Stripping and Crimping with Automated Machines.

Manual VS Automated

Cutting Process

In a manual process, the operator will have to measure the cable length and cut by hand.

It’s fine for small number of cable, but can you imagine if the operator needs to measure hundreds, if not thousands of cables of the same length. There will invariably be inconsistency of lengths during the measurement and the cutting process.

Phoenix Contact's Automated tool Cutfox 10


To address this, Phoenix Contact has a solution with the CUTFOX 10. You only need to input the length and quantity of cables and this machine will measure and cut automatically; precisely with expected length and quantity. So the operator can leave the machine and do other process.

Stripping Process

Stripping process looks simple and not critical, but this process will affect to crimping result.

With manual stripping, normally we do not pay attention with the length of the insulation we need to strip.

If the stripping is too long, the wire will be showed outside the cable lug insulation.

And if the stripping too short, the cable lug will not crimp the wire in crimping area properly.

Phoenix Contact's Automated Tool - WF 1000

WF 1000

WF 1000 is the solution for this stripping process.

We can set precisely the stripping length, cable size and stripping mode.

With 0.3s stripping process, we can boost the output yet maintaining high quality.

Crimping Process

Crimping is the most critical process where it will affect the connection between the cable and crimped connector.

With manual crimping, crimping results defer from operator to the operator.

Stability and consistency will depend on the individual operator.

Phoenix Contact is able to provide this consistency though automated crimping machines for  cable lugs, ferrules, and other crimped connectors.

Phoenix Contact's CF 500 Crimping Machine Phoenix Contact's CF 3000 Crimping Machine Phoenix Contact's CF 1000 Crimping Machine
CF 500 CF 3000 CF 1000

These machines will produce fast, consistent and high quality crimping.

Cable harnessing process setup

This cable harnessing process setup was created for one of our customers and it has increased their productivity and quality tremendously compared to the manual process.

If you would like more information and support, please contact email me at witonosurya@phoenix and I will get back to you as soon as I can.



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