: Warnecke, H.-J.; Emmerich, H.H.; Koller, S.

Abstract
The wire harness assembly process has not changed fundamentally for many years. All procedures except the pre-assembling of the individual wires are done by hand. The labor-costs of wiring are very high in comparison to the total costs of the assembly process. A pilot work station for the fully automated direct-assembly of wires into fluorescence lights has been developed. With the aid of a new connection technology and the help of an industrial robot and special tools the direct-assembly of individual wires into the light cases is possible. First test results show that the procedure of the direct-assembly works with a high availability and that this procedure is more cost effective in comparison to the traditional wiring harness assembly in many fields.