JMK develops customized wire harness equipment for specialized processing requirements that cannot be fully covered by standard machines. Based on the customer’s wires, terminals, seals, connector housings and finished harness samples, we can combine multiple processing stations into a coordinated automation solution.
Our custom wire processing machines cover connector housing insertion, terminal crimping, wire cutting and stripping, tin dipping, seal insertion, tube processing, glue dispensing, ultrasonic welding and inspection. Solutions range from an individual customized workstation to a complete automatic production line for complex wire harness assemblies.
A standard wire processing machine is suitable when the wire, terminal and production sequence remain relatively simple. More complex harnesses may involve multiple wire colors, different terminals, non-standard connector housings or several secondary processes.
JMK evaluates the complete manufacturing sequence before determining how the required functions should be integrated. Depending on the application, a customized production system may combine:
Wire feeding and fixed-length cutting
Single-end or double-end stripping
Single-end, double-end or multi-station crimping
Waterproof seal insertion
Wire twisting and tin dipping
Number tube or heat-shrink tube insertion
Tube marking and identification
Glue dispensing
Ultrasonic welding
Connector housing insertion
CCD visual inspection
Crimp force monitoring
Automatic alarms and defective-product separation
Connector assembly becomes more difficult when a harness includes multiple wire colors, terminals, connector types or cavity positions. Our customized connector housing insertion systems are designed around the actual harness structure and required insertion sequence.
Available configurations include:
Single-end housing insertion
Double-end housing insertion
Multiple connector housing processing
Multi-wire and multi-color insertion
Pin insertion combined with tin dipping
Terminal welding and housing insertion
Ultra-short wire processing
Three-ended crimping and housing insertion
Number tube processing before connector assembly
The JM-800, for example, is designed for automated processing involving multiple connector housings. Other configurations combine tin dipping, terminal crimping, tube processing or welding with connector insertion.
View our connector housing insertion machines for available configurations.
Not every harness requires connector housing assembly. Some projects need a dedicated combination of cutting, stripping, twisting, tinning, crimping, seal insertion, tube insertion or glue dispensing.
Our customized wire processing machines include solutions such as:
FAKRA and Ethernet connector production lines
Tube insertion and glue dispensing machines
Double-end wire tinning machines
Waterproof seal insertion and crimping machines
Cutting, stripping, twisting and seal insertion systems
Multi-process terminal crimping equipment
Each machine is configured according to the actual wire specification, processing sequence and finished-product requirements.
FAKRA and Ethernet harness assemblies involve connector-specific processes that may not be suitable for general-purpose terminal machines. JMK develops automatic production lines that coordinate the required wire preparation, connector processing and inspection stations.
Before designing the line, our engineering team reviews the cable type, connector components, assembly sequence, inspection requirements and target cycle time. Modular station design allows the production process to be arranged according to the actual harness rather than forcing the product into a fixed machine layout.
A customized wire harness machine should accommodate the required process without making operation and maintenance unnecessarily complex. We use modular station layouts so individual functions can be selected and arranged around the production sequence.
Depending on the project, modules may include:
Wire feeding and straightening
Cutting and stripping
Terminal crimping
Seal insertion
Tube feeding and marking
Tin dipping
Ultrasonic welding
Glue dispensing
Connector housing insertion
CCD inspection
Crimp monitoring
Finished-product collection
This modular approach also makes it easier to evaluate future process extensions when the product design or production requirement changes.
Inspection requirements should be determined according to the harness application, failure risks and customer acceptance standard. Selected customized systems can integrate monitoring and inspection modules within the production sequence.
Available options may include:
CCD visual inspection
Crimp force monitoring
Wire presence detection
Terminal position inspection
Connector housing insertion verification
Material shortage detection
Process alarms
Defective-product separation
The exact inspection scope depends on the wire, terminal, connector and measurable product characteristics. Inspection functions and acceptance criteria should therefore be confirmed during the technical evaluation stage.
JMK customized wire harness equipment can be developed for manufacturers serving:
Automotive wiring harnesses
New energy vehicle systems
FAKRA and automotive Ethernet connections
Energy storage equipment
Household appliances
Industrial control systems
Consumer electronics
Photovoltaic equipment
Telecommunications equipment
The final equipment configuration is determined by the actual harness structure rather than the industry name alone.
We review the wire, terminal, seal, connector housing, finished harness sample and production requirements provided by the customer.
Our engineering team separates the harness assembly into individual operations and evaluates which steps can be automated reliably.
We define the required processing stations, material-feeding methods, control logic, inspection modules and operator tasks.
Actual customer materials are used to validate critical processes such as stripping, crimping, sealing, tinning, welding or housing insertion.
After the technical solution is confirmed, the machine is assembled, programmed and tested according to the agreed process.
We provide commissioning guidance and operator training to support production launch. Learn more about our customization and technical services.
To evaluate a customized wire harness automation project, please provide:
Wire or cable specifications
Required wire lengths and tolerances
Terminal drawings and physical samples
Seal, tube and connector housing samples
Finished harness drawings or samples
Required processing sequence
Target production capacity
Inspection and acceptance requirements
Available factory space
Power and air supply conditions
Required changeover frequency
Complete material and process information allows us to evaluate technical feasibility and prepare a more accurate equipment proposal.
With nearly 20 years of experience in wire harness processing automation, JMK combines in-house engineering, modular machine design and wire processing experience to develop non-standard equipment for complex harness production.
We support projects from initial process evaluation and sample testing through system configuration, manufacturing, commissioning and operator training. Our goal is to provide a practical automation solution that matches the customer’s actual materials, required processes and production capacity.
Customized equipment is usually required when a standard machine cannot process the specific combination of wires, terminals, seals, tubes, connector housings or secondary operations used in the finished harness.
Depending on technical feasibility, the system may combine cutting, stripping, crimping, seal insertion, tube processing, tin dipping, welding, glue dispensing, connector insertion and inspection.
Yes. Physical samples of the wire, terminal, seal, tube, connector housing and finished harness help us evaluate feeding, positioning, processing and inspection requirements.
Yes. Multi-connector processing can be evaluated according to the connector structures, cavity arrangements, feeding methods and required changeover process.
These modules can be integrated into suitable projects. The inspection items, measurable defects and acceptance criteria must be confirmed during technical evaluation.
In some cases, a standard platform can be expanded with additional modules. For more complex processes, a new customized system may provide better stability and accessibility.
The project schedule depends on process complexity, material readiness, sample testing, machine configuration and acceptance requirements. A schedule can be provided after the technical evaluation is completed.
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