JMK customized wire processing machines are developed for specialized wire harness processes that cannot be efficiently completed by standard cutting, stripping or crimping equipment. We configure individual processing stations or integrated production lines around the customer’s actual wires, terminals, seals, tubes, connectors and finished harness requirements.
Available solutions cover terminal crimping, wire twisting, tin dipping, waterproof seal insertion, tube processing, glue dispensing and connector-specific production. We also develop automatic lines for FAKRA and Ethernet cable assemblies.
Wire harness manufacturers often need to combine several secondary processes after cutting and stripping. Performing each process on a separate machine increases material transfers, work-in-process inventory and dependence on manual operation.
Our custom automated wire harness equipment can integrate compatible processes into a coordinated production sequence. Depending on the application, the system may include:
Wire feeding and fixed-length cutting
Single-end or double-end stripping
Wire twisting
Single-end or double-end tin dipping
Terminal crimping
Waterproof seal insertion
Number tube or heat-shrink tube processing
Tube insertion and glue dispensing
Ultrasonic wire welding
Connector housing insertion
CCD visual inspection
Crimp force monitoring
Automatic alarms and defective-product separation
The final machine layout is determined after reviewing the complete harness assembly process and testing the customer’s materials.
Automotive FAKRA and Ethernet cable assemblies involve connector-specific preparation, assembly and inspection steps. These requirements usually cannot be handled by a general-purpose terminal crimping machine.
The JM-900 FAKRA/Ethernet automatic production line is designed around the required cable and connector assembly process. Depending on the project, individual stations can be configured for cable preparation, component feeding, connector assembly and process inspection.
Before developing the production line, we evaluate:
Cable type and dimensions
Connector components
Shielding and preparation requirements
Assembly sequence
Process tolerances
Required inspection items
Target cycle time
Product changeover requirements
This allows the equipment to be configured around the actual connector and production process rather than a fixed standard-machine structure.
Certain wire and terminal assemblies require protective tubes, sleeves or controlled adhesive application. These operations can be difficult to complete consistently through manual handling.
The JM-228 automatic tube insertion and glue dispensing terminal crimping machine combines tube processing, glue dispensing and terminal crimping within one system. Integrating these operations helps reduce manual transfers and maintain a more repeatable application sequence.
The applicable tube material, tube dimensions, adhesive properties, dispensing volume and curing requirements should be reviewed before equipment configuration.
Wire tinning is used when a stripped wire end must be prepared for soldering or downstream electrical assembly. Manual tinning can create variation in exposed length, solder coverage and finished wire appearance.
The JM-07 double-end tinning machine automates wire preparation and tin dipping at both wire ends. Depending on the project, tinning may also be combined with:
Wire cutting
Wire stripping
Wire twisting
Single-end terminal crimping
Waterproof seal insertion
Connector housing insertion
The appropriate tinning process depends on the conductor size, exposed length, solder specification and finished harness requirements.
Waterproof wire harnesses require the seal to be positioned correctly before the terminal is crimped. Incorrect seal orientation or placement can interfere with crimping and connector assembly.
JMK provides customized machines that integrate wire cutting, stripping, waterproof seal insertion and terminal crimping.
The JM-555A supports single-end or double-end waterproof seal threading and crimping configurations. The JM-560 combines wire cutting, stripping, twisting and waterproof seal insertion for multi-process harness production.
Available functions may include:
Single-end seal insertion
Double-end seal insertion
Wire twisting before crimping
Single-end or double-end terminal crimping
Seal presence detection
Terminal presence detection
Optional crimp force monitoring
Optional CCD visual inspection
Seal compatibility should be evaluated using actual wire, terminal and waterproof seal samples.
A customized wire processing machine does not need to include every available function. Unnecessary stations can increase equipment complexity and make operation, maintenance and changeovers more difficult.
We select modules according to the required production sequence. A customized system may contain:
Wire feeding station
Cutting and stripping station
Wire twisting station
Seal insertion station
Terminal crimping station
Tube feeding or marking station
Tin dipping station
Ultrasonic welding station
Glue dispensing station
Visual inspection station
Finished-product collection station
This modular approach allows the equipment to focus on the processes that directly affect the finished harness.
Quality-control functions should be configured according to the product risks and measurable defects. Selected customized wire processing machines can integrate inspection or monitoring modules within the production sequence.
Available options may include:
Crimp force monitoring
CCD visual inspection
Wire presence detection
Terminal presence detection
Seal presence and position inspection
Material shortage alarms
Processing parameter monitoring
Defective-product separation
Where production data exchange or factory-system connectivity is required, the communication method and data fields must be evaluated as part of the customization project.
Our customized wire processing machines can be developed for harnesses and cable assemblies used in:
Automotive electrical systems
FAKRA and automotive Ethernet connections
New energy vehicles
Energy storage equipment
Household appliances
Industrial control systems
Consumer electronics
Photovoltaic equipment
Telecommunications equipment
The final machine configuration depends on the wire harness process and materials rather than the application industry alone.
We review the wire, terminal, seal, tube, connector and finished-product samples together with the required production sequence.
Our engineering team evaluates material feeding, cutting, stripping, crimping and secondary processing requirements.
We determine the necessary stations, control logic, inspection modules and operator tasks.
Actual customer materials are tested to verify critical processes such as stripping, crimping, seal insertion, tinning, welding or glue dispensing.
The machine is assembled and programmed according to the confirmed technical solution, followed by processing and acceptance testing.
We provide commissioning guidance and operator training to support the transition from equipment acceptance to regular production.
Learn more about JMK customization and technical services.
Please provide the following information when requesting a customized wire processing machine:
Wire or cable specifications
Required processing lengths and tolerances
Terminal drawings and physical samples
Waterproof seal samples
Tube or sleeve specifications
Adhesive or solder requirements
Connector drawings and samples
Finished wire harness drawings
Required processing sequence
Target production capacity
Inspection requirements
Product changeover frequency
Complete samples and process information help us determine whether an existing machine can be adapted or a new customized system is required.
With nearly 20 years of experience in wire harness processing automation, JMK develops equipment for standard terminal processing and specialized non-standard production.
We support customers from sample review and process planning through equipment configuration, manufacturing, commissioning and operator training. Our engineering approach focuses on combining the necessary processes into a practical machine while maintaining accessibility for operation, changeovers and maintenance.
It is a machine configured around a specific combination of wires, terminals, seals, tubes, connectors and processing steps that cannot be handled efficiently by standard equipment.
Depending on technical feasibility, the machine can integrate cutting, stripping, twisting, crimping, seal insertion, tube processing, tin dipping, welding, glue dispensing and inspection.
Yes. JMK provides connector-specific automatic production solutions for FAKRA and Ethernet cable assemblies.
Yes. Selected configurations can crimp a terminal at one wire end while twisting or tin-dipping the other end.
Yes. Single-end and double-end waterproof seal insertion can be integrated with cutting, stripping and terminal crimping.
These functions are available for selected machines or as optional modules. Their suitability depends on the product and required inspection criteria.
Data connectivity can be evaluated for customized projects. The required communication protocol, data fields and factory system must be confirmed before development.
Please provide the wires, terminals, seals, tubes, connectors and finished harness samples, together with drawings and production requirements.
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