JMK fully automatic wire harness housing insertion machines combine terminal crimping with controlled connector housing assembly, helping manufacturers reduce repetitive manual insertion and maintain consistent wire harness production.
Depending on the selected configuration, our equipment can complete wire feeding, fixed-length cutting, stripping, terminal crimping and single-end or double-end housing insertion within one production cycle. Additional functions such as waterproof seal insertion, tube processing, wire twisting, tinning and visual inspection can be configured for suitable applications.
Manual housing insertion depends heavily on operator skill, especially when a harness contains several wire colors, terminals or connector cavities. Incorrect terminal orientation, incomplete insertion and placement in the wrong cavity can lead to rework and downstream inspection costs.
Our automatic housing insertion machines coordinate wire processing, terminal crimping and connector assembly through a controlled production sequence. This reduces material transfers between separate workstations and supports repeatable batch production.
Typical processing functions include:
Automatic wire feeding and cutting
Single-end or double-end stripping
Single-end or double-end terminal crimping
Terminal orientation and positioning
Single-end or double-end housing insertion
Multi-color wire selection
Waterproof seal insertion
Optional CCD visual inspection
Automatic alarms and defective-product separation
JMK provides different configurations to match the structure of the finished wire harness.
Single-end housing insertion machines process and crimp both wire ends while inserting one end into a connector housing. These systems are suitable when the opposite end remains exposed, uses a different termination process or is assembled at another workstation.
Double-end housing insertion machines insert the processed terminals at both ends of the wire into their specified connector housings. This configuration reduces manual handling and is suitable for repeatable jumper wires and other double-ended harness assemblies.
Available configurations include:
Double-end crimping with single-end housing insertion
Double-end crimping with double-end housing insertion
Multi-wire and multi-color housing assembly
Variable-length wire processing
Connector-specific customized insertion systems
Integrated cutting-to-housing production lines
The JM-601B double-end crimping and single-end housing insertion machine completes fixed-length cutting, double-end stripping, double-end terminal crimping and single-end connector housing insertion.
It is suitable for wire harness structures where only one wire end needs to be inserted into a connector during the automated production cycle.
The JM-600 fully automatic double-end crimping and housing insertion machine integrates wire cutting, stripping, double-end terminal crimping and double-end connector housing insertion.
Customers who require crimping without automated housing assembly can view our automatic terminal crimping machines.
Reliable housing insertion begins with consistent wire feeding, accurate stripping and stable terminal crimping. Our machines use servo-controlled motion and coordinated feeding mechanisms to position wires and terminals throughout the production cycle.
After crimping, the terminal is aligned with the programmed connector cavity and inserted according to the configured assembly sequence. This helps reduce variation caused by repetitive manual placement.
Actual insertion speed, supported connector structure, wire range and number of wire colors depend on the selected model and project configuration.
Different wire harnesses require different inspection standards. Selected housing insertion machines can be equipped with quality-control modules according to the terminal, connector and production requirements.
Available options may include:
CCD visual inspection
Crimp force monitoring
Wire presence detection
Terminal position inspection
Housing insertion verification
Material shortage detection
Automatic fault alarms
Defective-product separation
CCD inspection can be configured to check selected terminal or connector characteristics. Crimp force monitoring helps identify abnormal changes during terminal crimping. The exact inspection items and acceptance criteria should be confirmed before machine configuration.
Wire harness designs vary in wire size, color, length, terminal type, seal structure and connector cavity arrangement. JMK can configure the machine around the customer’s actual materials and finished harness requirements.
Optional or customized processes may include:
Multiple wire colors
Different cutting lengths
Wire twisting
Tin dipping
Waterproof seal insertion
Heat-shrink tube processing
Number tube integration
Additional crimping stations
Single-end or double-end connector assembly
Customized inspection modules
For non-standard connectors or multi-process projects, we can develop customized wire harness processing equipment based on customer-supplied samples and technical requirements.
Our wire harness housing insertion machines can be configured for electrical connection products used in:
Automotive wiring harnesses
New energy vehicle systems
Energy storage equipment
Household appliances
Industrial control equipment
Photovoltaic systems
Consumer electronics
Telecommunications equipment
The appropriate machine should be selected according to the wire specification, terminal type, connector structure, cavity arrangement, processing sequence, target output and inspection requirements.
Before selecting a machine, the complete wire harness assembly process should be reviewed rather than evaluating only the connector housing.
Please provide the following information:
Wire size, color and cutting length
Stripping length
Terminal drawing and physical samples
Connector housing drawing and samples
Connector cavity arrangement
Waterproof seal requirements
Single-end or double-end insertion requirements
Expected production output
Required inspection functions
Finished wire harness drawings or samples
Our team will use this information to determine whether a standard machine can meet the application or whether a customized configuration is required.
With nearly 20 years of experience in wire harness processing automation, JMK develops standard equipment and customized production systems for terminal crimping and connector housing assembly.
We support customers through sample evaluation, process planning, machine configuration, commissioning and operator training. By evaluating actual wires, terminals, seals and connector housings, we can recommend equipment that better matches the required production process.
It is an automated system that inserts a crimped wire terminal into a specified connector housing cavity. Fully integrated machines may also complete wire cutting, stripping and terminal crimping before insertion.
Yes. Double-end housing insertion machines can process and insert both ends during the same production cycle. Single-end configurations are also available.
Selected models support multi-color wire feeding. The supported number of colors depends on the machine configuration and wire harness structure.
Connector compatibility depends on the housing dimensions, cavity structure, terminal orientation and feeding method. Connector drawings and physical samples are required for evaluation.
CCD inspection is available on selected machines or as an optional module. The inspection items should be confirmed according to the connector and quality standard.
Depending on the application, the machine may be configured with seal insertion, tube processing, wire twisting, tinning, additional crimping stations or customized inspection functions.
We recommend providing the actual wire, terminal, seal, connector housing and finished wire harness, together with drawings and the required production process.
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