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The JM-700 High Voltage Wire Harness Production Line represents a fully automated, all-in-one processing solution engineered specifically for large cross-section cables. Moving beyond standard processing methods, this system fluidly integrates wire feeding, precise outer-stripping, wire number tube insertion, heavy-duty servo-driven terminal crimping, and heat-shrink tube positioning into a single, continuous workflow. Designed to handle the rigorous physical demands of thick, multi-layered cables, the equipment delivers exceptional consistency, eliminating the physical strain and variability typically associated with manual processing. Operators will notice the smooth, rhythmic operation of the synchronized modules, ensuring every harness produced meets strict electrical conductivity and mechanical pull-force standards. From the initial tactile grip of the feeding belts to the final heat application, every step is calibrated for maximum precision and reliability.
• Features a fully closed-loop flexible wire feeding system utilizing a specialized rubber belt mechanism. This design firmly grips heavy cables without marking or damaging the outer insulation jacket, enhancing feeding accuracy while preserving the tactile integrity and smooth finish of the wire surface.
• Incorporates a network-driven system to meet the rigorous industrial processing demands of photovoltaic wires. To ensure absolute compliance, the system supports real-time compression force monitoring and optional CCD visual inspection. Any deviation in pressure or placement triggers an immediate visual and auditory alarm, preventing defective products from progressing. It also supports MES network integration for comprehensive production traceability.
• Utilizes imported servo motor drives to ensure high precision, efficiency, and operational stability. The low-vibration motors provide a quiet, steady hum during operation, reflecting the exact mechanical tolerances achieved during high-speed production cycles.
• Runs on an industrial-grade computer operating system, offering a user-friendly and intuitive interface.
• Supports both manual and automatic debugging modes, making equipment setup faster and more efficient for operators managing frequent batch changes.
• Equipped with a servo-driven crimping system that maintains a stable compression ratio, fully meeting cross-sectional analysis standards. The system is highly adaptable, accommodating hexagonal, quadrilateral, and custom crimping applicators. Operators can execute rapid tooling changeovers to process a wide wire range from 2.5–300mm² for various non-standard terminals.
The following specifications detail the standard operational capacities of the JM-700. Our engineering team provides precise customization services, allowing modifications to the crimping force—ranging from 6T to 50T based on your specific terminal drawings and pull-force test requirements—ensuring the equipment perfectly matches your production demands.
Model | JM-700 High voltage wire Harness production line |
Capacity | Approx. 10s/pcs (at shortest tangent) |
Wire range | 2.5–300mm² (customizable) |
Cutting length | 400mm–4000mm |
Stripping length | 0–20mm |
Cutting precision | ±0.3%xL |
Crimp force | 20T servo crimping machine x2 (customizable) |
Detecting device | Low pressure,wire detection,pressing error;Optional:CCD visual inspection,Compression force monitoring. |
Control | PLC |
Power supply | AC380V 50/60Hz three-phase |
Aire supply | 0.5MPa,approx. 170N/min |
Temperature | 5°C – inner 50°C |
Humidity | 30%–80%RH (no condensation) |
Size | L6500xW5000xH1900mm (without protrusions) |
Weight | About 6000kg |
The JM-700 executes a flawless, synchronized sequence to transform raw, heavy cable into a fully finished, ready-to-install wire harness. The process begins with the automated payoff and straightening of the thick cable, feeding it precisely into the cutting module. Following an exact cut (ranging from 400mm to 4000mm), the rotary stripping blades cleanly remove the outer insulation without scratching or nicking the inner copper conductor strands.
Next, the automated transfer mechanism positions the exposed wire for tube insertion. Heat-shrink tubes or wire number tubes are accurately threaded onto the cable ends. The heavy 20T servo presses then execute the terminal crimping with immense, controlled force, creating a dense, cold-welded bond between the terminal and the copper strands. Finally, the heat-shrink positioning module moves the tubing over the crimped joint and applies uniform heat, creating a tight, environmentally sealed finish. This entire cycle takes approximately 10 seconds per piece, drastically reducing labor costs while maximizing output consistency.
The precision and heavy-duty capabilities of the JM-700 make it the ideal processing equipment for demanding industrial sectors that require large cross-section wire harnesses. The finished samples exhibit perfectly formed crimps, securely positioned heat-shrink tubing, and unblemished wire jackets. When handled, these finished harnesses feel solid and secure, ensuring optimal electrical conductivity and mechanical durability under physical stress.
These high-voltage assemblies are widely utilized in the manufacturing of new energy vehicles (NEVs), where reliable power transmission is critical for battery packs and electric drivetrains. Additionally, the equipment produces highly durable harnesses for large-scale energy storage systems, commercial photovoltaic (solar) installations, and heavy industrial power grids. By ensuring every terminal is crimped to exact specifications and fully protected by precisely shrunk tubing, manufacturers can guarantee the long-term safety and performance of their end products in harsh, fluctuating operating environments.
Investing in heavy wire processing equipment requires a reliable partnership. We provide comprehensive, end-to-end technical services tailored to your specific production needs. Before any commitment, our engineering team offers preliminary sample processing and thorough process evaluation based on your unique cable structures and terminal drawings. We assist in designing the optimal workflow and selecting the exact crimping force required to guarantee your harnesses pass all rigorous pull-force and cross-sectional tests.
Beyond equipment delivery, our commitment continues with full on-site installation, rigorous equipment calibration, and hands-on operator training. By combining heavy-duty machine construction with responsive technical support, we ensure your production line achieves maximum uptime, minimal material waste, and rapid return on investment. From initial consultation to long-term maintenance, our expertise empowers your facility to meet the highest industry standards for high-voltage wire harness manufacturing.
