JMK wire harness processing modules provide configurable stations for cutting, stripping, marking, sleeve insertion, waterproof seal feeding, terminal crimping, connector housing insertion and in-process inspection.
These modules can be integrated into JMK automatic wire harness machines or evaluated for customized production systems. Instead of using the same fixed configuration for every harness, manufacturers can select the processing and inspection stations required by their wires, terminals, seals, connector housings and quality-control procedures.
A complete wire harness processing line consists of several coordinated operations. Each operation requires different feeding, positioning, tooling and inspection methods.
JMK’s modular approach divides the production process into individual functional stations, including:
Wire feeding
Cutting and stripping
Wire marking
Number tube insertion
Heat-shrink tube processing
Waterproof seal insertion
Terminal crimping
Connector housing insertion
CCD visual inspection
Crimp force monitoring
Digital insertion force measurement
Material detection and alarm functions
Finished-product collection
The required modules are selected according to the actual harness rather than installing unnecessary functions within every production line.
The cutting and stripping module prepares the wire to the required length and exposes the conductor before terminal processing.
Depending on the integrated machine, its functions may include:
Fixed-length wire feeding
Single-end or double-end stripping
Full stripping
Partial stripping
Rotary cutting
Multilayer cable stripping
Cutting-length detection
Wire presence detection
Feeding and blade configurations should be selected according to the wire cross-section, insulation material, required stripping length and acceptable conductor condition.
Processed samples should be inspected for damaged strands, incomplete stripping, insulation marks and length variation before the production parameters are approved.
Marking and sleeving modules add identification or protective tubing to the wire during processing.
Available functions may include:
Laser number tube marking
Tube feeding
Tube cutting
Single-end or double-end tube insertion
Number tube positioning
Heat-shrink tube insertion
Heat-shrink positioning
Controlled tube heating
For example, the JM-201U integrates laser marking, double-end number tube insertion, heat shrinking and multi-station crimping within one automatic system.
The tube material, diameter, marking contrast and shrinking conditions should be confirmed through sample testing.
Waterproof electrical connectors require a rubber seal to be positioned on the wire before terminal crimping. Manual seal threading can be slow when the seal is small, flexible or used in high-volume production.
An automatic waterproof seal insertion module may include:
Vibratory bowl feeding
Seal separation
Seal orientation
Wire positioning
Single-end or double-end seal insertion
Seal presence detection
Material shortage alarms
Transfer to the terminal crimping station
The seal feeding and insertion mechanism must be configured for the actual seal dimensions, material hardness, wire diameter and insertion position.
JMK systems such as the JM-555, JM-560 and JM-800 can be configured with waterproof seal processing for suitable applications.
A servo terminal crimping module provides the controlled pressing movement required to join a terminal and conductor.
Depending on the machine and terminal, the module may support:
Single-end crimping
Double-end crimping
Multiple crimping stations
Programmable crimping movement
Adjustable crimping height
Terminal applicator changes
Different terminal combinations
Integration with crimp force monitoring
Integration with visual inspection
The crimping module must be matched to the terminal applicator, wire cross-section, terminal geometry and required crimp specification.
For high-current cables, JMK also provides high-voltage terminal crimping machines with higher pressing forces.
After terminal crimping, the connector housing insertion module positions the terminal and inserts it into the specified connector cavity.
Available configurations may include:
Single-end housing insertion
Double-end housing insertion
Multiple connector processing
Multi-color wire identification
Vision-guided terminal positioning
Programmed cavity selection
Digital insertion force measurement
Insertion fault alarms
The JM-800 uses vision-guided positioning and digital force measurement for supported connector insertion processes. Connector dimensions, cavity layout, terminal orientation and insertion sequence must be evaluated using actual samples.
For dedicated connector assembly systems, view JMK connector housing insertion machines.
Crimp force monitoring evaluates the force curve generated during terminal crimping. After a reference process range has been established, the system compares production crimps against that range.
Depending on the terminal and wire combination, CFM can help identify conditions such as:
Missing wire
Incomplete wire insertion
Missing conductor strands
Double-fed terminals
Abnormal terminal deformation
Incorrect material combinations
Tooling or process variation
CFM supports in-process monitoring but does not replace crimp height measurement, scheduled pull-force testing or terminal cross-section analysis.
The detection capability depends on the difference between a normal crimp and the defect being monitored.
CCD visual inspection can be positioned at different processing stages to check visible wire, terminal or connector characteristics.
Possible inspection items include:
Stripping length
Exposed conductor condition
Terminal presence
Terminal position
Seal presence
Seal position
Connector orientation
Terminal insertion position
Number tube presence
Marking position
Not every defect can be identified reliably by a camera. Lighting, component color, inspection angle, image resolution and defect size all affect the inspection result.
The inspection scope and acceptance criteria should be defined using actual conforming and defective samples.
Additional modules can be integrated according to the process risks and material-handling requirements.
Available functions may include:
Air-pressure detection
No-wire detection
No-terminal detection
Material shortage alarms
Wire color selection
Barcode scanning
Processing parameter storage
Finished-product counting
Automatic defective-product separation
Production data communication on supported systems
These functions should be configured around the production process rather than added only to increase the number of machine features.
A module should solve a defined processing or quality-control requirement. Before selecting an individual station, the complete harness workflow should be reviewed.
Please provide:
Wire specifications
Terminal drawings and samples
Seal drawings and samples
Number tube or heat-shrink tube samples
Connector housing drawings
Finished harness drawings
Required processing sequence
Target cycle time
Expected product changeovers
Defect types to be detected
Quality acceptance criteria
Factory data requirements
Available line space
This information allows the processing sequence, station layout and inspection method to be evaluated together.
Wire harness processing modules can be incorporated into equipment for:
Automotive wiring harnesses
New energy vehicle systems
Energy storage equipment
Household appliances
Industrial control cabinets
Consumer electronics
Photovoltaic equipment
Telecommunications equipment
FAKRA and Ethernet cable assemblies
The module configuration is determined by the harness design and production process, not only by the final industry.
JMK develops both complete wire harness machines and the functional technologies used within them. This includes wire handling, terminal crimping, waterproof seal insertion, vision inspection, crimp monitoring and connector housing assembly.
Our team can evaluate whether a required function should be added to an existing machine platform, installed as an independent station or incorporated into a newly customized production line.
Sample testing is used to confirm material feeding, positioning, processing and inspection feasibility before the final configuration is determined.
Some modules may be configured as independent stations, while others require integration with a JMK machine or customized production line. The control and material-transfer requirements must be evaluated first.
It compares production force curves with an established reference range and can help detect significant changes in wire, terminal or crimping conditions.
No. CFM monitors the crimping process, while pull-force testing directly measures the mechanical retention of a finished connection.
Depending on the camera position and product, it may check stripping length, conductor condition, terminal position, seal presence or connector insertion characteristics.
It can be configured for compatible seals, but changes in seal diameter, material, geometry or orientation may require different feeding and insertion tooling.
Some additions may be technically possible, while others require major mechanical and control changes. The existing machine model and available interfaces must be reviewed.
The current website supports vision-guided positioning and digital insertion force measurement on selected equipment. A dedicated pull-back verification function should be treated as a separate requirement and confirmed during project evaluation.
Selected equipment supports MES connectivity. The communication protocol, required data fields and existing factory system must be confirmed before integration.
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