Robotics Challenge 2025

Challenges and potential of automation

With the growing demands of electromobility and autonomous driving, the automotive industry is facing technological challenges. Until now, modern wiring harnesses comprising up to 1500 cables have largely been assembled manually on mold boards, often in regions with lower labor costs. However, this process is not only labor-intensive and costly, but also places high logistical demands. Automation solutions offer the potential to increase efficiency, improve precision and reliability and reduce the space required in production. Compact, robot-based assembly cells can be the solution to many of these challenges.

The miniaturization of connector systems and the increasing variety of cable types bring with them new technical requirements. Limited installation spaces in vehicle bodies require precise and intricate work steps that can only be carried out manually with great effort. This applies in particular to gripping and fitting miniaturized connectors, which in practice represents a considerable workload for the workers. These repetitive processes can be optimized and scaled through the use of innovative automation technologies.

Seven central process steps

In collaboration with industry experts, seven key process steps in wire harness assembly were identified that are to be automated as part of the challenge: from the provision of components to the assembly of connectors and fixing of cable bundles. © Arena2036

In collaboration with industry experts, seven key process steps in wire harness assembly were identified that are to be automated as part of the challenge: from the provision of components to the assembly of connectors and fixing of wire bundles. These steps form the basis for the development of modular robot cells that can be efficiently integrated into existing production processes.

As part of the upcoming challenge, research institutions and companies are invited to develop demonstrators that can map the entire process chain. The competition gives robotics companies the opportunity to present their transofrmation solutions directly to the industry and promote exchange with experts from the automotive industry.

Participants in the challenge can decide for themselves which of the identified process steps they would like to focus on. The aim is to develop creative and innovative approaches that stand out from conventional assembly processes and demonstrate new technical possibilities for wire harness production. At the end of the challenge, a demonstrator should be created that shows the practicality of the proposed solution.

Future prospects for the industry

The results of the Robotics Challenge 2025 will be presented at the Innovation Forum of the Transformation Hub Wire Harness on April 9, 2025. Successful teams from industry and science will present their innovations to a broad specialist audience from the wire harness industry. © Arena2036

The processing time for the participants is four months, starting on November 1, 2024 and ending on February 28, 2025. The results of the Robotics Challenge 2025 will be presented at the Innovation Forum of the Transformation Hub Leitungssatz on April 9, 2025.

Through the Robotics Challenge, the Transformation Hub Wire Harness contributes to the further development of wire harness production and to ensuring its future viability. Further information on participation, the detailed task description of the challenge and how to register can be found at Robotics Challenge 2025 - Transformation Hub Wire Harness

The Transformation Hub Wire Harness is part of the Future Fund for the Automotive Industry funded by the German government. The consortium - consisting of Arena2036, Bayern Innovativ and the Open Hybrid LabFactory - combines research and practice to drive forward the automation and digitalization of wire harness production.