Automating the manufacturing process of control cables for the automotive components industry

The automotive industry is of great importance to the global economy for all the jobs it generates, the materials it exploits, or the technical and technological development it drives. The control cables provide essential functions for any car, such as the opening of doors and windows, or activating the handbrake and accelerator. The process of assembling control cables involves numerous steps and the manufacture of various components, e.g., the spiral, inner and outer coating, spiral terminal, and terminals. This work deals with the injection process of control cable terminals. There is a need to separate the injection set into its constituent parts, namely the terminals and the feeding system (gate), which is carried out manually, potentially leading to health problems, e.g., tendonitis. This paper presents the development of an automated pneumatic system for the separation of control cable terminals from the feeding system. The novel pneumatic system addresses a significant gap in the automation of Zamak terminal injection by handling seven different terminal types under strict spatial limitations. The automated solution resulted in a 39% reduction in production time, enhancing the process efficiency. Moreover, by adopting the Design Science Research (DSR) methodology, the work contributes not only to industrial practice but also to the theoretical understanding of the process. This approach to automating a repetitive and ergonomically challenging task represents a step forward in the field of manufacturing technology that can be extended to other fabrication processes, leading to process improvements and competitiveness.