Which FAKRA Cable Assembly Steps Can Be Automated?

FAKRA cable assemblies are widely used in automotive electronics, including antennas, navigation systems, cameras, infotainment systems and other in-vehicle applications. As automotive electronics move toward higher production volumes, manufacturers need to maintain production efficiency while ensuring consistent assembly quality and process control.

A typical FAKRA cable assembly process may include coaxial cable cutting, stripping, crimping, connector assembly and final inspection. For high-volume production, several repetitive processes can be automated and integrated into a continuous FAKRA cable assembly automation solution.

So, which FAKRA cable assembly steps are suitable for automation? The answer depends on the product structure, production volume, target cycle time and quality requirements.

Common Challenges in FAKRA Cable Assembly

FAKRA cable assembly typically involves multiple consecutive processes. When these operations rely heavily on manual work, production efficiency can be affected by repetitive operations, product transfer between stations and inspection workload.

Coaxial cable processing is one of the key considerations. A FAKRA cable may include a center conductor, insulation, shielding and outer jacket. The stripping process needs to control the dimensions of each layer while protecting the center conductor and shielding structure.

Crimping is another important process. The center pin and outer conductor need consistent processing parameters to achieve stable assembly quality.

In addition, visual inspection, electrical testing and NOK handling can add significant labor requirements in high-volume production.

For mature products with higher production volumes, integrating cable processing, crimping, assembly and inspection into an automated system can reduce manual intervention and improve process continuity.

Which FAKRA Cable Assembly Steps Can Be Automated?

The automation level should be determined according to the specific product and manufacturing requirements. Common automation opportunities include:

Process	Automation Application
Coaxial cable cutting	Automatic length control and cutting
Multi-layer stripping	Automatic stripping and dimensional control
Center pin crimping	Servo-controlled crimping and process monitoring
Outer conductor crimping	Automatic positioning and crimping
Connector assembly	Automatic feeding, positioning and assembly
Vision inspection	Dimensional, positional and assembly inspection
Electrical testing	Continuity and insulation testing
Traceability	Code scanning, data collection and MES integration

Coaxial Cable Cutting and Stripping

Automatic cable cutting can produce cables to a defined length, while automated stripping can process the different layers of a coaxial cable.

MIJOINT’s FAKRA automation solution uses a three-blade concentric rotary stripping process. It supports 1–4 layer cold stripping with accuracy of up to ±0.1 mm while protecting the center conductor and shielding layer.

Center Pin and Outer Conductor Crimping

Crimping is a critical process in FAKRA cable assembly. Automated crimping equipment can use servo control to manage crimping position, force and speed for more consistent processing.

MIJOINT’s FAKRA solution uses a dual-servo crimping structure with crimping accuracy of up to ±0.01 mm. The pressure-displacement curve can also be monitored during the process.

Automatic Connector Assembly

After cable preparation and crimping, automatic feeding, positioning and connector assembly mechanisms can be configured according to the connector structure.

For higher-volume automotive cable assembly projects, integrating multiple consecutive processes into FAKRA assembly equipment or a complete production line can reduce manual product transfer between stations.

Vision Inspection and Electrical Testing

FAKRA cable assemblies may require inspection of assembly conditions, dimensions, continuity and insulation.

Integrating vision inspection and electrical testing into an automated line allows the system to automatically classify products as OK or NOK and reject defective products.

Production scanning and data collection can also be integrated to support process traceability.

MIJOINT FAKRA Cable Assembly and Inspection Line

MIJOINT has developed a fully automatic FAKRA cable assembly and inspection line integrating coaxial cable cutting, stripping, crimping, connector assembly, vision inspection and electrical testing into one automated production system.

View MIJOINT Fully Automatic FAKRA Wire Harness Assembly & Inspection Line

Reference performance of the FAKRA assembly line includes:

• Cycle Time: ≤6 s
• UPH: up to 1,200 pcs/h, single end
• Yield: ≥99%
• OEE: ≥90%
• Changeover: approximately 10 minutes

Actual production performance should be evaluated according to the specific product structure, cable specification and process requirements.

MIJOINT focuses on customized automation equipment and production line development. Rather than applying one fixed equipment configuration, MIJOINT develops and integrates process modules according to the customer’s product and manufacturing requirements.

With more than 200 R&D professionals, MIJOINT’s capabilities cover cable processing, precision assembly, high-precision joining and intelligent inspection, supported by project execution from solution development and engineering through equipment delivery.

How to Evaluate FAKRA Cable Assembly Automation

Not every FAKRA product requires a fully automated production line.

For products with frequent changes or lower production volumes, automating selected processes may be more suitable. For mature products with higher production volumes, a complete FAKRA assembly line may provide greater benefits.

When evaluating a FAKRA cable assembly automation project, manufacturers typically need to provide:

• Product drawings and key dimensions
• FAKRA connector and cable specifications
• Product samples or photos
• Monthly or annual production volume
• Target cycle time or UPH
• Current manufacturing process
• Vision and electrical inspection requirements
• Traceability and acceptance requirements

This information helps determine which processes should be automated and whether a standalone machine, modular equipment or a complete FAKRA assembly line is the right solution.

For further selection considerations, see our guide on how to choose an automated FAKRA cable assembly line.

Conclusion

FAKRA cable assembly automation is not simply about replacing manual operations with machines. The right approach is to match the automation level with the product structure, production volume, target cycle time and quality requirements.

From coaxial cable cutting and stripping to crimping, connector assembly, vision inspection, electrical testing and traceability, different processes can be automated and integrated according to the actual manufacturing requirements.

MIJOINT provides customized automation solutions ranging from individual process automation to complete FAKRA assembly lines, helping automotive electronics and cable assembly manufacturers improve production efficiency, reduce manual intervention and achieve more consistent process and quality control.

For a FAKRA cable assembly automation evaluation, customers can provide product drawings, samples, target production volume, target cycle time and inspection requirements for process and equipment assessment.

Discuss your FAKRA cable assembly requirements with MIJOINT.