Highly automated production of several million connectors

Intelligently linked and consistently automated

How to cope with the constantly increasing demand for plastic hybrid components in spite of space and personnel constraints? An international automotive supplier has opted for an intelligently linked system with two injection moulding machines and six robots – and is faring very well.

With around 3,000 employees worldwide, KE Elektronik is one of the most valued suppliers to the automotive and aviation industries. With production sites in Germany, the Czech Republic, Slovakia, northern Macedonia, China and Mexico, the company belongs to the American Amphenol Corporation – a leading manufacturer of connectors.

For some time now, the products manufactured by the 300-strong company at its headquarters in Kressberg-Marktlustenau have included engine fan connectors that are used in both hybrid vehicles as well as those powered purely by internal combustion engine. These connectors are so-called plastic hybrid components in which four metal contacts are overmoulded with three different plastics.

“The production of these connectors is a relatively complex process that involves numerous testing stages as well as complete traceability. In order to be able to meet the constantly increasing demand given the shortage of skilled workers, an intelligent automation solution was required,” says Jens Gradenegger, Team Leader Injection Moulding Automation at KE Elektronik.