Flexible Automation Line Powers Scalable Housing Production

HAHN Automation Group powers Production for Electronic Housings

The HAHN Automation Group delivered a fully automated solution for a global automotive and electronics manufacturer, enabling the high-volume production of two electrical housing variants. Designed for flexibility, performance, and future scalability, the system integrates advanced part handling, precise overmolding, and 100% inline testing, all within a space-optimized footprint. 

By connecting seamlessly to the customer’s MES and accommodating human-machine interaction, HAHN reinforces its role as a longterm automation partner.

#Electronics #Production #Housing #Overmolding

 

  • Scalable for Dual IMM Integration
  • Human-Machine Interaction Enabled
  • MES-Connected Testing & Traceability

 

Challenge

The customer needed a robust automation system to produce complex electrical housings with EloPins and stators in two variants. Key challenges included precise material handling, maintaining a 27-second cycle time with a four-cavity mold, and MES integration for part tracking.

The system had to allow manual tray loading without disrupting automation and ensure full traceability, including defect sorting by mold cavity and pattern.

 

Developing a Solution

The fully automated system by HAHN Automation Group meets current production needs and allows expansion with a second injection molding machine. It produces two variants of electrical housings. EloPins are cut and bent from a pre-stamped reel, while stators are manually preloaded into a mobile dolly—enabling decoupled, flexible material staging. A 3-axis robot inserts both components into the mold.

After overmolding, parts undergo mechanical and electrical testing for pin length, position, insulation, and continuity. Each part receives a laser-printed Data Matrix Code for traceability and is stored in a cooling rack. Compliant parts move to final assembly; non-compliant ones are sorted by mold cavity and defect type, enabling efficient troubleshooting. The system ensures high throughput, quality, and full traceability.

 

Process Overview

  1. Automated overmolding of EloPins and stators with synchronized handling
  2. 100% inline testing for electrical and mechanical quality, MES-integrated
  3. Modular cooling rack system (capacity: 4,300 parts)
  4. Human-machine interaction via decoupled tray loading system
  5. Defect sorting by mold cavity and pattern for
    full traceability

Cycle time: 27 seconds per 4 cavities; 533 pieces per hour

Results

The system produces 533 parts per hour with a 27-second cycle time (4 cavities), all within a compact 110 m² footprint. It supports two housing variants and allows future integration of a second molding machine. Inline testing ensures all parts meet electrical and mechanical specs, with MES connectivity for full traceability. Decoupling manual from automated steps increases flexibility and uptime. The result is a scalable, high-precision system ready for future demands.

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