POF & FFC Cables: Automation Challenges and Solutions
As the automotive industry becomes more electronic, (and to reduce the weight and volume of cables in vehicles), the usage of Flat Flexible Cable (FFC) and Plastic Optical Fiber (POF) is dramatically increasing.
Schleuniger designs and manufacturers semi- as well as fully automatic systems for processing Plastic Optical Fiber (POF) and Flat Flexible Cable (FFC/FPC).
Market for FFC / FPC Cables
The automotive market is moving to replace round wires in vehicles (where possible) with FPC cables because of the following advantages:
- Weight reduction of 50% or more
- Thin enough to fit in small spaces (above ceiling, under floor)
- Extremely flexible (can flex more than 1 million+ times)
- Production of cable assemblies can be fully automated
- Lower price and less parts
Based on these advantages, most automakers predict that FFC/FPC will comprise 30 - 40% of a vehicle's wiring harness in the next five years.
Schleuniger FFC / FPC Production Capabilities
Semi- and fully automatic machines which perform some or all of the following process steps:
- Feed the cable and cut it to length
- Inkjet print at any point along either side of the cable
- Strip the cable at any point on either side of the cable using a laser or a milling process
- Clean the cable
- Apply tape at any point on either side of the cable
- Place components (LED's, switches, etc.) at any point on either side of the cable
- Punch (notch) the cable at any point (freely programmable geometry)
- Slit the cable (one or multiple slits) at any point
- Coil and tie the cable assembly
- Crimp or ultrasonically weld connectors on the cable ends
- Install connector housings
- Electrical test and good/bad sorting
Market for Plastic Optical Fiber (POF)
Light is an excellent way to transmit data since it is not susceptible to electromagnetic (EMI) or radio frequency interference (RFI). POF works well for short distances, such as in vehicles) and is easier to work with than glass optical fiber (GOF). Although POF has been around for a few years, its use didn't take off until a consortium of 20 carmakers (mostly European) and 50 component suppliers got together to create the MOST (Media Oriented Systems Transport) standard. The MOST standard is a multimedia fiber-optic network optimized for automotive applications. It is a network developed by the automotive industry for the automotive industry. The figure below shows some of the typical devices that will be networked in future vehicles.
Schleuniger POF Production Capabilities
Semi- and fully automatic machines which perform some or all of the following process steps:
- Feeding, marking, cutting, stripping, coiling and tying of POF cable
- End finishing (grinding/polishing) of the fiber end
- Ferrule insertion on fiber
- Crimping of brass ferrules
- Laser welding of plastic ferrules
- Integrated non-destructive pull test to ensure cable assembly meets tensile spec
- Measurement of fiber endface position in ferrule (must be recessed by a certain amount)
- Integrated optical loss testing
- Good/bad sorting and stacking of completed assemblies
For additional information, please contact Pete Doyon, VP of Product Management, at (603) 621-2626 or via e-mail at PeteDoyon@Schleuniger.com.
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