Manual Labor Essential for Electric Vehicles... The Company That Succeeded in Robotization [Tech Talk]

Dependence on Manual Labor... If Wiring Fails, Car Factories Stop
Robots Lay, Adhere, and Cut Wires Directly
Reducing the Unit Cost of Electric Vehicle Production
Large-Scale Robot the Size of a Car Handles Entire Wiring Process

Aircraft and electric vehicles transmit signals and current through wires. The wires installed inside are arranged only by hand. This process is called a "wiring harness." It refers to a device that acts as the nervous system of a vehicle's electronic control system.

Meticulous manual work is essential, and errors are common, making this an area where machines have yet to make significant inroads. The British robotics startup Q5D Technologies has developed a robot capable of automating the wiring harness process, raising expectations for automation in this field. This is why the global aerospace and automotive industries are paying close attention to Q5D.

Dependence on Manual Labor... If Wiring Fails, Car Factories Stop

Wiring harness of Hyundai Motor Group electric vehicles. Hyundai Motor Group Blog

In February 2020, during the height of the COVID-19 pandemic, Hyundai Motor Company's production line came to a halt. This was because the factory in China responsible for wiring harness work had ceased operations.

The wiring harness process involves twisting wires together to form thick bundles that connect to sensors, control systems, and electric motors. The completed wiring is arranged inside electric vehicles or aircraft to connect each electronic component. There is currently no robotic arm capable of twisting thin wires into a bundle and placing them precisely at designated locations with the required level of dexterity. As a result, countries such as China and those in Southeast Asia, where labor costs are relatively low, have come to dominate the supply chain.

Robots Lay, Adhere, and Cut Wires Directly

Q5D robot head arranging wires according to a designated pattern. Provided by Q5D

Founded in 2018, Q5D attracted the attention of global electric vehicle and aerospace companies during the pandemic. Lockheed Martin, the world's largest defense contractor, participated directly in its seed funding, and since then, Q5D has established a pipeline worth at least $100 million with numerous companies. The "wiring harness robot" invented by Q5D is currently the world's first automated wiring system.

Q5D's robot resembles a printer. Inside a large rectangular frame, a "robot head" moves up, down, left, and right. Copper wire is extruded from the end of the head and arranged at designated locations. The robot also performs adhesion and insulation cutting tasks autonomously.

Peter Todd, Q5D's head of product development, said in an interview with Asia Economy, "We are the only company focused on 100% automation of wiring work. Q5D's cutting and finishing processes are automated by software, resulting in finished wire modules that are lighter and use less material than those produced by humans." He also emphasized, "Above all, the greatest advantage is the reduction in labor costs."

Reducing the Unit Cost of Electric Vehicle Production

Electric vehicle battery pack wiring harness demonstration. Provided by Q5D

Automating the wiring harness process could bring seismic changes to the automotive industry. Todd stated, "According to our own calculations, automating the wiring process will reduce the unit production cost of an electric vehicle by $200. Most of the savings come from labor costs, but the reduction in material and logistics costs is also significant."

Currently, most automakers import wiring harness components assembled overseas. However, if a Q5D robot completes the wiring process right next to the production line, there are no additional shipping or logistics costs. Most importantly, the risk of production stoppages due to sudden supply chain disruptions is greatly reduced. In particular, being freed from tariff concerns is a major advantage, as there is no need to pay intermediate goods tariffs on parts crossing borders.

Large-Scale Robot the Size of a Car Handles Entire Wiring Process

SQ25W prototype capable of performing wiring work for one passenger car in its entirety. Provided by Q5D

Automating the wiring harness process could also have a positive impact on Korea's automotive industry, which is focusing on electric vehicles. Todd commented, "Korean automakers are an exciting area for Q5D. For example, Hyundai's latest vehicles are equipped with advanced driver assistance systems, infotainment, and safety devices, which require much more wiring than before."

He added, "It is difficult to train skilled workers for wiring harness work, and maintenance costs are high. Robots can provide higher quality at lower cost and offer far superior design flexibility."

Q5D is currently preparing its large-scale wiring robot, the "SQ25W." Measuring 2.5 meters wide, 1.5 meters long, and 0.15 meters high, it is similar in size to the interior of a typical passenger car and is capable of performing all the wiring for an entire vehicle in a single process.