Application tooling: the unsung hero of connectivity

By Anthony Marcucci, Manager, Field Application Engineering, TE Connectivity

As vehicle architectures transform and industrial digitisation accelerates, the use of connectors, wire harnesses, circuit boards and more are expected to grow. In fact, the connector market is slated to more than double globally this decade, reaching $177.7 billion by 2032, while the worldwide wire harness market is poised to reach $58.4 billion by 2030. With that expansion comes the need for application tooling approaches that are faster, smarter, cost-effective and more sustainable.

From humble beginnings to fast-paced innovation

Believe it or not, application tooling has humble roots. More than 80 years ago, Uncas Whitaker founded what is now known as TE Connectivity (TE) with just two things: a ring terminal and a crimping tool. The company specialised in solderless, uninsulated electrical connections for aircraft and boat manufacturers that allowed electricians to make quick, removable wire connections without a heating element or flux. It was simple and instantly became immensely popular. Fast forward to the present and TE now generates over $14 billion in annual revenue, with application tooling being a key player in its overall success.

Thanks to modernisation and fast-paced innovation, application tooling has grown in step with the demands of the global market. Machines have become more precise and more accurate, and tools have been developed to handle smaller parts. As an example, in today’s ever-changing EV landscape, pin insertion machines are being designed to provide reliable connections in a miniaturised world. They can balance speed and precision in high-density control systems with miniaturised pins, which require corresponding tooling solutions. And with a high-speed platform that increases speed while safeguarding quality, machines are now equipped with a high-performance control unit that provides high throughput and low scrap rates enabling customers to transition from soldering processes to pin insertion with higher efficiency and reliability. Today’s machines are also designed for high-volume production making them extremely valuable to customers.

What hasn’t changed is the industry’s reliability on hand tools also referred to as portable tools. Today’s hand crimp tools have evolved in design over time but are still one of the most popular products in the market and for good reason. When it comes to cost-effectiveness, the hand crimp tool shines – whether it’s for a low volume job or where spaces are slim and it would be impossible to get a machine, like the inside of an airplane. Even customers that have an automated assembly line will often have the associated hand tool for that product as a back-up.

As time goes on, we can expect to see more battery-powered portable tools enter the market as a means for alleviating repetitive injuries, like carpal tunnel, and to confirm that tools have a large enough force output, beyond the capabilities of the human hand.

New challenges and opportunities pave the way for the future

Localisation has become increasingly important in several markets, especially China, where customers are demanding solutions that are not only robust and reliable but also meet the needs of the local supply chain while maintaining competitive pricing. Manufacturers are offering various tools, with different shapes, sizes, and functionality, that teams will use to prepare components for PCB boards or large wires for high-voltage applications. Oftentimes, these partners provide field service teams to set up equipment and train employees on how to use tools. They also offer remote and onsite troubleshooting when issues arise, as well as equipment repair when needed. This is a key value driver for companies and often the reason that one company may be awarded business over another. By having trained engineers in a local market, a company can rest assured that machine downtime will be minimal, which is critical from both a cost and productivity standpoint.

Beyond this, fast-paced industry development sets the stage for continued product evolution. For example, the tools used today for electric vehicles with advanced driver assistance systems will certainly look different than those used for the fully autonomous vehicles to come. Application tooling workforces can be prepared for constant change by adopting a mindset of continuous learning and working closely with both internal and external partners to meet their needs.

The powerful role of AI

As industries continue to progress, we can expect application tooling to use artificial intelligence (AI) systems to validate processing steps, track products through multi-step assembly lines, and communicate with machine execution systems to improve efficiency.

While human operators can perform visual inspections to identify many errors with terminal, die, or wire placement, AI systems can accurately decrease potential errors before they happen. For example, AI systems use cameras and sensors that are added to a high force press, electronically validating accuracy and improving traceability.

In the next few years, we will likely see more manufacturers fully automate assembly lines, using advanced AI to maintain product accuracy as cables travel from process to process and machine to machine. These robust systems will track products throughout the process, confirming that the appropriate equipment, such as the die set, was used and that important metrics were maintained, such as wire alignment, crimp height, and termination speed. They’ll also be able to perform advanced checks, such as validating that wires are correctly positioned or that the correct terminal is being used for the installed die set, is placed properly on the wire, and seated accurately in the lower die nest.

There’s no doubt that future will be one of constant innovation. By investing in the right tooling, working with partners to deploy and maintain solutions, and automating to scale production, companies can grow their businesses and increase throughput while also maintaining a positive bottom line.