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Tutorial – Bundling rail harnesses and assembly in record time

How the ATS3080 autotool system speeds up installation and reduces rail harness and assembly costs.

Speed and efficiency are essential features of the rail industry, and the ATS3080 autotool system delivers both of these precisely when you need it – when large volumes of fasteners are required for harness bundles in rail vehicles.

What makes the ATS3080 system so fast and so efficient for bundling harnesses in moving stock? For this, we need to look more closely at its design.

Firstly, the unique system design of this high-capacity tool allows waste free fastening and a completely flush cut for the safe bundling of diameters up to 80 mm. The two parts of the fastener come from two different dispenser wheels – one for the strap, and a second for the closure head. The strap is automatically inserted into the closure head and cut precisely at the head without waste.

Secondly, the autotool system is available with a set of "jaws" in three different sizes in order to optimize bundling and cycle time: 30 mm, 50 mm and 80 mm. The bundle diameter is mechanically detected to ensure harnesses are held securely even in the high-vibration environment of a rail vehicle. Depending on diameter, the cycle time of the tool ranges from 0.8 seconds to 1.3 seconds. Furthermore, time is also saved through not having to empty cleaning and waste boxes.

Design features of the ATS autotool system make it the ideal solution for high-volume production environments. It can be integrated into robotic arms on assembly lines for fully automated production or into an overhead suspension device.

And finally, the autotool system meets the high standards of safety set for rail vehicles. ATS3080 fastener material is made from PA6V0 classified according to R22, R23 and HL3. It is certified to EN 45545-2 European railway standard for fire safety. Outside serration of the fasteners makes it especially suitable for applications where cable might be sensitive.