As manufacturers seek to simplify integration, accelerate commissioning, and improve machine performance, HBK is bringing its long-standing expertise in force, torque, weighing, and strain measurement into today’s automation ecosystems through IO-Link connectivity, real-time industrial communications, and edge data processing.

Under the theme “From Sensor to PLC”, HBK will showcase nine interactive demonstrations illustrating how precise measurement data can be acquired, analysed and directly used to drive industrial control systems.

Visitors will see how HBK’s force, torque and weighing technologies integrate seamlessly into modern automation architectures to: improve process quality and repeatability; simplify machine integration; reduce wiring and control system complexity; and deliver actionable data for automation and continuous process optimisation.

Precision measurement in the IO-Link ecosystem

A key focus of the exhibit will be the integration of high-accuracy measurement technologies within the IO-Link ecosystem, enabling machine builders and system integrators to connect critical force, torque and weighing data directly to industrial control systems.

This approach extends the benefits of intelligent automation to applications that traditionally require measurement accuracy levels found only in testing and validation environments.

Live 6-DoF robotics demonstration

HBK will also present a live robotic cell featuring its custom-engineered 6-degree-of-freedom (6-DoF) force and torque sensors. The demonstration will show how real-time multi-axis measurements enhance robotic precision and control, even in compact installations where integration space is limited.

Also featured at the booth will be the new BMX60 interface module capable of streaming torque, rotational speed, angle and power with fieldbus connectivity and data rates up to 5 kHz.

Visitors will also be able to explore the FS12DBX optical digiBOX, which combines fiber optic FBG data acquisition with real-time control capabilities, enabling new approaches to machine monitoring and process control.

Throughout the event, HBK product managers and application specialists will be available to discuss visitors’ integration challenges, whether related to new machine development, production equipment modernisation, or industrial digital transformation initiatives.

Members of the media are invited to visit HBK at Booth 365, Hall 4A, to experience the demonstrations and discuss key topics including industrial automation, IO-Link, robotics and the integration of measurement data into modern control architectures.

The demonstration will combine robotic transfer, servo control, precise linear motion, geared motors, braking and conveyor technologies in one automated production cell. Visitors will see how the technologies operate together, supporting applications such as machine tending, packaging, palletising and material handling.

As manufacturers look to increase automation throughput while managing space constraints, production efficiency and changing operational requirements, machine builders face growing pressure to develop systems that are both capable and adaptable. Meeting these demands involves more than individual component performance. It also requires careful consideration of how motion, control and mechanical technologies work together across an automated system. This is the approach Regal Rexnord will present at SPS, demonstrating how its combined capabilities can help engineers address these interconnected requirements.

Extending robotic capabilities with integrated motion

One of the key highlights is the Thomson Movotrak Cobot Transfer Unit (CTU), a plug-and-play 7th axis solution that extends a cobot’s operating range by up to 10 metres. By enabling one cobot to serve multiple workstations or a larger production area, it increases production line flexibility and makes better use of floor space. Flexible mounting options suit different workspace layouts, and the CTU also features user-defined collision detection and Freedrive functionality for setting linear waypoints during setup.

Beyond the integrated demonstration, Thomson will showcase its range of electric and precision linear actuators for applications requiring controlled movement, high load capacity and repeatable positioning. The Electrak XD, HD and MD smart electric actuators offer solutions for different load requirements, with the XD providing dynamic load capacities of up to 25 kN. For applications requiring higher precision, T Series and PC Series actuators support loads of up to 60 kN with repeatability of ±0.05 mm, delivering superior performance as they are stronger, faster and come with a longer service life than other comparable units on the market.

Thomson will also present its ball screw and linear guidance technologies, including an outstanding precision ground ball screw that combines an extra-high lead of 100 mm with a high-load capability of up to 100 kN Cam, supporting applications where high-speed movement and substantial load handling are required. Additional displays will include miniature ball screws, compact linear systems for space-conscious applications, and a selection of linear bearings and guides for different machine design requirements.

Other Regal Rexnord brands will contribute complementary technologies to the showcase. Kollmorgen’s servo motors, drives and automation systems deliver precise, responsive motion for robotics and packaging machinery, while Portescap’s miniature motors are suited to space-constrained designs, including medical devices and compact automated systems. Bauer Gear Motor’s energy-efficient geared drives serve demanding automation environments, while Warner Electric’s electromagnetic clutches and brakes provide controlled engagement and stopping functions in industrial machinery.

“Design engineers are under increasing pressure to develop machines in less time while balancing high-performance, system complexity and ease of use,” said Anders Karlsson, Business Development Manager for Regal Rexnord’s Linear Motion Division. “At SPS, we want to show how Regal Rexnord’s integrated solution capabilities can help engineers simplify system design, reduce development time and apply proven motion technologies to their own automation projects.”

As AI expands into the physical world, robots are evolving into Physical AI systems capable of perceiving their surroundings, processing information, making decisions, and interacting with physical environments.

To address the requirements of robot development, Advantech presents a five-layer Robot Platform architecture comprising layer1 Perception, layer2 AI Computing & Motion Control, layer3 Functional Safety, layer4 Production & Validation, and layer 5 Deployment & Management. The architecture integrates key capabilities across the robot lifecycle, from perception and AI computing to safety, validation, and deployment.

“To scale robotics solutions in real environments, it requires safety to be considered in every layer, from the ground up. We’re closing the gap with NVIDIA IGX Thor, offering an industrial grade platform that’s purpose-built for safety-certifiable robotics applications,” said Magic Pao, Vice President of Applied Server Group, Advantech.

Building a complete robot platform

Developing robots for real-world deployment requires the integration of computing, sensing, motion control, safety, software, and validation. Advantech brings these capabilities together through an established ecosystem of platforms, technologies, and solution partners, helping Robot OEMs reduce the complexity of system development and integration.

Advantech’s platform integrates key components such as cameras and other sensing technologies, reduces the effort and time required for component integration and system testing. With safety-oriented design, diagnostic mechanisms, and supporting safety documentation, including safety analysis and FMEDA-related evidence, Advantech helps customers reduce the effort required for system-level safety integration and validation.

In addition, NVIDIA IGX Thor is part of the NVIDIA Halos safety platform for autonomous robots, helping developers engineer safety across design, validation and deployment. Advantech platforms support NVIDIA software and technologies, enabling customers to connect physical systems with simulation and digital environments for development and validation. Together, these capabilities help robot OEMs accelerate development, reduce integration and validation effort, and move more efficiently toward real-world deployment.

Functional Safety for Physical AI

As robots move beyond controlled environments and increasingly interact with people, machines, and dynamic physical environments, safety must become an integral part of the system architecture alongside perception and AI performance.

Functional Safety (FuSa) is therefore an increasingly important capability within the Physical AI platform. Advantech integrates safety architecture, Safety MCU, diagnostic mechanisms, Safety Manual, FMEDA, and engineering support into its robot platform. Its approach separates the AI compute path from an independent safety path, enabling the AI roadmap to support AI inference, vision, and control while the independent safety path monitors system health, detects faults, and provides mechanisms to support application-defined safe-state handling.

Advantech’s MIC-735-IT, powered by NVIDIA IGX Thor, can be configured with a Renesas Safety MCU and supports safety-related system integration. Advantech’s FuSa-ready approach provides the platform design, diagnostic mechanisms, and supporting evidence needed to support the customer’s functional safety lifecycle. Through DMS and system integration capabilities, Advantech can evaluate application-specific requirements across hardware, firmware, Safety MCU, and external safety controllers.

Advantech provides platform-level design and integration support to help customers address applicable functional safety standards, including IEC 61508 and ISO 13849. Final hazard analysis, system integration, validation, and system certification are carried out by the system integrator or end customer based on the specific application requirements, with Advantech providing platform-level design and integration support throughout the development process.

Central to the stand will be the SOAP Factory (Smart, Orchestrated, Autonomous Production), a connected production environment showing how these capabilities work together across design, operation and maintenance.

“Many manufacturers are being asked to increase productivity, improve resilience and respond faster to changing market demands, often while working within existing facilities and infrastructure,” said Vincenzo Monaco, managing director DACH, Rockwell Automation. “The transition from automation to autonomy is about helping them make better decisions across the production lifecycle, using industrial AI, software-defined automation and cybersecurity to unlock greater value from the assets and investments they already have.”

Highlights at the Rockwell Automation booth include:

Software-defined automation: As manufacturers seek greater flexibility, separating control software from hardware creates opportunities to simplify deployment and adapt production systems more quickly. Demonstrations featuring LogixEdge integrated industrial control and edge computing will explore how virtualised control brings IT and OT closer together. A flexible manufacturing demonstration will feature Rockwell Automation PartnerNetwork companies autonox Robotics and Comau, which will show how multiple robot technologies can operate within a common control environment.

Industrial AI: Rockwell Automation will showcase the newly launched FactoryTalk Conductor, an AI-native orchestration platform that connects AI agents, skills, workflows and automation software to help engineers accelerate system design, development and testing, as part of its factory demonstration. The demonstration will illustrate how intelligent technologies can support decisions throughout the manufacturing lifecycle. Additional technologies on display include FactoryTalk Design Studio, a cloud-based engineering environment for designing and programming industrial control systems, and Emulate3D digital twin technology, which enable engineers to simulate and validate production systems before physical deployment. FactoryTalk Analytics industrial analytics software, Fiix cloud-based maintenance management software and GuardianAI AI-powered predictive maintenance solution will also be featured, supporting predictive maintenance and data-driven operational decisions. A brownfield demonstration will show how existing production lines can be modernised without extensive equipment replacement.

Cybersecurity and compliance: With the Cyber Resilience Act (CRA), Machinery Regulation (MR) and NIS2 increasing the demands on manufacturers and machine builders, Rockwell Automation will demonstrate how cybersecurity can be integrated throughout industrial operations. Visitors will discover how SecureOT cybersecurity suite supports asset visibility, risk prioritisation and vulnerability management, alongside secure-by-design approaches to industrial networks and regulatory compliance.

Visitors are invited to booth 320 in hall 3C, where Rockwell Automation specialists will be available to discuss individual automation challenges and demonstrate integrated solutions developed with members of the company’s PartnerNetwork.

Visit the Rockwell Automation website for more information

See all stories for Rockwell Automation

AI and ML are becoming integral to the engineering design process for many industrial automation applications. AI can reduce the manual effort required to configure robot cells for changing production needs while maintaining reliable controls. Frameworks like OpenUSD also support system design and validation before deployment. This automation resource centre provides engineers with practical guides and expert insights into AI-assisted configuration, physical AI, and more.

Intelligent ML processes enhance existing automation systems by helping machines better interpret and respond to real-world environments. AI can also support system reconfiguration while keeping engineers involved in critical control decisions. Meanwhile, large language models help engineers navigate complex industrial data and streamline tasks, such as PLC programming. Moving beyond the digital realm, physical AI is being embedded directly into machines to help engineers build more flexible automation systems. This enables robots and machines to adapt to changing environments and production needs through sensing and real-time decision-making. Through this hub, engineers will have the latest information to better understand how emerging AI and ML technologies can be applied to improve engineering workflows, system adaptability, and enable intelligent industrial environments.

Mouser stocks a wide selection of industrial automation products, including the newest solutions for AI and ML applications. Here are a few examples:

RevPi Connect 5 industrial box PCs by KUNBUS combine high computing power with a modular design for industrial automation applications. Based on the Raspberry Pi Compute Module 5 (CM5), the RevPi features 32 GB eMMC memory, 4 GB or 8 GB RAM, and optional WLAN/Bluetooth connectivity. The PCs are designed for edge applications, including predictive maintenance, visual inspection systems, and more.

The Opta micro programmable logic controller (PLC) from Arduino integrates industrial automation capabilities with the flexibility of the Arduino ecosystem. Powered by a dual-core Arm Cortex processor, it supports real-time control, monitoring, and predictive maintenance with multiple connectivity options. Built-in security and remote management capabilities make it suitable for industrial and building automation applications.

Acuros CQD shortwave infrared (SWIR) cameras from onsemi provide high-resolution imaging and sensing across the visible, Near-Infrared, and SWIR spectrum. Featuring high frame rates, global shutter operation, and up to 70 dB of dynamic range, they are designed to meet demanding industrial imaging requirements. Applications include machine vision, automotive systems, fill-level monitoring, surveillance, and more.

The AFE-360DVK robotics development kits for vision AI from Advantech are powered by an Intel Core Ultra 125H processor and deliver up to 32 TOPS of AI performance. They support 3× LAN, 7× USB, 4× high-speed COM, and 2× CAN FD interfaces for connecting autonomous sensors and other devices. Industrial applications include autonomous mobile robots, automated guided vehicles, and more.

SPS 2026 marks an important milestone in Mouser’s further expansion into industrial automation. Building on its established electronic components business, Mouser is extending its industrial automation portfolio and supporting services to help customers design, build, maintain and optimise automation equipment and operations.

This expansion reflects the growing overlap between electronic components and automation products within customers’ applications, while electronic components remain central to Mouser’s offering.

At SPS, visitors can experience a personalised bottle production line, compete in an interactive LED challenge, take part in the Spin-to-Win game and a sourcing efficiency quiz, enjoy complimentary coffee, and speak directly with Mouser’s customer service team.

Mouser brings its established online purchasing experience, authorised manufacturer network, real-time inventory visibility, transparent pricing, global customer support and immediate shipment of in-stock products to the industrial automation market. Mouser.com also includes a dedicated industrial automation area, helping customers discover relevant products, manufacturers and product categories while retaining access to Mouser’s familiar electronic components experience.

Personalised bottle automation demonstration

Mouser will showcase an automated production line that creates a personalised bottle for each visitor. Visitors will enter their name using a  Phoenix Contact industrial touchscreen, before a Schneider Electric collaborative robot, fitted with Festo soft grippers, places a bottle onto a conveyor belt.

The demo will incorporate LAPP industrial cable management solutions, demonstrating the importance of reliable connectivity and cable protection in automated manufacturing environments. An inkjet printer adds the visitor’s name, and a Universal Robots UR3e cobot presents the completed bottle. Banner Engineering sensors and tower lights, alongside Telemecanique sensors, will also feature in the demonstration, showing how complementary automation technologies can be combined in a practical production-line application.

Interactive LED competition

Mouser will also present a custom wall-mounted display based on the Mouser “M” logo. The interactive installation incorporates Banner Engineering K50 Pro SL SQ industrial LED indicators, and haptic touch buttons. Participants compete in pairs to be the first to illuminate every LED segment in the letter “M.”

Each button press illuminates one segment, demonstrating the responsiveness, reliability and visual impact of industrial LED indication technology in a dynamic application. The winner will receive a Mouser giveaway.

Mouser’s customer service team will be available throughout SPS, giving visitors the opportunity to connect directly with the people who help support customers every day. The team will be on hand to answer questions about ordering, deliveries, and Mouser’s online services and tools, as well as share practical advice on sourcing industrial automation products efficiently to keep projects on schedule.

Cell and gene therapies (CGTs) treat life-altering diseases, such as cancers and genetic diseases, at the root level by modifying DNA, living cells or tissue. Among the most complex and advanced medical treatments under development, these therapies have the potential to deliver long-lasting or even curative treatment. However, access to these treatments worldwide is limited due to the costly, labour-intensive manufacturing processes involved.

“The challenge today is that the biology is phenomenal, but the manufacturing capacity and the ability to scale that to the world is not there.” Says Leo Steenson, Head of Robotics at Cellular Origins.

Cellular Origins set out to change this by developing a scalable, robotic system that could fit into existing or new manufacturing facilities. To automate cell therapy manufacturing, Cellular Origins needed a way to transport materials between different stations for each stage of the production process. Unlike systems that rely on higher-grade cleanroom environments, Cellular Origins’ method uses sterile tube welding to form closed connections, supporting operation in Grade C/D environments while mitigating contamination risk and reducing gowning requirements for operators. The whole system would be controlled by a unified software orchestration layer to track every step, coordinate equipment and process activities, and collect data.

It became clear to the Cellular Origins team that Integrated Mobile Robots (IMRs) would be the ideal solution to facilitate the transport of materials. It was important that the system could navigate autonomously around dynamic environments, enabling human interaction as required. Another key consideration was that the mobile robot base had an open interface that would allow it to be integrated with the central software system, as well as an industrial robot arm, which would sit on top of the mobile unit.

Collaborative, autonomous navigation

After considering multiple options, including AGVs which would require tracks to run on, Cellular Origins engaged with RARUK Automation for a demonstration of the MiR250 autonomous mobile robot (AMR), developed by Mobile Industrial Robots, a Teradyne Robotics company. The demonstration highlighted the model’s compact footprint and collaborative, autonomous navigation capabilities. Additionally, MiR’s Agility Boost feature enables faster, smoother navigation in narrow and dynamic environments, which makes the AMR ideal for operating within the space-constrained layouts CGT manufacturing requires.

“The MiR250 is the ideal size, weight, payload, but crucially it is the easiest to integrate.” Remarks Steenson.

A key differentiating feature for the MiR250 was its open architecture, which enables communication with a wide range of industrial systems and devices. This provides manufacturers with the freedom to build tailored automation solutions without being constrained by proprietary interfaces or rigid system designs.

“The MiR platform is what we call an open platform. It’s able to communicate with multiple different industrial devices,” explains Ross Lacy, Sales Director at RARUK Automation. “It allows the users to build a platform that fits into their application around that, so it’s quite unique in that sense.”

In addition to its flexibility to integrate with a range of technologies, the MiR250 (along with the rest of the MiR range) has smart charging capabilities. The mobile robot monitors its own battery levels and automatically docks for charging at a logical break point. When multiple MiR robots are managed by MiR Fleet software, the software coordinates jobs and charging schedules across the fleet. Robots can take turns charging while others continue working, helping maintain continuous, 24/7 operation.

“[MiR AMRs] can autonomously charge, they are scalable, they have a piece of fleet software that allows up to 100 to be used in the same environment,” says Lacy. “They are very straightforward to get to grips with and get going.”

After Cellular Origins selected the MiR250 as the foundation of its integrated mobile robot (IMR), the implementation process progressed rapidly. The platform’s ease of use enabled the team to begin operating the robot almost immediately following initial training. Working closely with RARUK Automation, Cellular Origins then focused on refining the system and addressing the technical requirements needed to integrate the MiR250 with its other technologies.

As Steenson recalls: “After some training with Ross and the team, we got [the MiR] running within hours and, after that, we worked very closely together to figure out all of the integration details. Within a few months we had a working IMR.”

Technical advice and support

As well as the strong technical foundation provided by the MiR250, the collaborative working relationship between Cellular Origins and RARUK Automation proved instrumental both during development and now, as the solution is deployed at scale. From technical advice and support to facilitating discussions with the manufacturer, Mobile Industrial Robots, as operations scale, RARUK Automation prides itself on being a local partner that streamlines and simplifies the automation process.

Reflecting on the partnership between the two companies, Steenson comments: “[RARUK Automation] brings that wealth of expertise: they’ve worked across multiple different industries, they’ve worked with mobile robotics for years. They’ve listened, they’ve understood and they’ve delivered time after time.”

A vision of scalable cell therapy manufacturing

Since its launch in May 2023, Constellation is the materialisation of Cellular Origins’ vision of scalable cell therapy manufacturing, with IMRs playing a central role in its flexible, automated ecosystem. The platform can achieve up to 30 times greater space efficiency, a 16-fold reduction in labour requirements and a 51% reduction in cost of goods compared with conventional manufacturing approaches, helping make advanced therapies more accessible and economically viable.

Crucially, by unlocking the cost-savings achieved through smart automation, Cellular Origins’ Constellation is improving access to life changing therapies – helping more patients receive the treatment they need.

Steenson concludes: “Success for Cellular Origins ultimately is in the treatment of the patients. Starting from the first dose through to tens-of-thousands and RARUK Automation enables us to do that as quickly as we possibly can.”

Visit the RARUK Automation website for more information

See all stories for RARUK Automation

“Physical AI fundamentally changes what robots can do, where they can operate and the value they can create,” said Marc Segura, President, ABB Robotics. “Robotic AI vision is the vital bridge between robot perception and physical actions, enabling robots to see, understand, and act in real time. Customers need a complete workflow to create, deploy and continuously improve it.

“OmniCore EyeMotion and AI Robot Trainer work together, in a continuous loop of data generation, AI model training, deployment and optimisation that advances AI-powered vision and makes physical AI a reality, across industries for both experts and newcomers to robotics.”

Designed for system integrators and automation partners, OmniCore EyeMotion powered by AI Robot Trainer simplifies the deployment and scaling of AI-powered vision applications across multiple customer sites and production lines, reducing dependence on AI specialists while accelerating commissioning and adaptation to production changes. Converting real shop floor images into deployable AI vision data, the tools connect image acquisition, AI model training, deployment and continuous improvement in a single industrial workflow, and convert perception directly to robot motion through automatic collision-free path planning.

The integrated solution reduces commissioning time by up to 90% and cycle time by up to 50% when combined with automatic collision-free path planning. A simple guided workflow and AI chatbot lead users through every step of the process, helping system integrators handle changing SKUs, lighting, layouts, and object variations. It combines synthetic and real-world image data with ABB Robotics’ industrial knowledge and is compatible with any brand of camera and sensor.

Together, AI Robot Trainer and OmniCore EyeMotion make advanced AI vision development accessible without specialised expertise, for vision applications from simple 2D pick and place to more complex 3D bin picking, quality inspection, sorting or assembly.

Visit the ABB Robotics website for more information

See all stories for ABB Robotics

The manufacture of wiring harnesses is one of the last major challenges in industrial automation. While robots have long been performing a wide range of tasks in many industries, the assembly of complex wiring harnesses has remained the domain of manual labour until now. The reasons for this lie in the nature of the task itself: cables are flexible, dimensionally unstable components that are difficult to handle.

That is why cable harnesses are still manufactured exclusively by hand. Cable harness manufacturing is a classic “migratory industry” that moves to countries with low labour costs because of this. However, with rising demands, the desire for greater resilience within supply chains, and the goal of bringing production back to high-wage countries, there is also a growing effort to automate this process.

Cellios, which emerged from the Fraunhofer Institute for Manufacturing Engineering and Automation (IPA) in Stuttgart and was founded in 2024, has developed a solution specifically for this purpose. The company specialises in the manufacture of robot-based automation systems for cable assembly. At the heart of its portfolio are modular robot cells that digitise and automate the manual cable assembly process. The project partner for the world’s first fully automated cable harness is TE Connectivity.

“Previous solutions often covered only partial steps of cable processing, meaning that pre-assembled cables had to be further processed manually. The goal of the project with TE Connectivity was therefore to fully automate the entire process, right up to electrical testing,” explains Dr. Frank Nägele, CTO at Cellios.

First fully integrated, fully automated wire harness

Achieving this requires overcoming numerous challenges. For example, the terminated cable ends, known as crimps, which are only a few millimeters wide, must be inserted into the corresponding connectors. The greatest challenge, however, is the cable itself. Because cables do not have a rigid shape, the position of the crimp in the gripper changes with every handling operation. To reliably guide the crimp into the tiny cavity of a connector, an accuracy of at least one-tenth of a millimetre is required.

“In addition to the technical issues, there are also complex process-related questions. After all, the objective is to automate a process that has been entirely manual. Components such as connectors, cable-processing machines, and so on are designed for use by humans, not robots. On top of that, there is an enormous variety of wire harness variants that we want to accommodate through the flexible design of our assembly cells,” explains Dr. Nägele.

Cellios’ answer to these challenges is a modular system. The company maps the various stages of wire harness assembly to different modules. The individual process steps include connector singulation, cable preparation, crimping, cable routing, producing splice connections with an ultrasonic welding device, taping, and finally end-of-line testing. The most difficult task to automate so far is routing followed by contact insertion. As described above, the robot has to insert crimps measuring only a few millimetres into the connectors.

Until now, this task has been performed exclusively by hand directly on the routing board and has required the operator to exercise the utmost concentration, visual acuity, and dexterity. In the newly developed robot cell, the robot moves the gripped component to a 2D camera. There, the position and orientation of the crimp are determined and sent to the robot as a correction for assembly. A second camera is used to measure the target position.

The robot can therefore reach its target position through precise corrective movements and reliably insert the crimp into the connector. The necessary sensitivity is achieved through force control and force monitoring: A force-torque sensor on the robot measures the forces during insertion and regulates them so that the crimp is inserted optimally. Machine vision ensures the required accuracy.

Giving robots sight

“Without precise ‘vision’, the robot would literally be blind and unable to make the necessary corrections reliably and independently,” explains Dr. Nägele. To overcome these challenges, Cellios turned to machine vision.

Sensors alone were not sufficient to determine the exact position (X-Y) and orientation (Z angle) of the crimp. Machine vision is therefore the system that helps the robot recognize the components to be inserted and identify deviations resulting from upstream process steps, such as crimping the cable, as well as from the unpredictable nature of the cables themselves.

“Without precise measurement, we would not be able to insert components with an accuracy of 0.1 mm, which is what we need to align the connector with the crimp,” adds Dr. Nägele. The robot cell is equipped with a range of different hardware components to meet these challenges. In addition to a robot, these include robotic taping applicators, force-torque sensors, devices for accurately gripping the connectors, and a conveyor system. Cellios uses two 2D cameras for image processing.

On the software side, the system uses Cellios software and MVTec MERLIC. Munich-based MVTec Software GmbH develops technologically leading software for industrial machine vision worldwide. MERLIC makes it possible to automate complex applications quickly, even without specialized programming expertise.

Efficient application development

Cellios selected MERLIC because of its practical low-code approach: The clearly structured configuration interface makes it easy to select all required tools using drag and drop. Thanks to its intuitive user guidance, MERLIC enables users to get started quickly with developing a machine vision application without requiring in-depth knowledge of programming or image processing.

“For innovative companies such as Cellios, time to market is crucial. MERLIC provides the perfect leverage here: Its graphical user interface makes it possible to configure complex machine vision applications, such as the precise matching of very small components, quickly and efficiently without sacrificing the performance of proven algorithms,” explains Ulf Schulmeyer, MERLIC Product Manager at MVTec.

MERLIC supports the application developed by Cellios in several ways. Within the image-processing workflow, powerful matching technologies enable the exact position and orientation of the crimps to be determined. In addition, MQTT and REST interfaces ensure seamless integration into the overall system, providing support that extends even beyond MERLIC’s core role as machine vision software.

MERLIC’s low setup effort and ease of use proved particularly advantageous: Two Cellios employees implemented the application using only videos and sample applications without any additional training. “Our collaboration with Cellios is an impressive demonstration of how machine vision is pushing the boundaries of what is possible in robotics. When robots learn to see with the same precision and flexibility as humans, even highly complex processes can be automated. MERLIC acts as the intelligence that translates image data into precise instructions for the robot,” Schulmeyer adds.

Pioneering advancement in wire harness assembly

The developments by Cellios and its project partner TE Connectivity are pioneering. The prototype was presented in November 2025, and the official market launch is planned for early 2027. The benefits of the solution extend far beyond simply increasing productivity: Automation makes wire harness production economically attractive again in high-wage countries such as Germany.

Shorter transport routes also significantly reduce the carbon footprint of production, setting new standards for sustainability. In addition, digital monitoring of every insertion operation improves quality and enables complete traceability of the wire harnesses.

Based on initial feedback and customer discussions, Cellios is already planning to extend the automation solution to additional wire harness variants and new areas such as control cabinet wiring. Future machine vision systems are also expected to be used for self-healing processes and advanced quality inspections.

The compact PushTrigger connectors offer high-performance connectivity for demanding industrial Ethernet applications, including automation, robotics, control systems, smart infrastructure, and transportation.

The HARTING ix Industrial PushTrigger IP20 connectors, now available at Mouser, feature a vibration-resistant push-pull locking mechanism and IDC termination, enabling fast, solder-free assembly. The PushTrigger IP20 connectors are compatible with all ix Industrial female connectors; and installation procedures remain the same when migrating from standard ix products. Up to 75% smaller than traditional RJ45 connectors, the PushTrigger IP20 series frees up space for additional connectors and assemblies while supporting Cat-6A Class EA transmission up to 500 MHz and data rates up to 10 Gbit/s.