Flexiv’s Automated Connector Assembly and Testing Solution

Connectors are essential components in virtually all electronic systems, as they enable energy and signal transmission between controllers, sensors, and actuators.

Often safety-critical, they come in multiple types and configurations that traditional automation solutions have difficulty accommodating.

Flexiv’s adaptive solution transforms connector assembly and testing by delivering unmatched speed, precision, and flexibility, coupled with the ability to adapt to your unique production environment.

Why Choose Flexiv’s Connector Solution?

Powered by advanced AI, optional computer vision, and industry-leading force sensitivity, our 7-axis Rizon robot intelligently identifies, positions, and assembles/tests connectors of all shapes and sizes, without the need for external compliance devices or reprogramming.

Whether you're in the automotive, telecom, or electronics sector, Flexiv ensures seamless integration, easy adaptability, and top-tier performance.

Solution Overview

Flexiv 's adaptive connector assembly and testing solution harnesses advanced force control to accurately "feel out" the location of sockets and connectors for joining or testing. Working without computer vision, external sensors, or compliance devices, operators can tailor an optimal work path by physically manipulating the robot in free-drive mode and plotting locations using the Elements graphical programming system. This ability to quickly create or refine the program enables rapid line changeovers, reduces commissioning time, and enhances overall efficiency and precision.

• Self-adjusting with minimal setup
• Handles complex, unpredictable tasks
• No need for extensive reprogramming or tooling changes

What Makes Our Robots Adaptive?

Flexiv’s adaptive robots are engineered to think and react in real time.

Unlike cobots that rigidly follow preset trajectories, adaptive robots use AI coupled with  torque sensors in each of their seven degrees of freedom and real-time force control to adapt to product variation, positioning changes, and external interference. This enables our robots to react to being bumped, insert a plug even if the socket is misaligned, and complete polishing and grinding tasks using standard off-the-shelf tools.

System Highlights

• AI Vision + Force Control: Instantly identifies connector types and positions, even in cluttered environments.
• Plug & Play Integration: Works with virtually any end effector. Minimal setup. No external compliance devices needed.
• Speed & Precision: Achieves sub-one-second assembly time with millimeter-level 6D pose recognition.
• Built-in Quality Assurance: Automatically checks plug insertion.

Industry Proven Applications

• Automotive Electronics: Wire Harness Connector Assembly
• Car Assembly: Secure Connector Insertion
• Consumer Electronics (3C): Smart Connector Insertion and Testing
• Home Appliances: Part Insertion and Connector Testing

System Components

• Flexiv Rizon Robot 
• Customizable End-of-Arm Tooling (EOAT)
• Material Handling Module
• Vision-Based Positioning Module
• Insertion Module

Key Specifications

• Connector Size Range: 3 mm to 60 mm
• Insertion Force: 0.1 N to 40 N
• Precision: Millimeter-Level Detection & Real-Time Obstacle Avoidance
• Adaptability: Instantly Transition Between Product Lines Using AI-Driven Knowledge Base

Boost Productivity. Cut Downtime. Future-Proof Your Factory.

Flexiv 's adaptive connector solution delivers the flexibility and intelligence your operations demand, with a proven track record in high-mix, high-precision environments.

Request a Quote and let us show you how Flexiv can transform your production line.