When we identified an opportunity to enhance our cable and connector casting process, we turned to our trusted partner, Emox AS, for help. As a result, we were able to streamline production and solve practical challenges in our workflow. This article describes how we co-developed a custom cable moulding workstation that streamlines production and solves practical challenges in our workflow.
In-house cable production at Ixys
At Ixys, we specialise in designing and manufacturing high-quality cable assemblies and solutions for demanding environments. Our commitment to precision, reliability, and efficiency drives us to continuously improve our production processes. For example, whether it is custom cable assemblies, overmoulding, or connector integration, we ensure that every product meets the highest standards of quality and performance.
A critical part of our production process involves cable and connector casting. Here, connectors are encapsulated to ensure durability, protection against environmental factors, and long-term reliability. This process requires meticulous attention to detail, because even the smallest inconsistency can impact the final product’s performance. Therefore, we are always looking for ways to enhance our workflows and reduce inefficiencies, as we did when we automated the process of mixing components in the moulding compound.
The challenge of connector casting and cable management
We needed a custom cable moulding workstation that could:
- Support connectors during the casting process
- Keep cables suspended and organised to avoid tangling or misalignment
- Prevent excess casting material from dripping onto the floor
Overall, these requirements were essential to improving efficiency, precision, and cleanliness in our production environment.
A custom cable moulding workstation
Through close collaboration with Emox AS, we co-developed a mobile custom cable moulding workstation tailored to our specific needs. As a result, we got a versatile and efficient system.
Key features of the custom cable moulding workstation
- Adjustable connector fixtures: Designed to accommodate different casting configurations, ensuring flexibility for various production scenarios.
- Cable suspension system: Keeps cables organised and elevated, reducing the risk of errors and improving workflow.
- Integrated drip trays: Collects excess casting material, maintaining a clean and safe workspace.
- Bosch Rexroth aluminium profiles: Provides a robust yet flexible framework that can be easily adjusted as needs change.
- Mobile construction: Allows the workstation to be moved effortlessly.
In addition, one of the standout features of this workstation is its modular design, which allows for future modifications and expansions as our production requirements evolve. Together with our automated mixing system, it forms part of a broader modernisation of our production line.
Local production and a low carbon footprint
By partnering with Emox AS, an engineering company based in Sandnes, Norway, Ixys supports local industry. This also shortens the supply chain. Producing and assembling the custom cable moulding workstation close to our own facilities reduces transport-related emissions and strengthens Norwegian industrial expertise.
Moreover, the custom cable moulding workstation frame is built with Bosch Rexroth aluminium profiles, which are low-carbon aluminium profiles made from CO2-reduced aluminium. As a Bosch Rexroth authorized partner in Norway, Emox supplied these profiles, ensuring a robust framework with a significantly lower carbon footprint than conventional aluminium.
Similarly, the custom components Emox produced in-house are designed around extended service life, a low environmental footprint, and increased utilisation of raw materials.
From sketch to finished workstation
This project began with Jann, our Production Manager, who identified an opportunity to improve our casting process. He sketched out the first concept for a custom cable moulding workstation that addressed our key challenges.
«The custom cable moulding workstation has improved efficiency and cleanliness in our production, and its modular design allows it to evolve with our needs.»
Jann Fatnes
Workshop Manager, Ixys
This initial sketch was therefore the first step in turning an idea into a tangible solution.
Emox transformed the sketch into a detailed technical drawing, incorporating their engineering expertise to ensure functionality, flexibility, and durability.
Ultimately, by combining Ixys’ operational insights with Emox’s engineering expertise, we were able to develop a solution that is both practical and innovative.
“The best solutions often start with the people who know the process best. By working closely with Ixys and understanding their specific requirements, we were able to turn their ideas into a practical, flexible workstation tailored to their cable moulding process.”
Torleif Carlsen
Engineering Manager, Emox
In conclusion, the custom cable moulding workstation has made our connector casting process more efficient, precise, and clean. Its modular design means it will continue to evolve together with our production needs.
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