More Efficient Control Cabinet Wiring

Automation for Competitiveness

According to a study conducted by WAGO in collaboration with Statista+ on automation in control cabinet and mechanical engineering, 70% of respondents see the greatest potential in increasing efficiency and productivity, 56% in enhancing competitiveness, and 41% in addressing the skilled labor shortage*. This clearly shows that automation is not just a tool for improving efficiency — it is a strategic necessity for staying competitive.

Fully Automatic Conductor Preparation

The WAGO Cabinet Wiring Robot features a fully automated conductor preparation station that handles up to 16 different conductors. Each conductor is cut to length, stripped, crimped, and printed — ready for precise use at each clamping point. This significantly reduces manual workload during wire assembly, one of the most time-consuming steps in control cabinet manufacturing. The system currently supports conductor cross-sections from 0.5 to 2.5 mm² (approximately 20 to 14 AWG) and conductor lengths between 300 and 2,500 mm (about 11.8 to 98.4 inches). After wire-end processing, each conductor undergoes a pull-out test to verify quality. If the quality of each conductor is assured, the fully prepared conductors are transferred either to the wiring robot or — optionally — to a skilled operator.

Compatible with Components from Any Manufacturer

The WAGO Cabinet Wiring Robot is a high-precision, modular portal robot with 4.5 axes, a 12-slot tool magazine, and up to 7 screw bits. It wires components from various manufacturers on DIN-rail assemblies, racks, or mounting plates in under 45 seconds per conductor. Both screw and spring pressure connections are supported, making the system ideal for diverse applications.

Process Safety

To ensure maximum quality, each screw connection undergoes a pull-out test after wiring. Spring connections are force-torque monitored. An integrated camera and laser system performs a target/actual comparison before each job to verify component placement. If deviations are detected, the robot adjusts its wiring path based on the digital order data to enhance process reliability.

Skilled Labor Relief

To streamline the process, the second side of each wire is pre-assembled. The operator only needs to lay and connect it on the back of racks or in cable ducts. Wires not handled by the robot are also pre-assembled and placed in a wire receptacle for manual use.

The operator is not made redundant. Instead, they are relieved of time-consuming manual tasks, such as wire preparation, and actively supported through one-sided wiring. Cable routing and connecting the second side of the wire remain the operator’s responsibility, as do the final inspections. However, thanks to the wire preparation station and the wiring robot, significantly more time is now available for these tasks. Health considerations also play an important role: For workers with musculoskeletal issues, support during wire preparation and/or wiring offers substantial relief in day-to-day operations.

Optimal Integration Options

A key advantage of the WAGO Cabinet Wiring Robot is easy integration into existing system environments — no 3D CAE engineering required. Simple cable lists and rail assembly data from tools like the WAGO Smart Designer Configurator are sufficient to operate both the wire preparation station and the robot.

Application Examples

1. Building Distribution Box Construction

The construction of distribution cabinets is an ideal application for the WAGO Cabinet Wiring Robot. Many components in the DIN 43880 rail-mount format share similar dimensions, and interference from adjacent, taller components is largely avoided. The open rack design, rear-side cable routing, and spacious layout provide optimal conditions for automated partial wiring, which simplifies downstream cable routing and second-side wiring. The robot’s wiring area spans up to 750 mm (approximately 29.5 inches) in width, allowing it to cover up to three fields within the distribution cabinet.

2. Control Cabinet Manufacturing

In control cabinet manufacturing, the mounting plate often provides ample space — typically 1,800 mm × 750 mm (approximately 70.9 × 29.5 inches) — especially when vertical cable ducts are installed along the sides.

The WAGO Cabinet Wiring Robot can be used effectively here, although its working area may be limited by densely packed components or pre-installed cable ducts. This can be addressed by optimizing the sequence, for example, installing cable ducts after wiring. A practical approach involves pre-assembling DIN-rails and feeding them to the robot via a rail carriage. The robot wires the rails, which are then mounted in their final position.

This method is particularly efficient in series machine production, where rail carriages can be loaded with either cabinet-specific sets or identical rails. Using multiple carriages ensures a smooth, continuous process.

Future-Proof Installation through Process Automation

Modular Robotic Stations for Control Cabinet Manufacturing

Automation in control cabinet manufacturing is a key factor for future readiness, especially in light of the skilled labor shortage and ongoing digitalization. Partial automation of process steps, such as wiring with the WAGO Cabinet Wiring Robot, changes how work is performed without eliminating essential tasks. Human expertise remains indispensable. Thanks to their skills — such as precision, adaptability, and process knowledge — operators can take on more qualified roles, including monitoring, coordination, and system control. This is also reflected in the findings of the WAGO and Statista+ study on automation. Companies in switchgear manufacturing that invested in automation reported not only cost reductions (79%) and faster production (58%), but also significant progress in addressing the skilled labor shortage by utilizing skilled workers more efficiently (68%) and relieving their workforce (63%)*.

*Source: WAGO and Statista+ study on automation in control cabinet and mechanical engineering