More Efficient Control Cabinet Wiring

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.

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.

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.

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.

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