Schalksmühle, November 2026. Flexible wire harness production with consistent quality and efficient throughput: With the VARICON 7000-Modula, Lumberg offers an entry-level fully automatic machine for processing discrete conductors with RAST connectors. Designed for basic wire harnesses, the system combines insulation displacement termination (IDT) with open wire ends or crimped terminations. It provides manufacturers with an automated solution for a broad range of harness configurations.

The VARICON 7000-Modula processes connectors supplied in linked strips from the RAST 2.5, RAST 2.5 Power, and RAST 5 systems, with pitches of 2.5 and 5.0 mm, respectively, and supports all available pin counts. It automatically separates the connectors and ensures efficient feeding of a RAST connector from any of these systems.

A key advantage is the ability to integrate an existing Lumberg semi-automatic machine. Within a single cable assembly, different, freely selectable wire lengths ranging from 70 to 1,150 mm can be processed using a three-, six-, or eight-position wire changer. This allows manufacturers to produce a wide variety of cable assembly configurations while retaining all the benefits of automated production. Both unterminated and crimp-terminated wire ends are supported. With cycle times of approximately 2.8 seconds for IDT-to-crimp connections and just 2.0 seconds for IDT-to-unterminated wire connections, the VARICON 7000-Modula also delivers high productivity and efficient processing.

The integrated quality assurance system includes precise insulation displacement termination (IDT), verification of wire end positions, and crimp force monitoring. The machine also features an interface for production data acquisition and remote configuration of cable assemblies. The VARICON 7000-Modula thus combines versatile cable assembly capabilities and process control with a cost-effective entry into fully automated production.

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