Supporting Quality Assurance and Labor Savings on Automotive Manufacturing Floors
Full-Scale Launch of "CARA": A Total Solution from Automated Connector Mating Verification to Equipment Installation

I-PEX Inc. (Headquarters: Shimogyo-ku, Kyoto; Representative Director and President: Reiji Konishi; hereinafter "I-PEX") is launching full-scale sales of CARA (Connector Assembly Robotics Automation), an automated connector mating assurance system that provides one-stop service from verification of automated connector mating through equipment installation.

In the automotive industry, driven by the shift to EVs and the advance of electronic control, achieving both automation of manufacturing processes and quality assurance has become a critical challenge.

CARA is a total solution that provides one-stop support—from initial assessment (consulting) through verification and equipment installation—to automate the highly challenging connector mating process. Verification for establishing the fundamental technology can be completed in as little as approximately one month, and by achieving both automation and quality assurance, CARA contributes to labor savings, higher productivity, and stronger traceability on the manufacturing floor.

Through this initiative, I-PEX will support the resolution of process challenges on manufacturing floors in the automotive industry and beyond, and accelerate its business development as an "Innovative Product development & Engineering solutions eXpert."

CARA Lab

Background

In recent years, labor shortages and lack of skilled technicians have become increasingly serious in the manufacturing industry, making productivity improvement through automation a key management challenge. In the automotive industry, advances in electrification (EVs) and electronic control have driven higher performance and higher-density mounting of in-vehicle electronic devices.

Against this backdrop, automation on manufacturing floors is accelerating. In the connector mating process, however, even slight misalignment or incomplete mating can lead to defects, making "quality assurance after automation" a major challenge.

In addition, automotive manufacturers and automotive parts manufacturers are placing growing demands on the visualization of quality data and traceability, expanding the need for systems that detect anomalies within the process and assure quality.

CARA: A Total Solution for Automated Connector Mating

CARA is a total solution for realizing automated connector mating. It provides one-stop service covering initial assessment (consulting), verification, equipment proposal, and manufacturing and installation.

CARA supports not only I-PEX connectors but also connectors made by other manufacturers, enabling optimal automation tailored to each customer's manufacturing process and product specifications. By integrating robotics, AI-powered vision systems, and sensing technology, it achieves highly precise connector mating operations.

Furthermore, torque sensors detect changes in force and abnormal loads during mating in real time, identifying abnormal conditions such as misalignment and incomplete mating within the process. The collected data can also be used for in-process quality assurance and enhanced traceability.

Features of CARA

• Verification for establishing fundamental technology in as little as approximately one month
• One-stop support from verification of automated connector mating to equipment installation
• Real-time detection of anomalies such as incomplete mating
• Mating assurance system aiming for a 0% defect rate
• Supports visualization of process quality and enhanced traceability
• Compatible with connectors other than those made by I-PEX

Future Outlook

I-PEX supports customers in solving challenges in their manufacturing processes by integrating technologies such as precision molds, connectors, sensing, and automation equipment. Through CARA, I-PEX will contribute to achieving both automation and quality assurance on manufacturing floors in the automotive industry and beyond, and will strengthen the development of its solutions business as an "Innovative Product development & Engineering solutions eXpert."

Related Links

CARA (Connector Assembly Robotics Automation) Product Page

CARA automated connector mating demonstration videos

Automated connector mating demonstration on a router (RF connector)

Automated connector mating demonstration (Board-to-Board connector, RF connector, FPC connector)

About I-PEX Inc.

I-PEX stands for “Innovative Product development & Engineering solutions eXpert” providing value in the form of inspiration and astonishment in the global marketplace. The company was founded in 1963 as Dai-ichi Seiko, a precision mold manufacturer, and has since produced numerous world-firsts and unique products and solutions. I-PEX currently operates in five business fields: Connectors, Contract Manufacturing (Automotive Components & Electronics Components), Molds & Equipment, MEMS Foundry, Energy Solutions. By delivering the sharpest tip to the world, we will contribute to exciting value-creation in the digitalized society by working globally with every client who open up the new era.