In high-speed production lines of industries such as new energy, automotive electronics, and consumer electronics, the cable stripping process faces a triple challenge: high speed, high precision, and zero damage. Traditional mechanical stripping easily damages conductors and is inefficient, while chemical stripping pollutes the environment and has poor adaptability, making it difficult to match the production pace and precision processing requirements of high-speed lines ("tens of meters per minute"). Fly Laser, deeply understanding the needs of high-speed line scenarios, has created a dedicated high-speed laser stripping solution. This solution deeply integrates laser technology with high-speed production logic, becoming an "efficiency engine" for high-speed line mass production with its core advantages of "ultra-high speed, ultra-precision, zero damage, and full adaptability," redefining the speed and precision boundaries of cable processing.
一、Technological Innovation: The Core Strength of Fly High-Speed Laser Stripping
Fly Laser, addressing the continuous, large-scale, and flexible production characteristics of high-speed lines, has achieved technological breakthroughs in core areas such as laser light sources, motion control, and intelligent adaptation. This has enabled the company to build a complete technology system adapted to high-speed scenarios, allowing the wire stripping process to resonate with the high-speed production line.
（一）High-Speed Light Source + Galvanometer: Unlocking Millisecond-Level Stripping Speed
Fly Laser utilizes a self-developed high-power pulsed laser source (covering ultraviolet, fiber, and green wavelengths), achieving microsecond-level energy output response speed. Combined with a high-speed scanning galvanometer (scanning speed up to 10m/s), it can instantly complete the process of "laser triggering - insulation vaporization - residue cleaning." For cables continuously transported on high-speed lines, it supports a "flying stripping" mode—without interruption, the laser synchronously and precisely strips the cable as it moves at a constant speed (up to 60m/min) along with the production line. The stripping time for a single cable is as short as 3 milliseconds, improving efficiency by 5-8 times compared to traditional mechanical stripping, perfectly matching the high-speed production demands of high-speed lines.。
（二）Intelligent Positioning + Energy Control for Precise Stripping with Zero Damage
In high-speed production, cable misalignment and specification differences can easily lead to stripping errors. Fly Laser is equipped with an AI vision positioning system with a positioning accuracy of ±0.01mm. It can capture the cable position and insulation layer thickness in real time and dynamically compensate for the laser trajectory. Simultaneously, it employs an "energy layering control algorithm" to automatically match the laser energy according to the cable material (PVC, silicone, fluoroplastic, PTFE) and the number of insulation layers, ensuring that the laser only acts on the insulation layer and does not damage the internal conductor, shielding layer, or braided mesh. Even for ultra-fine electronic wires with a diameter of 0.08mm and high-voltage wire harnesses with multi-layer composite insulation, it can achieve "complete insulation stripping, zero conductor breakage, and zero shielding layer damage," with a product qualification rate consistently above 99%.
（三）Modular Design + Seamless Integration, Adaptable to "All-Scenario" High-Speed Production Lines
Fly laser wire stripping equipment adopts an integrated modular structure, with a compact size. It can be flexibly embedded in various high-speed production lines such as belt conveyors, chain conveyors, and roller conveyors, without requiring large-scale modifications to existing production lines. The installation and commissioning cycle is 3-5 days. The equipment supports compatibility with multiple cable specifications—from 0.05mm diameter micro electronic wires to 50mm diameter industrial cables, from single-core wires and multi-core ribbon cables to coaxial cables and high-voltage wire harnesses. Seamless switching between different products can be achieved simply by adjusting parameters through software and quickly changing tooling, adapting to the flexible production needs of "multi-variety, small-batch" high-speed production lines.
（四）Intelligent Linkage + Online Inspection: Building a Solid Quality Defense Line Throughout the Entire Process
Fly Laser's wire stripping equipment can seamlessly integrate with high-speed production line PLC and MES systems, enabling real-time synchronization of production parameters and full traceability of production data. A built-in online inspection module immediately detects insulation residue, conductor damage, and stripping length after stripping. Defective products are automatically diverted and alarmed to prevent them from flowing into the next process. Simultaneously, an automatic dust removal system quickly cleans vaporized insulation residue, maintaining a clean production environment without the need for additional manual cleaning, further improving the overall production efficiency of high-speed lines.
二、In-depth Application Scenario: A Powerful Tool for Mass Production of High-Speed Wires Across Industries
Fly Laser's high-speed wire stripping solutions have been deeply implemented in core industries such as new energy, automotive electronics, consumer electronics, and rail transportation. Addressing the processing pain points of high-speed wires in different fields, Feilai Laser provides customized solutions, becoming a preferred partner for leading companies.
（一）High-Voltage Wiring Harnesses and High-Speed Cables for New Energy Vehicles: Dual Guarantee of Safety and Efficiency
High-voltage wiring harnesses for new energy vehicles (battery pack connection wires, charging pile cables) need to withstand high voltage and high temperature. They often employ multi-layer insulation structures made of fluoroplastics and silicone, and the conductors are multi-strand fine copper wires. The daily production capacity of high-speed cables reaches tens of thousands of wires. Fly Laser utilizes fiber laser flying wire stripping technology, supporting wire speeds of 30-60 m/min. It can achieve various stripping styles, including long-distance (up to 10 m), loop, and segmented stripping. After stripping, the conductor integrity rate is 100%, and the insulation layer residue rate is <0.05%, completely solving the safety hazards caused by traditional mechanical stripping, such as broken copper wires and incomplete insulation layer removal. Currently, it has been integrated into the high-voltage wiring harness high-speed production lines of companies such as CATL, BYD, and XPeng Motors, helping to increase the daily production capacity of a single production line by more than three times.
（二）High-Speed Data Cables for Consumer Electronics: Miniaturization and High-Batch Production Adaptation
Data cables (Type-C, Lightning cables) and FFC/FPC ribbon cables for consumer electronics such as mobile phones and computers are characterized by being "ultra-fine, ultra-thin, and highly integrated." High-speed production rates reach 30-50 cables per minute. Feilai Laser utilizes ultraviolet laser cold processing technology, achieving a stripping precision of ±0.02mm for micro-cables with diameters of 0.08-0.5mm, eliminating heat-affected zones and preventing insulation melting and adhesion. It supports fine processes such as "window stripping" and "segmented stripping," adapting to special stripping requirements for data cable interfaces and ribbon cable solder joints. It has been applied to high-speed production lines of companies such as Huawei, Xiaomi, and Luxshare Precision, achieving stripping efficiency of 800-1000 cables per hour with a defect rate controlled below 0.1%.
（三）High-Speed Lines for Automotive Electronic Sensor Harnesses: Balancing Precision and Stability
Automotive autonomous driving sensors and onboard electronic equipment harnesses are characterized by diverse specifications and large production volumes. High-speed lines require rapid switching between multiple product types. Fly laser wire stripping equipment supports a "one-click model change" function, allowing parameter switching between different harness specifications in just 30 seconds without tool changes. Combined with visual positioning compensation technology, it can handle minor twisting and misalignment issues in the harness, ensuring stable stripping precision. It is suitable for high-speed production lines for engine harnesses, interior wiring harnesses, etc., reducing the number of operators by 2-3 per production line and increasing overall production efficiency by over 40%. It has already entered the supply chains of automakers such as SAIC, FAW, and Tesla.
（四）High-Speed Rail Transit/Industrial Cables: Breakthroughs in Large Size and High Strength
Rail transit signal cables and industrial control cables are mostly made of large-diameter (10-50mm) high-strength insulation materials. Traditional stripping methods are inefficient and produce uneven cuts, affecting subsequent assembly. Fly Laser utilizes high-power fiber laser stripping technology, enabling rapid stripping of insulation layers up to 5mm thick at a stripping speed of 1.5-2m/min, producing smooth, burr-free cuts without the need for subsequent grinding. It supports long-distance continuous stripping, adapting to the continuous processing needs of high-speed extrusion production lines for industrial cables. It has already been applied in the production bases of companies such as CRRC and CRCC, significantly reducing processing energy consumption and labor costs.
三、Core Value: Creating "Visible Benefits" for High-Speed Line Production
Fly Laser's high-speed line laser stripping solution not only solves technical pain points but also brings tangible mass production value to enterprises, achieving a triple upgrade in "efficiency, quality, and cost"：
（一）Increased Efficiency, Breaking Through Production Capacity Bottlenecks
The flying wire stripping mode is completely synchronized with high-speed lines, increasing stripping speed by 5-8 times compared to traditional technologies. The daily production capacity of a single high-speed production line can be increased by 2-3 times. Taking new energy high-voltage wire harnesses as an example, traditional mechanical stripping of a single wire takes approximately 20 seconds, while Fly Laser only takes 3 seconds, significantly shortening the production cycle and helping companies quickly respond to large-scale order demands.
（二）Quality Upgrade, Reduced Losses
Zero-damage wire stripping technology increases the product qualification rate from the traditional 95% to over 99.9%, reducing rework and scrap costs caused by conductor damage and insulation residue. Simultaneously, high stripping consistency ensures the stability of subsequent welding and assembly processes, improving the reliability of end products.
（三）Cost Optimization, Increased Profit Margin
Labor Costs: Fully automated processing requires no manual intervention. A single high-speed production line can reduce the number of operators by 2-4, saving hundreds of thousands of yuan in labor costs annually.
Consumable Costs: Laser wire stripping eliminates tool wear, requiring only periodic maintenance of optical components. Consumable costs are reduced by over 60% compared to traditional mechanical wire stripping.
Energy Costs: Laser processing consumes only one-third the energy of traditional methods, and eliminates additional expenses such as waste disposal and chemical reagent procurement, resulting in overall cost savings of over 40%.
（四）Service Guarantee: Full Lifecycle Support for Worry-Free High-Speed Production
The equipment supports rapid switching between multiple specifications and materials of cables without the need to modify the production line. It can quickly adapt to the needs of new product development and order specification changes, helping enterprises cope with market changes and improve their ability to resist risks.
四、Service Guarantee: Full lifecycle support, worry-free high-speed production
Fly Laser always prioritizes customer needs, providing comprehensive, end-to-end service support for high-speed production lines, making cooperation easier and production more stable:
Customized Solution Design: Our professional technical team goes deep into the production site to analyze high-speed line speeds, cable specifications, and processing requirements, tailoring wire stripping solutions to your specific needs, including equipment selection, layout design, parameter debugging, and tooling development;
Installation, Commissioning, and Training: Senior engineers provide on-site installation and commissioning, ensuring seamless integration of equipment with the high-speed line until the preset production efficiency is achieved; we provide systematic training for operators and maintenance personnel, covering operating procedures, parameter optimization, and troubleshooting, ensuring quick mastery;
After-Sales Response and Maintenance: We provide timely troubleshooting solutions and on-site service (except in special areas); we conduct regular on-site inspections and maintenance of equipment, and update software systems to ensure continuous and stable operation of the high-speed line;
Technical Upgrade Support: As high-speed line capacity increases and cable specifications evolve, we provide equipment upgrade services to ensure solutions always adapt to production needs and extend equipment lifespan.
五、Future Outlook: Intelligent Upgrades Leading a New Direction in High-Speed Wire Stripping
Facing the development trend of "intelligentization, high speed, and greening" in the manufacturing industry, Fly Laser will continue its technological innovation: integrating AI big data analysis to achieve automatic cable material identification, parameter self-optimization, and real-time production status early warning; developing higher-speed laser light sources and galvanometer systems to adapt to ultra-high-speed production lines exceeding 100m/min; and launching miniaturized and integrated equipment to meet the high-speed wire stripping needs of more niche markets, continuously injecting new momentum into high-speed wire production.
In the race for high-speed wire mass production, speed and precision are indispensable. Fly Laser's high-speed laser wire stripping solution, with technology as its blade and efficiency as its core, eliminates the wire stripping process as a bottleneck to production capacity, empowering enterprises to seize market opportunities with "light-speed precision." Choosing Fly Laser means choosing more efficient production capacity, more stable quality, and more economical costs, making high-speed wire stripping faster, more accurate, and more worry-free!
This article was provided by the Fly laser Technology Team. Please indicate the source when reprinting. Inquiry Hotline: 0769-22255585
Official Website: www.flylaser.cn
