FCI Automotive announced the launch of what it calls the world's first complete interconnection system used in the automated assembly of flex cable harnesses for the automotive industry. The high-density and modular ModuPack system, designed to deliver reliability in automated volume assembly, helps reduce cable harness weight by 50% while reducing applied cost.

The heart of the ModuPack system is a range of pre-loaded modular multi-way connectors for flat flexible wiring, complemented by a comprehensive range of application tooling and training services designed to simplify the introduction of this new technology to existing plants or new facilities.

It offers connector modules pre-loaded with a combination of miniature and power terminals - and for the first time makes the replacement of most wires within the passenger compartment with flex cable practical.

ModuPack was created out of FCI's experience with flex interconnections systems for consumer applications, and its market-leading position in a range of automotive applications such as safety restraints. Another breakthrough with the product is its ability to be reel-fed into the assembly process, enabling automated mass termination to the flex circuitry.

For maximum reliability, the product features FCI's StarCrimp termination technology, which provides a robust multi-point termination requiring no preparation of the flex cable. Further development work has also ensured that existing crimping presses can be upgraded to handle this new technology so harness makers can adopt the technology with minimal disruption.

In addition to offering the versatility to connect flex-to-flex, flex-to-PCB, and flex-to-wire, ModuPack enables signal and power terminals to be combined within the same module using a variety of plated terminal configurations. The system also incorporates an innovative strain relief mechanism, which automatically secures the flex cable when the connector is terminated. This provides protection at all manufacturing stages -- from harness assembly through installation to in-service life. For maximum versatility, the ModuPack system will be available in both single and multi-row configurations.

FCI also offers a complementary range of components for all elements of flex harness structuring such as splicing, grounding, and shunting.