# Optimizing Assembly in Wiring Boxes Using API Technology for Digital Twin
## 5 Results  
The results achieved from automating the assembly process in wiring boxes using API technology for digital twin are as follows:  
* Novelty of the approach: this study is the first to apply a fully automated, digitally controlled process for fuse insertion, Figure 15, which solves existing quality and performance issues. * Accuracy and precision: The robotic system, integrated with digital twin technology, achieved a fuse insertion accuracy rate of 99.5%. This represents a significant improvement over manual insertion, which often results in misalignments such as angled or incomplete insertion, leading to a suboptimal electrical contact and potential rework. By utilizing real-time feedback from the digital twin, the automated system consistently ensured that fuses were inserted at the correct angle and depth, mitigating the common errors associated with manual assembly. * Force control and component integrity: Another critical factor in the automation process was the precise control of insertion force. The system applied just enough pressure to secure the fuse without causing damage, Figure 16. This is an improvement over manual processes, where excessive or insufficient force often leads to defects or damaged components. The force applied by the robotic arm was consistently  
Figure 15: The wiring box with fuses assembled by robot. measured and controlled, ensuring the reliable and secure insertion of each fuse, thus enhancing the quality and reliability of the wiring box assembly. * Time efficiency: The cycle time for manual fuse insertion typically ranged between 40 and 45 s per fuse, depending on the operator's skill and the complexity of the fuse box. With the automated system, this time was significantly reduced to 22-25 s per fuse, reflecting a nearly 50% improvement in efficiency. This reduction in cycle time was achieved without compromising accuracy or quality, making the automated process both faster and more reliable than manual alternatives. * System flexibility: The system demonstrated the flexibility to handle slight variations in fuse dimensions and box configurations. The combination of computer vision and digital twin technology allowed the system to adapt to these variations without requiring extensive recalibration or adjustments, showcasing its potential for handling different fuse box designs in dynamic production environments. The gripper design, optimized through iterative testing, enabled the robotic arm to handle delicate components with a minimal risk of damage. * Continuous operation and reliability: During extended testing, the system demonstrated high reliability, operating continuously over long periods without significant faults or errors. This robustness is crucial for its potential application in full-scale production environments, where continuous, uninterrupted operation is necessary to maintain productivity. The real-time monitoring capabilities of the digital twin allowed for ongoing adjustments to be made, ensuring optimal performance throughout the assembly process. * Gripper design optimization: The design of the gripper was optimized through multiple iterations to ensure that it could securely grasp the fuses without causing damage. The adjustments to the gripper's shape and the force it applied were crucial for handling the small, sensitive components involved in the assembly process. This iterative testing led to a gripper design capable of maintaining a firm hold on each fuse while allowing precise control during insertion. * Scalability and adaptability: The system's adaptability to different box configurations was another significant advantage. The automated process proved scalable and capable of handling various wiring box setups with minimal adjustments, making it suitable for a wide range of automotive applications. This scalability was further enhanced by the digital twin's simulation capabilities, which allowed for the virtual testing of multiple scenarios, reducing the need for physical prototypes.