Cable assembly is the process of combining cables and connectors for electronic or electrical applications, ensuring reliable connections in various industries.

In a cooperative partnership we support our customers from the development to the serial production of wire harnesses, no matter if for large or small series. We adapt to your needs. Using the latest software, we can route cable harnesses through complete assemblies (e.g. vehicle cabins) and derive drawings. If no corresponding documentation and drawings are available, we create them ourselves, including material lists and connection lists. Depending on the cable harness and the project, we provide this service free of charge if there is a realistic chance of also receiving the series order.

CRIMPING

Crimping creates homogeneous and gas-tight electrical connections between crimp contact and conductor. We can crimp almost all cable cross-sections with and without seal and thus create a non-positive and secure connection. Process monitoring is documented by crimp height, pull-off force, crimp force monitoring and micrographs.

SOLDERING AND TINNING

The soldering and tinning of cable connections in circuit boards and printed circuit boards is either done with a wave soldering machine or manually. From classic manual soldering to beam and reflow soldering – our specially trained employees guarantee consistent quality.

ULTRASONIC WELDING

Resistance and ultrasonic welding can be used to create excellent electrical connections for e.g. high-voltage applications. In addition to thermal plastics, non-ferrous metals such as copper, brass and various alloys are also suitable for the ultrasonic welding process.

SPLICING AND JOINING

Cable ends can be connected semi-automatically with parallel connectors, with splice tape or by ultrasonic welding. Splicing is the process of permanently connecting two or more electrical conductors. Different and identical types of conductors can be connected together. The stability of the connection can be checked by using the appropriate software.

WRAP / BRAID / BANDAGE

Wire harnesses can be wrapped by hand, semi-automatically or with CNC winding machines. The braiding of wire harnesses with special nylon or metal yarns as mechanical protection also allows the use in particularly rough environments (e.g. at particularly high temperatures) under heavy stress. Additionally, disturbing noises (e.g. knocking and rattling) caused by vibrations can be avoided. During taping, the individual cables are bundled and connected ready for installation.

TWISTING

In order to be able to transmit CAN bus signals without interference, for example, a process-safe twisting of the individual wires is necessary. With automatic twisting machines, predetermined lay lengths can be permanently maintained.

INSULATION AND CABLE PROTECTION

In addition to insulation, the protection of the cables against mechanical stress is also an important reason for the use of insulating sleeves (e.g. PVC, silicone, glass silk), shrink sleeves and corrugated pipes.

OVERMOULDING AND CASTING

The low-cost hot-melt process (low-pressure injection moulding) allows individual overmolding of sensors, circuit boards, plugs and cables to protect against mechanical stress (e.g. bend protection, strain relief, etc.) and to seal electrical components. Usually, the components are overmolded with a black thermoplastic elastomer (TPE) or polyamide (PA) or cast with resins. The tools required for this are usually made of inexpensive aluminium.

PRINTING AND MARKING

For the marking of cable harnesses, cables, housings, connectors, hoses etc. we use either the inkjet or the pad printing process. Both methods mark directly and are abrasion-resistant. In addition, there is also the possibility of attaching a label or an inscribed shrink sleeve for identification. The selection is made according to the quality requirements of the customer.

LABELLING

In order to facilitate the assembly and disassembly of wire harnesses and wire harnesses, they can be marked with e.g. written flags, printed heat shrinkable sleeves, labels etc. Data codes and company logos can also be applied. Tested cables receive a label with article numbers, test date and lot number as standard to ensure easy traceability.

MECHANICAL AND ELECTRONIC CONTROLS

Supported by international partners in the field of electronic development, we design and manufacture control units and electronic control systems according to customer specifications. The assembled circuit boards can be mounted on cable sets in our component assembly department or incorporated into products. On request, the boards can also be potted to protect them from external influences.

ELECTRICAL FINAL TEST

Before delivery, each cable harness is checked in a procedure individually agreed with the customer – by means of electrical, continuity, functional, visual, dimensional and geometric tests – for its electrical function, possible assembly errors and the presence of all components. All measurement results are recorded, documented and stored in an audit-proof manner in accordance with the applicable standards.