Machinery: Komax, Schleuniger, Schunk, Schäfer

Process

Monitored during processing, tested on the finished wiring harness.

Two kinds of control complement each other. The machines monitor every processing step while it happens. The final electrical test confirms at the end that the finished wiring harness is connected correctly.

Process monitoring
Takes place inside the machine while a wire is being made: does a blade touch the conductor? Is the stripping clean? Is the seal seated correctly? Is the force curve right during crimping? Any wire that stands out is sorted out immediately.
Final electrical test
Takes place on the finished wiring harness: is every wire connected to the right contact, are there open circuits or short circuits? High voltage, functional and load tests are added depending on the requirement.

Fully automatic cable machine Since 2020

Komax Gamma 450

In 2020 Powertune invested in a further fully automatic cable machine: the Komax Gamma 450. The wire runs from the reel into the machine, is cut to length, stripped at both ends and fitted with a single wire seal and a crimp contact: all in one pass, without a manual step between the individual stages.

ProcessesSingle wires for wiring harnesses and cable sets, with a seal and a crimp contact on both sides: each side has a C1370 crimp module and an S1441 seal module.
Suitable forRecurring wires in pre-series and series production, many similar cores, sealed connections.
MonitorsThe crimp force monitoring records the force curve of every crimp and detects deviations such as missing strands. The incision monitoring reports when a blade touches the conductor during stripping. Cameras (Komax Q1240) check the stripping and the seating of the seals; faulty wires are cut up and rejected. Before production starts, the crimp height is checked with the Komax 341 measuring device.
Your benefitThe first wire of an order is made in exactly the same way as the thousandth, with process data that can be documented.
Next stepThe finished cores go into assembly on the assembly board.

To series production Send your enquiry

Schematic · values as examples

Semi-automatic machine Investment 2026

Komax Delta 260

In March 2026 Powertune invested in a Komax Delta 260; the machine is in operation. An employee feeds the wire, the machine strips it, fits the single wire seal and crimps the contact, all in one operation. That is semi-automatic processing: the person sets the pace, the machine determines force and dimension.

ProcessesSingle wires and cores from cables that have already had the jacket removed and that are to receive a sealed crimp contact. The wire stays in a fixed position during processing, which also suits pre-assembled and multi core cables.
Suitable forSamples and small batch sizes, wires that do not come from a reel, and contacts that cannot be processed on the fully automatic machine. Short set-up times mean quick samples.
MonitorsCrimp force monitoring is integrated in this series and detects missing strands, wrong cross sections and insulation in the conductor crimp. The crimp height is set automatically.
Your benefitSingle pieces and pre-series parts are made with a monitored crimp as well, not only series production.

To the article about the investment To prototyping

Semi-automatic machine Investment 2026

Schäfer SealLine 240-1 ADVANCED

The SealLine 240-1 ADVANCED from Schäfer was added in March 2026 as well. It is in operation too. The operator inserts a single wire, the machine strips it, fits the seal and crimps the contact. Seals and contacts are fed in the correct orientation, and the operation starts automatically.

ProcessesSingle wires with a sealed crimp contact, including large seals and hard shell seals up to Ø 17 mm.
Suitable forSealed connections in samples, small series and series production, especially with seals that are larger than the fully automatic machine can handle.
Your benefitMore capacity for sealed contacts and therefore shorter lead times for samples and small series.

Technical article on single wire seals

Cutting to length and stripping

Komax Kappa 340 and Kappa 310

Before a cable receives contacts it has to be cut to length, and often the jacket has to come off. The Kappa 310 cuts and strips single wires and stranded wires. The Kappa 340 is built for the demanding cases: shielded multi core cables, battery, sensor, flat and high voltage cables. Since 2023 it has been working here with a rotary incision unit, a slitting unit and a pull-off device with a cable accumulator.

ProcessesSingle wires (Kappa 310) as well as jacketed and multi core cables with shielding, inner conductors and thick insulation (Kappa 340).
Rotary unitCuts into the jacket all the way round at a programmed diameter, over several layers as well. Strong on complex jackets and quick to change over.
Slitting unitSlits the jacket lengthwise. This makes intermediate stripping possible, and long pieces of jacket can be pulled off easily.
ZG 200 pull-off devicePulls the cable off the reel; the cable accumulator buffers material and relieves the cable.
Your benefitIdentical lengths and identical jacket stripping dimensions across the whole batch: the basis for a wiring harness that fits on the assembly board without rework.

Precision stripping Investment 2026

Schleuniger Strip B340

Four rotating blades arranged in an X shape cut into the insulation concentrically without damaging the conductor. That is decisive with fine strands, thin walled insulation and sensor cables: a damaged individual strand often only becomes apparent in service.

ProcessesSingle stranded wires, sensor cables and multi core cables up to an outer diameter of 9 mm.
Suitable forFine cross sections and sensitive insulation, where a concentric cut matters more than speed.
Your benefitClean stripping points without notched strands: a good basis for a crimp, a soldered joint or an ultrasonic connection.

To the article about the B340

Stripping single wires Since 2022

Komax Mira 230

The Mira 230 strips single wires and processes the inner conductors of multi core cables one after another in sequences: stripping and shortening without changing the program.

ProcessesSingle wires and the inner conductors of multi core cables, in programmed sequences as well.
EquipmentV blades for a wide range of cross sections without a blade change, thin grippers for short cable ends (8 mm insertion depth) and non marking grippers for sensitive surfaces.
Your benefitEven stripping with short ends and sensitive insulation as well: a good basis for a crimp, a soldered joint or a wire end ferrule.

Joining technology Since 2023

Ultrasonic splices with the Schunk Minic-III

Since 2023 we have welded strands with a Schunk Minic-III: several strands are welded together by high frequency vibration under pressure, without solder and without an additional sleeve. This creates an electrical node, for example a through node or an end node, that connects several cores reliably.

ProcessesBare strands of several cores in copper or aluminium, including mixed joints, brought together at one node.
Suitable forEarth and supply distributions and anywhere several cores come together electrically at one point.
MonitorsThe machine records the process data of every weld; a digital displacement measuring system measures the geometry of the node.
Your benefitCompact joints in the same material that are easy to protect inside the wiring harness. We agree with you which test a splice receives in your project.
In the editorYou can create an electrical splice explicitly in the wiring harness sketch, separately from the geometric branch.

Technical article on ultrasonic splices Sketch your wiring harness

Preparation and assembly

Twisting, taping, cutting.

Between contacting and the final test there are steps that a wiring harness needs just as much: twisted pairs, tape wrapping and tubing cut to length. We have machines for those too.

Schematic · values as examples

Twisting · since 2023

Komax bt 188 T

Semi-automatic twisting machine for two cables, optionally three or four, with an adjustable lay length, for low interference signal and data cables.

2 × 0.08 to 4 mm² · lay length 8 to 50 mm · twisted length approx. 200 to 2,300 mm

Taping · since 2021

KTHB Smart

Bench taping unit with an open winding head: wraps cables and wiring harness branches with adhesive tape, fed by hand, suitable for long branches, samples and small quantities.

Wiring harness Ø 3 to 25 mm · tape width 9 to 19 mm

Bundling · since 2023

KTB 50 E PLUS

Electric bundling machine: applies spot tapes for bundling, fixing, insulating and marking, in around 1.8 seconds per tape.

Bundle Ø 2 to 15 mm · tape width 9 to 50 mm

Cutting · since 2020

GlobalCut 100 PRO

Electric cutting machine, used here mainly for tubing: cuts tubing, flat tapes and stranded wires to length under program control.

Cutting width up to 100 mm · stranded wires up to 35 mm² · feed 1.5 m/s

Key data: typical values from manufacturer or dealer documents. KTHB Smart and KTB 50 E PLUS come from KABATEC, today Komax Taping.

Contact processing and assembly

Crimping presses, manual workstations, assembly board

Not every contact goes through an automatic machine. We process large cross sections, cable lugs, special contacts and single pieces on crimping presses with the matching tool. Tinning and soldering are done at ESD protected workstations.

AssemblyOn the assembly board the individual cores are laid out into the wiring harness, bundled, protected with corrugated tube, braided sleeve or heat shrink tubing, and marked.
Suitable forPrototypes, small series, battery and power cables, cable lugs, special contacts and the final assembly of every wiring harness.
Your benefitFlexible for the sample, careful during assembly and with the same documentation as in series production.
ToolsEvery contact needs its own crimping tool. Our crimping tools are set up for each contact and cross section range and carry their own tool number with a DataMatrix code. That way every tool is clearly assigned.

Electrical testing

What we test is the finished wiring harness.

Since 2011 our automated system has tested wiring, resistance and cable faults and recorded the results. We test continuity and short circuits on every wiring harness. High voltage, functional and load tests are added depending on the requirement. Today we work with two test systems from Engberts (iCAT): every connector of the wiring harness is plugged onto a matching test module, the test software guides you through the sequence and shows the result directly at the workstation.

TestsWhether every wire arrives at the right contact, whether there are open circuits or short circuits, and further characteristics to your specification on request.
DocumentationWe produce test records and measurement reports with every delivery on request.
Test modulesThere is a matching test module with the mating connector for every connector, marked with its own number and a DataMatrix code. According to the manufacturer the system recognises the position of the modules on the test bench and can be changed over to other wiring harnesses quickly, without adapter wiring. We test wiring harnesses with open cable ends on test boards: the ends are labelled and contacted through terminals.
DifferenceProcess monitoring assesses individual processing steps, the final test assesses the finished product. Only the two together give a complete picture.

Testing & documentation To quality management

Design

EPLAN Harness proD in our own design office

Since 2023 we have designed cable systems ourselves. From your 3D data, a drawing, a sample or a description we create the routing of the wiring harness in its installation situation. From that we derive the 2D drawing for the assembly board, bills of materials, cutting lists and work instructions.

You supplyWhat the cable set has to achieve: connections, installation space, environment, quantity. We are glad to use existing drawings or 3D data, but they are not required.
We supplyDesign, selection of cables, connectors and protection, samples and series production: all from a single source.
Your benefitShort distances between design and production: changes from the sample feed straight into the documents for series production.

To development & design

Investments

Machinery that grows with us.

Since 2020 we have invested deliberately in automation and process monitoring. An overview of the most important machines.

2020
A further fully automatic cable machine
In October a GlobalCut 100 PRO for tubing, flat tapes and stranded wires, in November a Komax Gamma 450 with two crimp modules and two seal modules, camera inspection, incision monitoring and crimp height measurement.
2021
Taping
In November a KTHB Smart taping unit for cables and wiring harness branches.
2022
Stripping single wires
In August a Komax Mira 230 with V blades and thin, non marking grippers.
2023
Ultrasonic welding, bundling, twisting, jacket stripping
In March a Schunk Minic-III for ultrasonic splices and a KTB 50 E PLUS electric bundling machine, in April a Komax bt 188 T twisting machine, in June a Komax Kappa 340 with a rotary unit, a slitting unit and a ZG 200 pull-off device.
2026
Semi-automatic machines and precision stripping
In March a Komax Delta 260 semi-automatic machine and a Schäfer SealLine 240-1 ADVANCED for sealed crimp connections, in June a Schleuniger B340. To the article

Dates according to company records. The overview names the most important investments since 2020. Further machines such as the Kappa 310 and crimping presses complete the machinery.

Digital production support

Planning, stock and traceability in the system.

Since 2018 we have worked with an ERP system; in 2019 an intelligent storage system and batch and process traceability were added. Since 2021/2022 an MES has planned the production orders by priority, date and customer requirement.

Your benefitDates can be planned reliably, and every delivery is traceable down to the individual wire.
Our own softwareOut of this practice our own software has grown under the WEKAS brand: POM (Production Operations Management) combines ERP, production planning, MES and quality inspection in one system.

Find out more about WEKAS To our company history

Request a quote

Which processes does your cable set need?

Send us a drawing, a bill of materials or a sample, or sketch your wiring harness directly in the enquiry form. We will choose the right processes and get back to you with a quote.

Send your enquiry +49 9321 3924811 info@powertune.de