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Wiring harnesses for the automotive industry
Precise cable systems for the mobility of tomorrow.
- electrical final testing
- 100 %
- from on board power to high voltage
- 12/24 V to HV
- for the assembly line
- Plug and play
Overview
Precise cable systems for the mobility of tomorrow.
Vehicle electronics are becoming ever more complex, and our cable systems with them. Powertune develops and manufactures wiring harnesses, cable sets and complete electrical solutions that integrate cleanly into existing vehicle systems.
From the classic 12/24 V on board power system for commercial vehicles to HV sections in electric and hybrid vehicles: with strict insulation concepts, effective shielding and safe separation of high and low voltage.
Services
What we do for Automotive.
- Development and adaptation of wiring harnesses
- Integration of new electronic components
- Engine wiring harnesses with braided sleeve and heat resistant corrugated tubes
- Sealed connector housings against moisture and salt
- Ready to plug in wiring harnesses with coded connectors
- Cable sets for motorsport engineering
- Reconstruction for classics such as the VW Golf 1
Every wiring harness we produce undergoes 100 % electrical final testing.
Applications
Examples from our production.
On board power
From the 12/24 V on board power system to the high voltage cable.
Modern vehicles connect control units, sensors, actuators and lighting through ever more cables. For this, Powertune manufactures wiring harnesses, cable sets and adapters for cars and commercial vehicles with 12 and 24 volt on board power systems as well as for high voltage sections in electric and hybrid vehicles.
In high voltage applications the focus is on the insulation concept, shielding and the safe separation of high and low voltage. We define the scope of testing with you, up to and including the high voltage test, according to your requirements.
Environment
Built for heat, oil, vibration and salt.
In the engine compartment and on the underbody, heat, oil, moisture, road salt and vibration act on every cable. We protect engine wiring harnesses with braided sleeve and heat resistant corrugated tubes, and we use sealed connector housings with single wire seals and cavity plugs.
The single wire seals are fitted by machine; on the fully automatic cable processing machine their position is monitored as well. You can read more about the processing under cable assembly.
Installation
Plug and play for the assembly line.
Ready to plug in wiring harnesses with coded connectors can be installed without special tools and rule out mix-ups. For retrofits, test benches and conversions we make adapter and extension sets, for example for differential locks, charging ports or engine management.
Classic cars benefit too: we reconstruct wiring harnesses from a sample, such as for the VW Golf 1. And we supply customers in motorsport engineering with cable sets in small quantities that have to be available quickly.
FAQ
Frequently asked questions.
What exactly is a wiring harness?
The structured bundling of all cables in a vehicle. It connects control units, sensors and lighting and forms the central infrastructure for power supply and data transmission.
Does Powertune offer plug and play solutions?
Yes. Ready to plug in wiring harnesses allow quick installation on the assembly line, without special tools and with minimal sources of error.
How is an engine wiring harness protected?
With braided sleeves, heat resistant corrugated tubes and hermetically sealed connectors. They protect against heat, oil, vibration, moisture and salt.
What does Powertune do to prevent cable fires?
Cross sections designed for the current load, crimped connections with force monitoring and an electrical test of every wiring harness for continuity and short circuits. A high voltage test is carried out depending on the requirement.
Do you produce cable sets for high voltage applications?
Yes. We supply high voltage cable sets, such as for electric and hybrid vehicles, with an insulation concept, shielding and safe separation of high and low voltage. We define the scope of testing, including the high voltage test, for each project.
Do you also supply adapter and retrofit sets?
Yes. Alongside wiring harnesses for series production we make adapter, extension and retrofit sets as single pieces, small series or series production, for example for differential locks, charging ports or engine management.
Request a quote
Your project in Automotive?
Send us a drawing, a bill of materials or a sample, or sketch your wiring harness directly in the enquiry form. We will get back to you with a non-binding quote.
More industries
Our expertise at a glance.
Mechanical engineering and roboticsPower, signals and data for machinery and robots
Special vehiclesEmergency, construction, expedition and special vehicles
Electrical engineering and control cabinetsReady to connect for control cabinets and controls
Module assemblyReady to install system solutions from a single source
Agricultural technologyRobust for agricultural machinery and heavy vehicles
AerospaceDrones, aircraft and space technology
Medical technologyCable systems for medical devices
Food technologyDurable for production and packaging lines
DefenseSafety critical applicationsAll industriesTo the overview