Cable assembly to your specification
Precision in every connection. Quality in every detail.
- from cutting to length to assembly
- All in house
- electrical final testing
- 100 %
- flexible production
- Prototype to series
Overview
Precision in every connection. Quality in every detail.
Cable assembly is the basis of reliable electrical connections in modern technical systems. Powertune develops and manufactures customised cable assemblies for mechanical engineering, special vehicle construction, electrical engineering, the automotive industry and other industrial sectors.
From simple connection cables to complex wiring harnesses and on board power systems, based on drawings, bills of materials, 3D data, samples or requirement specifications. We advise on the choice of cables, connectors, protection systems and fastening technology as early as the development phase.
Scope of services
Cable assembly at Powertune: what is included.
- Automated cutting to length and stripping
- Crimping with crimp force monitoring
- Tinning, soldering and ultrasonic welding
- Marking and printing of cables
- Assembly of cable sets and wiring harnesses
- Integration of electromechanical assemblies
High quality connectors, shielded cables and robust outer sheathing, for extreme temperatures, vibration and moisture.
Examples
From our production.
Process
From raw cable to ready to install lead.
Cable assembly means: cables are cut to length, stripped, fitted with contacts, seals and connectors, marked and built into ready to install cables or cable sets. At Powertune every one of these steps runs in our own plant in Kitzingen, on the machine that suits the cable in question.
- Cutting to length and stripping: Komax Kappa 310 and Kappa 340 R, for sensitive insulation the new Schleuniger B340 with four rotating blades, for single cables the Komax Mira 230.
- Crimping with single wire seals: fully automatic cable processing machines such as the Komax Gamma 450 with crimp force monitoring as well as seal position and stripping monitoring; for samples and small lots the semi-automatic Komax Delta 260 and Schäfer SealLine 240-1 ADVANCED.
- Joining: ultrasonic splices on the Schunk Minic III, soldering and tinning at ESD protected workstations.
- Twisting, bundling, protecting: Komax BT 188 T twisting machine, KABATEC KTHB Smart taping unit, KTB 50-E plus bundling machine and tube cutting with the GlobalCut 100 PRO.
- Marking and testing: labelling of cables and branches, electrical final testing with a test report.
Which machine we use depends on the cable, the contact, the quantity and the test requirement. The machinery page gives an overview of all our equipment.
Range
Which cables and leads we assemble.
We assemble single cores, sheathed and multicore cables, shielded signal and data cables, sensor cables, control and power cables. We process cross sections from 0.013 to 70 mm², and up to 95 mm² where required: from the finest strands to battery and power cables, with crimp contacts, wire end ferrules, cable lugs and connectors to your specification.
- Sensor and CAN bus sets, for agricultural machinery for example
- Control and data cables for machines and plants
- Battery and power leads up to 35 mm²
- Motor and control cables for drones
- Connection and extension sets for electrical engineering
- Adapter and retrofit sets for vehicles
You can compare cross sections in mm² and AWG in our AWG table. If you only need individual components (connectors, crimp contacts, cavity plugs or single wire seals), you will find them at powercable.de.
Enquiry
What we need for a quote.
A drawing, a bill of materials, 3D data, a sample or a requirements specification is enough for a solid quote. Quantities and call-off volumes, your target date and any special requirements for environment, sealing or testing also help.
If the documents are not ready yet, simply describe what the cable is meant to connect, or sketch your wiring harness directly in the enquiry form. The checklist for your enquiry helps with the preparation.
FAQ
Frequently asked questions.
What is cable assembly?
Cable assembly is the production of ready to install cables, cable sets and wiring harnesses to customer specification. Cables are cut to length, stripped, fitted with contacts, seals and connectors, marked, protected and tested electrically, so that they can be installed without rework.
What is the difference between cable assembly, a cable set and a wiring harness?
Cable assembly is the umbrella term for processing cables. A cable set combines several assembled cables for one application. A wiring harness bundles cables with branches, protection and a fixed geometry into a single part that is built on an assembly board. More on this under wiring harness manufacturing.
What are the advantages of a customised cable assembly?
Exact lengths and connections, shorter assembly times, fewer sources of error and higher operational reliability. Ready to install, tested cables go straight into the product, without rework on the assembly line.
Do you also produce small quantities?
Yes. Powertune produces single pieces, samples, pre-series, small series and series. For small lots we use semi-automatic machines with short setup times, for large quantities fully automatic cable processing machines.
How is the quality of the crimped connections assured?
The fully automatic machine monitors the force curve of every crimping operation as well as seal position and stripping; conspicuous cables are sorted out. We check the crimp height with a crimp height measuring device. In addition, every wiring harness is tested electrically for continuity and short circuits.
Which documents do you need for a quote?
A drawing, a bill of materials, 3D data, a sample or a requirements specification is enough. Please also tell us the quantity, your target date and any special test requirements. You can upload files in the enquiry form.
Which conductor cross sections do you process?
From 0.013 to 70 mm², and up to 95 mm² where required: from the finest strands to battery and power cables. Large cross sections and cable lugs are processed by hand with the matching tool.
Can I also buy connectors and crimp contacts separately?
Individual components around cable assembly (connectors, crimp contacts, cavity plugs and single wire seals, for example) are available from the distribution site powercable.de. The assembly work is done by Powertune.
Request a quote
Let us talk about your project.
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 services
Everything from a single source.
Wiring harness manufacturingWiring harnesses to drawing, sample or 3D data
Development & designCAD design with EPLAN, documentation to PPAP
PrototypingSamples, single pieces and pre-series
Series productionFully automatic cable processing machines, MES controlled and traceable
Testing & documentationProcess monitoring, electrical final testing, test recordsIndustry solutionsTo the overview