Development & design of cable systems
From requirements specification to production ready design.
- our own design office
- EPLAN
- documentation
- PPAP
- as the basis
- 3D data
Overview
From requirements specification to production ready design.
Since 2023 Powertune has run its own CAD design office with EPLAN. We develop and design complete cable systems to customer order, including prototyping, support during series production and documentation to PPAP.
From a drawing, a sample or an enquiry we create the CAD drawing, cutting lists and bills of materials for material procurement. In this way we support projects as a system partner for on board power system development and electrical integration in vehicles and machines.
Scope of services
Development & design at Powertune: what is included.
- Design of cable systems and wiring harnesses
- CAD drawings with EPLAN Harness proD
- Bills of materials, cutting lists and work instructions
- Selection of cables, connectors and protection systems
- Technical changes and optimisations
- Documentation to PPAP
We do not simply design to specification; we build ease of assembly, cost efficiency and operational reliability into every design.
Examples
From our production.
EPLAN in 2D and 3D
From 3D routing to production drawing.
Since 2023 we have designed cable systems in our own CAD design office with EPLAN Harness proD. The starting point is your 3D data, a drawing, a sample or a description of the task. From it we create the cable routing in the installation environment, and from the 3D model the 2D drawing for the assembly board.
Bills of materials, cutting lists and work instructions come directly out of the design data. Purchasing and production therefore work with the same data as the design office.
- Cable routing in the 3D model of the installation environment
- 2D production drawing for the assembly board
- Bills of materials, cutting lists and work instructions
- Revision statuses documented and traceable
Sizing
Selecting the right cables, connectors and protection.
Good design starts with the requirements: which currents and voltages flow? Which temperatures, media and movements act on the cable? Does it have to be shielded, sealed or particularly light? Cross sections, cable types, connectors and protection systems follow from that.
We also keep an eye on ease of assembly and cost efficiency: short cable runs, sensible separation points, available components and production without unnecessary manual steps.
Virtual pre-planning
Check digitally first, then invest in series production.
One particular advantage of our development work: you can plan and check your project virtually before you invest in tooling, assembly boards and series material. Cable systems, wiring harnesses and complete on board power systems are mapped digitally, checked for fit in the installation space and optimised early. That makes the later implementation precise, efficient and low in risk.
You decide what you need: development only, production only or both from a single source. That improves project planning and investment certainty.
- Digital model of the cable system, wiring harness or on board power system
- 3D model check of the fit in the installation space
- Installation space optimisation before the first sample
- Development only, production only or both, as you prefer
Documentation
Documents that hold up in series production.
For series projects we prepare the documentation to PPAP (Production Part Approval Process). With it you demonstrate that design, production process and testing meet the agreed requirements before series production starts.
After approval we continue to support series production: changes flow into the drawing, the bill of materials and the work instruction, and the revision status stays traceable for every delivery.
FAQ
Frequently asked questions.
Which data do you need to design a wiring harness?
Ideally 3D data of the installation environment, a drawing or a sample. If none of that exists yet, a description is enough: which components are to be connected, where they sit and which loads the cables are exposed to.
Which software do you design with?
With EPLAN Harness proD, both for the cable routing in the 3D model and for the 2D production drawing, bills of materials and cutting lists.
Do you take on the complete development of a cable system?
Yes. Since 2023 we have developed complete cable systems to customer order, including prototyping, support during series production and documentation to PPAP. You describe what the system has to do; we supply design, samples and series production from a single source.
What is PPAP?
PPAP stands for Production Part Approval Process, a procedure from the automotive industry for the release of series parts. It documents that design, production process and testing meet the customer requirements on a lasting basis.
Can you revise existing wiring harnesses?
Yes. We take on technical changes and optimisations of existing wiring harnesses, for example new components, changed lengths, easier assembly or alternatives for connectors that are no longer available.
Can I order only the development or only the production?
Yes. You can order development only, production only or both from us, depending on what your project needs.
What does virtual planning of a wiring harness achieve?
You can see whether the cable system fits into the installation space before you invest in tooling and series material. Wiring harnesses and on board power systems are mapped digitally, checked for fit in the installation space and optimised. That reduces the risk of expensive changes during series production.
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.
Cable assemblyReady to install cables, cable sets and wiring harnesses
Wiring harness manufacturingWiring harnesses to drawing, sample or 3D data
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