Wire Harnesses
High-performance and reliable transmission solutions
Tailor-made Wire Assembly
ALACsystems offers individual connections to the automobile periphery
In cooperation with our customers we develop solutions for wire harness applications using standard components which are available on the market, but also with integrated specific components like special cables and connectors developed and manufactured by ALACsystems.
Our current portfolio:
- Cable assembly for in-car infotainment systems
- Cable harnesses for interior and exterior vehicle lighting
- Coaxial cable assemblies / Antenna connections
- Cable connections for in-car microphone systems
- Cable harnesses with overmoulded electronics or components
- Cable harnesses with special and standard connectors
- FPC wiring harnesses
Product-specific competences
Know-How partner, development and production
ALACsystems reliably implements wire harnesses for application-specific requirements of our customers – from conception and prototyping to qualification and serial production. Modern high-capacity wire processing machines with in-line test systems and a high vertical range of manufacturing technologies for all market-relevant connection techniques ensure a high degree of automation, functional security and price competitiveness. Especially our high experience to develop own connector systems qualifies ALACsystems to better understand the customer requirements for wire harnesses. Please find details on our competences in the drop-down menu.
Development
- Preparation of requirements and performance specifications
- Feasibility studies
- Preparation of electric system circuit diagrams according to customer requirements
- Concepts for current distribution and fuses
- Dimensioning of cable cross-sections
- Development and design of cable connections (connectors, terminal blocks and soldered connections)
- Definition of the cable fastening (clamping connection and screw joints)
- Integration of electronic components and assemblies into the cable harness (light, sensor systems, etc…)
- Process conceptions and implementation of new processes into production as well as their validation
- Development of semi and fully automatic machines for production
- Development of injection moulding dies for overmouldings
- Development of the production drawings in 2D/3D
- Development of series test devices
- Definition of test and inspection processes
- Prototyping
- Product validation according to customer requirements
Tool and special machine construction
- Construction of gauges and production fixtures
- Manufacturing of injection moulding dies and overmoulding tools
- Manufacturing of progressive punching tools
- Manufacturing of semi/fully automatic production machines for connector systems
- Wire eroding and die sinking, CNC milling and grinding
- Manufacturing of copper electrodes
- Manufacturing of test devices (EOL)
Manufacturing technologies
- Machines for automatic cable processing for stripping, crimping, sealing, tinning and twisting processes (crimp force monitoring)
- Coaxial cable processing
- Injection moulding department (plastic parts, insert moulding, strain relief and overmoulding of electronic modules)
- Dispensers for dosed application of soldering paste
- Induction soldering, laser soldering and manual soldering
- Special machines for component assembly (in-house developments)
- Printing systems
Qualification
- Micro-section laboratory to analyse crimp connections, splices and other component groups
- X-ray system to analyse crimp connections, connector systems and electronics components
- Pull force measuring devices
- Vibration and shock test
- Climate chambers for environment and lifecycle testing
- Contact durability test devices
- Bending cycle test devices
- Complete validation according to OEM/customer specifications
