Sectors and Solutions: Automotive
Here you will find our all-round solutions for the automotive industry at a glance.
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Cable Assemblies
Cable Assemblies
Cable assemblies for the automotive industry From wheel arch to hatchback
The Coroplast Cable Assemblies division works worldwide on creating innovative solutions for the automobile industry. With some 5,700 employees working at a current total of 11 production sites, we are never far away from our customers. Both the major carmakers and their Tier-1 suppliers rely on the broad range of cable assemblies we offer. At the same time, these well-known customers appreciate our service philosophy and the wealth of problem-solving expertise the Coroplast engineers have gained through many years of experience. Over the last two decades, our Cable Assemblies division has continually grown from being a build-to-print supplier to a comprehensive provider of product development and technical solutions. We interact closely with our customers to design innovative, made-to-measure cable assemblies – actively controlling their development in tune with the latest trends and in a spirit of true partnership. That is the reason why cable assemblies made by Coroplast, which are meanwhile installed throughout entire vehicles, are far greater than the sum of their single wires: they represent a wealth of experience in development and production as well as continual improvement. We offer our customers comprehensive service, including design, development, 3D installation space analysis, prototyping and series manufacture at our state-of-the-art production plants.
The core competences of our Cable Assemblies division at a glance:
- Full service provider for all types of automotive cable assemblies
- Interdisciplinary design development and implementation from one single provider (enquiry, installation space analysis, 3D cable routing, prototyping, pre-series production, optimisation up to the series production stage, series process development, prototype qualification, series support)
- System specialist (with in-house cable, injection-moulding and production expertise)
- Advanced engineering and continuous improvement
- Coroplast technical department: in-house test and validation systems for testing mechanical, electrical and chemical environmental influences in accordance with established standards
We work with the following tools:
- CATIA V5 and NX (3D design and DMU)
- EBCable (wiring diagrams)
- LDorado and AutoCAD (2D applications)
- All commonly used interfaces to customers
How we work – together with our customers
At Coroplast, customer proximity is not just an empty phrase, but something we actively practise on a daily basis. It begins right at the project initiation phase and continues throughout the various process stages, right up to the finished product. In fact, many of our engineers not only visit customers regularly for meetings, they are often directly embedded as resident engineers in the development departments of our customers. We see this not only as actively practising our service mentality, but also as an opportunity to shape the course of development and remain at the very heart of current trends.
„We are not only close to our customers, we work closely together with them every day. That is how our developers always have their ear to the ground and get involved in new projects just as they are being initiated. That may be challenging, but it’s also very exciting!“
The knowledge we have gathered through decades of experience in the field of cable assemblies enables us to manufacture perfectly functioning technology for innumerable vehicles. The resulting figures are quite impressive:
- Currently, approx. 15 million vehicles are supplied worldwide per year
- That means 60 million cable assemblies
- These are spread over 400 active versions (versions are defined by the control of the axles, such as front-wheel drive, four-wheel drive, twist-beam, multi-link, the vehicle lengths, the spring deflections of the vehicles, and special equipment such as brake wear indicators or dynamic chassis control)
- To produce these we use over 200 machines for injection moulding (horizontal/vertical), ranging from flexible single cavity to highly complex tools with 32 cavities
- Our customers include well-known carmakers such as VW, BMW, Audi, Skoda, Seat, Daimler, Porsche, Lamborghini, Ford, PSA and many others.
Automation
A great deal of manual work is usually involved in the production of cable assemblies and injection-moulded parts. Coroplast offers its customers production concepts that are highly automated in pre-assembly and injection moulding. That not only ensures cost advantages and high quality, but also process stability and accountability – terms that are becoming increasingly important in conjunction with driver assistance systems and automated driving. The complete package consisting of development and manufacturing technology that we offer includes the comprehensive know-how that we have gained through decades of experience. Hence our customers can rely on the fact that we are always up to date with the current state of the art when it comes to developing modern production concepts.
„When it comes to developing automation concepts, our engineers are actively involved in the entire process of component development – from the initial design to the functioning tool until the parts roll off the production line.“
