Highly individual and made to measure Wire harnesses

Coroplast supplies wire harnesses for various components that need to be pre-assembled. For instance, motors, doors, roofs, tailgates, seats, air conditioners, generators, bumpers and front ends are all equipped with our wire harnesses. We also develop and produce modular cable assemblies for creating individual wiring solutions. Tailor-made solutions are of key importance when we manufacture our wire harnesses, as our products need to match individual customer requirements with 100 per cent precision. This is where our pronounced process experience and flexibility are a great advantage, as we analyse possible installation options, prepare test reports, optimise wire-routing processes and manufacture prototypes, which can only be implemented in close cooperation with the customer. These abilities enable us to provide customers with short development times, continual cost optimisation and process efficiency.

What our customers can expect from us:

A wealth of experience in manufacturing cable assemblies
Integrated component know-how gained through in-house development and the production of wires and adhesive tapes
Cooperation in Simultaneous Engineering Teams (SETs)
Development-based qualification
Preparation of wiring schematics
3D cable assembly routing and collision detection tests (DMU)
Preparation of wiring and component drawings
Interfaces to customers and suppliers
Preparation of functional models using 3D printing processes

Battery and generator cable assemblies

Battery and generator cable assemblies are subject to strict requirements. When manufacturing cable assemblies for these applications, we rely on the following specifications:

Insulation material: high-quality materials such as silicone
Conductor material: copper, aluminium
Cross-section: 16 to 70 mm²
Coroplast uses crimp terminals, cable lugs and die-cast contacts such as battery clamps

Engine wiring

The construction space around the engine is exposed to highly fluctuating temperatures and vibrations. For these applications, cable assemblies with intelligently designed jacket and protective materials made by Coroplast are required, which minimise weight and maximise reliability. We utilise:

Sealed connection systems
Single-core cables, heat-resistant up to 200 °C
Highly flexible silicone ground wires
Coroplast special-purpose adhesive tape for added flexibility and heavy-duty abrasion protection
stranded wires or sheathed cables for signal shielding
Sealed power distributors

Seat wiring

We develop autarkic cable assemblies not only for seats, but also for doors, roofs, valves, air conditioners, shock absorbers and other applications, including the respective peripheral equipment. Here, for example, we offer the following specifications:

Highly flexible single-core wires
Airbag conductors with ignition pill plugs
Motion compensation using braided sleeving
Abrasion protection tape
Specially designed fastening systems

Complete solutions, all from one supplier

The production and routing of autarkic cable assemblies involves a highly complex development process performed in close collaboration with our customers. The process, including the pre-development order, the 3D routing and the test phases in experimental vehicles up to the point when the autarkic cable assembly is finally installed in a series vehicle, can often take several years. At Coroplast, we have the distinct advantage of being able to rely on the experience and expertise of our other divisions throughout the entire process. For example, special-purpose tapes that exactly meet the protective requirements of the application can be suggested and developed in-house with a minimum of lead time. Our cable specialists can also provide us with bespoke tailored wires and cables, such as for high-temperature FEP conductors or silicone conductors with heat-resistant capabilities up to
200 °C.