Comline Introduction

Business Activities

Conceptualdesign,layoutdesign, planningandproduction

•Constructionofcompletevehicleelectrical systems–includingintegrationanddeve- lopmentofexistingcustomerdrawingsand extensivedocumentation,ifrequired

•Systemsaswellascompletecentralelectri- calsystemsforthecarandutilityvehicle industry,mobilemachinesandsimilarareas ofapplication

•On-boardelectricalsystemsforagricultural, loading,materialhandlingandconstruction machinery

•Cableharnessassemblieswithelectronic componentsaswellasassembledsingle wires–withcontactsandplugconnectors fromallreputablemanufacturers

•Instrumentpanelscompletewithcable harnessassemblyandswitches

•Assemblyandintegrationofsimpletohighly complicatedcableharnesseswithover 3000individualpartsincludingelectronic and/orelectromechanicalcomponents

•Fullyorsemi-automatedmanufactureof cableharnessassembliesofanylength

•Cuttingtosizeandcontacting(connection ofcontactstoconductors)allcablesin- cludingtextimprintonautomaticproduction plants

•Safetyswitchwithcableharnessassembly fittedbyinjectionmouldingforvehicleseats

•Batteryandignitioncableproduction includingcrimpforcemonitoringforcross- sectionsofupto150mm2

•Trailerconnectioncableswithallassociated plugconnections

•Manufactureandprovisionofanyrequired sheetmetalorsteelparts

•Controlcabinetconstruction

•Vehiclelightingofallkinds,bothinside andoutside

Cablecoveringoptions

•Plasticsheathing

•Alltypesofsleeving–suchasprotection andbraidingorcoveringwithnylonthread, insulationsleevingorcorrugatedtubing

Auxiliaryservices

•On-sitecustomerassistanceinallphasesof development,production,seriesproduction supportandsparepartssupply

•Professionalinstallationofallelectrical and/orelectroniccomponentsinthe customer'sfacility–includingprogramming, ifrequired

•Provisionofbought-inpartsandcomponents fromourlargepoolofsuppliersatshort notice

Customerbenefits

•Shortreactiontimes

•Orderprocessingindependentofpiece numbers–from1toover1,000,000pieces

•Just-in-timeandJust-In-Sequencedelivery option

•Broadrangeofbusinessactivitiesand well-assortedmaterialstocks–forshort reactiontimes

•Highlymodernprocessingequipment, supportedbyspecialsoftware–fortop standardproduction

Weonlyusequalityproductscompliant withtheregulationsoftheinternational automotiveindustry!

ComlineElektronikElektrotechnikGmbHKarl-Rapp-Straße1•92442Wackersdorf•GermanyPhone+499431/7565-0•[email protected]•www.comline-elektronik.de

Planning andDeveloping

The solutions that we develop are as

individual as the requirements of our custo-

mers. Quality, cost and flexibility – these are

the three primary criteria that we take into

consideration for all projects – from very small,

challenging series productions to consistently

precise manufacture of large piece numbers.

For development and construction, we

use software solutions specifically adapted

to cable harness design and production.

We support the creation of a vehicle or

machine from the design phase, throughout

development, and up to the acceptance and

series production phase (as well as the end-

of-series phase, if applicable). Quick progress

to the prototype phase is facilitated by the

fact that we build cable harnesses and central

electrical systems at a relatively early stage

of construction.

Orders that do not require any development

work from us are naturally also conducted

strictly according to customer specification.

Comline Elektronik Elektrotechnik GmbHKarl-Rapp-Straße 1 • 92442 Wackersdorf • GermanyPhone +49 94 31 / 75 65-0 • Fax 75 [email protected] • www.comline-elektronik.de

We do not use crimping to connect cables

at Comline: instead we use modern ultrasonic

welding techniques, which can be checked

more effectively during the manufacturing

phase, as well as permitting a more efficient

work style.

We produce data lines in-house - with a

Komax machine, which can be used to twist

different line types with freely selectable

lengths of lay.

Battery cables and lines can be cut to

size and stripped in one work step. Similar to

the ignition cables, these are also pressed

with crimp force monitoring. Cables with cross-

sections of up to 150 mm2 can be processed.

All cable systems and components are

manufactured with high dimensional accuracy.

This is largely attributable to our machinery,

which includes the best manufacturing equip-

ment available: several fully automatic

Komax machines take care of most of the

quality-relevant processing steps required

for cable harnesses of 32 metres in length or

more – from cutting to length, printing

according to specification, to crimping. The

entire process is monitored electronically

and all contact/conductor connections are

inspected by means of a quality assurance

system before release. Other cable harnesses

are manufactured under similarly strict

quality management conditions using Tyco

equipment with an electronic crimp force

monitoring facility.

Production andManufacture


We have specially adapted tools for the

approximately 800 different crimp contacts

included in our product range, and the

grinding marks of the connections created

are measured and analysed in our in-house

laboratory. These crimp connections are

100% compliant with the specifications of

the contact and tool manufacturers. Test

records for each crimp lot are optionally

available to our customers.

As partners of the German Association

of Construction Machine Engineers and

Master Craftsmen (VDBUM e.V.), we benefit

from a continuous exchange with our

product users. Feedback received is directly

implemented to ensure constant improvement

of our products and processes.

The consistently high quality of the entire

Comline manufacturing chain is not only

accounted for by our DIN EN ISO 9001:2008

certif ication. Fulf ilment of all required

specif ications is also guaranteed by our

implementation of extensive control and test

procedures in all production phases. Only

one example is the Weetech test systems we

use to test all cable harnesses and central

electrical systems. A complete and compre-

hensive test record can therefore be provided

on request.

Entire cable networks can be checked

using up to 64,000 connecting points and

passive components can also be included in

the tests. Functional tests of active com-

ponents can be performed, as well as high

voltage and insulation tests.

Quality andMonitoring


Documents

Comline Introduction