Engine cabling systems, frame cabling and door wiring harnesses for trucks, busses and special vehicles, all the way to complete on-board wiring systems. Forschner offers customized development, production, assembly and documentation from a single source. Naturally we also serve customers from other industries as reliable partners – for example, where complete wiring systems for medical appliances are concerned.
Variance requires flexibility
Whether in the automotive industry or medical technology, the steady increase in product customization places the highest demands on our work. The variety of options is constantly increasing – and the variance of cabling systems along with it. To make even minimal repetition rates economically efficient, we have made our production especially flexible. This includes intelligent details such as our modularized board design to reduce setup times, and also our vertical range of manufacture. That is what enables us to fulfill our customers' requirements down to the smallest detail and to effectively realize highly varied cabling systems – from the project planning phase to mass production.
We know ...
... that however diverse and varied a cabling system is, the quality always has to be high throughout.
Not only the automotive industry but further sectors such as the electrical industry or medical technology also rely on cabling systems from Forschner!
... that cabling systems and complete on-board wiring systems have to function reliably in the long term.
Our cabling systems carry on operating reliably for years and years: whether as engine cabling systems for special vehicles or commercial vehicles, or as systems for doors, heating and seats. Here, we are in a position to produce the highest volumes. We also have excellent references for everything related to complete onboard wiring systems with high failsafe performance and an overall length of up to 20 meters. This enabled us, for instance, to equip all the Unimog series from 1991 onward – and also city busses and coaches made by the world's leading manufacturers.
The development of cabling systems and vehicle-specific wiring harness variants place high requirements on engineers. In addition to the structural parameters of the application, complex technical data also has to flow into construction.
Single-core standard cables, multi-core special cables for data transfer via car-phone or iPod, innovative coaxial and flat lines, all kinds of shields, geometries, core and sheath materials: the properties of cables are just as varied as their target applications. Forschner is thoroughly familiar with all their idiosyncrasies, and can rely on a great wealth of experience.
Komax fully automatic machines, Ultrasonic welding plants for connections, Harness braiders, Fully automatic bandaging machine
Which wiring harness architecture matches your planned logistics concept in series production? Which types of modularization and segmentation will guarantee you maximum cost efficiency across the entire value chain? What is the optimal design for your on-board wiring systems, taking all environmental conditions into consideration? As a specialist for everything related to cabling systems in commercial vehicles, busses and electric subassemblies, we know that the best solution is always based on individual responses. We create tailored concepts – which are economically efficient in the long run. We realize method development, construction and prototyping hand in hand. All cable harnesses are laid and simulated in 2D and 3D. Ahead of assembly and production, this is how we guarantee that all parameters are perfect before series startup.
STEP BY STEP TO THE WIRING HARNESS
... how we can assume complete responsibility even for complex projects by means of structured processes and innovations.
Countless cables are combined into functional subassemblies, and in integrated Overall processes for low, medium and high volume production. With numerous intelligent details, we create efficient production processes. Exemplary here: our networked cable harness assembly with optimized cut sequences, or the modularized breadboard assembly to reduce downtimes. Consistent subdivision into module preassembly and final assembly guarantees effective workflow, as does our high vertical range of manufacture, thanks to which unnecessary interfaces are avoided. Crimping, marking of housings, welding of connectors, shrinking, molding – we do all of it in-house! This also includes state-of-the-art cable harness testing with numerous options, e.g. PIN straightness or secondary locking, as well as packaging with the customer's performance specifications and accurate logistics.
We know ...
... how to use efficient work sequences and powerful machines to enable a smooth production flow.
Cabling systems and on-board wiring systems from Forschner have a lot to offer
We know ...
... how we can turn a single-source offer – ranging from method development to ultra-precise logistics – into an all-round service package in the cabling systems sector!
Last-minute changes to the product? A quick prototype? We support you with all our commitment and now and then we even make the seemingly impossible possible. Since Forschner specializes in low repetition rates, even maximum variance where wiring harnesses are concerned is no problem.
The use of aluminum conductors, reinforced conductors with especially small cross-sections, PCB-based switch panels via press-in technology: today we're already utilizing the technical standards of tomorrow. High-voltage distribution systems for hybrid vehicles are a further topic here, underlining our expertise in the sustainable technologies sector.
Short transportation times, high security of supply, minimal logistics expense and no warehousing costs at the customer – all of it thanks to precise coordination of production and logistics. We offer the latest data management and a state-of-the-art IT infrastructure. Forschner secures its proximity to important markets by means of several international sites.
A broad machine park and the necessary personnel capacities enable us to realize all our development and production in-house – from smaller cabling systems to complete on-board wiring systems. Technologically, we play a pioneering role in this regard. Not least of all because we never shy away from continuously high investments in the best systems, plant and machinery.
Since the early 1990s we have successfully accompanied and served numerous customers, the majority of them from the automotive industry. Our references speak for themselves, in low and in high production volumes.
Highly efficient production with a high degree of automation has no adverse effect on the constantly high quality at Forschner. Each cable harness has to satisfy the highest requirements. Intensive cable harness testing ensures that our customers all over the world receive precisely what they have a right to expect from us.
Take advantage of our FOR-tech development support—we shorten development times and cut production and manufacturing costs thanks to unique proven know-how. At the same time we keep an eye on the overall process right from the start and support you on site with our resident engineers. See here to find out more.