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Business

Activities
Conceptual design, layout design,
planning and production

Cable covering options

Construction of complete vehicle electrical


systems including integration and deve lopment of existing customer drawings and
extensive documentation, if required

All types of sleeving such as protection


and braiding or covering with nylon thread,
insulation sleeving or corrugated tubing

Systems as well as complete central electri cal systems for the car and utility vehicle
industry, mobile machines and similar areas
of application

On-site customer assistance in all phases of


development, production, series production
support and spare parts supply

On-board electrical systems for agricultural,


loading, material handling and construction
machinery
Cable harness assemblies with electronic
components as well as assembled single
wires with contacts and plug connectors
from all reputable manufacturers
Instrument panels complete with cable
harness assembly and switches
Assembly and integration of simple to highly
complicated cable harnesses with over
3000 individual parts including electronic
and/or electromechanical components
Fully or semi-automated manufacture of
cable harness assemblies of any length
Cutting to size and contacting (connection
of contacts to conductors) all cables in cluding text imprint on automatic production
plants
Safety switch with cable harness assembly
fitted by injection moulding for vehicle seats
Battery and ignition cable production
including crimp force monitoring for cross sections of up to 150 mm2
Trailer connection cables with all associated
plug connections
Manufacture and provision of any required
sheet metal or steel parts
Control cabinet construction
Vehicle lighting of all kinds, both inside
and outside

Plastic sheathing

Auxiliary services

Professional installation of all electrical


and/or electronic components in the
customer's facility including programming,
if required
Provision of bought-in parts and components
from our large pool of suppliers at short
notice
Customer benefits
Short reaction times
Order processing independent of piece
numbers from 1 to over 1,000,000 pieces
Just-in-time and Just-In-Sequence delivery
option
Broad range of business activities and
well-assorted material stocks for short
reaction times
Highly modern processing equipment,
supported by special software for top
standard production
We only use quality products compliant
with the regulations of the international
automotive industry!

Comline Elektronik Elektrotechnik GmbH


Karl-Rapp-Strae 1 92442 Wackersdorf Germany
Phone +49 94 31 / 75 65-0 Fax 75 65-25
comline@comline-elektronik.de www.comline-elektronik.de

Planning

The solutions that we develop are as

and Developing

series production phase (as well as the end-

individual as the requirements of our custo-

of-series phase, if applicable). Quick progress

mers. Quality, cost and flexibility these are

to the prototype phase is facilitated by the

the three primary criteria that we take into

fact that we build cable harnesses and central

consideration for all projects from very small,

electrical systems at a relatively early stage

challenging series productions to consistently

of construction.

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

Orders that do not require any development


work from us are naturally also conducted
strictly according to customer specification.

Comline Elektronik Elektrotechnik GmbH


Karl-Rapp-Strae 1 92442 Wackersdorf Germany
Phone +49 94 31 / 75 65-0 Fax 75 65-25
comline@comline-elektronik.de www.comline-elektronik.de

Production

All cable systems and components are

and Manufacture
We do not use crimping to connect cables

manufactured with high dimensional accuracy.

at Comline: instead we use modern ultrasonic

This is largely attributable to our machinery,

welding techniques, which can be checked

which includes the best manufacturing equip-

more effectively during the manufacturing

ment available: several fully automatic

phase, as well as permitting a more efficient

Komax machines take care of most of the

work style.

quality-relevant processing steps required

We produce data lines in-house - with a

for cable harnesses of 32 metres in length or

Komax machine, which can be used to twist

more from cutting to length, printing

different line types with freely selectable

according to specification, to crimping. The

lengths of lay.

entire process is monitored electronically

Battery cables and lines can be cut to

and all contact/conductor connections are

size and stripped in one work step. Similar to

inspected by means of a quality assurance

the ignition cables, these are also pressed

system before release. Other cable harnesses

with crimp force monitoring. Cables with cross-

are manufactured under similarly strict

sections of up to 150 mm2 can be processed.

quality management conditions using Tyco


equipment with an electronic crimp force
monitoring facility.

Comline Elektronik Elektrotechnik GmbH


Karl-Rapp-Strae 1 92442 Wackersdorf Germany
Phone +49 94 31 / 75 65-0 Fax 75 65-25
comline@comline-elektronik.de www.comline-elektronik.de

Quality

The consistently high quality of the entire

and Monitoring

We have specially adapted tools for the

Comline manufacturing chain is not only

approximately 800 different crimp contacts

accounted for by our DIN EN ISO 9001:2008

included in our product range, and the

certification. Fulfilment of all required

grinding marks of the connections created

specifications is also guaranteed by our

are measured and analysed in our in-house

implementation of extensive control and test

laboratory. These crimp connections are

procedures in all production phases. Only

100% compliant with the specifications of

one example is the Weetech test systems we

the contact and tool manufacturers. Test

use to test all cable harnesses and central

records for each crimp lot are optionally

electrical systems. A complete and compre-

available to our customers.

hensive test record can therefore be provided


on request.
Entire cable networks can be checked

As partners of the German Association


of Construction Machine Engineers and
Master Craftsmen (VDBUM e.V.), we benefit

using up to 64,000 connecting points and

from a continuous exchange with our

passive components can also be included in

product users. Feedback received is directly

the tests. Functional tests of active com-

implemented to ensure constant improvement

ponents can be performed, as well as high

of our products and processes.

voltage and insulation tests.

Comline Elektronik Elektrotechnik GmbH


Karl-Rapp-Strae 1 92442 Wackersdorf Germany
Phone +49 94 31 / 75 65-0 Fax 75 65-25
comline@comline-elektronik.de www.comline-elektronik.de

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