Packaging and assembly systems for harnesses

In the past 20 years, we played a leading role in further developing packaging and assembly systems for harnesses. Unlike non-reusable packaging material, our solutions can be used several times to significantly reduce costs and resources.

These systems offer the following: simple packaging of the harness at the manufacturer’s plant, most efficient packing density in one transport box, optimal space utilisation per truck ideal transport protection, seamless storage in a sequence store, easy transport to the assembly line, insertion of the harnesses into the car body, error-free assignment of the individual main harness branches to the respective connecting location and routing of the individual cables to the appropriate electrical consumer.

Harness bags

Nowadays, every vehicle model is equipped with several individual harnesses. Each one of these harnesses has its own requirements when it comes to packaging and assembly.

Therefore, both the design and the materials of the harness bags have to be adapted individually. In doing so, our core competency to work out tailored solutions comes in useful. We develop and produce prototypes at our Dachau location and can present them to you within only a few days!

We developed harness bags that can be inserted into the car body manually, semi-automated or even fully automated.

We also manufacture bags with solid bottoms and side walls. Inlays made of different plastic and wood panels are used to reinforce the bags. Depending on your requirements, they can be especially light, abrasion-resistant, flexible or strong. As external materials, we use several variations—from cotton canvas to antistatic polyester fabric.

Our harness bags can carry weights from 1 to 80 kg.

The harness is divided in several main strands to make the installation as easy as possible for the assembly worker. The individual strands are packed in different-colored bags for a quick assignment and installation.

Installation and threading aids

To connect the individual cables with their final consuming device, they have to be run through holes in sheet metal and through rails. Oftentimes, thick cable harnesses have to be threaded through narrow holes. To do this, great force has to be applied, which increases the risk of damaging the cables. To solve this problem, we developed our installation and threading aids. We were granted several patents for their mode of operation.

Lipsticks invented many solutions that are nowadays used as a standard in the segment of threading aids. Among others, they include the tapered version of the threading aid, which eliminates the need of additional fixing of the cable, several ways to sew in the zipper and cover the puller, the development of joints between guide component and textile part of the threading aid as well as various installation aids for cable routing behind sheet metal.

Wrapping cloths

An easy way to package cable harnesses is the use of wrapping cloths. They usually consist of mesh material (polyester fabric, PVC-coated) and are closed with Velcro® fasteners.

Wrapping cloths can be used to package entire cable harnesses or individual branches.

In order to distinguish the individual wrapping cloths, mesh and Velcro® fasteners are marked with different colors. If necessary, the wrapping cloths can be equipped with pockets to stow and organize the individual cable branches and with card holders for labels.

Cable hooks

After the cable harness has been inserted into the car body, not all cables can be installed on the same cycle. They need to be temporarily stored away so that they do not impede the assembly. For this purpose cable hooks are used, which are made of plastic and are specifically designed to fit an individual cable and connector. To keep the cables under tension, the cable hooks can be equipped with wave-shaped spring elements.