We know.

Expertise passed on from person to person

Due to their complexity, emobility applications require specific technical solutions. Every vehicle, be it passenger car or HGV, is unique and is the result of detailed technical consultations. Our individual high-voltage distribution units and –harnesses are capable of meeting all your technical requirements.

We can fall back on a broad wealth of experience when it comes to cabling systems for different sectors, all the way to complete on-board wiring systems for busses, commercial vehicles and special vehicles. Our references speak for themselves. Together with you, we elaborate production and logistics concepts that go hand in hand with your processes.

With precision turned parts, the tiniest details in the processing stages can have considerable effects. This is why, as part of a constructive consulting session, we pay very special attention to customers' requirements. This enables us to guarantee that our production fulfills all requirements one hundred percent - and demand-based production concepts also result in an impressive degree of economic efficiency.

With SCR and fluid lines too, depending on the application, the most varied aspects need to be taken into consideration – for example, with regard to material selection, pressure resistance, distribution of heating power, etc., which concept best suits the intended use? With our comprehensive SCR system system expertise, we always find the right answers.

Through a combination of the most diverse disciplines such as mechanics, electronics and cabling, electromechanical systems demand comprehensive expertise on a large scale. With solid know-how and smart ideas, we advise you on the right coil design all the way to the completed subassembly.

Pure know-how

The R&D process regarding emobility as well as harnesses systems not only plays a vital role for future output, but is also very time consuming. This is where the later functions of all electrical and electronic components are established. With experienced developers as well as state-of-the-art tools such as. LDorado, Siemens NX or CATIA V5, we use a comprehensive 2D and 3D development process chain to achieve perfect results and rapid realization times, even with the highest variance. The wiring harnesses are designed and documented in accordance with circuit diagram generation and modularization. Flawlessly close cooperation with customers, which partially involves remote work on their systems, enables instant reactions – also in change management.

Especially with complex precision turned parts made according to customers' parameters, the design of production processes is crucial. We have CNC and multi-spindle technology as well as numerous surface treatment options. This technological bandwidth enables us to draw on plentiful resources as early as the development phase. Advanced simulation and design tools are of course standard in this corporate division at Forschner too.

Every cubic centimeter of our lines contains clear innovation. One example is the patent on the electrical contact. Examples here include a variety of patents for hose construction and the bonding techniques. Lines outside nitrogen reduction are also developed. For example, aroma lines with various appealing fragrances enhance ride comfort, and heated water-injection pipes reduce the CO2 load of gasoline engines. Our own process development, thermal and mechanical simulation tools, as well as high-end software such as Siemens NX, Inventor or CATIA V5 are all used in the development of our fluid systems.

Electromechanical systems are always based on several processing steps. How can a cable be perfectly integrated into a subassembly, or a coil be perfectly molded? We provide the answer to these and many other questions with our experience, also making use of internal synergies. The installation-space optimized design and sizing of coils is one of our great strengths. Design perfectly adapted to plastic is another.

Tested in general rehearsals

Be it high-voltage distribution units or customer specific cable harnesses which always make an optimal use of existing installation space: due to our efficient processes and lean structure we are able to fulfill all your needs for prototypes for emobility much faster than our competitors.

Repetition rates of less than one item a year – with coaches, for example – enable us to prove as early as series production of cabling systems that we can combine high variance with comprehensively high quality. During the construction of prototypes in the cabling systems sector, prototype construction is sent the production data – such as cutting lists and assembly board plans – directly from development. By means of this thorough and continuous processing chain, based on our CAD/CAE development tool, we guarantee the shortest production and reaction times. Combined with maximum quality.

In the most varied and also safety-critical applications, precision turned parts make an important contribution. Appropriate prototypes are essential here, to guarantee that the later series products are well integrated and can also perform their functions over the long term – something that has to be proven via pilot production tests. During the development process of an entire subassembly, customers often require changes that have an effect on the precision component. This is where our speed and flexibility become true success factors.

Prototypes are created step by step in the Forschner SCR Systems division. State-of-the-art tools in 2D and 3D create a seamless connection between conception, development, documentation and validation, right up to series-production prototypes.

Magnetic coil technology, welding technology, cable- and plastics technology: electromechanical systems involve numerous technologies. Their optimal interplay has to be secured by means of prototyping, to keep things running smoothly in low, medium or high volume production later on.

Efficiency in all series

Due to our extensive personnel and machining capacity, Forschner is ideally setup up to produce high voltage distribution units and harnesses in high volume and just in time. Synergies across our business units support us in our challenges.

We supply individual cabling systems each year in the six-figure range. Currently, for instance, 150,000 heating cables for auxiliary heating devices. Our potential is far higher, however, with production sites in the Czech Republic, Turkey, Ukraine and Mexico. Nevertheless, in the cabling systems sector it is not production volumes alone that keep our standards so high. Rather it is the enormous variance required by some on-board wiring systems. We respond to this with flexible production that is packed with intelligent details. Networked cable harness assembly including optimized cut sequences, pre and post assembly with our own crimping machines, and modularized boards are just three of many examples here. Module preassembly also reduces the amount of work required during final assembly.

For SCR systems, we can carry out mass production reliably, even in very large quantities. Various high-performance locations, distributed internationally according to our customer markets, are equipped for this with the corresponding machines and systems. Our broad corporate base makes us flexible - regardless of whether car or truck, or for diesel or gasoline. Komax fully automatic machines and Thermoform continuous lines are just two examples of our leading production technologies for SCR systems.

Series production of electromechanical systems at Forschner is also subdivided into two sites. Short runs take place at our headquarters in Spaichingen, while medium and high volume production takes place at Uherské Hradiste. We produce the systems by ourselves in their entirety: from winding the coils, welding and TPE molding to leadframe production, crimping and testing. Dispensing as far as possible with subcontractors saves costs and reduces throughput times. Our customers benefit from our smooth processes, especially where complex coils with sensors are concerned. We also master high production volumes without a problem. Our current annual production volumes for various molded electro-coils, for instance, or electromechanical IDC contact technology, run into the six-figure range.

Uniform everywhere

Our quality assurance measures are correspondingly far-reaching. Thus we independently conduct all validation processes in the area of emobility. This includes thermoshocking, heat and ice validation, vibration test and complete system simulation. For this we have invested in a state-of-the-art clean room in our headquarters in Spaichingen, south-west Germany.

In temperatures from -40° C up to 180° C, SCR and fluid lines must always remain operational and perform their function reliably. With our intensive measures for quality assurance, we ensure that this is always the case even over long periods of use. Uniformly high standards are used internationally in our test procedures.

Where electromechanical systems are concerned, we subject not only individual systems but also complete subassemblies to precision testing. We ensure, for instance, that every detail – from magnetic coil technology to the mechanical component all the way to cables, contacts and switches – is entirely suited to tough everyday industrial conditions in the long term.

No limits to deadline and delivery reliability

Data management and a state-of-the-art IT infrastructure are the basis of punctual deliveries – and this applies especially toarea of emobility and harnesses. In cars a number of components are integrated, which in turn are also dependent on the cabling. We coordinate turnaround times of materials and prefabricated products precisely to our customers' production, thereby reducing development times. The benefit here is high supply security, minimal logistics expense, and no warehousing costs at the customer. With several international sites, Forschner secures proximity to important markets.

With precision turned parts, too, we adapt and react to the high logistic requirements of demanding customers, primarily from the automotive industry. "Small components" in particular, which often have a major effect on the end product, must not be allowed to influence the market rollout process.

Diameters of 2 mm to 7.5 mm, but above all length variants of up to 20 meters for commercial vehicles and buses make SCR cables quite a large-volume cargo. We are very well equipped here. In addition, our smart logistics processes fit perfectly into the production processes of vehicle manufacturers and other relevant industries. It goes without saying that the sensitive cables are optimally protected during transportation.

Last but not least, our Electromechanical Systems division benefits from Forschner's broad global base. If required, customers can fall back on a proven logistics network here too, covering even peripheral aspects such as risk management and emergency planning.