Cable harnesses

Whether the design of interconnectivity solutions for machine tool applications or a wiring harness for a high-performance vehicle, PP Control & Automation applies significant experience in the production of cabling, cable harness and interconnectivity solutions.

The design and quality of any cable harness cannot be overstated as most failure in any associated electrical system is inferior quality of connectivity.

Therefore, PP C&A has invested £millions in automated production and test equipment for cable harnesses and utilise a 100% test regime to ensure reliability and performance – Over £1m has been invested in state-of-the-art fully automated cable preparation.

Single and multicore cable processing, including specialist cables and customer designed umbilical solutions all benefit from this significant investment in automation, as well as the skills required for delivering against a lean six sigma improvement approach to electrical engineering.

Furthermore, the design and manufacture of complete drag chain solutions, including the integration of hydraulics and pneumatics is a sought-after capability that PP C&A, as a specialist outsourcing partner has developed and refined alongside its world-first technology investments.

PP C&A incorporate several production steps in the manufacture of wire harnesses for machinery. Those steps will include working from technical drawings, verifying component locations and connections before procuring the wires, connectors, and terminals.

Physically assembling the harness includes cutting and stripping wires, attaching connectors and terminals, and bundling and securing the wires. Conducting thorough testing of the completed harnesses, including continuity testing, resistance testing, and high-potential testing, to detect any defects or issues is always adhered to.

Reliable connectivity

It is a well-documented fact that the single biggest contributor to machine downtime and field failure is caused by poor electrical connectivity.

Just one poor crimp connection can cause machine failure, and the sheer volume of electrical connections in and around a piece of complex machinery could make this particularly challenging.

In order to avoid the damaging costs associated with this failure, you will want assurances from your outsourcing partner or control panel builder that they recognise the importance of repeatable quality within their manufacturing processes.

PP C&A‘s solution to this challenge is the significant investment in automation for both cable manufacture and cable testing.

Addressing connectivity

Automated Test Equipment (ATE) is a term you may be familiar with. It uses automation to measure and evaluate connectivity for a given cable harness quickly and precisely. Such a process not only looks at ‘point to point’ accuracy of a harness, but it can also perform other checks in relation to its construction, such as high or low resistances, as well as carrying out other tests such as a Hi-Potential test, which checks the adequacy of electrical insulation.

By testing cables in this way, you minimise the opportunity for manufacturing errors not being identified and rectified before that cable harness gets integrated into a larger, more complex control system and the associated machinery. Faults can then develop later down the line, often once the machine is installed and commissioned (due to environmental conditions as well as vibration). At this point, identifying the issue can be extremely difficult and time consuming, leading to unnecessary and costly down time, particularly with intermittent issues.

An area of significant investment is in the automated production and ‘in process’ test (CFM – Crimp Force Monitoring) for single core cable production, which utilises a 100% checking regime of all crimps being applied, ensuring strip back lengths, crimp position and applied crimp force are all in line with the required specifications.

In 2019, PP C&A installed a world first in crimping technology – An Artos CRX33-GVM, modified for its exact production requirements. It provides shorter handling distances and can process cables at over 5 metres per second, whilst still maintaining very high levels of accuracy. Every single core cable goes through automated cable prep, automatic cutting, crimping, and identing with direct ink jet printing.

The design and build quality of any cable harness cannot be overstated when considering most failure in any electrical system is inferior quality of connectivity. By automating both the production and test of single and multi-core cables, PP C&A can minimise risk for both its customers and the end users.

In addition to automated cable preparation and ATE testing, other processes can be adopted to ensure optimum performance and reliability of a given system. PP C&A has designed bespoke functional test rigs for many of its customers, to fully simulate the desired operating requirements of a given control system, which often includes software to check all inputs and outputs are correctly connected and all signals are being seen and read.

Cable harnesses » PP benefits icons control and automation cabling wh 1 » PP Control & Automation
Cable cutting & crimping machinery

inc. ARTOS, Schleuniger, and Z+F

Cable harnesses » PP benefits icons control and automation cabling wh 2 » PP Control & Automation
Automated cable identing
Cable harnesses » PP benefits icons control and automation cabling wh 3 » PP Control & Automation
Torque tooling
Cable harnesses » PP benefits icons control and automation cabling wh 4 » PP Control & Automation
Automated test equipment

inc. CIRRUS

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Just one poor crimp

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PP Control & Automation invests £250,000 in ‘world first’ technology

A world first in ‘crimping’ technology has been installed PP C&A to help with increased demand for its strategic services.

‘world first’ crimping technology

A world first in ‘crimping’ technology was installed at a PP C&A’s award-winning facility to help it cope with increased demand for its strategic services.

The £250,000 investment in an Artos CRX33-GVM included modifications for its exact production requirements and allow it to operate faster and with greater reliability thanks to the unique software customisations provided.

Furthermore, integration of two of the latest Markem-Imaje Inkjet printers and the very latest in Z&F UNIC-GV Ferrule crimping units – the latter containing the very latest changeover technology complete a one-of-a-kind kit for the automation of cable processing.

Design for Manufacture & Assembly (DFMA)

Design for Manufacture and Assembly (DFMA) is a core discipline practiced at PP C&A and can be best understood as a set of guidelines and best practices for designing products in a way that makes them easy and efficient to manufacture and assemble.

The goal of DFMA is to reduce costs, improve quality, and increase efficiency during the manufacturing process.

DFMA can encompass several value add techniques, such as using standardised components, simplifying designs, and minimising the number of parts used.

Essentially, by following DFMA principles, PP C&A can help machine builders and OEMs design systems that are easier to manufacture, assemble, test, and maintain. Cost savings, improved quality, and shorter lead times are renowned key benefits to following these principles.


Minimising the number of parts


Using standardised components


Simplifying designs


Optimising tolerances


Reducing assembly steps


Improving accessibility for testing and repair


Minimising material waste


Key networks
& partners

PP C&A is always inspired by the many benefits of building partnerships as part of a wider strategy to support the trend for outsourced design, engineering and more specialist competencies required by OEMs involved in complex machine building.

Cooperation within a framework of customer specific needs and optimisation of those needs, alongside the ability to adapt and drive innovation is sought after now more than ever.

PP C&A’s technical partnerships with innovative technology suppliers, testing & approval bodies and industry associations facilitates the continuous development of the company, capturing emerging opportunities at speed thanks to an ‘on request’ pool of expert knowledge and know-how to dip into.

If leveraging the benefits of partnerships developed at PP C&A could help on your growth journey, then PP+ may be of interest. PP+ is an expansion of the traditional outsourcing model that considers the customer’s growth objectives and offers a single-source solution to industry-best resources and guidance.

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Cable harnesses » MAN Logo » PP Control & Automation

PP C&A is a proud and long-standing member of the Manufacturing Assembly Network, also known as the MAN Group.

The MAN Group is a network of manufacturing companies designed to share technical excellence in mechanical, electrical and electronic engineering processes.

As a customer and partner of PP C&A, access is open to numerous manufacturing disciplines from a single source and a more stable solution for complex, multi-discipline engineering projects.

The MAN Group consists of seven specialist manufacturers, one engineering design agency and the knowledge transfer of Warwick Manufacturing Group (WMG).

MAN Group engineering disciplines

Aluminium casting

CNC & conventional machining

Contract electronics manufacturing

Electrical & electronics assemblies

Forging

Metal stamping

Plastic injection moulding

Tube bending & manipulation


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Engineering & Production capabilities

A combination of production and engineering capabilities to suit your specific needs can be accommodated to deliver the desired result.

Such a solution can broadly be divided into module build, part machine build or full machine build – – whichever provides the optimum solution for you.

Get a quick glimpse at key capabilities by interacting with the solutions wheel below.

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Add these guides to your resource basket

There should always be a process of consideration when selecting the right outsourcing partner and understanding how that partner delivers against your requirements. That’s why PP C&A introduced the 3D process. It clearly defines the whole journey into three specific stages: Discovery, Decision, Delivery.

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In your basket

This collection of case studies examines some of the recent strategic outsourcing partnerships delivering against several business pains for machine builders and OEMs. This guide collects case studies published during 2021.

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In your basket

This guide highlights key technical supplier relationships covering a broad set of categories, from industrial design support and access to academia, and automation and legislation partnerships, to packing and shipping finished goods, all designed to add sought after value to customers.

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Strategic outsourcing case studies

Inventor-e iVendScale+

The way companies access inventory management is changing rapidly and leading the charge is Solihull-based Inventor-e.

Hedinn

PP Control & Automation and Hedinn are now engaged in their 13th project together and the largest yet, the construction of a new plant for Sildarvinnslan.

Needham Group (Interactive Case Study)

Play an interactive video with hotpoints that delve into the story behind the manufacturing partnership with Needham Group and the assembly of its N-Lase range of products.

Winbro Group Technologies

A strategic manufacturing outsourcing partnership – built on trust, integrity and maximising each other’s production expertise – is celebrating ten years together with the launch of the world’s most productive EDM drilling machine.

Collected customer case studies (2021)

This collection of case studies examines some of the recent strategic outsourcing partnerships delivering against several business pains for machine builders and OEMs, and how those partners are benefiting from the PP C&A approach.

Needham Group

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PP C&A’s core services

Making outsourcing easy

We believe in meeting you, listening and understanding your needs first and foremost.

If you are considering PP C&A’s cable harness and interconnectivity solution services or you wish to review your outsourcing strategies, we would welcome the opportunity for discussion.







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