Manufacturer of cable sets, cable harnesses, assemblies and control systems for industry, automotive and medical technology
BGE Elektrotechnik GmbH
Gerstungen (Headquarters/Production) · Bad Nauheim (Branch office)New on Amplifa
About BGE Elektrotechnik
BGE Elektrotechnik GmbH is a medium-sized contract manufacturer based in Gerstungen (Thuringia) that has been working with the processing of cables and wires since 1978. The service portfolio includes cable sets and wiring sets for luminaire, control and switchgear cabinet construction, on-board electrical systems and cable harnesses for the automotive and vehicle industries, connection cable sets for electronic, pneumatic and hydraulic functional units, as well as connection modules with individually configured wire cross-sections from 0.1 mm² to 50 mm². In the area of assemblies, BGE manufactures ultrasonic or resistance-welded contact assemblies, switching and PCB assemblies with integrated wiring, and function-tested electrical control systems, among other things for mobile air conditioning units. The offering is complemented by wire/cable cutting, plastic injection moulding technology (overmoulding of device sockets and connectors onto straight and spiralised wires) as well as development services from prototype construction to series production. Wires conforming to DIN or UL/CSA standards are used. Customers come from the automotive and vehicle industries, mechanical engineering, robotics automation, industrial truck manufacturing, medical technology, luminaire manufacturing and electrical installation engineering. Annual revenue is approximately €7 million.
- Site
- Gerstungen
- Processes
- Cable set/cable harness assembly (cable sets, wiring sets, on-board electrical systems, control and, Ultrasonic or resistance-welded contact assemblies (busbar/switching contacts with, Switching assembly mounting with integrated wiring and connection cable; PCB assemblies, Wire/cable cutting: cutting and assembly of bulk cable, wound, packaged and, Plastic injection moulding technology: overmoulding of cold and warm device sockets and connectors, Control system construction: complete electrical control systems (e.g. for mobile air conditioning, Charging cables straight and spiralised (Flexicord spiral cables), Connection modules with interface connectors and individual wire configuration
- Materials
- Cables and wires to DIN standards, Cables and wires to UL-CSA standards, Copper (wire cross-sections), Connection strands 0.34 mm² – 16 mm², Plastic (injection moulding technology), Copper (wire cross-sections 0.1–50 mm²)
- Certificates
- DIN EN ISO 9001:2015, DIN EN ISO 14001 (elements), ISO 9001, ISO 14001 (elements)
- Founded
- 1978
- Employees
- approx. 90
- Industries
- Automotive and vehicle industry, Mechanical engineering, Robotics automation, Industrial trucks, Medical technology/electro-medicine, Luminaire manufacturing
- 01
Product development / prototype construction
- 02
Wire/cable cutting
- 03
Cable assembly (cable sets, cable harnesses)
- 04
Ultrasonic/resistance welding of contact assemblies
- 05
Plastic injection moulding technology
- 06
Assembly and control system mounting, function testing
Materials and Processes
Cables and wires to DIN standards
Standard wires for cable sets, cable harnesses and control system construction.
Cables and wires to UL-CSA standards
Approved wires for applications with international approval requirements.
Copper (wire cross-sections 0.1–50 mm²)
Connection strands and connection modules, including strands from 0.34–16 mm² for welded contact assemblies.
Plastic (injection moulding technology)
Overmoulding of cold and warm device sockets and connectors onto straight and spiralised wires.
Locations
Gerstungen
DEHeadquarters and production (new factory building 1994 in Thuringia)
- Lot size
- Prototypes to series production
- Materials
- Wires to DIN and UL-CSA standards, plastic
- Facilities for cable assembly and processing
- Ultrasonic/resistance welding systems
- Injection moulding technology
Bad Nauheim
DEBranch office (since the merger in 2021, formerly Lehmann Kabel GmbH)
Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Cable set/cable harness assembly (cable sets, wiring sets, on-board electrical systems, control andAssembly | – | – | – | Series production | Cables and wires to DIN standards, Cables and wires to UL-CSA standards |
| Ultrasonic or resistance-welded contact assemblies (busbar/switching contacts withJoining | – | – | – | – | Connection strands 0.34 mm² – 16 mm² |
| Switching assembly mounting with integrated wiring and connection cable; PCB assembliesAssembly | – | – | – | – | Connection strands |
| Wire/cable cutting: cutting and assembly of bulk cable, wound, packaged andAssembly | – | – | – | – | Cables/wires (DIN or UL-CSA standards) |
| Plastic injection moulding technology: overmoulding of cold and warm device sockets and connectorsPlastics | – | – | – | – | Plastic, Wires to DIN or UL-CSA standards |
| Control system construction: complete electrical control systems (e.g. for mobile air conditioningAssembly | – | – | – | – | Cable harnesses, Housings with protection rating, Mounting plates |
| Charging cables straight and spiralised (Flexicord spiral cables)Assembly | – | – | – | – | Wires to DIN/UL-CSA standards |
| Connection modules with interface connectors and individual wire configurationAssembly | – | – | – | – | Copper conductors (wire cross-sections 0.1 mm² – 50 mm²) |
| Stamped partsForming | – | – | – | – | – |
| Bent partsForming | – | – | – | – | – |
| Services: product development, prototype manufacturing, development from prototype construction toEngineering | – | – | – | – | – |
Additional services
Reference customers
Quality
BGE is certified to DIN EN ISO 9001:2015 and has been working according to elements of the environmental standard DIN EN ISO 14001 since 1995 (Reg. No. 73 100 192). A dedicated QA service is available for IMDS, material compliance and complaint enquiries.
| Evidence | Gerstungen |
|---|---|
| ISO 9001 | |
| ISO 14001 (elements) |
History
- 1978
Foundation of Ing.-Büro Bicking
- 1983
Conversion into HKV Elektro GmbH
- 1990
HKV Elektro GmbH establishes a branch in Eisenach
- 1992
Acquisition of a competitor in Lauchröden, production with approx. 35 employees at 4 locations
- 1993–94
Consolidation of all locations, renaming to BGE Elektrotechnik GmbH
- 1994
New factory building in Thuringia, 63 employees
- 1995
Certification to DIN EN ISO 9001 and elements of DIN EN ISO 14001 (December 1995, Reg. No. 73 100 192)
- 2010
Focus on the automotive industry
- 2019
Lehmann Kabel GmbH becomes a 100% subsidiary
- 2021
Merger of BGE and Lehmann Kabel into BGE Elektrotechnik GmbH, headquarters in Gerstungen, branch office in Bad Nauheim
- 2022
Full concentration on expanding the core field of electrical engineering
- 2023
30th company anniversary at the Gerstungen site, certificate of honour from the Erfurt Chamber of Commerce (IHK)