Cable assembly and wired assemblies: crimping, soldering, potting and system building from first sample to series production.
Pahling GmbH
Ruppertshofen (DE) · Gotse Delchev (BG)New on Amplifa
Cable assembly and system manufacturing since 1985
Founded in 1985, Pahling GmbH is an owner-managed family business in its second generation, headquartered in Ruppertshofen on the Swabian Alb. The company manufactures assembled cables and electrical assemblies: individual wires, cable sets, cable harnesses, connector assemblies as well as control and servo cables, including for Ethernet, Profinet and CAN. The processes include crimping (over 800 crimp dies), soldering with lead- and halogen-free solders, resistance spot welding, potting and molding, UV bonding, 3D printing, mechanical machining as well as the assembly of wired assemblies and control cabinets according to EPLAN data. Processed are cables up to 185 mm² cross-section or 40 mm outer diameter, heat-shrink tubing, fabric and flat ribbon cables. Every batch is 100 % tested (continuity, high-voltage and functional testing) and documented according to IPC/WHMA-A-620. The production facility in Gotse Delchev (Bulgaria) scales series and volume orders; the UL approval enables export to North America. Lot sizes range from single pieces to 100,000 pieces per month.
- Site
- Ruppertshofen
- Processes
- Cable assembly (individual wires, cable sets, cable harnesses, connector assemblies, control and, Crimping, Soldering (lead- and halogen-free solders), Resistance spot welding, Screwing/assembling (wiring of assemblies, control cabinet & system building), Potting / 2K potting (molding), UV bonding, 3D printing (test plugs and more)
- Materials
- Heat-shrink tubing, Fabric cables, Flat ribbon cables, Lead-free and halogen-free solders, Copper cables/copper wires, Copper cables / copper wires, Lead- and halogen-free solders, Potting/molding compounds, UV adhesive, hotmelt
- Certificates
- ISO 9001, UL approval (assembled cables, production for export to North America), UL approval (Other)
- Founded
- 1985
- Industries
- Mechanical and plant engineering, Automation technology, Drive technology, Electrical engineering/electronics, Device manufacturing, Industries requiring assembled cables and electrical assemblies
- 01
Inquiry & feasibility check
- 02
Quotation & project management
- 03
Material procurement & production control (ABAS)
- 04
Sample building / 0-series & approval
- 05
Production (assembly, manufacturing) in DE and BG
- 06
100 % final inspection & documentation
- 07
Shipping from headquarters in Ruppertshofen
Cables, materials and processes
Copper cables / copper wires
Assembly of individual wires, cable sets and cable harnesses up to 185 mm² cross-section and 40 mm outer diameter.
Heat-shrink tubing
Processing on special machines for insulation and mechanical protection.
Fabric cables
Special material for application-specific cable sets.
Flat ribbon cables
Processed on SP 101, LC 100 and CAB FS100 machines.
Lead- and halogen-free solders
For soldering processes on digital soldering stations from Weller and JBC.
Potting/molding compounds, UV adhesive, hotmelt
For overmolded connectors and potted modules.
Locations
Ruppertshofen
DEHeadquarters, production (cable assembly, system manufacturing, sample workshop), shipping
- Part weight / size
- Cables up to 185 mm², cables up to 40 mm outer diameter
- Lot size
- 1 piece to 100,000 pieces/month
- Materials
- Copper wires, heat-shrink tubing, fabric and flat ribbon cables
- Komax AutoCut-Line
- Komax 320/330/331 (rotary head)
- SP 101 / LC 100 / CAB FS100
- Contact press EPS2001
- Crimping machines Rennsteig, WEZAG/WDT
- Stripper-crimpers Zoller+Fröhlich
- 4-indent crimp technology DMC
- Soldering stations Weller/JBC
- Potting mixing system Fritz Giebler
- UV bonding system Delo
- Hotmelt system Schäfer
- Electric screwdrivers Delvo
- Inkjet printing systems
- 3D printing
Gotse Delchev
BGProduction (series and volume orders)
- Lot size
- Series and volume orders
Components and products
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Cable assembly (individual wires, cable sets, cable harnesses, connector assemblies, control andJoining | – | – | – | 1 piece – 100,000 pieces per month | Copper wires/cables up to 185 mm² cross-section, Heat-shrink tubing, Fabric cables, Flat ribbon cables |
| CrimpingJoining | – | – | – | 1 piece – 100,000 pieces per month | Cables up to 40 mm outer Ø, Cable cross-sections up to 185 mm² |
| Soldering (lead- and halogen-free solders)Joining | – | – | – | – | – |
| Resistance spot weldingJoining | – | – | – | – | – |
| Screwing/assembling (wiring of assemblies, control cabinet & system building)Assembly | – | – | – | Single piece | – |
| Potting / 2K potting (molding)Plastics | – | – | – | – | – |
| UV bondingSurface | – | – | – | – | – |
| 3D printing (test plugs and more)Additive | – | – | – | – | – |
| Mechanical machining (custom distributors)Machining | – | – | – | – | – |
| Printing/laser engraving/marking (inkjet systems, wire marking)Surface | – | – | – | – | Wires, Cables |
| Cutting (cut-to-length) and strippingJoining | – | – | – | – | Wires, Cables, Heat-shrink tubing, Fabric and flat ribbon cables |
| Testing (continuity, high-voltage and functional testing, 100 % final inspection)Testing | – | – | – | – | – |
| Sample building / prototypes / first articles (sample workshop)Engineering | – | – | – | 1 piece | – |
| Special fixtures (test benches, crimping fixtures, routing and winding aids)Assembly | – | – | – | – | – |
20 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Cutting/crimping machine (AutoCut-Line) | Komax AutoCut-Line | – | Cables up to 40 mm outer Ø | – | Ruppertshofen |
| Cable assembly machine | Komax 320 | – | up to 40 mm outer Ø | – | Ruppertshofen |
| Cable assembly machine | Komax 330 | – | up to 40 mm outer Ø | – | Ruppertshofen |
| Cable assembly machine with rotary head | Komax 331 | – | up to 40 mm outer Ø | – | Ruppertshofen |
| Processing machine for special materials | SP 101 | – | Heat-shrink tubing, fabric and flat ribbon cables | – | Ruppertshofen |
| Processing machine for special materials | LC 100 | – | Heat-shrink tubing, fabric and flat ribbon cables | – | Ruppertshofen |
| Processing machine for special materials | CAB FS100 | – | Heat-shrink tubing, fabric and flat ribbon cables | – | Ruppertshofen |
| Pneumatic stripping machine | – | – | – | – | Ruppertshofen |
| Inkjet printing systems (black and blue) | – | – | – | – | Ruppertshofen |
| Contact press | EPS2001 | – | – | – | Ruppertshofen |
| Pneumatic crimping machine | Rennsteig | – | – | – | Ruppertshofen |
| Pneumatic crimping machine | WEZAG/WDT | – | – | – | Ruppertshofen |
| Stripper-crimper | Zoller+Fröhlich | – | – | – | Ruppertshofen |
| 4-indent crimp technology | DMC | – | – | – | Ruppertshofen |
| Digital soldering station | Weller | – | – | – | Ruppertshofen |
| Digital soldering station | JBC | – | – | – | Ruppertshofen |
| Potting mixing system | Fritz Giebler | – | – | – | Ruppertshofen |
| UV bonding system | Delo | – | – | – | Ruppertshofen |
| Hotmelt system | Schäfer | – | – | – | Ruppertshofen |
| Electric screwdriver | Delvo | – | – | – | Ruppertshofen |
Additional services
Quality and testing
Every batch is 100 % tested by continuity, high-voltage and functional testing and traceably documented according to IPC/WHMA-A-620; test reports, batch documentation as well as first article inspection reports/PPAP are provided upon request.
| Evidence | Ruppertshofen | Gotse Delchev |
|---|---|---|
| ISO 9001 | ||
| UL approval (Other) |
History
- 1985
Founded as an owner-managed family business in Ruppertshofen; today run by the second generation.