Electrical manufacturing: cable assembly, control cabinet construction, welding processes and Macromelt overmolding through to ready-to-install assemblies
TH electronic GmbH
Mühlhausen, GermanyNew on Amplifa
About TH electronic
TH electronic GmbH in Mühlhausen (Thuringia) is a specialized manufacturing partner for electrical assembly and cabling. The company performs assembly of complete units, cable assembly, wiring harnesses, connector assembly, control cabinet and switchgear construction as well as terminal boxes to customer specification – from smallest quantities to series production. In the field of joining technology, resistance welding for electrically conductive materials and ultrasonic welding of stripped copper conductors with cross-sections up to approx. 10 mm² are offered. Sensitive electronics such as cables, connectors, sensors and circuit boards are gently overmolded using the Macromelt hot-melt process (Technomelt); in addition, conventional potting/encapsulation is carried out. Power and control cable assembly is performed according to customer-specific specifications with jacket materials such as PUR and TPE for small and medium volumes. Customers come, among others, from the automotive, mechanical and plant engineering, energy technology, traffic engineering, medical technology as well as the food and pharmaceutical industries. In addition, the company offers electrical planning and design, installation, service and maintenance of electrical systems, automation technology, circuit board assembly and procurement consulting.
- Site
- Mühlhausen
- Processes
- Assembly of complete units (mechanical and electrical components, manual assembly through to, Cable assembly (custom wiring harnesses, stranded wires, cable sets for mechanical engineering and, Connector assembly, Automotive cable assembly, Electrical engineering cable assembly, Control cabinet construction / wiring of control cabinets (custom solutions to circuit diagrams,, Switchgear construction, Automation technology control cabinet construction
- Materials
- Copper, Stainless steel, Polyester, Powder-coated sheet steel, Sheet steel (painted), Technomelt (Macromelt hot-melt), PUR (cable jacket), TPE (cable jacket)
- Certificates
- ISO 9001
- Industries
- Automotive, Mechanical and plant engineering, Energy technology, Traffic engineering, Medical technology, Food and pharmaceutical industry
- 01
Planning and design
- 02
Procurement of cables and components
- 03
Cable assembly / control cabinet construction
- 04
Resistance and ultrasonic welding
- 05
Macromelt overmolding / potting
- 06
Assembly of complete units
- 07
Testing and delivery
Materials and Processes
Copper
Conductor material for ultrasonic welding with cross-sections up to approx. 10 mm² and cable assembly.
Stainless steel
Housing material for terminal boxes and control cabinets in corrosive or hygienically sensitive environments.
Sheet steel (painted)
Material for custom control cabinets built to circuit diagrams.
Polyurethane (cable jacket)
Jacket material for power and control cables with high abrasion and media resistance.
Thermoplastic elastomer (cable jacket)
Jacket material for flexible industrial cables.
Technomelt (Macromelt hot-melt)
Environmentally friendly material for gently overmolding cables, connectors, sensors and circuit boards.
Polyester
Lightweight, chemical-resistant material for outdoor terminal boxes.
Sites
Mühlhausen
DEManufacturing and administration
- Lot size
- Smallest quantities to series (Macromelt: single pieces up to 10,000 pieces)
- Materials
- Copper, stainless steel, sheet steel, polyester, PUR, TPE, Technomelt
- Ultrasonic welding system (generator, sonotrode, welding head)
- Resistance welding machine with control system and current transmission system
- Macromelt/hot-melt overmolding system
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Assembly of complete units (mechanical and electrical components, manual assembly through toAssembly | – | – | – | – | – |
| Cable assembly (custom wiring harnesses, stranded wires, cable sets for mechanical engineering andAssembly | – | – | – | Smallest quantities/small series | Copper |
| Connector assemblyAssembly | – | – | – | – | – |
| Automotive cable assemblyAssembly | – | – | – | – | – |
| Electrical engineering cable assemblyAssembly | – | – | – | – | – |
| Control cabinet construction / wiring of control cabinets (custom solutions to circuit diagrams,Assembly | – | – | – | – | Sheet steel (painted), Stainless steel |
| Switchgear constructionAssembly | – | – | – | – | – |
| Automation technology control cabinet constructionAssembly | – | – | – | – | – |
| Terminal box manufacturing (custom sizes, individual painting/coating, protection ratings IP23 toAssembly | – | – | – | – | Stainless steel, Polyester, powder-coated sheet steel, painted surfaces |
| Power cable and control cable assembly to customer-specific specifications (small and mediumAssembly | – | – | – | small quantities – medium quantities | Copper, PUR (jacket), TPE (jacket) |
| Resistance welding (joining electrically conductive materials, without filler materials;Joining | – | – | – | Small series – Large series | electrically conductive materials |
| Ultrasonic welding (joining of stripped conductors, copper, cross-sections up to approx. 10 mm²)Joining | – | – | – | – | Copper |
| Macromelt (hot-melt overmolding of cables, connectors, sensors, circuit boards; seriesPlastics | – | – | – | Single pieces/prototypes – Series up to 10,000 pieces | Technomelt (Macromelt hot-melt) |
| Potting/encapsulationPlastics | – | – | – | – | – |
| Contract manufacturing (electrical engineering)Assembly | – | – | – | Smallest quantities | – |
| Circuit board (manufacturing/assembly)Assembly | – | – | – | – | – |
| Installation of electrical systemsAssembly | – | – | – | – | – |
| Planning and design (electrical planning and construction)Engineering | – | – | – | – | – |
| Service and maintenance of electrical systemsAssembly | – | – | – | – | – |
| Procurement consultingEngineering | – | – | – | – | – |
3 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Ultrasonic welding system (generator, sonotrode, welding head) | – | – | Copper cross-sections up to approx. 10 mm² | – | Mühlhausen |
| Resistance welding machine (with control system and current transmission system) | – | – | – | – | Mühlhausen |
| Macromelt/hot-melt overmolding system | – | – | – | – | Mühlhausen |
Additional services
Quality
Welded joints are tested by pull-off tests, electrical tests and visual inspections. Every control cabinet undergoes a quality control with mechanical, visual and electrical testing (including the grounding system) before delivery.
| Evidence | Mühlhausen |
|---|---|
| ISO 9001 |
History
- ca. 2019–202
Ultrasonic welding in use for about five to six years (statement relative to website publication).