COMPETENCIES
Research and Development
From idea to serial production with global footprint
Voltaira, as a trusted partner in the automotive supplier industry, develops and manufactures sensor as well as High Voltage and Low Voltage wire harness solutions for the automotive industry. From custom emission control harnesses to electrical powertrain HV cable assemblies as well as active & passive safety harnesses, Voltaira products has enabled innovations in the ever fast-evolving mobility industry.
Globally well-known, leading vehicle OEMs and eBike manufacturers trust our technology know-how and manufacturing expertise. Voltaira enables new market trends, such as electrical mobility and autonomous driving by providing state-of-the-art cable solutions and a strong business partnerships to Tier1 and OEMs.
From idea to serial production with global footprint
Our product developments are designed to cost to be competitive in the mobility market, robust to meet customer requirements, as well as designed for manufacturability to reduce production cost and assure repeatability on highest quality levels. Our Advanced Product Quality Planning (APQP) process is guiding us through the development process from the initial idea through serial production. The ability to provide these engineering and development services worldwide, makes us a unique and valued ally to our global customer base.
With a full range of in-house capabilities, we are able to develop, design, manufacture and deliver tailored product solutions which meet or exceed customer expectations.
Global Product and Process Development
A structured global engineering organization, with strong regional representations allows Voltaira to collaboratively develop specialized product and process solutions to enable system providers in the mobility industry. Harsh Environments, fast and robust signal integrity, size limitations as well as secure sensor and electronic adaptions are challenges which drive innovation in our R&D teams and result into specialized cable assembly solutions that surpass customer expectations. All our products are designed not only to exceed customer requirements but also with the manufacturability in mind and therefore allow simplified, cost effective assembly equipment solutions. Globally installed engineering systems assure that development data is globally available at any time and lessons learned are shared instantly.
Development expertise
Voltaira has extensive know-how in the required manufacturing technologies to ensure a high-quality product production. Computer aided design and simulation tools as well as the ability to create prototypes and required assembly fixtures simultaneously and our in-house testing ability improve the development turnaround time significantly and point to potential shortcomings in our Product and Equipment Developments in very early stages.
Process And Equipment Development
Voltaira has the capability to design, manufacture and build product assembly stations which range from manual through semi-automated to fully automated assembly cells. We integrate state-of-the-art technology processes to build, test, measure, verify and trace mark our customer products to assure 100% satisfaction and ZERO defects.
Product verification and validation testing
Voltaira has a wide range of laboratory measuring and testing equipment to support production quality, product verification, product validation and failure analysis.
Present the research & development flow
Concepting /pre-development 3D CAD PRODUCT Design Simulation Rapid prototyping Product verification CMM measuring, x-ray ... Accredited Product validation testing Sampling /low volume production Process planning In house machine shop capatibilities (CNC-milling/turning, wire- EDM, grinding,...) Process and Equipment Design & Development (Automation) Industrialization - Lean Production planning In house quipment build and assemby Production planning, Product Lifecycle Management, APQP, Quality Management, supply Chain and Logistics, Project Management, Change Management
Voltaira competences
Wire Processing
Pre-feeding (straighten wires)
100% HV insulation verification (pin holes, splice detection, other cable damages)
In House calibration of crimping station
Cut, strip, seal, crimp both sided of the wire
Laserweld integration
Strand twisting & tinning integration
Compacting of wire ends
100% seal positioning verification
100% crimp height verification
Prettl Quick exchange system (for faster crimp die and terminal exchange)
Prettl internal designed crimp tooling
Connector assembly
Fully POKA-YOKE connector assembly
Full terminal engagement verification (with tug test & switch pins)
Fully automated TPA engagement
100% insulation color detection
Bad part locking (key release + scrap sensor release)
Coded Quick exchange modules for different connectors types (fast change over
100% insulation color verification
100% wire orientation check
Verification of supplier pass thru quality concerns
100% leak testing (negative pressure)
Guided assembly
Auxiliary assembly processes for sensor side
Ceramic assembly stations for O2 applications
Metal sleeve clenching stations for O2 applications
Automated plastic ultrasonic welding stations (Horn switches)
Wire twisting stations
Sensor controlled, manual and semi automatic assembly presses (EPS, Door handle switch assy)
Lead bending and cutting machines (Hall IC’s, capacitors, resistors, etc.)
fully automated switch into leadframe assembly including lead bending, indexed resistance welding and metal stamping (separating)
Laser marking, leak testing
And more…
Sensor attachment
Semi automated, vision- and sensor controlled sensor attachment stations (resistance welding, EPS, door handle)
Semi automated, camera controlled splicing (splice band) stations with integrated linear actuators for indexing of multiple splices e.g. Seat belt applications
Semi automated, camera controlled solder stations
Crimped (splice crimp) sensor attachments
Integrated spring loaded pins
Fully automated wire to leadframe resistance welding with servo indexing (Horn Harness)
Sensor encapsulation/ -protection
Low pressure overmolding of electronics
2K potting of sensors, antennas or switches
Injection overmolding of Terminals (USCAR connector interfaces e.g. wheelspeed)
Prettl “Tight” Duroplast overmold with Thermoplast final mold
2K injection molding to allow flexible sealing function (e.g. door handle switches)
LCP terminal overmold (high temp applications- temp. sensor)
sensor housing injection molding (horizontal and vertical Arburg machines)
Harness protection and routing features
Corrugated tube cutting (cutting on wave crest)
Fiberglas tube cutting
Pvc tube cutting
Taping fixtures for accurate tape length and positioning
Spot tape dispensing units
Taping stations
Heat shield sleeve cutting and sensor controlled assembly stations
Harness length wise taping (twist protection-EPS)
Tube adapters and routing channels
Grommet assembly stations and grommet overmolding
Semi automated Poka Yoke, sensor controlled clip assembly boards
Pneumatically controlled zip tie guns
Quality and Product Validation/Testing
100% EOL testing with 2D data matrix code laser marking (Co2, Yag) with integrated 2D code scanner, leak tester & bad part cutter
Crimp cross section Lab
USCAR21 accredited Test Lab (wire/crimp connection verification)
Load frame (pull force & travel measurements)
Optical / with touch probe measuring devises
SPC for Crimp dimensions
3D CAD and CAE tools for preventative quality planning (moldflow)
Climate Chambers, salt spray tester and
Surface roughness measuring, CMM, visual
X-Ray for non-destructive quality verification
100% crimp force monitoring & more
Shipping/ Warehousing
Standard packaging (cardboard with plastic inlay)
Manual packaging station with Cycle Counting System with an accuracy of 99.8%
FIFO system
Bar code scanners for Finish Goods
Capability for daily shipments 24hrs.
SAP inventory Management
Global Tech Centers
