Custom Wiring Harness for Automotive Test Systems: Complex Multi-Connector Assemblies
At Kabeltechnik, we specialize in producing custom wiring harnesses for demanding applications in the automotive and industrial electronics sectors.
One of our recent projects involved the manufacturing of a complex, multi-connector cable assembly designed for integration into a vehicle testing system built by a major TIER 1 supplier. This setup allows engineers to simulate and validate various motion and detection sensors used in modern vehicles during development.
Project Overview
This cable harness included:
Up to 220 pins distributed across different connector interfaces
Modular heavy-duty connectors (Han-Eco® style) at one end
Automotive-grade ECU connectors (Yazaki-style) at the other
Color-coded and labeled wires for easy identification
Twisted pairs and shielding for signal integrity
Protective sleeving and organized bundling for long-term durability
Use Case: Modular Test Systems for OEMs
This wiring harness was built to support a modular and intelligent testing platform capable of simulating multiple sensor signals—such as radar, gyroscope, proximity, and movement detection.
For the OEM, this approach offers:
Fast and accurate ECU validation
A reusable system adaptable to multiple vehicle models
Lower total testing costs and faster development cycles
The custom cable design ensures compatibility, signal stability, and mechanical reliability during all test procedures.
Why Kabeltechnik?
✔️ Custom-built assemblies designed for each project’s unique requirements
✔️ Complete traceability of wires, connectors and specifications
✔️ Clean, organized layouts for efficient integration and maintenance
✔️ Automotive-grade standards applied to production and testing.
From development benches to final validation lines, we help engineering teams connect their systems with confidence
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