Cable Production

Nursan Kablo designs, develops, and manufactures wire harnesses for passenger cars, light and heavy commercial vehicles, buses, military and agricultural vehicles, as well as other equipment and the smooth and corrugated tubes required for the production of these harnesses.

Nursan manufactures high-quality single-strand and multi-strand automotive and battery cables. The 0.22 mm2 – 10.00 mm2 cross-section standard cables and the 10.00 mm2 – 90 mm2 cross-section battery cables are produced on the PVC extrusion lines, which use heat-sensitive polymer materials.

Cable extrusion process involves coating the cables by passing an insulation material such as PVC or PE heat melted in an extruder through a specially designed mould with the forward movement of a screw in a barrel. The total annual capacity of the 5 extrusion lines at Nursan manufacturing facilities is 450,000 vehicles sets.

Rosendahl Extruder: 1200 m/min.
Nokia Maillefer Extruder: 1000 m/min.
65 mm2 Extruder: 200 m/min.
2 x 90 mm2 Extruders: 200 m/min.

PVC Corrugated Tube / PVC Smooth Tube Production

We use extrusion, a method that melts the plastic granules under heat and pressure by rotating a screw in a barrel covered with a heater and powered by a motor, to produce PP corrugated and PVC smooth tubes. Nursan produces these tubes, used to protect wire harnesses from the elements and other external factors and to create a seal in-house. Nursan currently has two extruders:

PP Corrugated Tube Extruder: 50 m/min.
PVC Smooth Tube Extruder: 50 m/min.

CSC (Cutting – Stripping – Crimping)

Stripping a cable is typically needed to connect it to another fixture or cable. The CSC operation required to strip the outer surface of an insulated electrical wire is performed professionally on a range of wires from small scale, fine strands to large tecks and auxiliary cables.

The CSC operation can be performed mechanically or automatically.

Mechanical crimping is performed on manual presses, supported with CQM control systems. On the other hand, automatic CSC machines are equipped with the latest technologies, and support multiple simultaneous operations such as plug sealing, double crimping, and cable twisting. Nursan currently has 41 automatic CSC machines across its production with a total annual production capacity of 450,000 car sets.

Mechanical Splicing

Mechanical splicing is another method of bonding wires. The conductive parts of multiple wires are spliced with mechanical splicing on manual presses and the area of welding is subsequently protected either by shrinking a tube or splicing tape.

Ultrasonic Wire Splicing

CSC takes place when high frequency vibrations, induced by electrical energy, create internal friction, which leads to instant heat increase. The Ultrasonic wire splicing method enables the conductive parts of multiple wires to be securely welded.

At Nursan, we use the best ultrasonic wire splicing solutions needed for different applications.

PVC Injection

PVC injection requires sound knowledge about processing the dry materials and granules. At Nursan, we use advance PVS Injection technologies to achieve efficient, cost-effective productions.

PVC injection can be applied on harness ties to seal certain areas in the vehicles. We design the moulds and injectors that we will use in this process based on the type of raw material and the number of projected presses.

Assembly Lines

The wiring harness system production process is designed according to project volume and specifications. The number of boards and the size of the conveyor that will be used in the assembly line are determined after feasibility and capacity studies are finalized. The assembly process takes place on T-Conveyors (10-24 panels), Penta Conveyors (5 panels) or fixed tables (1 table). The system also includes various benches and machinery used in preparations before the assembly process starts. All wire harnesses undergo 100% electrical tests on special test benches.