cable manufacture

Cable Machinery

By | fo, installation engineering

Machinery and Production Lines for Cable Production and Cable Manufacture

KHU Sondermaschinen develops, designs and fabricates stock and custom machinery and production plants for the cable and wire industry. Our customers value the quality and performance of our cable production plants and automated cable harness plants. Among complete cable production plants we offer a comprehensive supply of components, such as pay-off, take-up, caterpuller and capstans, stranding machinery, twisters and much more. If you can not find what you are searching for please contact us for we are happy to make machinery that does not exist yet. We concentrate on innovative designs to supply our customers with revolutionary products giving them the key competitive advantage.

Cable Manufacture

By | Uncategorized
We provide machines and equipment for automated cable preparation and manufacture, ranging from stations for manual operation to fully automatic cable harnessing lines. Our systems are built in linear or round table transfer designs and perfectly tailored for processing your product. It is also possible to integrate more stations at a later point for processing a variety of products with one single automatic cable manufacturing line. As an experienced system integrator we can provide you the best suited system to realize fully automated cable harness production.


We provide different kinds of Pay Off’s and Take-Up’s depending on your purpose.


For optimal de-reeling and stable cable processing down the line we provide custom designed dancer systems.

Cutting to length

We have developed processes for automatic de-reeling, measuring, feeding and cutting cables to length for a broad variety of cables, e.g. energy cables, data cables, wires, coax cables…


For stripping cable jackets we have developed specific processes for best repeatability results and therefor maximized process safety.

Stripping Outer Conductor

For safe stripping of coax- and antenna cables we have designed a system for valley and peak detection in order to precisely cut and strip outer conductors.

Dielektrikum Einschneiden und Abziehen

Equipment for cutting and removing of dielectric without residues.

Inspection & QM

We measure cable prep and stripping levels prior to applying connectors to make sure that all specifications are within tolerance for cables with best electrical conductivity und pristine cable quality.

Connector assembly

Thanks to a lot of different cable manufacturing machines that we have delivered to our customers, we have gained much experience also with handling connectors and processing them by soldering, welding, crimping and pressing.

Inline Overmould

For our automatic cable manufacturing lines we have developed an overmould process for over moulding cables automatically and within the cable processing line.

Cut to length and strip

For partial automatisation of cable harness we provide compact machines, which produce cables that are cut to length, stripped and conveniently presented to the operator.


With our innovative solder feed measuring we provide soldering stations for induction brazing and resistance soldering with dual monitoring. By that we make sure that the soldered contacts are a 100% within the specification and your cables perform at their best.


Automated stations for cable crimping.


By | KHU, portfolio, portfolio, portfolio

Leading companies from many industries rely on the products and services of KHU Sondermaschinen. We have planned, designed, engineered, manufactured, built and started a high number of machines and plants for our customers.

The diversity of our past projects has enriched our experience, making us a competent and innovative partner the most challenging tasks.

Here is a list of a few chosen products.

Automated processing machines
Boring Machine for Special Screws
Milling and Boring Machine
Worm-Milling Machine
Production Plants
Can Closing Machine
Filter Production Plant
PVC Profile Extrusion
Testing Equipment
Crush Test
Torsion Test
Test Cell for thin metal sheet production
Paper Printing Machinery
Paper Web turning Equipment
Post- Press Packaging Facility
Longitudinal Perforation Machine
Plants for Chemical Industry
Gas Bottle Filling Plant
Can Closing Machinery
Assembly Facilities
Bogie Lifting Stand
Welding Facility for Stovepipes
Product development
Escalator Stair
Safety Carabines
Paste Extrusion
Dual Paste Extruder

Makromelt machine

By | Uncategorized
This machine is designed to inject liquid synthetic, so called makromelt onto assembled cable ends.
Up to 24 moulds are mounted on a round table. A servo motor drives a piston pump which injects the hot liquid synthetic by volumetrically metering into the mould.
The water cooled moulds are easy to replace which adds to productivity and efficiency.
With this machine it is also possible to use various moulds at the same time thanks to the individually adjustable amount of makromelt volume per station. This makes cable manufacturing very efficient for cables with different types of plugs.
Above the pump is the heated repository which will refill itself automatically by the means of a suction device.
Production sequence
The desired volume of makromelt is defined on the control panel.
After pre heating, the machine starts the automatic manufacturing process.
The plugs are placed upwards into the moulds while the cable is free-hanging. Longer cables can be attached to the cable holder beneath the mould.
For the alignment of the pins a fitted counter plug is to be mounted. Hence the round table feeds the injection tool with the cable by rotation. The mould with the inserted plug is then pressed pneumatically towards the opening of the injection tool starting the moulding process automatically.
After attaining the volume the mould goes back into the starting position and the round table rotates to the next station.
The round table is designed to hold 10 or 22 stations for cooling of the injected makromelt, depending on the machine type.
When reaching the end position the finished cable is to be removed from the machine.
Technical data

Dimension (LxWxH): approx. 400 x 300 x 250 cm
Weight: approx. 2000 kgs
Injecting volume: up to 150 ccm
Injection speed: up to 3,5 l/min
Cycle time of round table: approx. 0,5 – 1 sec.
No. of stations: up tp 24
Volume of heated repository: approx. 4l
Capacity of suction device: 150kgs/h
Heating capacity of injection device: approx. 4kW
Nominal cooling capacity: approx. 14kW
Electrical supply: 3~400V/50Hz
Pneumatics connection: approx. 5bar, 250l/min

Cable Manufacturing Plant

By | cable, cable, cable, cable, cable manufacture, cable manufacture, cable manufacture, cable manufacture

This construction is built for the automatic harnessing of cables (wires) and cable loops for the automotive industry. This KHU cable assembly plant handles two-componant glued and pressed cable shoes. It produces and insulates the cable loops and afterwards tests and monitors the finished product. The entire plant is operating automatically, ensuring high-end quality products for maximum safety of the end customer.