Electro-Mechanical Production Plant
Contact
Maciej Banaś
Tel.: +48 76 724 12 62
Mobile: +48 725 250 850
E-mail: maciej.banas@mercus.com.pl
Renata Zięba
Tel.: +48 76 724 83 40
E-mail: renata.zieba@mercus.com.pl
Wiertnicza 1
59-101 Sobin
Tel.: +48 76 724 83 40
E-mail: HW@mercus.com.pl
Get directions
The Electro-Mechanical Production Plant of MERCUS Logistyka Sp. z o.o. has been manufacturing electrical wire harnesses since 1991. It is a highly specialized facility ranked among the leading manufacturers of electrical wire harnesses. The plant has more than 100 cable-processing machines capable of handling cables with cross-sectional areas ranging from 0.15 mm² to 240 mm² and performing a wide range of specialized operations required in wire harness production.
Based on a tabular specification provided by the customer, containing cable descriptions, connection points, and connector types, submitted in CAD or Excel files, conventional paper drawings, or product samples, we prepare offers for the supply of wire harnesses, complete equipment wiring, or complete control cabinet wiring.
This solution provides the following benefits:
- Reduced supply chain and procurement handling costs, as well as reduced inventory of raw materials required for wire harness production.
- On-time deliveries and reduced lead times.
- Access to advanced manufacturing methods, modern equipment, and technologies.
- Professional production of electrical wire harnesses, including connection and electrical parameter testing.
- High repeatability and quality.
- Lower prices of supplied wire harnesses.
- Reduced production time for the final product.
The electrical wire harnesses we manufacture are used in the following industries:
POWER ENGINEERING
- Electrical wire harnesses for wind power plants – diagram below
- Electrical wire harnesses for photovoltaic power plants
- Electrical wire harnesses for UPS systems
- Electrical wire harnesses for low-voltage and medium-voltage switchgear
- Electrical wire harnesses for power converters
MACHINERY INDUSTRY
- Compressor wire harnesses
- Wire harnesses for mining machinery
- Engine wire harnesses
OTHER INDUSTRIES
- Control wire harnesses for industrial automation
- Heat pump wire harnesses
- Wire harnesses for household appliances
ZPEM uses the following technologies in the production of electrical wire harnesses:
- Processing and application of RAST 2.5 and RAST 5.0 IDC connectors
- Processing and application of IDC edge connectors
- Processing and application of IDC connectors for flat cables
- Microconnector processing
- Automatic and semi-automatic connector crimping with active Crimp Force Analysis (CFA) control
- Crimping of insulated ferrule terminals
- Connector welding and cable compaction using ultrasonic or resistance welding
- Soldering
- Inkjet printing on cable insulation
- Thermal printing on cable insulation
- Heat-shrink tubing application
- Assembly of sockets and plugs with tightening torque control
- 2D and 3D wire harness assembly
- Auxiliary operations including cable tying, taping, threading, gluing, twisting, cutting, and stripping
- Laboratory testing of electrical and mechanical parameters
Quality Management
The Plant has implemented and maintains a Quality Management System compliant with the PN-EN ISO 9001:2015 standard (initial certification date: October 30, 1998). The current ISOQAR CEE certificate, No. 16826-QMS-001PL, is valid until November 19, 2027. This ensures that the final product is released only after all required tests have been completed in accordance with quality control plans and applicable procedures.
The Plant also holds UL certification for components and wire harness production in accordance with the UL 817 standard (ZPFW2, ZPFW8), authorizing the manufacture and sale of products in the United States and Canada. The components used, production processes, and workmanship quality are inspected by an Underwriters Laboratories Inc. inspector and marked with UL Recognized Component marks, Type (A) or (B).
In accordance with the requirements of the Quality Management System, products are verified at all stages of the production process using statistical methods. Where necessary, a 100% final inspection of the product is carried out.
Quality control activities include:
- Incoming inspection
- Process and in-process inspections
- Final inspection
During inspections, electrical and mechanical parameters are tested, including:
- Voltage drop at connections with female terminals or cable lugs
- Insulation resistance measurement
- Dielectric strength of insulation
- Verification of the continuity and addresses of electrical connections against the technical documentation
- Pull-out force of the terminal or cable lug from the wire
- Connection force between female and male terminals
- Terminal push-out force from the housing
- Cross-sectional analysis of crimped or IDC connections
- Gas-tightness testing
- Measurement and adjustment of tightening torque
- Since 2001, ZPEM has also manufactured high-pressure hydraulic hoses for heavy-duty machinery, including:
- Single-wire braided hydraulic hoses
- Two-wire braided hydraulic hoses
- Four-spiral hydraulic hoses
Hydraulic hoses are statistically tested at a dedicated test station using a static test pressure equal to 240% of the working pressure.
We use modern equipment manufactured by Finn-Power and Uniflex.
Our suppliers of materials for hydraulic hose production include Semperit, Eaton SEL, and Stomil Bydgoszcz.
Sale of Materials for Electrical Wire Harness Production
