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Complete E-Systems

Solutions for Electrified Mobility & Energy Storage 

Safety Engineered Through Quality

Precision Contacting to Full‑Vehicle Endurance Testing


Electrified mobility depends on two fundamentals: reliable energy flow and robust system performance under real‑world conditions. Schunk bridges the gap between component manufacturing and on‑road operation. 

We ensure process reliability for the “nervous system” of electrified vehicles and energy storage systems. Precision ultrasonic welding creates durable, low‑loss electrical connections throughout the vehicle electrical system and the battery management system (BMS). 

To validate system‑level durability, our advanced environmental simulation and test systems expose complete vehicles to the full spectrum of real‑world conditions - from Arctic cold to desert heat, from highway driving to off‑road operation. 

Maximum safety — from the cable harness to the drive‑in test. 

Solutions

Products for Safe E‑Systems from Schunk

Wiring Harnesses and Battery Management

Ultrasonic welding is the proven joining technology for high‑quality automotive cable harness production. It creates fast, clean, and highly stable metal‑to‑metal connections for strands, terminals, and splices - without solder, minimising heat input and thermal damage.

  • Maximum process reliability for strands and splices 
    Consistently reproducible quality, even with thin conductors and complex cable bundles. 

  • Very short cycle times for series production 
    Robust, fast, and clean processes - ideal for fully automated production lines. 

  • No thermal stress on conductors 
    No weakening of materials, ensuring long service life and high vibration resistance in automotive applications. 

Drive‑In Environmental Test Chambers for Complete Vehicles

Precise environmental simulation for performance testing, validation, and homologation of electric vehicles and hybrids of all sizes.

  • Comprehensive climatic loads
    Simulate heat, cold, humidity, solar radiation, wind (and combined stresses) to evaluate durability, safety, and performance under real‑world conditions.

  • Versatile test applications
    Integrate dynamometers, hydropulser’s, solar simulation, semi‑wind tunnel concepts, and altitude simulation within drive‑in or walk‑in chambers for full‑vehicle scenarios.

  • Standards - compliant system integration.


Solutions are engineered in line with relevant automotive testing standards, with configurable safety packages (e.g. reinforced structures, gas extraction, fire detection) according to risk profiles and EUCAR hazard levels where applicable – ensuring reliable and reproducible results. 

Contact Person in the Field of E-Systems

Testing
Contacting
Battery Technology
Battery Technology

Learn more about our BW20, DS35 and FPC-Welding.

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Drive-in emissions and Performance test-chamber with rollers
Drive-in emissions and Performance test-chamber with rollers

Application brochure

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Ultra What?
Ultra What?

Introduction to ultrasonic metal welding

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Wire Harness
Wire Harness

Learn more about our terminal and splicing machines.

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Schunk Expertise for Every Step of Battery Production

Battery Manufacturing