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13 December 2017

Convert showcases capabilities at Southern Manufacturing Show

Convert Ltd, the UK’s leading manufacturer of cable looms and harnesses, is showcasing its capabilities at the Southern Manufacturing and Electronics Show 2018.

The show will be Convert’s first exhibition event of 2018. It follows an extremely successful year in which the Kent-based electrical engineering company worked on a range of innovative projects including: designing a 250-metre loom for the first UK trials of an autonomous grocery delivery vehicle; designing a miniature grommet to house the wiring for a lamp unit on a luxury British sports car and winning a prestigious Bright Sparks award.

Convert specialises in the automotive, public transport and scientific/medical sectors, manufacturing cable harnesses for car head and rear lights, passenger gates at railway stations and a range of scientific equipment. 

With its highly trained staff and continual investment in state-of-the-art equipment – including Komax Gamma 255 fully automatic crimping machine and Artos MTX-5 crimping machine – Convert’s complex cable looms and harnesses are manufactured to the highest quality, delivered on time and at competitive prices.

Dave Lord, Convert’s Managing Director, said: “This will be our 11th year exhibiting at the Southern Manufacturing and Electronics Show and we’re really excited to be in the brand new exhibition hall! The show is always at the top of our exhibition list. It’s quite simply the UK’s most successful engineering and electronic show, providing great leads and networking opportunities.”  

Convert will be sharing its stand with SK Electronics, a Manchester-based PCB assembler, with whom it works in partnership.

Convert has been in business for 12 years, initially employing nine people when it was set up in 2006. It has grown significantly and now employs 30 members of staff. 

Visit Convert at the Southern Manufacturing Show 2018 on stand: A155


  Press Releases. 


Rachel Price, Aro PR and Marketing: tel   01752 894 786  mob: 07806321333

Produced and issued by:  Aro PR and Marketing

26 September 2017


Convert’s cable harness used in UK’s first driverless grocery delivery trial.

Convert Ltd, one of the UK’s leading manufacturers of cable looms and harnesses, is celebrating after a cable harness it designed and manufactured was used in the UK’s first driverless grocery delivery trials.

Shape Machining – a leading composites manufacturer –  approached Convert to design and manufacture a cable harness for a project they were working on to build the cargo compartments for a prototype autonomous electric delivery van developed by Oxbotica, a leading driverless car software firm, and trialled by Ocado Technology.

The real world trials, which took place in the Royal Borough of Greenwich, saw a self-driving delivery van, called CargoPod delivering grocery orders to over one hundred Ocado customers. 

Similar in size to a small milk truck, CargoPod is equipped with eight cargo compartments designed to carry small amounts of shopping.  Once CargoPod is loaded up with groceries, the customer is notified from a ‘mobile warehouse’ located around a mile from their home, and then again once it has reached their front door. The compartment with the customer’s groceries lights up when CargoPod arrives at their house. The customer then presses a button to unlock their box and collect their shopping bag.

Dave Lord, Convert’s Managing Director, said: “We’re very excited CargoPod has successfully completed its trials.  This was a great bespoke project to work on.  With four doors on each side, each with their own LEDs, door locks, sensors and internal lights, CargoPod was a challenge as it required a complex loom in order to connect all the different components to a power source and control unit.”

Convert’s loom for CargoPod required approximately 250 meters of cabling – the length of five Olympic swimming pools.

Glen Pascoe, Shape Machining’s Development Manager, said: “We approached Convert to help us with the cable harnessing and electrical system integration for CargoPod. I’d worked with them in the past and had always been impressed with their abilities and approach. They met every engineering challenge I threw at them.  Using limited drawings to work from Convert had to design the assembly from our customer’s requirements and outline specifications which they did brilliantly, delivering the finished cable harness in under three months.” 

Graeme Smith, CEO from Oxbotica, said: “Last mile delivery is a growing challenge as our cities become denser and more congested. In this new project we are working closely with Ocado Technology to deploy our Selenium autonomy system into a novel last-mile delivery application in Greenwich as a part of the GATEway project. This is truly a UK success story about CCAV and Innovate UK enabling a young British company to become established and to be able to demonstrate mature world-class technology capabilities within a real-life dense urban environment.”

CargoPod was developed by Oxbotica as part of the GATEway Project (Greenwich Automated Transport Environment), a world-leading research programme, led by TRL and funded by UK government and industry. It aims to demonstrate the use of autonomous vehicles for ‘last mile’ deliveries and mobility, seamlessly connecting existing distribution and transport hubs with residential and commercial areas using zero emission, low noise transport systems.

CargoPod is guided by Oxbotica’s state-of-the-art autonomy software system Selenium, which enables real-time, accurate navigation, planning and perception in dynamic environments. Using data from lasers and cameras placed around the vehicle, Selenium allows the vehicle to know where it is, what’s around it, and where to go next.

CargoPod can cover a distance of 30 kilometers on a single charge, at speeds of up to 40km/h and can carry a total of 128kg of groceries at a time.


Press Releases. 

Rachel Price, Aro PR and Marketing                          t .01752 894 786      m. 07806321333

Produced and issued by:                                                              Aro PR and Marketing


Case Study

Convert’s stand-a-lone waterproof grommet solves Wipac’s lamp wiring challenge for British luxury sports car


In early 2015 Wipac - a world class design and manufacturing company specialising in high technology exterior LED lighting for the prestige automotive market – started work on a new lighting project for a British luxury sports car manufacturer.


The brief required Wipac to design a waterproof yet compact high performance LED lighting system with an external profile of between 3-5mm for the sealed connector which would house the wiring.


Vince Bailey, Wipac Head of Purchasing, said: “It’s standard industry practice that all lamp units for high performance LED lighting systems are waterproof.  Internal space constraints are also becoming a critical issue as demand increases for us to produce more complex lamps, with a high number of different internal elements, but not to increase the overall size of the finished lamp.”


Clearly, in order to provide a water-tight finished unit, the traditional methods of mounting 35mm electrical connectors onto the lamp housings would not be feasible due to their physical size. To find a solution, Wipac turned to Convert - their long standing electrical engineering company and one of the UK’s leading manufacturer of cable looms and harnesses.


“We’ve worked with Convert for seven years,” said Vince. “They provide cable harnesses for all our head and rear lights.  We knew we could trust Dave and the team to come up with an innovative design solution.”


To overcome this challenge, Convert’s team of engineers - which included Quality and Engineering Manager, Josh Boakes, who recently won a coveted Electronics Weekly Bright Sparks award - conceived a design with a grommet that would be integral to the cable harness for the lamp enclosure.  A second vehicle grommet was also required to protect the vehicles internal compartments from the potential water ingress.


However, a number of hurdles had to be overcome when sourcing the grommet.


Firstly, whilst it’s not unusual to use grommets for traditional filament bulb lamp enclosures, commercially available parts for these styles of lamps didn’t provide the required level of moisture projection.


Secondly, the high temperature cable required in LED lighting made this design even more demanding.


Dave Lord, Convert’s Managing Director, said:  “We started trials to find an automotive grade material that would be malleable enough to make final lamp assembly feasible and that would bond to the cable insulation to provide the waterproof seal.  However, we found the materials that bonded to the cable were too stiff to allow final assembly.  Similarly, softer materials wouldn’t create the required bond due to the special properties of the high temperature cable outer insulation jacket.”


“It soon became obvious that a new solution was needed to overcome this problem,” said Dave. “It was then we had our Eureka moment and developed the concept of the stand-a-lone grommet.”


This new style of grommet required cable tunnel guides of exactly the correct size to allow the cable to pass through the grommet. This created a waterproof seal once fixed to the cable harness, which in turn would be stable and secure when fitted to the finished lamp.


To produce the initial parts, Convert invested in a low volume mould machine and tooling.


“During 2015 the grommet dimensions were defined and we started to produce prototype parts,” said Dave.  “Through product testing the cable guide theory proved successful, however the assembly team on the car production line were finding the finished parts inconvenient to assemble into the car.  So after a further design review, we identified alternative design concepts for the vehicle grommet.    We re-designed the grommet and produced the prototype tooling for this new solution.  The re-designed grommet passed the required tests to meet the waterproofing standard IP66K to which Wipac works, meaning it was able to withstand water spray at 145PSI (Pounds per Square Inch) from 3 metres for a test duration of 2-3 minutes.   Thankfully all previous assembly line issues were resolved too!”


The new lighting project moved into pre-production in early 2016, and into volume production a few months later.





Convert’s stand-a-lone waterproof grommet is now also successfully used in Wipac’s lamps for both a British luxury car manufacturer and a British high performance sports car manufacturer.


For more information on Convert, visit:


For more information on Wipac, visit:







Press Releases. 


Rachel Price, Aro PR and Marketing                              t .01752 894 786      m. 07806321333


Produced and issued by:                                                   Aro PR and Marketing


Convert Ltd Newsletters.  

To keep our customers up to date with our news, we started publishing a company newsletter in Spring 2017. Please find links below to all our Newsletters, if you would like to sign up to receive the newsletter please contact us. 

2017 Newsletters:

Spring 2017 Newsletter. 

Winter 2017 Newsletter.




Other News pages:

Press Releases. 

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