Alpha 358 – fully automatic crimping machine

Introduction

Cables up to 35 meters (27.34 yards) in length can now be processed at high speed on a machine just four meters (4.37 yards) long.

The Alpha 358 fully automatic crimping machine sets new standards in the processing of long cables.

Coiling and binding cables directly in the fully automatic crimping machine frees up substantial space and offers considerable quality advantages.

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Key features:

Ultra-easy further processing of long cables
No risk of damaged contact parts, even with long cables
Only a small production area required
High production output

Area of application

The Alpha 358 is designed for the two-sided crimping and seal loading of long cables. If fitted with an ingenious coiling and binding system, this machine can save you the production space otherwise required for long deposit units.

Wire coiler

The coiler is fully integrated in the machine. The coiling process can be optimally adapted to the material being processed in order to optimize the output. With its controlled processes, the coiler ensures perfectly coiled cables even at high processing speeds. The coiled cables are bound individually with easily removable tape and then placed in the machine for simple removal.

This approach eliminates the time-consuming tasks of hanging up and removing the cables at the laying board. In the process, the risk of damaging the contact parts during handling is minimized. A maximum amount of time is saved in the further processing of the cable.

Quality monitoring

The coiler speed is synchronized with the wire drive. The pull exerted on the conductor is constantly monitored. Gentle coiling is therefore guaranteed.

Crimp-height measurement and fully automatic pull-out force measurement are integrated in the process sequence. Optional material-change detection and the optional barcode scanner help to prevent materials from getting mixed up.

The processes are constantly checked against the specified values during production with functions that monitor crimp force, seals, splices, end of wire supply, and length. Any cables with processing defects are removed and an appropriate number of cables are post-processed automatically to replace them.

Fast changeovers

In most machines, changeover times offer the biggest potential for optimization. With options like the manual wire selector and/or the quick-change system for crimping tools, materials and tools can be prepared for the next job while the machine is running.

Jobs can also be recorded and edited with TopWin while the machine is running. The changeover time is displayed, providing an easy method for optimizing the workflow.

mci 712/722 crimp module

Presses with integrated crimp force monitoring and analysis for crimping forces up to 20kN.

Just one teach crimp is required.
Creep speed (slow motion) and other key functions can be controlled right at the press.
Split cycle function
Programmable stroke
Crimp tool mount with quick-change system
The mci 722 crimp press also features programmable crimp height adjustment.

mci 765 seal module

Module with integrated seal monitoring.

The most important functions can be operated right at the module.
Quick-release locks for all seal-dependent application parts.
Existing applications can be used.
Automatic setup and SPM seal position monitoring

TopWin

The TopWin graphical user interface is designed for quick and simple data input. With its easy-to-understand structure, users are able to master the machine in no time at all. All relevant parameters can be entered and saved conveniently. User tips are presented clearly in graphics. Access rights to all important input parameters can be managed with a permission editor. The optional interface, the WPCS (Wire Processing Communication Standard), allows Komax machines to be networked and easily integrated into existing production processes. The supplemental TopNet networking software assures optimum production management.

Technical data

Length range
2500mm–35000mm (98in.–114ft.)

Length accuracy
Repeat accuracy ±(0.2%+1mm (0.039in.))

Stripping lengths
0.1–35mm (0.004in.–1.38in.)

Stripping lengths with partial pull-off
35mm (1.38in.)on both sides

Wire cross sections*
0.22–6mm2 (AWG24–AWG10)

Wire draw-in speed
max. 10m/s (33ft/s)

Noise level
<75dB (without crimp module)

Electrical connection
3×208–480V/50–60Hz 5kVA

Pneumatic pressure
5–8bar (73–116psi)
9m3/h 318ft3/h)

Weight
approx. 1300kg (2866lb.)

Dimensions (WxHxD)
4390mm x 1780mm x 1700mm (2154mm)
172.8in. x 70.1in. x 70in. (84.8in.)

*Certain extremely hard, tough wires may not be able to be processed even if they are within the indicated cross section range. In case of doubt, we are happy to produce samples of your wires.

Accessories

The Alpha 358 can be customized with various accessories to meet specific customer needs.

Preliminary processing of wires

Inkjet marking
Variety of wire feed systems
Standard straightening unit/manual cable selector

Measuring devices

Integrated crimp height measurement
Integrated pull-out force measurement
Fully automatic pull-out force measurement

Crimping module accessories

Terminal feed with paper take-up unit
Contact strip chopper (chopper)
Quick-change tool system

Process monitoring

Crimp force monitoring
Seal monitoring
Splice detection
Wire-end detection
Spark tester

Other accessories

Automatic guide tube changer
Material change detection
Barcode scanner

Services

Komax also offers optimum after-sales support.

Putting the module into operation
Production assistance
Training for different levels of users
Worldwide customer service network with seamless supply of spare parts

For more information please contact:

Komax Corporation
1100, East Corp.
Grove Drive
Buffalo Grove, IL 60089-4507

Tel. +1 / 847 537 6640
Fax +1 / 847 537 5751
mailto: Komax Corporation
Internet: http://www.komaxusa.com