komax USA
 

Professionals in Advanced Automation

Alpha 477 – fully automatic crimping machine

Introduction

The Alpha 477 fully automatic double crimping machine allows you to process two different wires simultaneously to produce your choice of double crimp or single wires. With four processing stations at the lead termination and two at the trailing end, you have a large number of possible processes at your command.
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Key features:

  • No conversion required when switching from double crimp to single wire production
  • Double crimp connections can be produced side-by-side or one above the other
  • Integrated head separation and batch sorting
  • Active good/bad wire sorting
  • An ergonomic layout assures the operator optimum accessibility and minimal walking/reaching  distances.
  • mci 722/mci 712 assure superb flexibility and shorter changeover times.
  • Integrated quality monitoring (CFA, SPA-iL) with automatic post-production of defective parts
  • Accommodates up to six processing stations
  • Great ease of operation thanks to TopWin software
  • Networking possibilities with reliable WPCS and TopNet

Technology

The two wire drives are fitted with highly dynamic AC-servo axes and an integrated anti-slip system. With this sophisticated handling technology, two wires can be fed in parallel and their ends cut to length and terminated in a controlled process. Wires are handled gently throughout. For example, the gripping force exerted on the two wires can be programmed separately and saved for each wire.
The two wires are brought together in the double gripper module, where double crimps can be produced either side by side or one above the other.

Maximum flexibility

The machine is laid out to accommodate up to six processing stations. When combined with the double gripper module, integrated as part of the standard equipment, and the double wire drive, the Alpha 477 can produce V connections out of two different wires with two different seals and three different crimp contacts. It can handle cross section ratios from 1:4 onward with no trouble at all as well as total cross sections as large as 6mm2. With a mere click of your mouse, you can choose between double crimp and single wire processing or switch from one job to another.

Wire deposit system

The standard configuration of the Alpha 477 includes a wire deposit system with batch sorting. This deposit system assures a reliable transition from one batch to the next, even when the machine is producing double crimp connections. An integrated head separation feature is also now featured in the deposit system. It allows the two wires to be separated at the end with the double crimp. If placed in a portable deposit tray, the processed wires can then be removed easily and conveniently outside the safety zone.

User friendly

Maximum ease of operation

The machine has a large swivel radius of 400mm and an upward opening safety cover, making it highly accessible to the operator. An expandable wire deposit system plus the TopWin user interface are two further user friendly features that assure great ease of operation.

TopWin

TopWin is a Windows®-based graphical user interface designed for quick, easy data input. Thanks to its simple and logical structure, users can fully master the machine in no time at all. All the important parameters can be conveniently set and saved. Error messages are presented in clear, uncluttered graphics. A special editor (Permission Editor) can be used to manage access rights for all entry parameters. With the optional WPCS (Wire Processing Communication Standard) interface, Komax machines can be networked together and easily integrated into existing production processes. The supplemental networking software known as TopNet is the ideal tool for achieving optimum production management.

Technical data

Length range 60mm - 80000mm (2.36in - 3149.61in)
Optional from 35mm (1.38in)
Length accuracy ±0.2% (min. ±1mm)
Stripping lengths Both ends 0.1-35mm
Wire cross sections* 0.22mm2 – 4mm2 (AWG24–AWG12)
Cross section ratio > 1:4
Double crimp (wire A+B) < 6mm2
Wire feed speed max. 10m/s
Noise level <75dB (without applicators)
Electrical connection 3x208-480V/50-60Hz; 7kVA
Pneumatic connection 5–6bar
Air consumption 22m3/h
Weight
Approx. 1900kg (including 2m conveyor belt, two crimping modules and two seal modules)
* 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 wire.

Accessories

There are a number of different accessories available with which you can adapt the Komax Alpha 477 to your own specific needs and expand its capabilities as desired.

Preliminary wire processing

  • Ink jet marker
  • Hot stamp marker
  • Wire feed systems

Crimping module accessories

  • Height adjustable lift pedestals
  • Paper winder
  • Carrier strip chopper
  • Valve set for pneumatically operated advance
  • Pressure regulation set
  • Monitoring of length-wise and cross-wise transport of terminals

Crimping types

  • Crimp module mci 722
  • Crimp module mci 712
  • Seals module mci 761

Process monitoring

  • Anti-slipping system (ASS)
  • Crimp force analyzer (CFA)
  • Seals presence analyzer (SPA-iL)
  • Splice detection
  • Quality assuranceKomax 331, 341, 351, 371

Further modules

  • Sleeve module
  • Twisting/fluxing/tinning
  • MIL crimp module
  • Ferrule module

Wire deposit systems

  • Conveyor belt, basic module, 2m or 4m
  • Conveyor belt, extension module, 4m

Optionen

  • Wire measurement table
  • Tower light
  • Magnifying glass
  • Keypad
  • Deposit table with control cabinet
  • Uninterruptible power supply (UPS)
  • WPCS networking and TopNet

Services

Komax also provides superb after-sales support:
  • Commissioning
  • Training courses for different levels of users
  • Production coaching and assistance
  • Worldwide customer service network with complete range of spare parts
  • Professional consulting services
 

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
 

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