Wire processing in control cabinet manufacturing

The potential for automation in wire processing in control cabinet construction is enormous, in individual and series manufacturing. Unfortunately, control cabinet makers often erroneously believe that automation can only be profitable with large series of identical sets of equipment. However, there are optimum solutions for automation that range from semi-automatic processing for manufacturing individual units and small series all the way to fully automatic manufacturing of large series.

Optimum automation in control-cabinet cable processing relies on electronic data being available for parameters such as cable length, marking and cable-end processing. This data is converted from a wiring list to a cut job or even generated directly in an ECAD system. If the data is not available in electronic form, it is can usually be programmed quite conveniently with machine software.

Automatic wire processing yields ready-to-install cables cut to the right length, terminated as desired and labeled in any specified color with an inkjet marker. The ends of the conductors are fitted with end ferrules, crimp contacts or MIL crimps or ultrasonically compacted. The customized marking satisfies marking requirements and greatly simplifies the wiring of stranded wires in the control cabinet. Even semi-skilled staff can do the wiring easily, quickly and above all, inexpensively.

Depending on the solution and type of production involved, you can cut costs by as much as 50 percent compared with today’s conventional methods. You can dramatically reduce the time and costs required not only for wire processing but also for the wiring itself. The cables can be labeled automatically with addresses and produced to be arranged by module, so wiring can be done without diagrams and at a much faster rate.

The strand is efficiently cut to length and stripped but can also undergo a wide range of other types of processing. The cable ends can be fitted with end ferrules, crimp contacts or MIL crimps or can be compacted ultrasonically. Sleeve mounting and other types of processes are also available. Ultrasonic compaction is becoming especially wide-spread. This technology is used to compact the individual stranded wires. All conductor sizes can be processed in any compaction length with a single module. End ferrules are no longer required on conductors with compacted ends.

Marking is done in selectable colors using an inkjet marker (the color usually being white and/or black). Texts can be generated automatically using a wiring list or the ECAD system and then transferred to the machine. It is also possible to do direct programming with user software. A conductor usually has the address marked on both ends. The marking can also be imprinted repeatedly along the entire length of the cable. Once wired, the cable can be clearly identified at any time in the cable duct. Neat, consistent marking also reduces the costs of final inspection and testing.

All automation solutions from Komax are perfect for use in individual or series production of control cabinets. The potential savings are tremendous. With its comprehensive product range and great experience in control cabinet construction, Komax can address customers’ specific needs and offer optimum automation solutions to address them.

For small-volume production

The machines in the Kappa family allow you to cut to length, strip and mark stranded wires and cables with perfection. The data can be imported conveniently over a network, from a database or from an ECAD system. The produced conductors are then contacted manually or using a bench-top module and then wired in the control cabinet.

For medium-volume production

The fully automatic crimping machines in the Gamma Family are flexible, fully automatic processing machines for cutting to length and processing wire ends and marking stranded wires. The conductors can also be automatically fitted with end ferrules, crimp contacts or MIL crimps or ultrasonically compacted. Data can be imported conveniently over a network, from a database or from an ECAD system.

For large-volume production

The Zeta 633 is a highly flexible cable processing center suitable for individual and sequential production. The machine can process sequences of as many as 36 different stranded wires in any order and accommodate five different processing stations for ferrules, ultrasonic compaction, crimp contacts or MIL crimps. In most cases, this setup eliminates the need for any machine changeovers or conversions. The individual cable sequences are produced by module or panel, bound and laid in the deposit tray. The machine can also operate independently in an all but unmanned “ghost shift” thanks to an automatic job reloading function. Data can be imported at will over a network, from a database or directly from the ECAD system.

You can use the Zeta 656 to load components with different terminal contacting such as spring-loaded, push-in or contact flabs on one end or both ends automatically. The customer specifies whether the system will run sub-harnesses (inserted on both ends) or just one-ended component insertion.
Pallet loading and unloading is done while component insertion is being done on the second pallet pair. This ensures continuous production. Integrated force sensors monitor the entire component insertion process, thus ensuring top quality.

To optimize capacity utilization on the system, you can integrated a flex bundler upstream from the Zeta 656 in the machine transfer. This allows you to orient and bundle non-loaded conductors in preparation for undergoing further manual processing.

You can directly import the production data for batch size 1 or for series production via a network, via a database or from ECAD. You can archive quality data relevant to processing and thus ensure traceability at all times.