Lead Makers and Harness Makers

Transcription

1 and Harness Makers

2 and Harness Makers Application Tooling and Equipment Portfolio Applicators Crimp Machines and Equipment Electrical Test Equipment FFC-FPC Equipment Hand Tools IDC Machines Lead Makers Magnet Wire Equipment MOST Equipment Pin Insertion and Press-Fit Machines SOLARLOK Equipment Tooling for Raychem Heat Shrink Products Wire Preparation Equipment Installation, Inspection and Service as well as Training and Short Term Rental Crimp Applicators within EMEA region MOST is a trademark of SMSC Europe GmbH.

3 and Harness Makers Efficiency and Flexibility in Cable Production High quality demands are placed on modern cable production. Small batch sizes and just-in-time production are the order of the day. Fast and easy retooling of the machines is an increasingly important consideration. For this reason fully automatic crimping machines have been designed to meet all these requirements. TE Connectivity offers a wide range of fully automatic crimping machines. From compact and flexible fully automatic machines to linear transfer systems. Every fully automatic machine is on state-of-the-art technologies and designed to produce a wide range of wire applications from simple crimp to crimp applications to complex insertions from terminals in housings. The modular design and integrated quality controls with good/bad andling enable maximum flexibility and process reliability. Due to the multi-lingual user software the fully automatic crimping machines can be used almost everywhere in the world. For more information please contact your TE Application Tooling (AT) representative. 1

4 and Harness Makers Table of Contents Page Lead Makers Gamma Fully Automatic Crimping Machine Gamma Fully Automatic Crimping Machines Gamma 333 PC and Gamma 333 PC-B 5 Fully Automatic Crimping Machines Alpha 355 / Alpha 355 S 6 Fully Automatic Crimping Machines Alpha Fully Automatic Crimping Machine Alpha 433 H 8 Fully Automatic Crimping Machine Alpha Fully Automatic Crimping Machine Alpha 488 S 10 Fully Automatic Crimping Machine Zeta 633 and Zeta 633 L 11 Fully Automatic Crimping Machine Harness Makers Zeta Fully Automatic Wire Harness Manufacturing Machine Zeta Fully Automatic Wire Harness Manufacturing Machine 2

5 Gamma 255 Fully Automatic Crimping Machine The Gamma 255 lead maker is a flexible fully automatic crimping machine for efficient wire processing. It processes cross sections in a range from mm 2 /AWG 36 to 2.5 mm 2 / AWG 14. It is compatible with all commercially available applications. It also handles double-sided crimped wires as short as 20 mm. The entire cross section is processed using programmable, highly dynamic servo-drives and V stripping blades. As part of its standard equipment, the machine has a prefeeder, splice, wireend and knot detection, as well as two wire straightening units. A bad wire handling system with automatic postproduction is also integrated in the Gamma 255 lead maker. To verify quality, you can also integrate devices for measuring crimp height and pull-out force right into the production process. The compact layout is carefully thought-out and allows you to change over from crimping to twisting, fluxing and tinning very fast. TopWin is a trademark of Komax AG. Gamma is a trademark. With its vertically opening safety cover, the Gamma 255 lead maker is readily accessible from all sides. Operations and material handling are convenient and simple. The reliable TopWin software user interface adds to this high level of user convenience in over 20 different languages. Reliable processing of a larger range of cross sections Double side crimping or twisting, fluxing and tinning (even lead-free) Can handle double side crimped wires as short as 20 mm Minimal footprint thanks to a compact design High equipment standards TopWin software with graphical user interface Readily accessible Over 20 different languages available ,000 mm Length accuracy Up to 500 mm: ± 1 mm > 500 mm: ± 0.2% of the wire length mm mm 2 (AWG 36 AWG 14) Wire draw-in speed max. 3 m/s <75 db (without crimp module) Electrical connection 3x V 50/60 Hz 1x 230 V 50/60 Hz Pneumatic connection 5 6 bar / kpa (73 87 psi) 3 m 3 /h 870 kg gross (with packaging) * The Gamma 255 lead maker may also be able to process wires outside the indicated cross section range. Certain types of extremely hard, tough wires may not be able to be processed even though they are within the indicated cross section range. In case of doubt, we are happy to produce samples of your wires. 3

6 Gamma 263 Fully Automatic Crimping Machine ,000 mm Length accuracy (0.2% +1.0 mm) mm with partial strip mm mm2 (AWG 26 AWG 12) Wire draw-in speed max. 6.0 m/s <75 db (no crimp module) Electrical connection 3x V 50/60Hz 5 kva Compressed air connection 5 8 bar / kpa ( psi) 3.0 m 3 /h 870 kg (1,918 lbs) * Extremely hard and tough wires may not be able to be processed even if they are within the above cross section range. If you are in doubt about your wires, we are happy to process samples of them. Gamma is a trademark. Although compact in size, this fully automatic crimping machine combines simplicity and functionality with economy and process reliability to deliver a high piece output. It is a real hit when it comes to obtaining excellent value for money. Whether you opt for the roller or belt drive, you can adjust the use of this device to your individual needs and be doing so yourself in no time at all. The machine is designed for one and two-sided crimping and for one-sided seal loading. The wire transport system ensures gentle processing of varying conductors with cross-sections ranging from mm2 (26 12 AWG). Proven quality monitoring systems are integrated. A second integrated encoder ensures maximum length and repetition accuracy for stripping and wire length. In spite of its compactness, this model ensures that all processing stations are highly accessible. Fitted with safety covers that open vertically, the modules are readily accessible from all sides. All controls are modules are arranged in a neat and orderly manner. The new touch screen control based on the TopWin graphical user interface is designed for fast and easy equipment operation. The layout is logical and easy to understand so user training can be kept quite short. The optional WPCS (Wire Processing Communication Standard) interface allows Komax machines to be networked and easily integrated into existing production processes. Small investment for high production output Belt or roller drive in one machine for gentle wire handling Well known and proven crimping press technology Compact and user friendly on small floor space Highly ergonomic thanks to the touch screen control 4

7 Gamma 333 PC and Gamma 333 PC-B Fully Automatic Crimping Machines ,000 mm Optionally from 30.0 mm Length accuracy (Repeat) (0.2% + 1 mm) Side 1: mm Optionally from 28.0 mm Side 2: mm mm 2 (AWG 24 AWG 10) Optionally from 0.13 mm 2 (AWG 26) Wire draw-in speed 6 m/s Gamma PC 10 m/s Gamma PC-B <75 db (without crimp module) Electrical connection 3x V 50/60 Hz Pneumatic connection 5 6 bar kpa (73 87 psi) 6.5 m 3 /h 1,200 kg (2,649 lbs) gross Dimensions (W x D) 3,137 x 1,377 mm Height with cover closed: 1,790 mm Height with cover open: 2,670 mm The Gamma 333 PC lead maker is a flexible fully automatic crimping machine for efficient wire processing. It processes cross sections in a range from mm 2 (AWG 26 AWG 10). Short conversion times, additional applications and a user-friendly user interface with multiple-language capability. The Gamma 333 PC and Gamma 333 PC-B lead makers (B-version with beltdrive) makes it all possible! With its third processing station and state of the art control software, you are provided high flexibility and an even more efficient way of meeting your wire processing needs. With an additional processing station on side 1, the Gamma 333 PC lead maker enables you to crimp both ends of the wire, to create double crimp connections with three different contacts, to carry out one-ended seal application, tinning or ink-jet marking. In addition, process monitoring is all integrated to ensure that the wire is cut to length and stripped perfectly. Exact reproducible settings for processing stations Maintenance-free step and servo motor of top quality Very short conversion times thanks to integrated processing modules Highly comfortable and convenient to operate thanks to graphic-based TopWin software User specified language more than ten different languages to choose from Integrated good/bad sorting Can be networked with additional WPCS (Wire Processing Communication Standard) software TopWin is a trademark of Komax AG. Gamma is a trademark. * 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 5

8 Alpha 355 and Alpha 355 S Fully Automatic Crimping Machines Alpha 355 Lead Maker The Alpha 355 lead maker is designed for one and two-sided crimping and seal loading. It even handles doublecrimp connections involving varying lengths and the same wire types without any problem. The precise dual-channel blade system allows for a large range of wire sizes without blade changes. 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. Short changeover times Reliable process monitoring High production output Setup of next job while production of current job is underway WPCS (Wire Processing Communication Standard) Integrated quality measurement with quality monitoring, CFA+ (Crimp Force Analyzer), SPM (Seal Position Monitor) Alpha 355 S Lead Maker The Alpha 355 fully automatic crimping machine is a proven performer and now available in a model offering the flexible selection of modules. The high safety cover and the flat table design is the most striking difference between this version and the Alpha 355 lead maker. It allows processing modules not specifically designed for certain machines to be mounted. One of the two module slots on each processing side is fitted with special mounting tables to accommodate the various mounting methods. Combined with the ingenious open-ended software interface, the flexibility of the Alpha 355 S lead maker can be increased. Flexibility in module selection Reliable basic machine Open-ended software interface WPCS Q-monitoring, CFA+ (Crimp Force Analyzer), SPM (Seal Position Monitor) ,000 mm Optionally from 30 mm Length accuracy (Repeat) (0.2% +1.0 mm) mm with partial pull-off Beginning of wire: 47.0 mm 1 mm End of wire: 35.0 mm 1 mm mm 2 (AWG 24 AWG 10) Optionally from 0.13 mm 2 (AWG 26) Wire draw-in speed max. 12 m/s <75 db (without crimp module) Electrical connection 3x V 50/60 Hz, 5 kva Pneumatic connection 5 8 bar / kpa ( psi) 9 m 3 /h 1,300 kg (2,866 lbs) including two crimp and seal modules * 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. Alpha is a trademark. 6

9 Alpha 356 Fully Automatic Crimping Machine ,000 mm Optional mm Length accuracy (Repeat) (0.2% +1.0 mm) mm with partial pull-off 47.0 mm on side mm on side 2 Optionally up to 80.0 mm mm 2 (AWG 24 AWG 10) Optionally from 0.13 mm 2 (AWG 26) Wire draw-in speed max. 12 m/s <75 db (without crimp module) Electrical connection 3x V 50/60 Hz, 5 kva Pneumatic connection 5 8 bar / kpa ( psi) 9 m 3 /h approx. 1,400 kg (3,090 lbs) * 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. The Alpha 356 fully automatic crimping machine has room for up to seven processing stations. A wide variety of configurations are possible, in fact, almost any combination of crimping, seal loading, fluxing/ tinning, twisting, fitting with insulating sleeves and end sleeves for strands as well as bulk turned contacts and customer-specific processes. In a configuration featuring three crimping presses, for example, you can crimp the three wire ends for double-crimp connections with different contacts or select different articles without a machine changeover. With the rotating wire selector and the TopWin user software, you can complete most of the preparations for the next job while the current one is still being produced on the machine. Crimping tools, contact rolls and other application-specific parts can be changed without tools. Thanks to the use of the modern technology, the production output and the degree of process control is extremely high in this machine generation. High flexibility with up to seven processing stations Both standard and customerspecific processes can be integrated Wide choice of different processing configurations High productivity thanks to the latest technology Integrated quality measurements Next job can be prepared while machine is processing current job Combinable in networks using WPCS (Wire Processing Communication Standard) interface TopWin is a trademark of Komax AG. Alpha is a trademark. 7

10 Alpha 433 H Fully Automatic Crimping Machine ,000 mm Length accuracy 1.0 mm or <0,2%, depend of the wire length mm with partial strip Side 1: 35.0 mm 1 mm (optional 50.0 mm) Side 2: 35.0 mm 1 mm 0, mm 2 / AWG 24-6 Wire feed speed max. 10 m/s <75 db (without crimp module) Electrical power 3x V 50/60 Hz, 5 kva Pneumatic pressure 5 6 bar / kpa (73 87 psi) 9 m 3 /h 1,200 kg (with 2 presses and lifting pedestal) The Alpha 433 H lead maker is a flexible fully automatic crimping machine for efficient wire processing. Large wires no longer pose a problem. The machine is capable of processing large wires from mm2 / AWG 24-6 (fine-wire conductors). The P104 crimping press delivers the requisite force to process large terminals. Terminals can be crimped on both ends but seals can also be loaded at one end. Wire processing to very exacting standards great versatility without conversion. The Alpha 433 H fully automatic crimping machine is based on state of the art technology and is designed for processing single conductors as well as double crimp connections. Safe and trouble-free processing of large cross-sections up to 16 mm2 The know-how of the staff, which has been acquired on the Alpha 433, can be used Crimp press P104 with 40 kn (8 992 lbf) crimp force Integrated crimp force monitoring (cfa 326) Easy handling by TopWin Wide range of accessories TopWin is a trademark of Komax AG. Alpha is a trademark. * Fine-stranded wires possible (FLY 16; 16 mm 2, 128 single wires, PVC insulation) => For coarse stranded wires prior feasibility test recommended 8

11 Alpha 477 Fully Automatic Crimping Machine 60,0 80,000 mm Optional from 35.0 mm Length accuracy (Repeat) (0.2% +1.0 mm) Both ends mm Optional 50,0 mm on side mm 2 (AWG 24 AWG 12) Optionally from 0.13 mm 2 (AWG 26) Cross section ratio > 1:4 Double crimp (wire A+B) < 6 mm 2 Wire draw-in speed max. 10 m/s <75 db (without crimp module) Electrical connection 3x V 50/60 Hz, 7 kva Pneumatic connection 5 8 bar / kpa ( psi) 22 m 3 /h Approx. 1,900 kg (including 2 m 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. 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. 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. 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. 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 module assure superb flexibility and shorter changeover times Integrated quality monitoring CFA (Crimp Force Analyzer), SPM (Seal Position Monitor) 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 special software TopWin is a trademark of Komax AG. Alpha is a trademark. 9

12 Alpha 488 S Fully Automatic Crimping Machine The Alpha 488 S produces fully automatically twisted-pairs out of two single bulk wires completely cut-to-length and terminated, with all quality controls included. The modular composition of the system provides superb flexibility. Four processing stations at the wire beginning and two at the wire end offer extensive processing possibilities. The machine layout accommodates up to six processing stations. The system can also be used for the processing of two untwisted isometric single wires and is available in the versions of four, seven and ten meters. In combination with the crimping modules mci 722 or mci 712 and the seals module mci 765 C as well as with the quick-change systems and the integrated quality monitoring systems the Alpha 488 S ensures high process reliability and extremely short changeover times. The optional interface WPCS (Wire Processing Communication Standard) allows the machine to be networked under TopWin. With this open interface, the machine is easy to integrate into existing production sequences. Complete processing of two single bulk wires into twisted pairs with processed ends Fully automatic twister featuring well-proven as well as innovative quality monitoring systems for maximum process control Highly reliable and proven TopWin graphical user interface on touch screen for efficient machine use Networking possibilities with reliable WPCS TopWin is a trademark of Komax AG. Alpha is a trademark ,000 mm 700 7,000 mm ,000 mm Optional from mm Final length of twisted pairs Length accuracy (Repeat) (0.3% +1.5 mm) Side 1: mm Side 2: mm 2x 0.22 mm 2 2x 2.5 mm 2 (AWG 24 AWG 14) Optionally from 0.13 mm 2 (AWG 26) Open wire ends mm optionally mm on side 1, depends on pitch, cross section and end processing Pitch length Programmable from mm programmable accuracy: 10%, max. 5 mm Wire draw-in speed max. 5 m/s <75 db (no crimping module) Electrical connection 3x V 50/60 Hz, 10 kva Pneumatic connection 5 6 bar / kpa (73 87 psi) 12 m 3 /h Including two crimping modules and two seal loading modules Alpha 488/4 m: approx. 2,800 kg (6,173 lbs) Alpha 488/7 m: approx. 3,400 kg (7,496 lbs) Alpha 488/10 m: approx. 4,000 kg (8,818 lbs) * Extremely hard and tough wires may not be able to be processed even if they are within the above cross section range. If you are in doubt about your wires, we are happy to process your samples. 10

13 Zeta 633 and Zeta 633 L Fully Automatic Crimping Machine 240 3,000 mm standard tray ,000 mm optional Length accuracy 1.0 mm or <0.2% depending on wire length mm with full strip mm with partial strip mm 2 (AWG 24 AWG 10) Optionally from 0.13 mm 2 (AWG 26) Useable transfer length mm Zeta 633 (basic machine) mm Zeta 633 L (basic machine) mm Zeta 633/Zeta 633 L extension Wire draw-in speed max m/s <75 db (without crimp modules) Electrical power 3x V 50/60 Hz, 10 kva (basic machine) Pneumatic pressure 5 6 bar / kpa (73 87 psi) 12 m 3 /h Approximately 1,560 kg (3,440 lbs) * 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. Zeta 633 is a highly flexible fully automatic crimping machine used for just-intime production. With its flexible machine concept, the Zeta 633 lead maker opens up an almost unlimited number of possibilities for handling small jobs and wire sequences. Up to 36 conductors are available for wire feed without changeover. Wire transport can be adapted to the specific properties of each conductor. Applying the loop transfer principle, the device feeds the two wire ends of the loop individually one after the other to the appropriate processing station. Modules can be configured as desired along the entire length of the Zeta 633 lead maker. That means total flexibility for each area of application. The Zeta 633 standard machine accommodates up to five processing stations, the Zeta 633 L Version even 8 processing station. If needed, both Zeta versions can be successively expanded and still have space for additional processing stations. The wires can be bundled or deposited in predefined order as a chain. Up to 36 different conductors can be processed without changeover Station layout can be defined as desired Full integration of existing processing stations High processing quality TopWin software: Existing user expertise can be applied immediately. Excellent accessibility and safety Expandable Prepared for Zeta 651 and Zeta 655 machines Fully integrated quality monitoring with good/bad sorting Customer specified special applications possible TopWin is a trademark of Komax AG. Zeta is a trademark. 11

14 Harness Makers Zeta 651 Fully Automatic Wire Harness Manufacturing Machine Together, the Zeta 633 and Zeta 651 harness makers offer a reliable and attractively priced complete solution for the single-sided loading of single and double row blocks. The Zeta 633 fully automatic crimping machine applies the loop transfer principle to feed the two wire ends of the loop individually one after the other to the appropriate processing station. With the Zeta 651 harness maker, the contacts are mechanically centered prior to loading and optionally rotated, if need be. The use of the reliable loading head and the process monitoring systems of the Zeta 656 harness maker ensure optimum loading. The entire loading process is monitored, from insert in chamber to correct locking. Blocks are fed automatically and can be replenished while the machine is running. Feed and deposit can be adapted to meet the respective needs of the specific customer. The long deposit system with batch separation and integrated bad part cutter is used for producing harnesses with long conductors up to 3000 mm in length. Fully automatic block loading Full integration into TopWin software Integrated process monitoring with good/bad separation Automatic block feed Blocks can be replenished while machine is running. Economical production of harnesses undergoing single-sided loading TopWin is a trademark of Komax AG. Zeta is a trademark. Wire cross section mm 2 (AWG 24 AWG 6) Outside cable diameter 4.0 mm Lengths of processed cables Single-sided processing ,000 mm Double-sided processing mm / ,000 mm Loadable blocks Single and double row blocks Piece output Cycle time: 1.5 s per loading operation* Block loading time: 1.5 s* Monitoring of loading process Collision End force for loading Contact locking Block feed Vibratory bowl feeder Linear rail Customer-specific solution on request Wire deposition Simple deposition for wires up to 1,000 mm long Deposition for wires up to 3,000 mm long Customer-specific solution on request Electrical/pneumatic connections Directly from Zeta 633 harness maker Accessories The Zeta 651 harness maker can be fitted with various accessories to meet specific customer requirements such as block closing, secondary locking, etc. * Piece output depends on wire length and block/contact combination. 12

15 Harness Makers Zeta 656 Fully Automatic Wire Harness Manufacturing Machine Piece number output* One-ended loading 1.5 s per loading operation Two-ended loading 1.5 s per loading operation Shortest wire length With one-ended loading mm For jumper connections at both ends mm** For complex loading operations mm** * mm 2 (4.0 mm 2 ) (AWG26 AWG 13/AWG11) Outside diameter of cable Maximum of 4.0 mm Wire end storage unit Rotary storage unit with a maximum of 30 storage slots Process monitoring (integrated) Collision monitoring (block cavities) Monitoring of loading force Monitoring of terminal interlocking Block feed Carousel with pallets customer specific solution on request Pallet system Loading field (W x H x D) x x mm Connection electrical/pneumatic Directly from Zeta 633 harness maker *** Piece number output depends on wire length and block/terminal combinations. *** Depends on wire harness structure *** Wires outside the indicated cross section range can also be processed on the Zeta. In case of doubt, we are happy to produce samples of your wires. The Zeta 656 harness maker is a block loading robot designed to taken into account the ever smaller sizes of production batches. Thanks to its machine design, the Zeta 656 harness maker allows investment costs to be amortized in parallel on different types of wire harnesses, markedly reducing the cost per lead set. The Zeta 656 harness maker allows new applications to be subsequently incorporated. With the flexible pallet carousel, the most varied types of wire harnesses can be produced just-in-time and changeover times are very short. All the operator has to do to change over to a new type of block is switch the two pallets. The loading of each and every block is monitored and controlled by a force sensor. The Zeta 633 basic machine has a 36-wire changer and several crimping stations with automatic crimp height adjustment, allowing far more than 300 different wire/terminal variations to be processed without any changeover at all. In combination with a machine extension, another four processing stations can be accommodated. Moreover, wire marking systems can be connected, allowing different wires within the same harness to be marked with the operator s choice of black or colored text. Extremely broad variety of harnesses on one machine no application-specific parts New applications can be easily added later on Economical even for tiny production batches Non-contact position recognition for the terminals Uniform top quality processing high degree of process reliability Integrated quality monitoring with good/bad sorting Short amortization period Zeta is a trademark. 13

16 FOR MORE INFORMATION PLEASE REFER TO FOR REGIONAL ASSISTANCE PLEASE REFER TO While TE Connectivity has made every reasonable effort to ensure the accuracy of the information in this catalog, TE Connectivity does not guarantee that it is error-free, nor does TE Connectivity make any other representation, warranty or guarantee that the information is accurate, correct, reliable or current. TE Connectivity reserves the right to make any adjustments to the information contained herein at any time without notice. TE Connectivity expressly disclaims all implied warranties regarding the information contained herein, including, but not limited to, any implied warranties of merchantability or fitness for a particular purpose. The dimensions in this catalog are for reference purposes only and are subject to change without notice. Specifications are subject to change without notice. Consult TE Connectivity for the latest dimensions and design specifications. Tyco Electronics Corporation PO Box 3608, Harrisburg, PA 17105, USA Phone: or toolingsales@te.com Tyco Electronics AMP GmbH, Germany All rights reserved. Raychem, SOLARLOK, TE Connectivity, TE connectivity (logo) are trademarks. Other products, logos and company names mentioned herein may be trademarks of their respective owners Revised