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Alpha 356 – Multifunctional Fully Automatic

Crimping Machine

Introduction

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 combinations 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.
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Key features:

  • High flexibility with up to seven processing stations
  • Both standard and customer-specific 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 interface

Area of application

The Alpha 356 is designed for using the broadest selection of different processing modules, including special customer-specific modules. 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.

Increased productivity

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 most modern technology, the production output – and the degree of process control – is extremely high in this machine generation.

Maximum flexibility

The table design allows the mounting of up to seven processing stations. That means besides crimping, block loading, end twisting, and tinning, you can also accommodate the attachment of insulating sleeves and end sleeves for strands as well as bulk turned contacts (MIL crimp), the processing of twisted pairs, or ultrasonic compaction or welding.
In addition to the standard processes, there is ample space for customer-specific processes, options and accessories.
With an additional interface, in combination with the ultra-flexible TopWin software, even customer-specific processing stations can be integrated with analog inputs and outputs.

Quality monitoring

Crimp-height and pull-out force measurement are integrated in the process sequence. Fully automatic pull-out force measurement is also available as an option. The measured results from the measuring devices are transferred automatically to the user software and compared with the set values. Incorrect entries can be avoided in this way. Production cannot commence until the measured results match the specified values.  The material is scanned in with the optional barcode scanner prior to the start of production and compared with the stipulated values. This step prevents materials from getting mixed up.  
The processes are constantly monitored during production. In the event of an error, incorrectly processed cables are automatically removed and post-produced.

712/722 crimping module

Presses with integrated crimp force analysis (CFA) for crimp forces up to 20kN.
  • The mci 722 crimp press also features programmable crimp height adjustment.
  • Just one teach crimp is required.
  • Creep speed (slow motion) and other key functions can be controlled right at the press.
  • Double stroke for closed contacts
  • Programmable stroke
  • Tool fixture featuring quick-change system

mci 765 seal module

Module with integrated seal position monitoring (SPM) of absolute values in millimeters.
  • Automatic setup of the seal position (SPM).
  • 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.

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. User tips are presented clearly in graphics. Customer-specific processing stations can be integrated into the machine’s production sequence. The optional interface, the WPCS (Wire Processing Communication Standard), allows Komax machines to be networked and easily integrated into existing production processes.

Technical data

Length range
60mm–65000mm (2.36in.–213ft.)
Optional 30–60mm (1.18in.–2.36in.)
Length accuracy
Repeat accuracy ±(0.2%+1mm (0.04in.))
Stripping lengths
0.1–35mm (0.004in.–1.38in.)
Stripping lengths with partial pull-off
47mm (1.85in.)on side 1  
35mm (1.38in.)on side 2
Optionally up to 80mm (3.15in.)
Wire cross sections*
0.22–6mm2 (AWG24–AWG10)
Optionally from 0.13mm2 (AWG26)
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. 1400kg (3090lb.)
*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 356 can be customized with various accessories to meet specific customer needs.
Preliminary processing of wires
  • Inkjet marker
  • Hot-stamp marker
  • K106/ads117/119 de-reeler
Processing modules
  • mci 712/722 crimping module
  • mci 782 twisting module
  • ioc 785 tinning module
  • mci 765 seal module
  • mci 792 sleeve module
  • Double gripper module
  • AEH module for end sleeve for strand
  • MIL crimp module
  • Welding and ultrasonic modules
  • Customer-specific special modules
Wire deposition
  • Basic module, 2m (78.7in) or 4m (157.5in)
  • Extension module, 2m or 4m
Measuring devices
  • Fully automatic pull-out force measurement
  • External measurement of crimp height and pull-out force
  • WPCS, TopConvert, TopNet
Process monitoring
  • Crimp force analysis (CFA)
  • Material change detection
  • Seal position monitoring (SPM)
  • Splice detection
  • Wire-end detection

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
 

Pour plus amples information, veuillez contacter:

Komax AG, Dierikon
Tel. +41 (0)41 455 04 55
mailto: Komax AG Dierikon
 

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