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Alpha 455 – fully automatic crimping machine
Introduction
This fully automatic crimping machine was developed with customer needs firmly in mind. That explains the minimal setup and changeover times, the reliable and fully automatic quality measurements and the layout that meets the toughest ergonomic standards.
Area of applications
The Alpha 455 is specially design for just-in-time production. Downtimes become crucial where batch sizes are relatively small and the machine requires frequent changeovers. The objective in these cases is to minimize the time needed for setup and changeover while always guaranteeing the highest standards of quality.
Ultra-short changeover times
The mci 722R is the product that guarantees the efficient setup of the fully automatic Alpha 455 crimping machine. This innovative new rotary press table was specially developed for the Alpha 455 and allows the latter to be converted while production is still going on. The tools and terminals for the next two jobs are changed while the current batch is still being produced. The manual wire selector further reduces changeover times. A wire for the next batch is set up while the current batch is still under production. If need be, the manual wire selector can be turned to feed the second wire into the machine in seconds so it is available for further production. The optional guide tube changer allows you to automate this step in the changeover and keep downtimes to a minimum.
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.
Modules
mci 722R crimping module
This is the only crimping press that accommodates up to three applicators at the same time. The tool changeover is fully automatic or triggered at the press of a button. The programmable crimp heights ensure maximum precision. Integrated crimp force analysis with three-zone evaluation detects good/bad wires with great precision while recording the errors in detail. The force and travel path of the tappet are both measured directly in the process. As a result, even the tiniest errors are measured, including errors involving terminals with minimal “head room”. Measured quality data is saved continually by the Alpha 455 and is thus available for statistical evaluation at any time.
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.equipment.
Technical data
| Length range | 60mm - 65000mm (2.36in.-213ft.) Optional 30mm (1.18in.) |
|---|---|
| Length accuracy (Repeat) | +- (0.2% +1.0mm (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 section* | 0.22 - 6.0mm2 (AWG24 - AWG10) Optionally from 0.13mm2 (AWG26) |
| Wire draw-in speed | max. 10m/s (33ft/s) |
| Noise level | <75dB (without crimp module) |
| Electrical connection | 3x208 - 480V 50/60Hz 5kVA |
| Pneumatic connection | 5 - 8bar (73 - 116psi) |
| Air consumption | 9m3/h (318ft3/h) |
| Weight | approx. 1300kg (2870lb.) |
Accessories
The Alpha 455 can be customized with various accessories to meet specific customer needs.
Preliminary processing of wires
- Inkjet marker
- Wire feed systems
- Straightening unit, standard/manual wire selector
Measuring devices
- Fully automatic pull-out force measurement
- Integrated referencing of wire lengths
- External measurement of crimp height and pull-out force
Wire deposition
- Basic module, 2m (78.7in.) or 4m (157.5in.)
- Extension module, 2m (78.7in.) or 4m (157.5in.)
Crimping module accessories
- Additional tool position for rotary table press (includes tool fixture, chopper, paper winder)
- Back terminal feed (from rear)
Process monitoring
- Crimp force analysis (CFA)
- Material change detection
- Seal position monitoring (SPM)
- Splice detection
- Wire-end detection
Other accessories
- Automatic guide tube changer
- Double gripper module
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
- Introduction
- Area of applications
- Ultra-short changeover times
- Quality monitoring
- Modules
- TopWin
- Technical data
- Accessories