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Zeta 655 – Block Loader
Introduction
With its fully automatic Zeta 655 block loader, Komax has implemented a concept incorporating many innovations that open up whole new possibilities for the automatic production of wire harnesses.
Key features:
- 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
Economy
The Zeta 655 is the first block loading robot designed to taken into account the ever smaller sizes of production batches. Thanks to its machine design, the Zeta 655 allows investment costs to be amortized in parallel on different types of wire harnesses, markedly reducing the cost per lead set.The Zeta 655 allows completely new applications to be subsequently incorporated into it easily and with absolutely no trouble.
Technology
With the flexible pallet carousel, the most varied types of wire harnesses can be produced just-in-time and changeover times are reduced to virtually nil. Terminal-specific parts are eliminated. 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. Komax‘s patented measuring process monitors the entire loading operation, from the wire‘s entry into the cavity to its correct interlocking in the block.
Flexible Basic Machine
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 white text.
User friendly
The equipped pallets are loaded and unloaded while the machine is running and wires are placed on the second pallet. The block loader is operated from the sliding console on the fully automatic Zeta 633 crimping machine using the TopWin user interface. The software automatically calculates the order of loading within a wire harness to make the setup of new harnesses as simple as possible. The software also calculates the management of the various holding grippers in the rotary storage unit for chaotic harnesses.
Technical data
| Piece number output* | One-ended loading1.5s per loading operation Two-ended loading1.5s per loading operation *Piece number output depends on wire length and block/terminal combinations. |
|---|---|
| Shortest wire length | With one-ended loading 240mm For jumper connections at both ends 280mm–440mm** For complex loading operations 280mm–640mm** **Depends on wire harness structure |
| Cable cross sections*** | 0.22mm2–2.5mm2 (4mm2) |
| Outside diameter of cable | Maximum of 4mm |
| 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 Customerspecific solution on request |
| Pallet system | Loading field (WxHxD)164200120mm |
Connection electrical/ pneumatic |
Directly from Zeta 633 |
***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 for you.
Accessories
The Zeta 655 can be tailored to a customer‘s specific requirements by adding various types of accessories, e.g. block closing, secondary interlocking, etc. We are happy to send you a quotation for your specific requirements.