Research and development:
quality monitoring and standardization

In the year under review, Komax launched the new Alpha 355. The latest Komax "star attraction" is considerably easier to access thanks to the positioning of the cutting head beneath the wire line. The use of carbon fibre technology makes it possible to produce rugged, lightweight swivel heads, and the "convertible hood" significantly reduces the size of the machine. The higher numbers of platform units purchased with the Alpha 355 (motors, controllers, CPU 2000) will also impact positively on the gross profit margin in the long term. The Alpha 355 boasts novel features in the form of cast aluminium module tables and a lightweight cover of the type already used for the Alpha 455.

In the Alpha 455, measurement of the pull-out force is now an integral part of the machine and carried out fully automatically. The motor currents on the pull-off axes, which are proportionate to the pull-off forces, are calibrated and recorded as the pull-off force. Integration of this destructive test into the machine cycle provides a highly reliable means of detecting incorrectly parameterized production processes. Komax has also succeeded in creating the basis for an improved force analysis process and further increased the quality monitoring of the crimping process thanks to measuring equipment developed in-house.

Three generations of Kappa machines have been developed since Komax was founded in 1975. In 2006, the first preproduction models of the fourth Kappa generation, the Kappa 350 and Kappa 330, were presented to the sales force at the International Sales Meeting following intensive alpha testing.

The latest generation features an electronic platform, developed in collaboration with an external partner. It is based on touchscreen operation and is equipped with state-of-the-art sensors (optical cable end monitoring and electronic conductor detection). The electronic conductor detection system allows optimum setting of the insulation stripping blade to a high degree of precision and without the need for electrical grounding of the cable.

There has been a marked increase in the use of DOMINO modules and the standard range of platform components. During the year under review, the various system business subsidiaries agreed on a joint supplier in a further project aimed at utilizing synergies in the field of process engineering, platforms and project management. Komax will continue to implement this backbone strategy.

The development of the photovoltaic market varies greatly from region to region, but in Europe, California and in certain countries of the Far East it has been dramatic, with an exceptionally steep growth curve. In the conventional market for monocrystalline or polycrystalline solar cells, infrared and inductive soldering processes have been introduced recently in addition to conventional (hot-bar) and hot-air soldering for making the contacts between the cells. Komax is well positioned with the Xcell 2500 and Xcell 3000 (parallel stringers with dual output) in both technical and commercial terms. At its Rotkreuz plant, Komax is developing specific contact attachment processes for the expanding thin-film technology sector and is building up its expertise in this field.