komax Holding
 

Professionals in Advanced Automation

Zeta 633 – fully automatic crimping machine

Introduction

New design for a fully automatic crimping machine that can be expanded at will and transformed into an insertion system.
Here, Komax incorporates trends in wire processing and consistently implements them.
As a result, the Zeta 633 meets the growing need for unlimited flexibility.

Key features:

  • 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: Existing user expertise can be applied immediately.
  • Excellent accessibility and safety
  • Newest technology
  • Successively expandable
  • Prepared for Zeta 651 and Zeta 655 block loaders
  • Fully integrated quality monitoring with good/bad sorting
  • Customer specified special applications possible

Area of application

Zeta 633 is a highly flexible fully automatic crimping machine used for just-in-time production. With its flexible machine concept, the Zeta 633 opens up an almost unlimited number of possibilities for handling small jobs and wire sequences.

Flexibility

Up to 36 conductors are available for wire feed without changeover. Wire transport can be adapted to the specific properties of each conductor.
Modules can be configured as desired along the entire length of the Zeta 633. That means total flexibility for each area of application.
The wires can be bundled or deposited in predefined order as a chain.
The Zeta 633 also serves as the basic machine for the Zeta 651, Zeta 655 and splice module (SP). Customer-specific modules such as IDC processing can also be installed.

Technology

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 Variably programmable shuttles make this possible. All wire movements are carried out with highly dynamic servo axes. The basic machine accommodates up to five processing stations. If need be, the machine can be successively expanded and has space for up to ten processing stations.

User friendly

Optimum access and personal safety were two top priorities in the design of the Zeta 633.
The safety cover opens vertically, allowing excellent accessibility from all sides. All material handling is done consistently from one side of the machine. The wire selector can be set up conveniently at the press of a button. The well-known TopWin user interface and a user console that slides along the entire transfer section are further features that maximize operational convenience. Produced wires or bundles can be removed while the machine is running.

Quality monitoring

Crimp-height and pull-out force measurement are integrated in the process sequence. 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.

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.

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.

Technical data

Length range
240mm–3000mm(9.45in–118in.)Standard tray
240mm–10000mm(9.45in–394in.)Optional
Length accuracy
+/-1mm (0.039in.) or <0.2% Depending on wire length
Stripping lengths
0.1mm–25mm(0.004in.–0.98in.)With full strip
0.1mm–42mm(0.004in.–1.65in.)With partial strip
Conductor cross sections*
0.22mm2–6mm2 (AWG24–AWG10)
Useable transfer length
1800mm (basic machine)
1720mm (extension)
Wire draw-in speed
max.10m/s (33ft/s)
Wire selector
Max. 36 cables
Noise level
<75dB (without crimp modules)
Electrical connection
3×208–480V 50/60Hz
10kVA (basic machine)
Pneumatic connection
5–6bar (73–87psi)
Air consumption
12m3/h (424ft3/h)
Weight
Approximately 1560kg (3440lb)
*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

Various types of accessories can be added to the Komax Zeta 633 to adapt it to specific customers requirements.
Preliminary processing of wires
  • Inkjet marker black/color
  • Expandable wire selector
Crimping module accessories
  • Height adjustable lift tables
  • Terminal feed with paper take-up unit
  • Contact strip chopper (chopper)
Process monitoring
  • Splice detection
  • Contact supply monitor
  • Wire-end detection
  • Seal monitoring
  • Crimp force monitoring
  • Check on projecting strand
Further modules
  • Sleeve loader
  • Twisting module
  • Fluxing and tinning module
  • Option for short wires (85–110mm)
  • End sleeve modules
  • Wire end compaction
  • Chain bundling
Other accessories
  • Wire feed system
  • Wire tray for long conductors
  • Station tables
  • WPCS

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
 

For more information please contact:

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

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