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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.

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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 656 block loaders
Fully integrated quality monitoring with good/bad sorting
Customer specified special applications possible

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Function

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 and Zeta 656. 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.

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Applications

Cutting
Cut pulled strands / Precision cut
Full strip
Half strip
Double sheath cables
Crimping
Ink-Jet marking
Sequence
Double crimping
Split cycle
Seal insertion
Twisting / Tinning
Sleeve insertion
Ferrule crimping
MIL-Crimping
Wire end solidifying

Cutting

Cut pulled strands / Precision cut

Full strip

Half strip

Double sheath cables

Crimping

Ink-Jet marking

Sequence

Double crimping

Split cycle

Seal insertion

Twisting / Tinning

Sleeve insertion

Ferrule crimping

MIL-Crimping

Wire end solidifying

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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
Wire cross sections*	0.13mm2–6mm2 (AWG26–AWG10)
Useable transfer length	1800mm (basic machine) 1720mm (extension)
Wire feed 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)

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

Wire cross sections*

0.13mm2–6mm2 (AWG26–AWG10)

Useable transfer length

1800mm (basic machine)
1720mm (extension)

Wire feed 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)

*Extremely hard and tough wires may not be able to be processed even if they are within the above cross section range. If you are in doubt about your wires, we are happy to process samples of them.

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Software

TopWin .

The optional interface WPCS (Wire Processing Communication Stand-ard) allows Komax machines to be networked under TopWin. With this open interface, the machine is easy to integrate into existing production sequences.

TopNet is a clearly arranged mana-gement software with functions for the centralized creation and management of parts, articles and jobs that help you to optimize your production operations.

TopConvert can be used to convert already existing job and article lists to WPCS format. This data can then be directly processed by fully automatic crimping machines.