The term H-MTD stands for High-Speed Modular Twisted-Pair Data, a connector based on Ethernet technology for wired networks. For several years now, the automotive industry has been increasingly challenged to significantly speed up the data connections in their vehicles. Just one high-resolution display requires a data throughput of more than 3 Gbit/s. Added to this are connections for 4K camera systems, radar, rear-seat entertainment, autonomous driving, infotainment, etc. Wiring systems traditionally used in automotive engineering are no longer adequate for handling this. What is actually needed is Ethernet, which we are familiar with from our computer networks with their ever-increasing data throughput requirements.

Tricky processing of multi-part connectors

Compared to standard network applications, much higher demands are placed on this automotive Ethernet hardware. In addition to high bit-rate data transmission, robustness against vibration, high temperature resistance, savings in installation space and weight continue to be important factors.

In practice, there is already a huge variety of such cables available with many different connections. Shielded and unshielded twisted pair cables as well as new high-performance cables are used. These are tricky to process. The connectors consist of several elements that have to be positioned and aligned with each other with pinpoint accuracy.

The Lambda 416 H-MTD ensures high processing quality

In short: these cables are almost impossible to process by hand. For this reason alone, automation is a must. That is why Komax got started early on in developing a machine for this purpose. For half a year now, with conviction and also a little pride, we have been able to offer the Lambda 416 H-MTD for this promising wire processing business. It enables the efficient, semi-automatic processing of such wires and is modular in terms of hardware, machine control and user interface. Proven, integrated test systems guarantee high-quality processing, which then enables the required high volumes of data to be transmitted.

Innovative, patented processes

What does semi-automatic mean here? The operator inserts the unprocessed wire into the machine, which then performs the following processes: automatic orientation (patented), precise crimping of the support sleeve, processing of the braided shield, film removal (patented), precise preparation of the inner contact and crimping, and insertion into the outer contact and crimping. The result of these processes is a wire that is fully processed at one end.

There is also comprehensive quality control with crimp force monitoring, tactile and optical measurement. Thanks to its modular design and clearly structured user interface (HMI), the machine is easy to set up and configure.

Komax is ready for full automation

The Lambda 416 H-MTD is now in use. Our customer thinks “that the machine doesn’t run badly at all”, which is high praise indeed among us Bavarians. Due to this positive result, he can now be confident that the machine will provide him with the required quality and that he will be able to secure orders for larger quantities.

In short: full automation is the next issue. Komax is ready. Our Lambda range already includes 12 process modules for this purpose which are suitable for many of the connector systems on the market today.

Would you like to learn more about what the Lambda 416 H-MTD could do for you in this promising business area? The author will be happy to provide you with more information.