Alpha 530

Alpha 530

Crimp to Crimp

  • Alpha 530

    Alpha 530

  • Alpha 530

    Absolutely precise processing with single-line blade holder

  • Alpha 530

    Quick and reliable setup directly on the crimping module

  • Alpha 530

    Uniform guide tubes

The robust all-rounder

Unrivaled robustness and durability

  • Reliable processing of wire cross sections ranging from
    0.13 to 6 mm²
  • Production of special and complex applications thanks to flexible machine configurations
  • Solid and reliable processes with powerful, durable technology
  • Reduced maintenance costs thanks to the unique approach to wearing parts
  • Designed for demanding ambient conditions

Precise and outstanding quality

  • First time right – perfectly synchronized machine processes enable excellent CpK results
  • Highly robust machine configuration
  • Can be retrofitted with unique quality checking systems such as Q1250 scalable and ACD
  • Wires handled carefully, gently during processing

Productive due to fast changeover

  • High productivity performance thanks to ultra-fast machine setup and operation
  • Quick and highly efficient changing of cables, crimp tools, terminal rolls
  • New deposit system for maximum output

Stable, tried-and-tested technology combined with innovative solutions secures and increases the added value of your company. Alpha 530 – the fully automatic wire processing machine for crimping and loading of seals – on both sides – meets these criteria with its solid, powerful technology. In addition, double crimp, sleeve assembly and ferrule assembly can also be efficiently processed and the strands twisted and tinned. The quick set-up and changeover times of Alpha 530 contribute to high productivity. High process capability and retrofittable quality options such as Q1250 scalable and ACD meet the highest quality requirements.

Maximum productivity in no time at all

Short distances for the operator between crimping, cable and cutting stations, as well as LED-illuminated work zones increase productivity. The user interface is clearly structured and can be expanded. The user guidance is sequence-controlled and can be individually adapted. 
Changeovers with the Alpha 530 can be even faster using the optional linear wire quick changer and the stationary (STC) terminal quick change system.

Quick changeover; set up in parallel

Simple, fast set-up and changeover concepts enable short distances and speed up the processes for changeover and set-up. The Alpha 530 is time-saving and ergonomic to operate via touch screen, keyboard and mouse. The intuitive user interface makes it possible to load the next job on the fly – as well as prepare material and tools. Control displays and LED-illuminated work areas optimize and enhance user guidance.

First-time-right approach – minimal rejects

Top precision, even at maximum system performance and excellent CpK results – the machine processes and the functions for quality assurance are perfectly attuned to each other. The reliable EtherCAT technology guarantees optimum processes.

Quality assurance by Komax

Komax develops and produces its own quality assurance technology. This QA technology meets the highest standards of the automotive industry. Also available are the integrated optical stripping, seal and crimp monitoring function (Q1250 scalable) and crimp force monitoring (CFA+/CFA) for detecting missing strands and other crimp faults. The optional Automatic Conductor Detector (ACD) reduces operator intervention and ensures quality control of even the finest wires. The ACD detects the slightest contact between the blade and the conductor strand during the stripping process.

Gentle wire guidance

The pneumatic wire straightener enables high feed-in speed and excellent deposit quality even with difficult conductor material. With the actively controlled roller pressure, any changes in the cable containers and draw-in speed are compensated. To avoid indentations on the cables during machine stops, the roller pressure is automatically reduced.
The speed of the deposit conveyor belt is automatically adjusted, assuring neat and gentle wire deposit. The deposit tray features a smooth surface to prevent any cable damage.

Automotive Configuration

Available processing modules

  • Crimp modules C1370/C1360/C1340
  • Seal modules S1441
  • Seal-, strip- and crimp quality monitoring Q1250 scalable

Industrial Configuration

Available processing modules

  • Crimp modules C1360/C1340
  • Ferrule modules AEH-LS/ AEH-G
  • Double gripper module
  • Sleeve module
  • Tinning module X1585
  • Twisting module X1582

The market leader’s quality and expertise

Komax assures the maximum per­formance capability of the Alpha 530 by delivering holistic, comprehensive quality. It considers all components and rounds out these efforts with local services globally.

Wire cross sections

0.13 – 6 mm² (AWG 26 – 10)*

Wire draw-in speed
Max. 9 m/s (29 ft/s) belt drive 
Outer diameter of conductor
Max. 5.1 mm (0.20 in)
Length range
60 – 65 000 mm (2.35 in – 213 ft)**
optional 30 – 60 mm (1.18 – 2.36 in.)
Full stripping
0.1 – 18 mm (0.004 – 0.71 in.)
optional up to 29 mm (1.14 in.)
Half stripping
15.5 mm (0.6 in)
optional up to 35 mm (1.38 in.)
Crimp force
1 – 22 kN (224 – 4946 lbf.)
Process modules side 1 / 2
2 / 2
Noise level
< 80 dB (without crimp tool)
Electrical connection
3 × 208 – 480 V / 50 – 60 Hz / 5.6 k VA
Compressed air connection
5 – 8 bar (73 – 116 psi)
Air consumption Crimp / Crimp
Crimp-Seal / Crimp-Seal

< 7 m³/h (247 ft³/h)

< 11 m³/h (388.5 ft³/h)
Weight (incl. 2 crimp modules) 1.3 t (2’866 lbs.)

* Very hard or tough wires may not be able to be processed under certain circumstances although they are within the specification. Komax offers feasibility tests for  testing the wires in advance. The processing of larger wire cross sections is possible on request. 
** Wire length tolerance ±(0.2% + 1 mm (0.039 in))

 

 

Cutting Cutting
Cutting pulled strands Cut pulled strands
Full stripping Full strip both sides
Half stripping Half strip both sides
Core processing Inner conductor 2pol crimp
Coaxial and triaxial cable processing Coaxial cable
Double sheath cable processing Triaxial cable
Intermediate strip Intermediate strip
Crimping Crimping cc
Double crimping Double crimping Alpha 530/550
Split cycle for closed barrels Split cycle both sides
Seal insertion Sealing both sides
Twisting / tinning Twisting and tinning
Sleeve insertion Sleave insertion G333
Ferrule crimping Ferrule crimping
MIL crimping MIL Crimp
Wire end solidifying, splicing, welding Wire end solidifying
Hot stamp marking Hot stamp marking with strip
Inkjet marking Inkjet