Alpha 560
40 years cutting edge

Alpha 560

Crimp to Crimp

  • Alpha 560

    Alpha 560

  • High-precision crimping process for large conductor cross-sections.

    High-precision crimping process for large conductor cross-sections.

  • Quick and reliable setup directly on the crimp module.

    Quick and reliable setup directly on the crimp module.

  • Can easily process large seals up to Ø18 × 21 mm.

    Can easily process large seals up to Ø18 × 21 mm.

  • Minimal training required thanks to the clearly structured user guidance in the Komax HMI.

    Minimal training required thanks to the clearly structured user guidance in the Komax HMI.

Alpha 560 – Powerful for conductor cross-sections up to 16mm² (AWG 6)

Wide processing spectrum

  • Reliable processing of conductor cross sections of 2.5 to 16 mm² (AWG 14 – 6) with crimp terminals up to 55 mm (2.16 in.) in length
  • A variety of processing possibilities at four or more stations (on request)
  • For large seals with max. length 21 mm (0.83 in.) and max. Ø 18 mm (0.71 in.)
  • Processing of wires up to 8 m in length (12 m on request)
  • Suitable for large terminal reels up to Ø 800 mm (31.5 in.)

High efficiency and productivity

  • Optimized work processes thanks to innovative process module setup
  • Minimal training required thanks to the clearly structured user interface Komax HMI
  • Minimal downtime due to setup directly on the module

Robustness and durability

  • Consistently high performance even in rough environments
  • Quality components from the proven Alpha 5xx platform
  • Inexpensive handling of replacement and wear parts thanks to the common parts concept

The Alpha 560 is a powerful, fully automatic wire processing machine for one- or two-sided loading with large terminals and seals. Two stations each process conductor cross sections of up to 16 mm² (AWG 6). The Alpha 560 is extremely easy to operate and provides reliable, robust production. Operation via the touchscreen requires just a short training course and is supported by the intuitive Green Button user guidance system. This and the innovative HMI controller ensure great flexibility and short changeover times. Another outstanding feature is the fully integrated end-to-end quality monitoring from the stripping process to the finished crimp.

C1380 crimp module for maximum productivity

With a crimp force of 50 kN, even demanding terminals can be processed with ease. Higher crimp forces are available upon request. Wire positioning directly on the module reduces the time required for setup, changeover and sampling. In the current process, the fully integrated CFA+ and CFA crimp force monitoring guarantees the highest quality with minimal rejects. A powerful cutting mechanism cuts terminal strips up to 1.2 mm (0.05 in.) thickness. 

S1441 G seal module for high flexibility

The module reliably processes up to 380 different seal variants. Thanks to the automatic, intelligent seal detection function and the stored SST (Smart Seal Track) parameters, set-up time can be reduced to a minimum. 

Q1240 quality monitoring for traceable, high-quality 

The wear-free, optical quality monitoring function is fully integrated in the Alpha 560. The Q1240 quality tool monitors strip quality and seal insertion and automatically rejects defective products. Product quality can be traced end-to-end via statistics, image capture and the network.

Optimal setup and operation

The innovative machine and process module setup greatly simplifies work processes. Set-up processes are automated and require only minimal training. Efficient setup directly on the module yields significant time savings. Additional operating functions at the cable-feed and on the modules simplify processes further. In just a few steps, a new wire can be requested, precisely positioned and prepared. The production process can be adjusted and optimized during operation. 

Future-oriented quality concept

Fully integrated quality tools monitor the entire manufacturing process through to the finished product. The monitoring functions for the crimping process (CFA+/CFA) as well as the seal position and the strip quality (Q1240) ensure maximum quality with minimal rejects. The measurement data for the produced articles is stored locally and can be traced via a network. The optional verification and documentation of the implemented specifications ensure demonstrable quality according to industrial standards. 

Simple and flawless operation with Komax HMI

Assisted by the intuitive user guidance system of the HMI operating software, the Alpha 560 can be set up in just a few steps and operated by any staff member. The open HMI interface always enables complete transparency concerning the production process. It enables the integration of external control tasks and applications. 

Robust, reliable design

This solid system ensures consistent reproducibility of the products in the required quality. Powerful servomotors position the swivel arm with unrivaled repeat accuracy. The mechanical and electronic components are well protected from dirt and ambient influences and also suitable for environments with high temperatures and moisture.

 
Wire cross-sections 2.5 – 16 mm² (AWG 14 – 6)*
Wire outer diameter
3 – 8.5 mm (0.20 in.)
Length range**
60 – 8,000 mm (2.35 in. – 26 ft)
12 m (39 ft) upon request
Full strip
max. 29.5 mm (max. 1.16 in.)
Partial strip max. 35 mm (max. 1.38 in.)
Crimp force* 1 – 50 kN (224 –11,240 lbf.)
Process module side 1/2 2/2
Noise level < 80 dB (without crimp tool)
Electrical connection 3 x 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) 1.40 t (3,087 lbs.)
* Very hard or tough cables may not be processable although within specification. Komax offers feasibility tests for prior testing. Processing of larger conductor cross-sections possible on request.

** Repeating accuracy ± (0.2% + 1 mm [0.04in.])





Cutting Cutting
Cutting pulled strands Cut pulled strands
Full stripping Full strip both sides
Half stripping Half strip both sides
Double sheath cable processing Triaxial cable
Coaxial and triaxial cable processing Coaxial 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 A355S Z651 Z656
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