Gamma 450
40 years cutting edge

Gamma 450

Crimp to Crimp

  • Gamma 450

    Gamma 450 – Reduced to the Max

  • Gamma 450

    Fast cable insertion without cross section-dependent guide elements.

  • The stationary quick terminal changer STC (optional) reduces changeover times.

    The stationary quick terminal changer STC (optional) reduces changeover times.

Best-in-class setup and changeover

High level of process stability and comprehensive monitoring

  • New machine platform based on tried-and-tested Alpha technology
  • Complete quality monitoring, thanks to a fully integrated quality concept

Fast setup and changeover

  • Quick manual wire change
  • Short replacement times for tools and terminals thanks to STC
  • Reduced changeover times thanks to machine operation at the crimp module

Compact machine design and efficient operation

  • Simple and user friendly
  • The machine design meets global ergonomic requirements
  • Komax HMI software with Green Button for error-free and efficient production
  • Comprehensive transparency across the entire production process

Cost-effective maintenance

  • Conveyor belt can be used on both sides
  • Good machine access for short maintenance times
  • Common-parts strategy with Alpha 530/550 reduces complexity and costs for spare parts

 

The compact, fully automatic Gamma 450 processes crimps and seals on both sides and takes up minimum space. It guarantees high production availability and traceable quality. The wire processing machine has all the necessary key functions and can also be extended for specific purposes using an extensive range of options. High-performance modules ensure seamless quality monitoring. Optimized quick-change systems reduce set-up and changeover times. Handling is intuitive and ergonomic – easy and error-free thanks to the Komax HMI operating software. This combination contributes significantly towards achieving stable and optimal productivity.


Gamma 450 – exceptionally economical

The Gamma 450 fulfills all the requirements of future-proof, cost-effective wire production. The precise modules and functions required can be customized individually on four stations. With these supplementary options, the compact machine provides the required functional scope, powerful performance and seamless quality monitoring. Ergonomic working conditions, logical workflows and the simplest possible user guidance all promote a cost-effective production process. Maintenance costs have been optimized by having a common-parts strategy. This makes the machinery less complex, brings down costs for spare parts and reduces training requirements.

Maximum availability and efficiency

The Gamma 450 processes crimps and seals with cross sections of 0.13 to 4 mm² on both sides. The proven, robust technology ensures continuous machine availability with minimal downtimes. Shorter routes and stringent processes between work zones improve the workflow and the productivity. Operation of the machines is aided by optimal lighting in the work areas and dimensions that are adapted to suit global standards.

 

Fast setup and changeover

The optional STC quick terminal changer enables the terminal rolls and crimp tools to be changed during operation. The time-saving insertion of the wire into the belt drive takes place without the need for additional cross-section dependent guide elements. The option to use both sides of the drive roller ensures it has an above-average service life.

Full quality assurance and traceability

All integrated and optional modules and functions ensure seamless quality control. Perfectly coordinated with each other, they meet the high demands of the automotive industry. Integration with the MES manufacturing execution system provides documented traceability. The integrated CFA+/CFA crimp force monitoring detects missing individual wires and crimped insulation. The optional automatic conductor detector (ACD) ensures quality, even for the finest conductors. It detects the slightest contact between the blades and conductor strands during cutting and stripping. The Q1240 quality tool monitors strip quality and seal insertion and automatically rejects defective products.

Simple and flawless operation with Komax HMI

Supported by the user guidance in the HMI operating software, the Gamma 450 can be set up in just a few steps. The large touchscreen makes operation of the HMI user interface easy. The use-case-driven design of HMI also ensures error-free data input while the Komax Green Button guides the user through the wire processing step by step.

Q1240 strip quality monitoring for maximum quality

The Q1240 quality tool visually monitors strip quality and seal insertion.Product quality can be traced end-to-end via statistics, image capture and network feedback.

Tried and tested C1340/C1360/1370 crimp modules with CFA+/CFA

The efficient user guidance and wire positioning directly on the module allows the shortest setup and changeover times. CFA+/CFA- guarantees the highest quality and minimal rejects. Combined with the time savings, this can increase productivity considerably. Features like the stroke and split cycle can be programmed easily. The C1370 adjusts the crimp height automatically during programming.

S1440 seal module for maximum flexibility

The module automatically fits wires with conventional seals and mini-seals. The combination of precision mechanics and the new seal position monitoring function guarantees a high degree of process safety and maximum productivity. The module can be simply and quickly switched from one seal variety to another.

 

 Wire cross-sections 0.13 – 4 mm² (AWG 26 – AWG 12)
 Wire outer diameter max. 3.9 mm (0.15 in.)
 Length range 60 – 65,000 mm (2.35 in.– 213 ft)
 Full strip 0.1 – 16.5 mm (0.004 – 0.65 in.)*
With optional double blade up to 21 mm (S1) and 35 mm (S2)
 Partial strip 0.1 – 16.5 mm (0.004 – 0.65 in.)*
With optional double blade up to 21 mm (S1) and 35 mm (S2)
 Crimp force 1 – 22 kN
 Process modules Side 1 and side 2 2 stations
 Noise level < 80 dB (without crimp tool)
 Electrical connection 3 x 208 – 480 V; 50/60 Hz; 2.5 kVA or 3 x 400 V, 50/60 Hz, 2.5 kVA
 Compressed-air connection recommended operating pressure 5 – 8 bar (73 – 116 psi) 6 ±0.5 bar (87 ±7.25 psi)
 Air consumption of crimp /crimp seal crimp / seal crimp

<6 m³/h (212 ft³/h) <9 m³/h (318 ft³/h)

 Weight (incl. 2 crimp modules + 2 seal modules)  920 kg (20828 lbs)
* Depending on cable material
** 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
Crimping Crimping cc
Double crimping Double crimping Alpha 530/550
Split cycle for closed barrels Split cycle both sides
Seal insertion Sealing both sides
Inkjet marking Inkjet