Omega 745/755

Omega 745/755

Harness Manufacturing

  • Application machine Omega 745/755

    Application machine Omega 745/755

  • Flexible housing rail system: up to four different housing types can be supplied at the same time.

    Flexible housing rail system: up to four different housing types can be supplied at the same time.

  • The hybrid assembly arm inserts the cable into the housing.

    The hybrid assembly arm inserts the cable into the housing.

  • Example of an additional function: a customized tool closes the secondary lock on the connector housing

    Example of an additional function: a customized tool closes the secondary lock on the connector housing

  • Example of interim storage of finished product: the completed wire harnesses are collected on a customized rail of any length until they are unloaded by the operator.

    Example of interim storage of finished product: the completed wire harnesses are collected on a customized rail of any length until they are unloaded by the operator.

Omega 745/755 application machine

First-class engineering services – customized products 

  • The Omega 745/755 offers a customized block feed and deposit system for the wire harnesses.
  • The fully automatic feeding system and processing of up to four different connector housings enables the production of wire harnesses with double-sided loading.
  • The Omega 745/755 can be changed over to produce a different wire harness with minimal engineering effort. This flexibility means a high level of investment protection for our customers.

Integration of optional follow-on Processes

  • The base machine for the Omega 745/755 offers sufficient space for the integration of additional processes associated with loading, e.g.:
  • Automatic closing of the secondary lock on the connector housings
  • Optical process monitoring
  • Reading of data matrix codes for product traceability
  • and much more

Full automation for minimal labor requirement

  • Specially customized solutions can result in even higher levels of automation and almost autonomous production.
  • This rationalization means that one operator can operate and monitor several machines at once. Savings in labor costs can then be made.
  • Full automation also minimizes operator influence on quality.

Individualization as competitive advantage

The Omega application version has all the previously described benefits and properties of the Omega 740/750. What sets it apart is the automated solution developed specifically for the customer for the feeding and further processing of housings and the depositing of wire harnesses. The Omega 745/755 is not a ready-made product but a flexible basic machine with intelligent software, interchangeable process modules and customized application components to meet the special requirements and specific needs of our customers.

The customization aims to provide our customers with a decisive economic advantage. This is primarily achieved through rationalization and the associated savings in labor costs. Komax is the global market leader in the wire processing sector. Our applications allow our customers to benefit from the wealth of specialist knowledge and expertise of the Komax development team, enabling them to find a tailored solution that meets their every need.

Piece output, single-sided and double-sided loading*

1.8 sec per insertion sequence
Shortest wire length

For single-sided loading:
240 mm (9.45 in.)

Double-sided jumper connections:
300 – 560 mm** (11.81 – 22.05 in.**)

Complex loading:
300 – 780 mm** (11.81 – 30.71 in.**)

Strip length

up to 25 mm (0.98 in.) 

Wire cross-sections***
0.13 – 2.5 mm² (AWG 26 –14)
Outer wire diameter
Max. 4 mm (0.16 in.)
Usable transfer length Omega 74x
1880 mm (74 in.), up to five C1370 crimp modules
Usable transfer length Omega 75x
2880 mm (113.4 in.), up to eight C1370 crimp modules
Usable transfer length extension
1840 mm (72.4 in.), up to five additional C1370 crimp modules
Wire changer
Max. 36 wires (in increments of six wires)
Wire end storage
Rotary storage unit with a maximum of 30 storage spaces
Process monitoring (integrated)

Collision monitoring (block chambers)
Insertion force monitoring
Terminal locking monitoring

Block feed

Fully automatic block feed by spiral or linear conveyor

Pallet system loading area (W×H) 280 × 200 mm (11.02 × 7.87 in.)
Maximum width of connector housing 1st and 2nd housings: 100 mm (3.937 in.)
3rd and 4th housings: 60 mm (2.362 in.)
Electrical connection 3×208–480V, 50/60 Hz/10kVA 
Compressed air connection 6 bar (87 psi)
Air usage 22 m³/h (777 ft³/h)
* Piece output is dependent on wire length and housing/terminal combinations. 
** Dependent on wire harness structure.
*** Certain extremely hard, tough wires may not be able to be processed, even if they are within the indicated cross-sectional area. If in doubt, we are happy to provide you with samples of your wires.
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
Double crimping Double crimping different wire
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
Inkjet marking Inkjet Zeta
Block loading / Wire harness production Block loading double sided
Sequence processing Sequence Zeta