Zeta 620

Zeta 620

Harness Manufacturing

  • Zeta 620

    Zeta 620

  • The bundler sorts the batches and fixes the matching wires with adhesive tape in one process step.

    The bundler sorts the batches and fixes the matching wires with adhesive tape in one process step.

  • The Zeta 620 offers space for two process modules.

    The Zeta 620 offers space for two process modules.

  • The optional inkjet markers are integrated into the chassis by means of a drawer.

    The optional inkjet markers are integrated into the chassis by means of a drawer.

  • Zeta 620 Wire samples

    Zeta 620 Wire samples

Zeta 620

Cost-efficient automation process

  • Enormous time savings of up to 50% due to higher efficiency and accuracy
  • Significant simplification in production 
  • Continuous data flow from ECAD or DLW to the machine
  • Cost-efficient just-in-time production for batches of any size
  • Optimal wire depositing

High productivity

  • Complex jobs are completed quickly and without great effort
  • Batch or sequence production without changeovers
  • Automatic wire changer with up to 24 different wires
  • Automated marking of the wire by inkjet and tube marking
  • Processing of five different ferrules with the CM F20 module

Reliable processing with the highest quality

  • Sequential processing of single-conductor wires in the cross-section range 0.5 – 6 mm²
  • Consistently high quality thanks to fully automatic production

Attractive entry-level model with low space requirement

  • Compact dimensions 2150 × 1545 mm 
  • Fits in any room
  • Up to two inkjet markers can be optionally integrated

The compact, fully automatic Zeta 620 wire processing machine produces entire parts lists and stores wires sorted and labeled, all in the tightest of spaces. Tried and tested Zeta technology and attractive module options simplify production considerably and ensure noticeable time and cost savings. Take advantage of this low-cost entry point into automation and secure a significant competitive advantage, both now and in the future.

Time savings of up to 50%

Manual processes cost time. The Zeta 620 reduces manual work to a minimum. It automatically assembles all wires required and prepares them fully equipped in the correct sequence and length – including labeling and terminals. The wires then only have to be laid at the control cabinet. Manual processes such as cutting to length, stripping, labeling and inserting sleeves are eliminated. 

Continuous data flow from ECAD to the machine

Production data can be sent directly to the machine from specific ECAD systems via the Komax WPCS interface. Exporting data from ECAD systems to a cutting list is also possible. This is converted into readable data and inputed, eliminating the need to manually program articles on the machine. This is highly efficient for any batch size – even a batch size of one.

Consistently high quality thanks to automation

Fully automatic production guarantees reproducible, consistent quality. Automated data transfer eliminates sources of error, as no manual input is required at the machine.

 

Wire bundles simplify subsequent wiring in the control cabinet

Depending on the job, wires can be produced, sorted and bundled in an ideal sequence, in one process step. The wire bundles make it quicker and easier to lay wires in the control cabinet. Batches can be taken out in advance while production is running. The binder type is freely defined for each wire, independent of the production mode (batch or sequence production).

Reliable sequential processing 

The special cutting head with three pairs of blades allows cross-sections from 0.5 to 6 mm² to be processed perfectly in sequence. High-quality, durable blades and components allow high processing speeds, which shortens throughput times accordingly.

Required materials available at any time 

Versatile control cabinet construction requires many different materials, such as wire types and ferrules. These are available on the Zeta 620 without the need for changeovers. The automatic wire changer contains up to 24 different wires from the entire cross-­section range. The automated marking system labels the wires optimally and the ferrule module then fits them with up to five different ferrules.

Wires equipped easily with five different ferrules

The CM F20 is an attractive, flexible solution for control cabinet construction. Five different taped ferrules with cross-sections of 0.5 – 2.5 mm² and crimp lengths of 8 or 10 mm can be processed quickly and easily in sequence. Special ferrules (Multinorm, AWG) are also not a problem. The ferrule rollers are inserted without tools or component changeovers. The touch display is intuitively designed. A two-stage process ensures reliable processing. Automatic cable centering adjusts to the cross-­section. The CM F20 is a high-performance ferrule module that is easily integrated into a fully automatic Komax machine such as the Zeta 620.

DLW – the simple alternative

For automation of the control cabinet construction process, an important requirement is to collect the production data, including the wire length. DLW (digital lean wiring) software developed by Komax offers the ideal solution for this with its clear focus on simplicity and flexibility.

Virtual wiring

On the basis of a photo or a 2D drawing, technicians can complete the wiring virtually on a screen using DLW. This is a highly efficient method of determining the wire lengths per connection. The production data is then converted and loaded onto the wire processing machine, which produces the wires ready for installation.

 

Technical data Zeta 620

Outer wire diameter Max. 6 mm (0.24 in)
Wire cross-sections 0.5 – 6 mm² (AWG 20–10)
Wire length tolerance

±0.5% + 2 mm (0.079 in)

Wire length range for double-sided
processing

240 mm to 4 m (9.44 in to 13.1 ft)

Wire length range for one-sided
processing

60 mm to 4 m (2.36 in to 13.1 ft)
Wire changer

Maximum 24

Strip length

Up to 25 mm (0.98 in)

Number of stations

2

Piece output, AEH – AEH

360 pcs/h

Piece output, stripped on both sides

700 pcs/h

Weight Approx. 700 kg

Module combinations

Station 1 Station 2

CM F20

CM F20
AEH-LS
CM 1/5

AEH-LS

CM F20
AEH-LS
CM 1/5

M1650 Tube

M1650 Tube
CM F20
AEH-LS
CM 1/5
CM04 Duo CM F20

Technical data CM F20

Cross-section range

0.5 – 2.5 mm² (AWG 20–14)

Ferrules Z+F ferrules on rolls,
0.5 – 2.5 mm² (AWG 20–14)
Type: N,HL (standard) / S-N,S-HL (Multinorm, AWG)

Ferrule length

8 mm or 10 mm

Crimp form

Trapezoid crimp form

Operating pressure

5 – 6 bar

Dimensions (W×D×H)

205 × 397 × 491 mm without castors
283 × 460 × 635 mm with castors
Weight

26.5 kg


Cutting Cutting
Cutting pulled strands Cut pulled strands
Full stripping Full strip both sides
Half stripping Half strip both sides
Ferrule crimping Ferrule crimping
Wire end solidifying, splicing, welding Wire end solidifying
Inkjet marking Inkjet Zeta
Tube marking Tube marking
Sequence processing Sequence Zeta