Alpha 355 – fully automatic crimping machine
Introduction
Short setup and changeover times, integrated quality measurements, and top performance
are the three main features of the Alpha 355 fully automatic crimping machines.
Key features:
- Short changeover times
- Reliable process monitoring
- High production output
- Setup of next job while production of current job is underway
Function
The Komax Alpha 355 is designed for one and two-sided crimping and seal loading.
It even handles double-crimp connections involving varying lengths and the same wire types without
any problem.
The ultra-precise dual-channel blade system allows for a large range of wire sizes
without blade changes.
Fast changeovers
In most machines, changeover times offer the biggest potential for optimization.
With options like the manual wire selector and/or the quick-change system for crimping tools, materials
and tools can be prepared for the next job while the machine is running.
Jobs can also be recorded and edited with TopWin while the machine is running. The
changeover time is displayed, providing an easy method for optimizing the workflow.
Maximum quality control
Crimp-height measurement and fully automatic pull-out force measurement are integrated
in the process sequence. Optional material-change detection and the optional barcode scanner help to
prevent materials from getting mixed up.
The processes are constantly checked against the specified values during production
with functions that monitor crimp force, seals, splices, end of wire supply, and length. Any cables
with processing defects are removed and an appropriate number of cables are post-processed automatically
to replace them.
User friendly
The drive unit for the blade head is placed underneath, giving the machine a neat
and ergonomic layout. All processing stations have safety covers that open vertically for optimum access,
and application-specific parts like applicators and contact rolls can be changed without tools. Controls
are placed at decentralized positions, allowing the necessary machine functions to be triggered during
setup. All setting and adjustment procedures can be controlled from the TopWin graphical user interface
in the operator’s choice of over 20 different languages.
Applications
| Cutting |  |
|---|---|
| Cut pulled strands / Precision cut |  |
| Full strip |  |
| Half strip |  |
| Double sheath cables |  |
| Intermediate strip |  |
| Crimping |  |
| Hot stamp marking |  |
| Ink-Jet marking |  |
| Sequence |  |
| Double crimping |  |
| Split cycle |  |
| Seal insertion |  |
Technical data
| Length range | 60mm–65000mm(2.36in.–213ft.) Optionally from 30mm(1.18in.) |
|---|---|
| Length accuracy (Repeat) | ±(0.2%+1.0mm (0.04in.)) |
| Stripping lengths | 0.1–35mm (0.004–1.38in.) |
| Stripping lengths with partial strip | Beginning of wire 35mm ±1mm (1.38in. ±0.04in.) End of wire 35mm ±1mm (1.38in. ±0.04in.) |
| Wire cross section* | 0.22mm2–6.0mm2 (AWG24–AWG10) Optionally from 0.13mm2 (AWG26) |
| Wire draw-in speed | max. 12m/s (39ft/s) |
| Noise level | <75dB (without crimp module) |
| Electrical connection | 3×208–480V 50/60Hz, 5kVA |
| Pneumatic connection | 5–8bar (73–116psi) |
| Air consumption | 9m3/h (318ft3/h) |
| Weight | 1300kg (2866lb) including two crimp and seal modules |
*extremely
hard, tough wires may not be able to be processed even if they are within the indicated cross section
range. In case of doubt, we are happy to produce samples of your wires.
Software
TopWin .
The optional interface WPCS (Wire Processing Communication Stand-ard) allows Komax machines to be networked under TopWin. With this open interface, the machine is easy to integrate into existing production sequences.
TopNet is a clearly arranged mana-gement software with functions for the centralized creation and management of parts, articles and jobs that help you to optimize your production operations.
TopConvert can be used to convert already existing job and article lists to WPCS format. This data can then be directly processed by fully automatic crimping machines.
Processing modules
The Alpha 355 can be customized with various accessories to meet specific customer
needs.
Accessories/options
The Alpha 355 can be customized with various accessories to meet specific
customer needs.
Preliminary processing of wires
- Variety of wire feed systems
- Inkjet marking
- Straightening unit, standard/manual wire selector
Measuring
devices
- Integrated crimp height measurement
- Integrated pull-out force measurement
- Fully automatic pull-out force measurement
Wire
deposition
- Basic module, 2m or 4m
- Extension module, 2m or 4m
Crimping module
accessories
- Quick-change system for tools
- Terminal feed with paper take-up unit
- Contact strip chopper (chopper)
- Process monitoring
- Crimp force monitoring
- Seal monitoring
- Spark tester
- Splice detection
- Wire-end detection
Other accessories
- Automatic guide tube changer
- Double gripper module
- Material change detection
- Barcode scanner
- Set for small cross sections
- Set for halogen-free conductors
- Touch screen control
Services
Komax offer to you an optimal support by individual Service offers.
- Introduction
- Function
- Applications
- Technical data
- Software
- Processing modules
- Accessories/options
- Services