THE WAY TO MAKE IT

Alpha 488 – Economical processing of twisted pairs

Introduction

Drawing on continuous stock, the Alpha 488 fully automatic twister produces twisted pairs completely cut to length and terminated with all quality controls included. The modular design of the system ensures maximum flexibility. Four processing stations at the lead termination and two at the trailing end open up an array of processing possibilities.
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Key features:

  • Complete processing of continuous stock into twisted pairs with processed ends
  • Gentle handling of base stock to ensure high-quality end products.
  • Also possible to process different open ends up to 125mm in length on side 1 (as an option)
  • Usable as well for two-end crimping and seal loading on two identical single wires
  • High degree of flexibility and reduction of conversion times thanks to the mci 722 und mci 712
  • Integrated quality monitoring (DLA, TFA, SPM, CFA/CFA+, etc.), also during twisting (TFA)
  • Active good/bad sorting
  • Accommodates up to six processing stations
  • Great ease of operation thanks to TopWin software
  • Networking possibilities with reliable WPCS and KomaxCAO

Function

This machine’s high output of twisted pairs results from the parallel processing of the two conductors and a division of overall processing into three main processes, all optimally synchronized with each other. The linear wire draw-in unit with integrated delta length analyzer (DLA) assures the gentle handling of the wires. The twisting head with AC servo-drive is the heart of the Alpha 488. The integrated twist force analyzer (TFA) guarantees uniform twisting by analyzing the forces exerted during twisting and regulating the subsequent adjustment movements of the twisting head.

Maximum flexibility

Drawing on continuous stock, the Alpha 488 fully automatic twister produces twisted pairs completely cut to length and terminated. It can handle wire cross sections ranging from 2×0.22mm2 (AWG24), optional from 2×0.13mm2 (AWG26) to 2×2.5mm2 (AWG14) with no trouble at all. Four stations on side 1 and two stations on side 2 open up flexible processing possibilities such as two-ended seals loading and crimping. Of course, the Alpha 488 is also ideal for the processing of individual conductors.

User friendly

The system is extremely user friendly. Its stations swivel in a radius of 400mm, making them readily accessible to the operator. Elements like a wire deposit tray with integrated batch sorting and post-production of defective wires are part of the standard equipment. The TopWin user interface and the sliding operator’s console along the pull-out unit further increase the convenience of this system. In combination with the Komax mci 722 or the mci 712 crimping modules and the mci 765 C seals module plus the quick-change systems and the integrated monitoring units, the Alpha 488 offers maximum process reliability and ultra-short conversion times. Its modular design assures unbeatable flexibility.

Applications

Cutting
Cut pulled strands / Precision cut
Full strip
Half strip
Twisted pair
Crimping
Hot stamp marking
Ink-Jet marking
Split cycle
Seal insertion

Technical data

Length range
700mm–4000mm (27.6in–157.5in)
700mm–7000mm (27.6in–275.6in)
700mm–10000mm (27.6in–393.7in)
Optional from 150mm (5.9in)
Final length of twisted pairs
Length accuracy ±0.3% (min. ±1.5mm)
Stripping lengths Side 1: 0.1–18mm / Seite 2: 0.1–35mm
Wire cross sections* 2×0.22mm2–2×2.5mm2 (AWG24–AWG14), optional from 2×0.13mm2 (AWG26)
Open wire ends 30–99mm (optionally. 30–125mm on side 1), depends on pitch, cross section, and end processing
Pitch length Programmable from 5mm to 80mm
Wire draw-in speed max. 5m/s
Noise level <75dB
Electrical connection 3×208–480V/50–60Hz; 10kVA
Pneumatic connection 5-6bar
Air consumption 12m3/h
Weight
Including two crimping modules and two seals modules
Alpha 488 / 4m: approx. 3000kg
Alpha 488 / 7m: approx. 3700kg
Alpha 488 / 10m: approx. 4400kg
* Certain 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

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 488 can be customized with various modules to meet specific customer needs:

Accessories/options

There are a number of different accessories available with which you can adapt the Komax Alpha 488 to your own specific needs and expand its capabilities as desired.

Preliminary wire processing

  • Ink jet marker
  • Hot stamp marker
  • Wire feed systems

Crimping module accessories

  • Paper winder
  • Carrier strip chopper
  • Valve set for pneumatically operated advance
  • Pressure regulation set
  • Monitoring of length-wise and cross-wise transport of terminals

Process monitoring

  • Twist force analyzer (TFA)
  • Delta length analyzer (DLA)
  • Crimp force analyzer (CFA/CFA+)
  • Seal position analyzer (SPM)
  • Splice detection
  • Quality assurance Komax 331, 341, 371, Generic Barcodescanner

Deposit systems

  • Deposit cells 4m, 7m or 10m

Further accessories

  • Short lengths (starting from 150mm)
  • Different open ends up to 125mm in length on side 1
  • Tower light
  • Wire measurement band
  • Magnifying glass
  • Keypad
  • Uninterruptible power supply (USV)
  • Set for small gauges
  • Set for non-halogen wires
  • Air-conditioner
 

For more information please contact:

Komax Germany
Tel. +49 / 911 32 49 50
mailto: Info Komax Deutschland
 

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