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Zeta 656 – Block loading
Introduction
Producing wire harnesses reliably with high process stability. The Zeta 656 performs
this task with speed and precision. This block loader is also compelling for its great flexibility and
short changeover times.
Key features:
- Fully automatic harness production even when miniature components are involved
- Seamless quality monitoring of all process steps
- Fully automatic post-production
- Manufacture of different kinds of harnesses on a single machine
- High availability thanks to minimal work involved with changeover
Function
The Zeta 656 is designed for double sided block loading. Teamed up with the Zeta
633 basic machine, it creates a standardized total solution for the automatic production of wire harnesses.
Mini-components
With its ultra-precise insertion technology, the Zeta 656 can process wire cross
sections of 0.13mm² (AWG26) and multi-row housings featuring a grid element spacing of 1.25mm (0.049in)
without any trouble.
Manual insertion of these miniaturized components is difficult and prone to error.
Technology
The housings are mounted on a pallet system to permit very flexible production of
the widest range of harness configurations. It is easy to implement any changes in the wire harness
or to set up completely new harnesses.
Precise movement axes powered with a spindle drive allow highly dynamic and fast
insertion processes.
From preinsertion and actual insertion to final insertion and interlock testing,
the complete insertion process is monitored by the integrated precise force sensor so top quality is
guaranteed.
User friendly
The pallets are loaded and unloaded with the machine running while the machine is
producing a harness on the other pallet. A safety light curtain protects the user from the hazardous
area during this work. Operations can be expanded to a third pallet to increase machine autonomy to
an even greater extent.
The «post production» option is used to replace incorrectly crimped conductors and
fit them with components automatically. No operator intervention is required.
Applications
| Cutting |  |
|---|---|
| Cut pulled strands / Precision cut |  |
| Full strip |  |
| Half strip |  |
| Double sheath cables |  |
| Crimping |  |
| Ink-Jet marking |  |
| Sequence |  |
| Double crimping |  |
| Split cycle |  |
| Seal insertion |  |
| Twisting / Tinning |  |
| Sleeve insertion |  |
| Ferrule crimping |  |
| MIL-Crimping |  |
| Wire end solidifying |  |
Technical data
| Piece number output* | One- and Two-ended loading1.5s per loading operation *Piece number output depends on wire length and block/terminal combinations. |
|---|---|
| Shortest wire length | With one-ended loading 85–110/240mm For jumper connections at both ends 280mm–440mm** For complex loading operations 280mm–640mm** **Depends on wire harness structure |
| Cable cross sections*** | 0.13mm2–2.5mm2 / 4mm2 (AWG26–AWG13/AWG11) |
| Outside diameter of cable | Maximum of 4mm |
| Wire end storage unit | Rotary storage unit with a maximum of 30 storage slots |
| Process monitoring (integrated) | Collision monitoring (block cavities) Monitoring of loading force Monitoring of terminal interlocking |
| Block feed | Carousel with pallets Customerspecific solution on request |
| Pallet system | Loading field (WxHxD)164x200x120mm |
| Connection electrical/ pneumatic |
Directly from Zeta 633
|
***Wires
outside the indicated cross section range can also be processed on the Zeta. In case of doubt, we are
happy to produce samples of your wires for you.
Software
The software add-on for the Zeta 656 block loader covers the automatically calculated
insertion sequence and helps to simplify the setup of new wires. The software calculates the management
of individual holder grippers in the rotary storage unit for «chaotic» harnesses.
TopWin .
Опциональная система работы в составе сети WPCS (Wire Processing Communication Standard - Система Связи в Обработке провода) позволяет Komax линиям соединится в производственную сеть под управлением TopWin. Это открытый интерфейс, который позволяет произвести легкую интеграцию на производство.
TopNet это система управления данными, раздачи заданий на линии и получения обратной связи от них, позволяя произвести оптимизацию производства, увеличив тем самым производительность участка в целом.
TopConvert позволяет конвертировать (преобразовать) Ваши существующие данные о заданих, артикулах и прочих, в формат WPCS. Данные после преобразования доступны для прямой передачи в автоматические линии.
Accessories/options
The Zeta 656 can be tailored to a customer‘s specific requirements by adding various
types of accessories, e.g. block closing, secondary interlocking, etc.
We are happy to send you a quotation for your specific request.
Services
Komax предлагает оптимальную последующую поддержку оборудования Service offers.
