Heavy Duty Cable Strip Cut Machine – The Best Places to Look for Wire Control Hardware Dealers to Be Able to Minimize Manufacturing Costs.

Semiautomatic benchtop stripping and terminal press machine really are a staple of every harness assembly shop. They’re just the thing for high-mix, low-volume wire processing applications. But, if you need to produce 1000s of identical crimped wires inside a shift, you want a fully automatic cutting, stripping and crimping system.

Fully automatic machines tend to be faster plus more consistent than semiautomatic equipment. They are able to combine multiple operations in one setup and automatically separate rejected leads.

Automatic equipment removes a persons element from high-volume wire processing applications, while improving quality and reducing costs. As an illustration, state-of-the-art automatic crimping machines can process wires at rates above 4,000 pieces each hour with absolute precision and then in-process inspections.

However, manual crimping is susceptible to variations by the operator, such as prematurely positioning a wire into a terminal before crimping, contributing to mistakes and low quality. Automatic machines eliminate this variation.

“Fully automatic machines need fewer operators to perform exactly the same tasks,” says Erich Moeri, manager of applications engineering at Komax Corp. “Therefore, these are more potent. Generally, you can expect to reduce floor area. There’s less equipment and you will eliminate some intermediate storage, like the need to store precut wires.

“Fully automatic machines will also give a better quality product, as a result of integrated quality checks,” adds Moeri. “In addition, they supply a far higher output.”

“Wire harness shops is capable of doing more utilizing the same level of human resources,” notes Rich Schwartz, vice president of engineering at Schaefer Megomat USA Inc. “Fully automatic machines also allow shops to visit after more and larger jobs. In some instances, a unit could pay money for itself in a year.”

That’s important, because going from semi- to completely automatic equipment requires a big investment. While semiautomatic wire processing equipment can run $15,000 to $30,000, fully automated machines average $50,000 to $75,000. Engineers must avoid falling inside the trap between machine capability and actual use on the plant floor.

Since today’s machines are engineered with quick change-overs in mind, most professionals believe there exists a location for fully automatic equipment in high-mix, low-volume wire processing applications.

As an example, Komax offers a machine particularly for that. “The Zeta 633 crimping machine includes a wire sequencer option where you can have 36 different wires ready with the heavy duty cable strip cut machine always,” Moeri highlights. “Changing wire is done by the click of your mouse.”

Engineers at many equipment suppliers have designed numerous quick-change features inside their machines to significantly lower set-up time. Artos Engineering Co. recently unveiled the Cr.22, that may tackle a wide range of applications, like weather sealing, crimping, twisting and tinning. Even though the machine are designed for low-volume runs requiring multiple change outs during production, furthermore, it can accommodate high-volume runs.

“Diversity in production is very important,” says John Olsen, president of Artos Engineering. “Today, customers want options and adaptability.

“The answer to justifying an investment inside an automatic system is to hold the equipment producing parts as efficiently as possible with minimal downtime,” explains Olsen. “Older automatic machines might take up to twenty or so minutes to put together and change from a job to another.

“This was acceptable when the machine could process a huge number of wire at one time and run for a long time in the initial set-up,” adds Olsen. “However, if a customer wish to manage a few hundred pieces and alter to another one job, that volume of change-with time negates productivity.”

With quick-change carts, sensors that track wire core size, and all sorts of servo-driven technology, fully automatic machines could be set up in a matter of seconds vs. minutes. Most new-generation machines also provide built in quality checking features, that is vital for wire harness shops doing automotive-related applications.

“These varieties of customers are looking for machines offering the best number of fully integrated quality checks,” says Moeri. “We offer equipment where operators start with downloading ‘jobs’ from an enterprise resource planning system and view material with the machine using a bar code scanner for process verification.

“Product quality concerns might be addressed by automatic crimp height measurements, crimp height adjustments, pull-force monitors and seal position analyzers,” Moeri points out. “Afterwards, they may seek out feedback about the product manufactured by automatically uploading critical information straight back to the ERP system. That addresses traceability issues.”

User-friendly controls and software make everything that possible. As an example, Schleuniger Inc.’s new CrimpCenter 36 S boasts efficient motor programming and internal Ethernet communication along with a maximum feed rate of 8 meters per second. Additionally, it features a touch-screen monitor and intuitive operating software.

“The combination makes programming not so difficult to ensure even novice operators quickly feel at ease,” says Gustavo Garcia-Cota, crimping product manager. “Standard TCP/IP protocol allows for easy machine networking. The optional EASY ProductionServer software helps optimize order processing and allows engineers to check and gather valuable production data from practically around the globe.”

As wire gets smaller and smaller, it will become harder to take care of. Which will undoubtedly spur more investment in fully automatic equipment that can easily grip thin wire.

“Machines equipped with powerful servo motors and optimized programming in the process axes look after precise and fast motion sequences,” says Schwartz.

His company recently unveiled copper wire stripper that that will process wire as small as .08 millimeter squared.

“The Megomat 1000 comes with an unusually large variety of wire cross sections that could be processed,” claims Schwartz. “It are designed for approximately AWG 8 wire. And, the arrangement in the cutting blades dexjpky35 for very short wire overhangs.”

An application-controlled, adjustable wire guide system eliminates the usage of tubes in the gripper. The programmable gripper jaw openings are automatically adjusted. “A large, two-side enabled swing radius of both gripper arms provides flexibility in realizing different applications,” says Schwartz.

However, regardless of how much they embrace fully automatic equipment, most wire harness shops must keep a few manual and semiautomatic machines accessible. Applications involving cables, large-gauge wire, twisted-pair leads and shielded wires still demand a few of these tools.