Komax AG: THONAUER GmbH

Iota 330

Cutting machine

The Iota 330 is the all-rounder of cutting machines. It cuts through pipes reliably and with ease (belt drive), as well as plastic straps, pneumatic hoses, shrink tubing, ribbon cables and much more. The belt drive ensures that the material is handled with care.
Where high production volumes are required, up to four tracks can be operated in parallel.

Technical data

Length range	1–1,00,000 mm
Length accuracy	+/- (1 mm + 0,2 % x L)
Maximum admission height	16–25 mm in the center of the belt drive
Maximum admission width	82 mm

Mira 230

Stripping machine

The programmable Mira 230 by Komax is the answer to today’s demands in wire processing with a large mix of products. The machine meets the high demands with an extraordinary range of applications, easy handling and boosted productivity. Thanks to special functions and its article library, it achieves reproducible top quality. It is first choice for multi-conductor processing owing to its suitability for sequence processing.

Technical data

Line cross-section (stripping)	0.03–8 mm², AWG 32–8 ¹)
Max. external diameter	6.5 mm
Stripping length	1.5–46 mm
Stripping length with cutting	46 mm - cutting length
Cutting length	46 mm - stripping length
Pull-off length	0.01–46 mm

¹) In the case of lines and conductor diameters of over AWG 10 that are difficult to process, we recommend sampling prior to purchase

Cosmic 32M / 32M CDD

Electrical stripping machines

They process single conductors and inner conductors of multi-core cables. The portable machines are easy to operate and have extremely short cycle times.

The Cosmic 32M CDD satisfies the ever tougher quality requirements in wire processing. Your integrated conductor damage detector is unique in this price category.

Technical data

	32M	32M CDD
Wire range	0.03–3.3 mm² (AWG 32–12)
Stripping length	1–25 mm
Features	--	Integrated conductor damage detector

Cosmic 42R / 48R / 48RX

Stripping machines for coaxial and semi-flexible cables

Highly precise processing of multi-layer cables. The Cosmic 48R processes coaxial, triaxial and other multi-layered cables in up to 9 steps. The Cosmic 48RX is optimised for the stripping of semi-flexible coaxial cables. All have a twisting function.

Technical data

	42R	48R	48RX
Application	Micro coaxial wire	Coaxial-, triaxial and other multilayer cables	Semi-flexible coaxial cables
Conductor cross section	0.005–1.5 mm²	0.013–13 mm² (AWG 36–6)
Resolution diameter	0.01 mm
Maximum pull-off length	40 mm

Cosmic 927R / 927RX / 60R-L

Stripping machines for processing demanding conductors

The rotating blade heads of the Cosmic 927 series provide the perfect solution for processing demanding insulation.

Technical data

	927R	927RX	60R-L
Applications	High variety of conductors	Thin, strong sticking isolations (eg Teflon)	For high stripping length
Wire outside diameter	0.25–5.3 mm	0.25–5.3 mm	2.5–10 mm
Stripping length	1–25 mm	1.5–25 mm	3–200 mm
Twisting function	Available	Available	--

Kappa 310 / 315 / 320

Cutting and stripping machine

Power, performance and a new type of sensors are the three key features of the fully automatic Kappa cutting and stripping machines. Interfaces to pre-feeders and inkjet printers are integrated. Easy to use touch screen.

Technical data

	Kappa 310	Kappa 315	Kappa 320
Wire cross section	0.02–6 mm²	0.05–10 mm²	0.05–10 mm²
Max. stripping length: Full strip Partial stripping	100 mm, 999.9 mm
Cable transport speed	4 m/sec.	2 m/sec.	4 m/sec.
Transport system	Single rolls

Kappa 322 / 330 / 350

Cutting and stripping machine

Powerful cutting and stripping machines for bigger cross sections. High processing speed guaranties short production cycles. The Kappa 322 offers the simultaneous stripping of multi stranded wire (e.g. power cables). Gentle belt drive transport of wire. Interfaces to printer, pre-feeder and deposit systems.

Technical data

	Kappa 322	Kappa 330	Kappa 350
Wire cross section	0.05–16 mm²	0.22–35 mm²	2.5–120 mm²
Max. stripping length: Full stripping, Partial stripping	100 mm 999 mm	180 mm 999 mm	290 mm 999 mm
Cable transport speed	4 m/sec.		4.8 m/sec.
Transport system	Dual rolls or belt drive

Kappa 331

Powerful cut and strip machine with rotating knife unit

Round, multilayered cables, with and without shielding, are precisely stripped in multiple steps. The machine can be changed over quickly, making it ideal for flexible use.

Technical data

Conductor cross section	0.22–35 mm²
Max. outside diameter	16 mm
Length range	1–800,000 mm
Versions	Universal machine with swivel guide, Universal/coax-machine with split guides

bt 712

Bench top crimping press

The semi-automatic bt 712 bench top model is compelling for its modern technology and sets new standards in quality and speed.

This all-purpose press accommodates the use of all common commercial crimping tools. The crimp force analyser, in combination with the bad part cutter, offers highest possible production quality.

Technical data

Crimping force	20 kN
Wire cross section	up to 6 mm²
Programmable crimp height	+5/-3 mm
Features	easy to use, crimp force analyser

bt 722

Bench top crimping press

This bench top press is outstanding in terms of short cycle times, short changeover and setup times, programmable crimp height and the user-friendly TopTouch interface. These features, combined with the optional programmable stripper and bad part cutter, ensure top quality finished conductors regardless of the machine operator.

Technical data

Crimp force	20 kN
Wire cross section	up to 6 mm²
Programmable crimp height	+0.2/-0.8 mm
Features	Integrated crimp force analyser, sequence processing

bt 752

Bench top crimping press

The Komax bt 752 delivers three processes in a single device: stripping, seal loading and crimping. Reliability and top production performance, e.g. short installation and setup times, coupled with the user-friendly TopTouch interface are the features that make this semi-automatic device such a compelling product.

Technical data

Crimp force	20 kN
Wire cross section	up to 6 mm²
Programmable crimp height	+0.2/-0.8 mm
Features	Seal loading

MIKO

Networking of bench-top presses

MIKO (Manufacturing Interface Komax) is the name of the new data interface for bench-top machines bt 712, 722 as well as 752. With MIKO, you can integrate bench-top machines seamlessly into the production process, greatly improving product quality and production efficiency.

Gamma 255

Fully automatic crimping machine

The Gamma 255 is specially designed to crimp small cross section and short cable lengths. No matter what the task, from double side crimping to twisting, fluxing and tinning, the Gamma 255 carries it out with compelling process control and minimal changeover times. In spite of its compactness, this device has fully integrated quality-monitoring and feed systems as part of its standard equipment.

Technical Data

Wire cross section	0.0123–2.5 mm² (AWG36–AWG14)
Length range	15–10,000 mm
Stripping lengths	0.1–15 mm

Gamma 263 S

Fully automatic crimping machine

Although compact in size, this fully automatic crimping machine combines simplicity and functionality with economy and process reliability to deliver a high piece output. It is a real hit when it comes to obtaining excellent value for money. Whether you opt for the roller or belt drive, you can adjust use of this device to your individual needs yourself in no time at all.

Technical Data

Wire cross section	0.13–2,5 mm² (4 mm² on request)
Length range	40–20,000 mm (1.75 in–65.6 ft)
Stripping lengths	0,1–20 mm (0,004–0,79 in)

Gamma 333 PC/B

Fully automatic crimping machine

This fully automatic crimping machine stands out from the rest for the high daily productivity it achieves through short changeover times and high availability. This thoroughly tried-and-tested machine is also available with a belt drive. That means optimum force transmission and increased output for long and difficult- to-process conductors. A supplementary unit that is ideal for a broad processing range.

Technical Data

Wire cross section	0.13–5 mm² (AWG26–AWG10)
Length range	60–65,000 mm (optional 30–65.000 mm)
Stripping lengths	0.1–15 mm (optional side 1–28 mm)

Alpha 355

Fully automatic crimping machine

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.

Technical Data

Wire cross section	0.13–6 mm²
Length range	60–65,000 mm
Stripping lengths	0.1–35 mm

Alpha 355 S / 356

Fully automatic crimping machine

Along with the most frequent standard processes of crimping and seal loading, you can obtain a large variety of processing modules such as: fitting with insulating sleeves, ferrules and ultrasonic or resistance welding modules.

Technical Data

	355 S	356
	up to 5 process modules	up to 7 process modules
Wire cross section	0.13–6 mm²
Length range	60–65,000 mm
Stripping lengths	0.1–35 mm

Alpha 433 H

Fully automatic crimping machine

The Alpha 433 models are unsurpassed in their flexibility. Seal loading on one or both wire ends, various terminals and double crimp connections of different lengths, and the same wires can be processed without difficulty.

Technical Data

Wire cross section	0.2–16 mm² (AWG24–AWG5)
Length range	60–65,000 mm
Stripping lengths	0.15–18 mm

Alpha 477

Fully automatic crimping machine

The Alpha 477 fully automatic double crimping machine allows you to process two different wires simultaneously to produce your choice of double crimp or single wires. With four processing stations at the lead termination and two at the trailing end, you have a large number of possible processes at your command.

Technical Data

Wire cross section	0.22–4 mm² (AWG24–AWG12), Optional from 0.13 mm² (AWG26), Double crimp (cable A+B) <6 mm²
Length range	60–80,000 mm (optional 35–80,000 mm)
Stripping lengths	Both ends: 0.1–35 mm

Alpha 530

Fully automatic crimping machine

The Robust All-rounder

The Alpha 530 is a fully automatic crimping machine for one and two-sided crimping and seal loading. The machine is optimized for fast setup and conversion times, thus increasing your productivity. Crimp force monitoring CFA+ is standard. QC options, such as automatic conductor detection (ACD) and strip quality check (SQC), can be retrofitted and satisfy the highest quality requirements.

Technical Data

Wire cross sections	0.13–4 mm² (optional 5 mm²)
Wire draw-in speed	max. 9 m/s
Crimp force	1–22 kN

Alpha 550

Fully automatic crimping machine

The Alpha 550, the newest latest fully automatic crimping machine for two-sided crimping and seal loading, fulfils your requirements towards for productivity, flexibility, and quality.

At Features high speed for top maximum unit cost performance
Ultra-fast conversion for maximum productivity
First-time-right setup approach for almost no rejects
Robust system and versatile options
Quality control at its best

Technical Data

Wire cross sections	0.13–6 mm² (AWG26–12)
Wire draw-in speed	up to 12 m/s
Crimp force	1–22 kN

bt 188 T / bt 288

Semi-automatic twisting machines

Twisting two, three or even four wires is so easy with the bt 188 T. With the precise multi-conductor twisting option, three or four conductors can be twisted perfectly with no pitch errors. As with twisted pairs, the result is a uniform pitch length with high reproducibility over the entire twisted length of the cable.

Technical Data

	bt 188 T	bt 288
Wire cross section	2 × 0.08 to 2 × 4 mm² (Optional: 3 or 4 wires)
Pitch length	8–50 mm
Twisted length	from 300 mm to 12 metres in 3-metre steps
Twisting lines per machine	1	2

Zeta 630

Harness Manufacturing Zeta

The Zeta 630 makes switchboard construction efficient and just in time. Thanks to the economical automation process, cable assembly is highly productive, starting with batch size 1. Automated processes and lot or sequential production without retooling shorten production times by up to 50 percent. The automatic wire changer provides up to 36 different lines, and the CM 1/5 GS module processes up to five different wire end ferrules. The reliable, fully automated production ensures consistent high quality.

Technical Data

Line cross-sections	0.22–6 mm² (AWG 24–AWG 10)
Wire changer	max. 36 wires (in steps of 6 wires)
Lengths with double-sided processing	240–3,000 mm standard trough 240–5,000 mm optional
Lengths with one-sided processing	85–3,000 mm standard trough 85–5,000 mm optional
Number of stations	2

Alpha 488 S

Fully automatic twisting machine

Alpha 488 S produces twisted pairs fully automatically out of two single bulk wires completely cut to length and terminated, with all quality controls included.

Technical Data

Wire cross section	2 × 0.22 to 2 × 2.5 mm² (Optional: from 0.13 mm²)
Pitch length	5–80 mm
Twisted length	700–10,000 mm

Zeta 633 / 633 L

Fully automatic crimping machine

Zeta 633 is a highly flexible fully automatic crimping machine used for just-in-time production. With its flexible machine concept, the Zeta 633 opens up an almost unlimited number of possibilities for handling small jobs and wire sequences. Up to 36 conductors are available for wire feed without changeover. Wire transport can be adapted to the specific properties of each conductor. Modules can be configured as desired along the entire length of the Zeta 633. That means total flexibility for each area of application. The wires can be bundled or deposited in predefined order as a chain.

Technical Data

	Zeta 633	Zeta 633 L
Wire cross section	0.13–6 mm² (Optional up to 10 mm²)
Stations	5	8
Length range	240–3.000 mm standard, 85–10,000 mm optional
Wire selector	36 wires

Zeta 651 / 656

Fully automatic crimping machine, block loading

The Zeta 656 produces wire harnesses reliably with high process stability. It performs this task with speed and precision. This block loader offers a convincing combination of great flexibility and short changeover times. Together, the Zeta 633 and Zeta 651 provide a reliable and attractively priced complete solution for the single-sided loading of single and double row blocks. Single-sided loading has never been so economical.

Technical Data

	Zeta 651	Zeta 656
Wire cross section	0.13–2.5 mm²/4 mm²
Outside cable diameter	4 mm
Block feed	Automatic, only one side	Carousel with pallets, both sides
Wire selector	36 wires

ads 112

Wire pull machine

The ads 112 wire pull machine is the perfect choice for the optimum feeding of wires from reels, Conipacks or drums. Wire is transported by two synchronous toothed belts. Wires ranging from fine to coarse are fed powerfully yet gently to the processing stations, as are non-round wires. Changeovers are quick and easy.

Technical Data

Wire cross section	up to 28 mm
Width of flat cable	max. 28 mm
Weight of wire reel	max. 100 kg

ads 115

Wire delivery system

The Komax ads 115 is a wire feed system that can be used very flexibly with Komax automatic cutting and stripping machines. You can easily change the position of the linear storage unit to put it in the ideal spot for every application. Reels up to 400 mm in diameter, loose rings and ribbon cable can be used on the de-reeling stand. The quick clamping system allows the various reels to be changed quickly.

Technical Data

Reels	Dia. 600 mm x width 250 mm x core dia. 14–95 mm
Wire cross section	max. 4 mm²
Weight holding capacity	max. 20 kg

ads 119 / ads 123

Wire delivery system

The reel-clamping system is combined with a simple lifting mechanism that allows you to change heavy wire reels effortlessly. Convenient setup functions like slow advance and reverse travel make rapid reel changes even easier. The powerful motor operates extremely quietly and smoothly.

Technical Data

ads 119

ads 123

Wire reel:

Max. diameter
Max. width
Max. weight

600 mm
500 mm
100 kg

1000 mm
750 mm
600 kg

Wire:

Diameter
Wire cross-section

up to 15 mm
up to 35 mm²

up to 35 mm
up to 95 mm²

dps 375

Deposit system

The variable dps 375 wire deposit system has a mobile frame and active wire ejection for process-orientated use. This model comes with programmable batch size sorting, making it the perfect companion for an automatic Kappa cut-and-strip machine of the third generation. Wires up to 3.5 m in length are sorted and deposited.

Technical Data

Wire diameter	max. 35 mm
Wire length	approx. 150–3.500 mm
Conveyor belt	--

KA 3000 / KA 6000

Deposit systems

These wire deposit units are intended for depositing "over-length conductors“ neatly and extended to full length. The KA 3000 deposit unit is suitable for depositing wires up to about 3.000 mm in length; the KA 6000, for depositing wires up to about 6.200 mm in length. The maximum wire diameters for the two models are 18 mm and 35 mm, respectively. With the KA 3000-2 model, two separate batches can be deposited in separate trays.

Technical Data

	KA 3000	KA 6000
Conductor diameter	max. 18 mm	max. 35 mm
Conductor length	350–3.000 mm	350–6.200 mm
conveyor belt	active

KRI 800-T / dps 272

Coiler

The KRI 800-T wire coiler is designed for the efficient coiling of long conductors. After coiling, the guide posts automatically lower, and the safety cover opens to allow easy removal of the coiled wire. The KRI 800-T is particularly well suited to large-size conductors.

The Komax dps 272 coiler is the perfect choice for coiling over-length cables. With its dual-drum design and automatically sliding safety cover, processing is fast, reliable and safe.

Technical Data

	KRI 800-T	dps 272
Wire diameter	max. 35 mm	max. 15 mm
Wire length	min. 1.000 mm
Inside diameter of coil, Outside diameter of coil	250–600 mm, max. 750 mm	100–300 mm, max. 400 mm
Coil weight	max. 80 kg	max. 10 kg

dps 261

Binder

The Komax dps 261 binder binds wire coils quickly and gently. Its ease of operation and great reliability make this device an ideal supplement for all coilers. The knot created in binding is easy to undo. The Komax dps 261 binder is operated with a foot pedal. A high degree of safety and reliability are ensured by the needle slide clutch. The Komax dps 261 binder not only processes wires. It can also be used to bind other products.

Technical Data

	dps 261
Inside diameter of coil	min. 120 mm
Coil height/push-through height	max. 145 mm
RPM of turntable/speed	approx. 0.67 sec./cycle

ims 295 BC / BS / MC

Inkjet printer

The Komax ims 295 BC (Black Colour), ims 295 BS (Black Small) and ims 295 MC (Multi Colour) inkjet marking systems excel in their high marking speeds and in the simple and reliable way in which they process the wire. All IMS marking systems have two different interfaces, an RS232 and an Ethernet (TCP/IP). That means they can be operated with current as well as future Komax machines. They are particularly suitable in combination with automatic Kappa strippers and with the Alpha, Gamma and Zeta fully automatic crimping machines.

Technical Data

	ims 295 BC	ims 295 BS	ims 295 MC
Min. font height	1,3 mm	0,9 mm	1,3 mm
Inks	Non-/lightly pigmented	Non-pigmented	Highly pigmented
Maximum marking speed	8 m/s	9 m/s	8 m/s

MicroForce 70

Crimp Force Monitor

Missing strands and insulation inside the crimp are frequent reasons for defective contacting in modern wire harnesses. Every single crimp therefore has to be monitored to ensure proper functioning. MicroForce 70 enables gapless crimp force monitoring to be carried out easily and efficiently and meets the highest standards of quality and performance.

Technical data

Cross section range	0.35–6 mm² (AWG 22–AWG 10)
Dimensions L × W × H	146 × 46 × 106 mm

MicroForce 80

Crimp force monitoring

The MicroForce 80 is currently the best crimp force monitoring system on the market. It detects missing strands or insulation that has been caught in the crimp, and can be retrofitted to all crimp presses.
Its many features mean it offers incredible efficiency, high productivity and flexibility. For example, it has product libraries to reduce retooling times, measurement data are saved on an external USB drive, and there are sensitivity settings and the facility for sequence processing. The color touch display provides an image of crimp curves in order to better assess the crimp quality.

Technical data

Cross sectional area range	0.35–6 mm² (AWG 22–AWG 10)
Display	5.0 inch color display with touch functionality
Special features	Sensitivity setting, product memory, data interface, sequence processing, headroom adjustment, predefined access rights

MicroLab 10

Mobile micrograph laboratory

The MicroLab 10 enables micrographs to be taken quickly and easily regardless of the location. It covers all relevant processing steps – from cutting and polishing to etching and visualization. The compact carry-case design enables the quality of crimp and splice connections to be assessed with minimum effort and maximum effectiveness.

Technical data

Processing range	Ø 0.30–2.50 mm
Cross section range	up to 5.00 mm²

MicroLab 30

Micrograph laboratory

The MicroLab 30 micrograph laboratory offers a fast and flexible way to produce a micrograph. The wide cross section range lets you monitor most of your production. The fully automated process run results in a perfect micrograph without external influence.

Technical Data

Wire range diameter	dia. 0.50–10.00 mm
Cross section range	0.08–80.00 mm²

MicroLab 35

Micrograph laboratory

MicroLab 35 is designed for the fast creation of grinding patterns of contacts up to a diameter of 3 mm. The fully automated transport system and the tried-and-tested technology facilitate short processing times. The parallel processes allow the continuous creation of one grinding pattern per minute. Laser-supported, the sample is clamped quickly, hence defining the grinding surface precisely. Without repositioning, MicroLab 35 grinds the sample on its own. As soon as it has reached the analysis unit, it is electrolytically cleaned, the grinding pattern is recorded and analysed.

Technical data

Wire range diameter	dia. 0.30–3.00 mm
Cross section range	0.08–6.00 mm²

MicroLab 55

Micrograph laboratory

The MicroLab 55 grinding pattern laboratory facilitates the generation of grinding patterns of all types of crimp available on the market, both transverse and longitudinal grinding. This also applies to products such as printed circuit boards or housings outside the automotive area. The optimum arrangement of the individual modules makes very short processing times possible. A reproducible sample preparation is 100 % guaranteed, since no repositioning of the sample between the individual machining steps is necessary.

Technical Data

Wire range diameter	dia. 0.50–23.00 mm
Cross section range	0.08–400.00 mm²

SmartVision

Micrograph analyser

The program analyses the micrographs of the widest variety of crimp connections established on the market. It can photograph, measure, evaluate and document the entire terminal in addition to transverse and longitudinal sections. It guides users reliably through the standard and the respective measured variables.

Technical data

Analyzable types of crimps	B-Crimp, IDC, longitudinal grinding, Aluminium, Copper
Deposited industry standards	USCAR 21, PSA 9634115099, TYCO 114-18022-10, Renault 36-05-019, VW-Norm 60330