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Automated cable harness production

Cable assembly means the production of ready-to-connect cables, cable systems and cable harnesses, fitted with plugs, contacts or wire end ferrules. Many different, finished materials and cable types are required, especially for the versatile manufacture of control cabinets.

The industry places great demands on flexibility in automated cable harness production. In the automotive industry, for example, smaller and smaller cable cross-sections are required due to their lower weight and the smaller installation space required. There is a need to make many different cables and contacts without changeovers, just-in-time, and from batch size 1. A current challenge for the automotive sector is mastering the population of housings. Komax has responded to these changes in the market and has been developing professional fully automatic cable making machines for decades in order to meet the new standards. Of course, Thonauer has these machines in their range. 

When compared to manual methods, a mechanical cable assembly machine reduces the manufacturing time many times over. For example, in control cabinet construction it is reduced by up to 50 %. In addition, fully automatic production can achieve a continuously high quality level, since faulty cables are sorted out automatically. 

Batch production or sequence production is possible, as well as the one-sided and two-sided processing of cables, without changeovers. You receive the required cables in the correct order with the desired labeling by inkjet printing, ready bundled for further processing. Cables with cross-sections of 0.22 to 6 mm² can be processed. A continuous flow of data from ECAD (Electrical Computer Aided Design) or DLW (Digital Lean Wiring) to the machine is also guaranteed. 

The machine's automatic cable changer means that up to 36 different cables of different cross-sections are available. The highlight is the CM 1/5 GS module, which can even handle up to five different wire end ferrules. Up to 13 process modules are available for cable harness production: 

  • Crimping
  • Grommet positioning
  • Twisting
  • Tinning
  • Sleeve insertion
  • Double gripper
  • Wire end ferrules
  • MIL crimps
  • Welding
  • Ultrasonic compaction

Together we will find the right machine for your cable assembly. Call us now or contact us via the request form.

 

Zeta 640 / 650

Fully automatic cable assembly machine

Different cables and contacts are processed automatically without having to change over. This makes batch size 1 possible without any special effort. The manufacturing time is reduced by up to 50 % compared to traditional manual methods. A consistent data flow from the planning software to production reduces errors and increases cost-effectiveness.

At the end you get the cables you require in the correct order with the desired marking, and bundled ready for further processing.

 

Technical data


Zeta 640Zeta 650
Number of stations / with expansion5 / 108 / 13
Number of cables36
Process modulesCrimping, fitting seals, twisting, tinning, sleeve loading, double gripper, ferrules, MIL crimping, welding, ultrasonic compaction
Quality assuranceIntegrated crimp height and pull-out force measurement, crimp force monitoring, splice detection, incision monitoring, material change detection and material verification, Seal position monitoring, contact end detection

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-sections0.22–6 mm² (AWG 24–AWG 10)
Wire changermax. 36 wires (in steps of 6 wires)
Lengths with double-sided processing240–3,000 mm standard trough;
240–5,000 mm optional
Lengths with one-sided processing85–3,000 mm standard trough;
85–5,000 mm optional
Number of stations2

Omega 740 / 750

Fully automatic cable harness manufacturing machine

The Omega 740 and 750 are used for the fully automatic production of cable harnesses that are fitted from both sides. Up to 36 different cable types can be processed at the same time. With up to eight processing stations, almost all manufacturing processes can be reproduced and cable assemblies can be made efficiently without change overs. Marking is automated, using two ink-jet printers. The Omega passes the cables to a connected block loader fully automatically.  With many improvements such as optical monitoring, a larger carrier plate and much more, it can now even fit the smallest connector housings or other components, fault-free.

 

Technical data


Omega 740Omega 750
Number of stations / with expansion5 / 108 / 13
Number of cables36
Process modulesCrimping, fitting seals, MIL crimping, ferrules, ultrasonic compaction
Quality assuranceIntegrated crimp height and pull-out force measurement, crimp force monitoring, splice detection, incision monitoring, material change detection and material verification,
Assembly: Collision, insertion force and contact locking Monitoring
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