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Fully automatic machines for cable processing

Manual processes such as cutting, stripping, crimping, twisting or cable harnessing cost time and, above all, money. Cable processing can be automated using a fully automatic machine.

Thonauer offers fully automatic solutions for processing cables, fully or partially. Our staff will gladly advise you so that you have a solution that works for you in business terms.

To the products:

Fully automatic cutting, stripping, crimping

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 section0.01232.5 mm² (AWG36AWG14)
Length range1510,000 mm
Stripping lengths0.115 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 section0.13–2,5 mm² (4 mm² on request)
Length range40–20,000 mm (1.75 in–65.6 ft)
Stripping lengths0.1–20 mm (0.004–0.79 in)

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 section0.216 mm² (AWG24AWG5)
Length range6065,000 mm
Stripping lengths0.1518 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 section0.224 mm² (AWG24AWG12),
Optional from 0.13 mm² (AWG26),
Double crimp (cable A+B) < 6 mm²
Length range6080,000 mm (optional 3580,000 mm)
Stripping lengthsBoth ends: 0.135 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 sections0.134 mm² (optional 5 mm²)
Wire draw-in speedmax. 9 m/sec.
Crimp force122 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 sections0.136 mm² (AWG2612)
Wire draw-in speedup to 12 m/sec.
Crimp force122 kN

Fully automatic cable harness production

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

DLW – Digital Lean Wiring

Software for switch cabinet construction

With an efficient data processing, the DLW (digital lean wiring) software from Komax provides automation in switch cabinet construction. This means that a significant amount of time is saved in comparison to manual manufacturing, even with a batch size of 1.

Compared to conventional ECAD systems, the usage does not cause any cost-intensive maintenance of the components since the cable length can be determined by virtual wiring. It can be done by means of a photograph of the cabinet or a 2-D drawing. Existing data can easily be imported. Alternatively, Komax offers a camera for photographic dimensioning with a round shot in several individual images. The images are then put together into a dimensionally accurate overall picture and imported into the DLW.

The DLW also features an easy-to-handle user interface with touch screen. The DLW Viewer guides the operating staff through the entire wiring path, allowing even less specialized personnel to perform this step.

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

MES – manufacturing execution system

Software solution for the cable processing industry 4.0

The production software jointly developed by Komax and iTAC has been perfectly custom-tailored to the needs of cable manufacturing. The end-to-end solution has been designed for the entire value chain – from goods receipt through all production steps all the way to goods issuing – of cable processing companies of any size.

The software can be used for automated planning, control and monitoring of the entire production: machines, manual workplaces, auxiliary materials, material flow, resources, etc. Processes can be optimally standardized, defective production can be prevented, and the product quality can be significantly boosted. This makes it possible to produce complex products in the desired quality on schedule.

Fully automatic cable twisting

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 Tbt 288
Wire cross section2 × 0.08 to 2 × 4 mm²
(Optional: 3 or 4 wires)
Pitch length850 mm
Twisted lengthfrom 300 mm to 12 metres in 3-metre steps
Twisting lines per machine12

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 section2 × 0.22 to 2 × 2.5 mm²
(Optional: from 0.13 mm²)
Pitch length580 mm
Twisted length70010,000 mm
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