Semi automatic crimping machines for industrial applications

Crimping cables is an alternative to welding and soldering. This method is now the preferred way to create secure bonds between conductors and contacts. Semi-automatic crimping machines provide good support, allowing many more crimp connections to be produced in a given period of time compared to exclusively manual production. Moreover, this method brings with it lower fault rates and consequently higher quality. This makes it possible to comply with international standards and regulations, such as the crimp quality laid down in the quality criterion in DIN 46228. Another variant is a fully automatic crimping machine which you can also find on our website.

Thonauer offers the right crimping tools for crimping loose, linked, insulated and uninsulated wire end ferrules. Even special sizes (S) of wire end ferrules with plastic collars can be processed. Other crimping materials include insulated compression cable lugs, non-insulated tubular cable lugs and crimp lugs. Processing single conductors, multi-core cables, even with short stripping lengths, turned and electrical contacts, flat plugs and butt connectors pose no problem. Both small and large cross-sections can be crimped.

The highlight of our product range is the bt 752 by Komax, which can even combine three processes - stripping, positioning grommets and crimping - all in one device. Some machines manufactured by Zoller + Fröhlich also combine stripping and crimping functions in one.

The advantages of our crimping machines:

Very fast changeover, setup and cycle time
Active quality control even during setup
Integrated crimp force monitoring
Integrated defective part handling
Simple operation with top touch
Saving of machine and processing parameters
Programmable crimp height
Toolless exchange of the die adapter
Uses all standard crimping tools

So that you have a comprehensive solution for your production process, we also provide you with the appropriate interface for data exchange between your Manufacturing Execution System (MES) and the crimping presses. Komax's Manufacturing Interface (MIKO) is thus a prerequisite for the implementation of Industry 4.0. Thonauer’s range also includes suitable wire end ferrules as well as dies and adapters.

Together we will find you the right crimping equipment. In addition to standard applications, we can also develop customer-specific applications at any time. Make an appointment for a consultation now, with no obligation!

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

The Manufacturing Interface Komax – MIKO for short – is the interface for real time data exchange between your Manufacturing Execution System – MES for short – and cable processing machinery such as crimp presses and fully automated machines. This means that it is an essential for implementing Industry 4.0. Using this interface you will be able to improve process quality, completely document quality and increase the utilization of your machinery. See the data sheet for more information.

TT Crimp Press

TT Crimp Press

The TT Crimping Press is available either in semi-automatic (for bench-top use) configuration or in full automatic (integrated into a cut and strip machine) configuration. The standard stroke is 40 mm, but other different strokes are available upon request. The 135.8 mm ± 0.02 mm crimping height allows the TT to accept all the mini-style applicators fitted with the standard T-coupling. A proprietary safety cover guarantees the operator a perfect view of the crimping zone while enjoying complete protection from any hazard. Mecal’s own CFA crimp force analyser can be fitted as an option.

Technical data

Force	20 kN
Stroke	40 mm
Crimping height	135.8 mm ± 0.02 mm

AM 02 C / AM 02.1 C

Electro-pneumatic crimping machines for loose, insulated and uninsulated ferrules

The AM 02 C / AM 02.1 C ("Compact") is an electro-pneumatic, modular stripper-crimper for rapid and reliable processing of loose insulated and uninsulated ferrules of small cross sections. Features: easy tool change, short tooling time, quick processing and crimping quality which conforms to DIN 46228.

> Thonauer delivers suitable ferrules as well.

Technical data

	AM 02 C	AM 02.1 C
Wire cross section	0.14–0.34 mm²	0.25–0.75 mm²
Crimping length	6/8 mm	5–10 mm

AM 02 universal / AM 04 / AM 04.1

Stripping and crimping machines for loose, insulated ferrules

Electro-pneumatic, universal stripper-crimper for rapid and reliable processing of loose insulated ferrules. Crimping quality conforms to DIN 46228. The AM 02 CK is a special version of the AM 02 universal, with integrated crimp force monitoring.

> Thonauer delivers suitable ferrules as well.

Technical data

	AM 02 universal	AM 04	AM 04.1
Ferrules
Wire cross section	0.5–2.5 mm²	4–10 mm²	4–10 mm²
Crimping length	6–12 mm	8–12 mm	9–15 mm

Unic-L / Unic-LS / Unic-LZ

Stripping and crimping machines for loose, insulated ferrules.

Electro-pneumatic stripping and crimping machines.

> Thonauer delivers suitable ferrules as well.

Technical data

	Unic-L	Unic-LS	Unic-LZ
Ferrules	Single	Single	Twin
Wire cross section	0.5–2.5 mm²	0.5–2.5 mm²	2 x 0.5–2 x 1.5 mm²
Crimping length	8 mm	6/8/10 mm	8 mm

CR 03 K / Crimper G / Crimper-LS

Crimping machine for insulated ring tongue and ferrules

> Thonauer delivers suitable ferrules as well.

Technical data

	CR 03 K	Crimper-G	Crimper-LS
Ring tongue ferrules	Loose	On reel	Loose
Type	--	DIN 46228	DIN 46228
Wire cross section	0.5–6 mm²	0.5–2.5 mm²	0.34–4 mm²
Crimping length	--	8 mm	6–12 mm
Power unit	Electro-pneumaticundefined

ECM 04 / UNIC-G / UNIC-GS

Stripping and crimping machines for insulated ferrules on reel.

Reliable processing of ferrules on reel. Crimping quality conforms to DIN 46228. The ECM 04 is also available as a version with a built-in rechargeable battery for optional battery operation, the ECM 04 E.

> Thonauer delivers suitable ferrules as well.

Technical data

	ECM 04	UNIC-G	UNIC-GS
Ferrules
Power unit	Electrical	Electro- pneumatic	Electro- pneumatic
Wire cross section	0.5–2.5 mm²	0.5–2.5 mm²	0.5–2.5 mm²
Crimping length	8 mm	8 mm	8 / 10 mm
Features	Easy change of cross section	Automatic cross section selection	Crimping length 8 / 10 without tool change

UNIC-GV

Stripping and crimping machine

Processing of 5 different ferrules on rolls, without changing tools or rolls. Easy operation via touch display. Also suitable for Multinorm ferrules (ferrules with extended collars). This device is ideal where the ferrules are changed frequently, as there is no downtime for tool changes.

> Thonauer delivers suitable ferrules as well.

Technical data

Ferrule	on a roll
Conductor cross-section	0.5–2.5 mm²
Crimp length	8/10 mm

UP 14 / UP 14 BA / UP 14 Z

Pneumatic crimping machine for loose contacts

The perfect tool for beginners because of its good value for money. Use of all WEZAG die sets also possible, with optional positioner.

Technical data

	UP 14	UP 14 BA	UP 14 Z
Crimping force	14 kN at 6 bar
Processable cross-sections	insulated cable lugs 0.25–6 mm², non-insulated pipe cable lugs and crimp-type cable lugs 0.5–16 mm², insulated and non-insulated wire ends 0.14–50 mm², twisted contacts 0.14–16 mm², non-insulated FASTON flat plugs 0.14–6 mm², non-insulated pipe cable lugs and butt connectors 1.0–6.0 mm²
Special feature	Standard	Automatic contact retaining system	With compulsory sequence control

SSC

Pneumatic safety crimping machine for loose contacts

The patented safety mechanism does not release the crimp if the opening of the dies exceeds 5.9 mm. Therefore, safety protection covers are not needed which speeds up the production process.

Technical data

Crimping force	max. 35 kN at 6 bar
Features	Safety mechanism

UP 35 / UP 35 BA

Pneumatic crimping machine for loose contacts

Due to its innovative design this almost maintenance-free machine needs less space. It is light and can be easily transported with the provided T-handle. Operation is simplified through the use of the safety foot pedal - the hands remain free to insert the terminals and the conductor. No tools are required for easy exchange of the die adapter.

Technical data

	UP 35	UP 35 BA
Crimping force	35 kN at 6 bar
Features	--	Automatic contact holding system

UP 60

Pneumatic crimping machine for loose contacts

Powerful universal machine. Features: safety foot pedal offers short cycle time; tool-less die set exchange; integrated LED Illumination; integrated counter.

Technical data

	UP 60
Crimping force	max. 75 kN at 6 bar
Opening dimensions	Stroke min. 6–32 mm

UP 65

Hydraulic crimp machine for loose contacts

The UP 65 hydraulic benchtop crimp machine offers even more power for processing loose electrical contacts of up to 400 mm². Owing to the newly-developed, integrated hydraulic unit, the machine is space-saving, quiet and easy to install. The machine is flexibly usable, since it has to be connected only electrically.

Technical data

Max. crimp force	150 kN
Max. stroke	40 mm
Features	Electronic counter, 30-program disk space, Programmable crimping height, Die sets are easy to change

UP 150

Hydraulic table crimping machine

The UP 150 is a real space saver thanks to its integrated hydraulic power unit. This powerful machine makes the processing of large cross-sectional areas easy. One highlight is its integrated crimp force monitoring system, which always gives the right result. This table crimping machine also allows the crimping range and stroke to be set individually.

Technical data

Crimp force	150 kN
Special features	Integrated crimp force monitoring, tool-free quick-change adapter

Semi automatic crimping machines for industrial applications

bt 712

bt 722

bt 752

MIKO

TT Crimp Press

AM 02 C / AM 02.1 C

AM 02 universal / AM 04 / AM 04.1

Unic-L / Unic-LS / Unic-LZ

CR 03 K / Crimper G / Crimper-LS

ECM 04 / UNIC-G / UNIC-GS

UNIC-GV

UP 14 / UP 14 BA / UP 14 Z

SSC

UP 35 / UP 35 BA

UP 60

UP 65

UP 150

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