LEAD TWIST Wire Twisting System

The device is used for twisting of single wires. It consists of a drive unit with the twisting head and a compensating element. In all versions of the device there is an option to activate the device by means of a foot switch. A lot of working memory allows the parameterization and storage of up to 999 wire sets. An integrated touch screen offers usability. The number of windings can be freely selected both forwards and backwards. The motor speed can be adjusted as well as the start and stop ramp. In addition, precise lay lengths without lay errors can be achieved with two cores. A good dynamic twist of more than two wires is possible. The single wire cross-section can be between 0,25 - 2,50 sqmm. Harnesses up to 15 m can be processed.

Grommet expander EXPANSORA TRES Pneumatic three-pronged device incl. Positioning Unit

EXPANSORA TRES is a pneumatic table-top device with advanced function, operating at 6 bar working pressure. Flexible grommets can be spread with the help of this three-pronged device. The assembled cable set can be removed by the hand lever attached to the tool. Both cables and hoses can be fed through the expanded grommet. The pull-off unit offers a useful addition to the simple pneumatic bench tool. The cable set or hose is pushed through the expanded grommet to the target position. Positioning aids with sensory or mechanical sensing can be integrated for this purpose. By activating the pull-off unit, the grommet is set down on the cable set/hose in a process-safe manner. Time-controlled, the device returns to the home position.

Braid Twister BSV 1006

The braid twister BSV 1006 is used for machine twisting of shield wires and single strands. It produces a reproducible twisting result for crimp force monitoring. The unit can be adjusted to all cross sections by a programmable motor control with clockwise/anticlockwise rotation. This automation reduces the amount of manual labor required. The shield twister is applicable for small series and large series and processes twisting lengths from 10mm. Optionally, it can be equipped with an automatic guide.

Technical data

Braid cutter BSF 1004

The shield milling cutter is used for the complete removal of the shielding at the ends of coaxial cables and shielded cables. By adjusting the tool to the respective cable, damage to the insulation of the inner conductor can be excluded. The specific milling tools depending on the cable type are easily and quickly interchangeable.

Technical data

Shield Brush BSB 1005/B

This device is used to unbraid cable shields for a brush length of up to max. 70 mm. Due to quickly exchangeable brushes, the device can be individually adapted to the respective cable type. It is suitable for processing small batches and large series. It also has adjustable width and speed, and reverses direction of rotation. In addition, it can be optionally equipped with an automatic start.

Technical data

Spool Unwinder SAR800 - 1250

The tension-free cable dispenser can feed the uncoiled material to the assembly machines without counter-drawing. The non-contact sag control eliminates errors such as material-damaging stretching of the insulation sheath.

The device settings allow individual adaptation to the workplace at hand. The unwinding speed can be controlled with the DHS1000 D non-contact sag control or a KSP/LSP series cable accumulator.

Technical data

Fully automatic cable assembly machine

The Zeta 620 assembly machine provides wires on two process models fully equipped for control cabinet construction – including labeling and terminals.

Manual processes take time and require properly trained personnel. The Zeta 620 wire processing machine simplifies the wire assembly process. It produces complete parts lists fully automatically and sorts and labels the wires. Up to 24 wire types and up to five different ferrules can be processed without conversion. Module options customize the process to customer requirements and also simplify complex production processes. After the assembly and disbursement in wire bundles by Zeta 620, the wires only need to be routed in the control cabinet. Manual processes such as cutting to length, stripping, labeling and inserting sleeves are completely eliminated – with reproducible and continuous quality.

Technical data

Fully automatic crimping machine

Alpha 565 is suitable for crimping and seal assembly for the application of ferrules or MIL crimps, tinning, twisting, solidifying, ultrasound, welding, etc.

With seven process stations, the Alpha 565 wire processing machine offers plenty of space for special processing and individual processes. Customer-specific applications are easily and effectively integrated. Thanks to the modular machine design, even complex assembly processes such as dual core wire processing, ultrasonic solidifying or welding processes are possible. Elements such as the Y1582 twisting unit, the Y1585 fluxing and tinning module, the DC double gripper module, the AEH-LS ferrule module, the S1441 seal module and the selection of various crimp modules can be integrated individually. This means that the machine also meets changing and complex requirements. Accurate processing is ensured thanks to the CFA+/CFA, ACD and Q1250 quality process monitoring.

Technical data

Crimp Height Measurement Device

Precision crimp height measurement device for verification of non-insulated crimp terminals. The CHM can be used as a stand-alone device or integrated into the Komax machines* for quality verification.

The device consists of an anvil to support the crimp and a descending measuring tip on a dial gauge to determine the height of the crimp. A spring-loaded lamella in the center of the anvil ensures the exact positioning of the terminal. This centering aid minimizes operator-induced errors and guarantees correct measurement of the crimp height.

Technical data

Fully automatic crimping machine
The CrX-44HD can handle the largest-gauge applications. The machine leads the industry by taking on large-gauge copper and aluminum wires of up to 95mm2 (000 AWG), with fully-automatic crimping to 70mm2 (00 AWG).

The powerful processor features a heavy-duty feed drive, cutter head and wire grippers. The “Pick and Place” terminal technology allows for fast changeovers of the terminal gripper and die set and lower tooling costs. Different loose-terminal feeding systems can be incorporated, including feeding bowls and feeding tracks, both of which can be easily exchanged for different terminal set-ups.


Technical Data

Depending on the contact type and cross-section, the right WDT-branded die for hand tools or machines can be used, easily and at low cost. The widest range of contact types can be processed in this way, from wire end ferrules to tube cable lugs or twisted contacts. Further dies and tool heads are available for almost all types of loose contact.

Technical Data

Set 441 red/blue/yellow	Set 66 (D)	Set RM 4	CSV 10 - F 4,8
0.5 - 6.0mm2 dies for insulated press cable lugs	0.1 - 10.0mm2 dies for insulated crimp cable lugs (mandrel crimp)	0.14 - 4.0mm2 dies for twisted contacts incl. RM positioner	0.5 - 1.0/1.5 - 2.5mm2 tabs + receptacle for 4.8mm width tabs to DIN 46247 Sheet 2

The STCS-SYX is a heat shrink system based on infrared technology capable of processing up to six meters long harnesses. The equipment can be supplied only as onesingle main module suitable to process products up to one meter long and extension modules are available to enlarge the machine’s production area.

The ISAC14 (Integrated System Automatic Centering) is a newly developed system to integrate to the existing STCS-CS14 to guarantee the centering of the heat shrink tube on the splice. It’s an automatic system, developed as an addon for STCS-CS14 and it’s compatible with all the previous versions of this model.

Stripping and crimping machine for loose, insulated ferrules

Electro pneumatically driven stripping and crimping machine. Crimp quality according to DIN 46228. Special feature: Two cross-sections of any lengths can be processed at the same time. You can switch between preset cross-sections at the push of a button. Thonauer can also supply you with the right ferrules.

Technical data

	AM 04 Duomatic
Ferrules
Conductor cross-section	4– 10 mm²
Crimp length	8–12(18) mm

Battery Crimp Tool EHC 13

EHC 13 Battery Crimp Tool is designed for the crimping of loose piece contacts in small and medium volumes. Small and larger cross sections can be crimped in areas especially difficult to access. The ergonomic design and wide range of crimping profiles provides flexibility and efficiency to your manufacturing environment. The “Quick Connect System” combines the ability to change tool heads and die sets easily to provide several industry standard and custom crimp solutions. An additional benefit is offered with the cutting tool head, which provides the capability to cut cables up to a diameter of 54 mm.

Electric crimping machine for contact processing

The WDT UP15 electric crimping machine is the perfect introduction to contact processing. The extensive tool head system with the option for customer-specific solutions and the stepless tool head for ferrules ensures you will have maximum processing flexibility. The user-friendly touch display enables easy access to additional settings and service options. The linear movement with sequence control ensures the highest crimping quality. It is also suitable for automotive applications.

Technical data

Inkjet printer

The Ax family can be operated stand-alone or in-line. The simple installation and operation together with the easy ink tank change minimize your operating costs. The Ax family is designed to be integrated into a production line and prints on the products in defined positions.

Technical Data

The M611 is very popular with customers who want to print labels quickly with smartphones and who are fond of technology. Easy operation for spontaneous printouts. The portable BradyPrinter M611 can be operated via a smartphone and is suitable in combination with the Brady Workstation app “Express Labels” for the identification of cables, components and laboratory samples as well as for complex identification in the electrical field. Using a smartphone, you can easily create 1D and 2D codes and barcodes, serialize data and benefit from a comprehensive image library.

Technical data

The BMP61 is also available with WLAN function and as a bundle with the WS, etc. It is a state-of-the-art printer and very popular in switch cabinet construction and outdoor applications. The BMP™61 label printer offers several user interfaces, a touch screen, different connectivity options and various options for managing and storing data. The printer prints extremely quickly pre-cut and continuous labels as well as labels in bulk with a width of up to 50.8 mm. Customized labels can also be printed. The BMP™61 comes with the Brady Workstation Suite for product and cable identification, so you can start designing professional labels immediately.

Technical data

Heavy cable wire cutting and stripping

The Artos CS-370 cutter can strip and cut heavy wires with a diameter of up to 35 mm and a length of just 50 mm with high performance and precision.

The robust wire leveler guides the product on the Artos CS-370 to the precise cutting device. The servo feed drive takes over the additional driving force to enable hands-free and safe working. Optionally, a rotary blade can also be upgraded to make even more accurate cuts without damaging the wires. This cutting module enables several alternatives to stripping for multi-layer and shielded wires. In addition, the Artos CS-370 can be equipped with inkjet wire marking and a wire slitter in order to combine further wire processing steps in one machine.

Technical Data

A high speed fully automatic coil winding machine with advanced PC control of multi axis servo systems, for winding inductive devices with fine wire in medium and large volume. Applications include relay coils, magnetic head coils, LCD coils, transformers, ignition coils, inductors, sensor coils, solenoids, and other bobbin-wound products.

Technical data

Heavy duty coil winding machine

The E-1200 is a floor standing style winding medium sized machine. This machine is specially designed for the manufacture of solenoids and power and distribution transformers from 10 to 1,200 KVA, using aluminium or copper wires, including rectangular or flat wires with a special guider.

Technical data

The foil and insulation de-reelers are provided with an automatically controlled brake system, which applies a constant tension to the materials during the winding process. The winding unit is equipped with a pressure roller system and the machine is supplied with two expanding mandrels for the copper foil and two for the paper insulation. There are various configurations possible, up to 300 mm width. This allows winding of primaries easily and with very short production cycle times.

Technical data: Custom made

Tape Cutting Machine

The tape dispenser dispenses and cuts any length of tape. Either on pressing a button or automatically as soon as a cut piece is taken.

Technical data

Cutting tool, for precise cutting of copper and aluminium cables.

Technical data

Stripping and cutting tools

For fine-stranded and solid conductor; useable for all insulations. The stripping length can be adjusted with a limiter.

Technical data

Crimping tools for ferrules

Crimping tool for ferrules (according to DIN 46228 part 1 and 4) with and without plastic collars.

Technical data

The hand tool actuator is a universal assistance for any manual hand tool. The hand tool is operated by the lever. This makes it easy to work for longer periods with hand tools.

Stripping machine for coaxial and triaxial cables

Rotating flat blades guarantee high-level precision when processing coaxial or triaxial cables.The Mira 440 can process up to 9 conductor layers within one sequence and guarantees a high degree of productivity thanks to additional features such as bar code scanning.

Technical data

Stripping machines for coaxial and semi-flexible cables

Highly precise processing of multi-layer cables.

Technical data

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

Cutting and stripping machine

The Kappa 330 comes in two configurations, as a single head variant with a knife line and a dual head variant with a double knife head together with the additional option of separating and stripping the inner conductor of a sheathed cable. The Kappa 330 also offers other options such as programmable slitting, processing ribbon cables and integration of various sensors for process monitoring.

Technical Data

Cutting and stripping machine

The power pack in the Kappa family from Komax, made for large cable cross-sections. Thanks to a clever sensor system, when setting up the machine, the cutting losses can be reduced to a minimum. This is a cost factor, especially with large cross-sections. With a large number of knife geometries and the option of using customer-specific knives, this machine is also suitable for difficult conductors and processing high-voltage automotive cables used in electric vehicles.

Technical Data

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

Delta series: Delta 220 / Delta 240 / Delta 260

The basic model of the Delta 220 series offers simple crimping with integrated crimp force monitoring – optionally with bad crimp cutter and stripping unit.

The Delta 220 fully automatic wire processing machine enables high repeat acuracy and process quality thanks to the precise and robust mechanics. The integrated CFA/CFA+ crimp force monitoring system checks the quality during the crimping process and thus enables high processing quality. In contrast to Delta 240 and 260, the crimp height is set manually. Set-up and changeover are easy. Thanks to the brilliant color display and the Komax HMI Delta graphic user interface, operation is simple and user-independent with a storage space of up to 5,000 articles and 1,000 wires. Optionally, Delta 220 can also be equipped with a stripping unit and the bad crimp cutter for easy sorting out of faulty crimps.

Technical data

Bench Top Stripper/Crimper BT-SC

The Exmore benchtop crimping presses are designed for the production of single and multi-conductor cables. The crimp presses are not only available with a standard foot pedal, but also with a two-handed activation or start sensor. These crimping presses are outstanding in terms of short cycle times, short changeover and setup times. The “patent pending” drive system ensures the short cycle time with a long crimping time.

Technical Data

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

Fully automated crimping machine

The combination of simplicity, functionality, efficiency and process reliability, along with a high output on minimal floorspace, make this fully automatic crimping machine a sure-fire investment in terms of an excellent cost/performance ratio.Equipped with all standard quality tools from Komax, it ensures a high level of stability and monitoring.

Technical Data

Fully automated crimping machine

The most powerful crimping machine from Komax is impressive thanks to its high-quality processing of large contacts and sleeves.Wire cross sections of up to 16 mm2 can be processed on the Alpha 560.Thanks to the HMI, operating the machine is child’s play; all high-quality tools are also integrated with ease.

Technical Data

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

Fully automatic crimping machine

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

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

Fully automatic twisting machine, including end securing

With the Sigma 688 ST, Komax offers its customers the option of fully automatic crimping of wires, fitting them with a sleeve, twisting them and additionally securing the open end.This meets OEM requirements for fully automatic UTP wire production.

Technical data

This semi-automatic un-twisting machine offers high production efficiency in combination with perfect processing quality. It is also easy to operate, attractively priced and guarantees accurate performance. With its compact dimensions, it can be placed on any bench top hardly taking up any space. The intuitive software (touchscreen operated) enables you to save the un-twisting parameters.

Technical data

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

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

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.

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

Multi Connection Machine

The Wire-XL / Wire-XXL can be equipped with a wide variety of modules for the following processes: Stripping multi-conductor cable, shrinking of contacts and sensors, compacting, welding, fluxing-soldering, splicing, housing insertion, etc. Various modules are also available for quality control, such as crimpheight measurement, colour detection, crimpforce monitoring, pullforce measurement, camera, insertion force, insertion depth, etc. It’s designed for high volumes in the automotive, industrial and aerospace sectors.

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 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

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

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

Coiler

As uncomplicated additional devices in the processing line, the KRI 450 wire ring winders create perfectly shaped and bound wire rings with an inner diameter of at least 120 mm.

The KRI 450 is a powerful piece of peripheral equipment that very carefully prepares wires for downstream processes. When in use, the KRI 450 C picks up the wire directly in a guide tube. The winding arbors then turn the wire into a flat-shaped wire ring. After processing, the arbors lower and the cover opens automatically. Heavy wire rings can also be pushed away flat over a table. Models with CB and CBP offer additional steps: The CB models have an integrated manual spot-taping station; the CBP models, on the other hand, are fully automatic winding-spot taping machines and therefore do not require any manual intervention.

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

Inkjet printer

Working together with Domino, the latest generation of Komax inkjets impresses with its compact construction and its very user- and maintenance-friendly design. Equipped with RFID readers, the modules used are continuously checked and the operator informed in good time of any events. This technology, can, for example, prevent filling with the wrong ink.

Technical data

Cutting machine

The extremely reliable and solid universal cutting machine has been designed to process a wide range of different materials. In addition, Ulmer and Thonauer can also adapt the cutting machine to your needs.

Punching cut for tubes, foamed rubber, sealing profiles. Shearing cut for flat and round cables and stranded wire, shrinking tubes. Tube cut for several tube materials.

Optional bevel cut blades available.

Technical data

Cutting machine

The SG 400 V has been designed especially for the cutting of large-sized cables or lateral cuts respectively. Multi-core cables are cut to an outside diameter of 26 mm and cross section of up to 150 mm².

The robust and powerful feeder (as used in the ZG 400 B2) enables precise positioning of the cutting material.

Technical Data

Hose cutting machine

The hose cutting machine SSM 60 is suitable for cutting closed and slit corrugated tube, PVC, rubber hose as well as further types of hose with an outer diameter of up to 60 mm. The use of the guillotine cut (blade is fixed in a 45° angle) makes for a precise cutting angle as well as high cutting quality.

Technical Data

Corrugated tube cutting machine

Corrugated tubes are used in slit and non-slit versions to protect cables and harnesses, for instance, in the automotive and machine construction industries. Tubes from medical devices or white goods can also be processed. Precise and reliable cutting at the wave top is important. High cutting quality is important to ensure tightness at the contact point. 

To do this, a rotating knife is used to avoid sharp edges damaging inner wires.

Technical Data

Mini Applicator

The Mini Applicator processes linked terminals with a cross section of up to 6 mm². This Evolution crimping tool is available in side-feed and end-feed versions. It fits all presses with a T-coupling and a crimping height of 135.8 mm. It can be used with bench top presses as well as with fully automatic crimping machines.

We deliver the right applicator for almost all contacts.

Technical data

Mini-Applicator

The Restyling mini-applicator crimps on-reel terminals with a thickness < 1.2 mm, pitch < 27 mm and wire section from between 0 and 10 mm². Mechanical side-feed system for linked terminals to be unrolled left to right. Can be fitted to any benchtop or automatic press having a crimping height of 135.8 mm (mounting plate to press T-coupling). Available as: left-side-feed (MRS), end-feed (MRF), pneumatical left-side-feed (MRSP), pneumatical end-feed (MRFP)

We deliver the right applicator for almost all contacts. 

Technical data

Electrical stripping machines

Continuous change of wire cross section without tools. Continuous change of stripping length from 3 to 20 mm; integrated spare knife; full or partial stripping possible.

Technical data

Electrical stripping machines

Continuous change of wire cross section from 0.05 to 6 mm² without tools. Continuous change of stripping length from 3 to 20 mm; integrated spare knife; full or partial stripping possible.

Technical data

Electrical stripping machines

A sensor measures the cable diameter and automatically defines the corresponding cutting depth. Full and partial stripping is possible.

Technical data

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

Modular stripping and crimping machine

The AM 03 series from Zoller + Fröhlich offers different models of electro-pneumatically-driven stripping and crimping devices for the processing of loose, twisted pin and socket contacts. The contacts are automatically fed via a vibration conveyor.

Technical data

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

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

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-pneumatic

Ferrules

Wire end ferrules create first-class, solderless connections, ensuring precise, long-term operational reliability.

Zoller + Fröhlich is the inventor of ferrules with plastic collars that are used for solderless connections in cable assemblies throughout the world. Thonauer supplies the entire range. We supply ferrules with or without plastic collars, from 0.14 to 150 mm² in different colors and different termination lengths, assortment boxes, ring or spade lugs, blade receptacles, etc. Our range also includes taped or loose ferrules.

Z + F is the only company in the world to have had all their insulated ferrules UL-certified  since 2012, and CSA-US certified since 2002. This not only applies to loose wire end ferrules with a cross-section from 0.14 to 50 mm² (AWG 26-1), but also to twin wire ferrules and taped ferrules.

Ferrules and cable lugs from Zoller + Fröhlich GmbH also comply with the RoHS (Restriction of certain Hazardous Substances) regulations. For processing the ferrules, Thonauer offers a wide range of hand tools and crimping machines for semi-automatic processing.

We would be pleased to advise you of our extensive range.

Coax Shielding Cutting Device

The BERI.CO.CUT is a highly accurate device for cutting shieldings and braidings of the type found in coax cables with multiple layers. In particular high voltage cables used in the new generation of electric vehicles can be processed with the BERI.CO.CUT reliably, within seconds and cost-effectively.

Technical data

Crimp force monitoring

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

Integrated optical stripping, sleeve and crimp monitoring for Komax fully automatic machines

The Q1250 is integrated into the latest generation of Komax crimp machines, checking the quality of the stripping, the correct processing of the sleeve and the crimp quality during processing. This means that there is no need for a visual inspection by the machine operator at the end of a batch. The digital eye also helps when setting up the machine, shortening the changeover times.

Technical data

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

Pneumatic cable stripping unit

The AM.STRIP.1 is a universally usable, semi-automatic cable stripping machine for use in harsh industrial environments for economical production of small and medium volumes. Its special knives, adapted to the processed cable, can process nearly every available cable on the market.

Technical data

Pneumatic stripping machine with rotating blades

With the semi-automatic stripping machine AM.ALL.ROUND you can perform high-precision round cuts and strip jobs quickly, easily and safely. Easy stripping of demanding insulations, where conventional cutting and stripping processes are not sufficient or even not possible.

Technical data

Laser marking device

When compared to other marking methods, its greatest advantage lies in the elimination of consumables (e.g. ink) and the fact that the system requires no maintenance. The MRO 200 is particularly suited to small and medium-sized quantities.

Technical data

In-line Wire and Cable Laser Marking Solution

Laser marking is one of the fastest marking processes available in the market, without usage of additives e.g. ink or any other undesirable substance. The laser beam does not wear, it produces a highly accurate, repeatable marking time after time. Laser marking is therefore the most economical solution when wires or cables must be identified.

Technical Data

Laser printing system

UV-laser printing system for high volumes. Cable marking of thin or asymmetric conductors without damage to the insulation. Ideal for aerospace and military applications, because the lettering no longer wears off.

Technical data

Laser printing system

UV laser printing device for inline applications. Ideal for integrating into a production line. Komax offers ready-made solutions for integrated use with Kappa or Zeta (UVM03).

Technical data

RapidShare enables the automated processing of wires and cables at machine output. It is a modular and flexible solution where workstations-output sorting, labelling, grouping, storage etc. - adapt according to your needs. Linked to a Ulys Modena machine equipped with an automatic cable loading system, the RapidShare system offers advanced cable grouping and sorting functions to accelerate production of electric harnesses. The complete equipment includes the multispool cabinet, Automatic Feeding System, the Ulys Modena machine and the RapidShare system.

An ideal tool for checking your cable markings, EasyContrast ensures an accurate and repeatable contrast measurement in compliance with EN 3475 – 705 and SAE AS 4373 standards. EasyContrast has been designed to meet the latest requirements of the aviation industry as part of Airbus’ AIPS and Boeing’s BAC5152 process. EasyContrast is very easy to use and allows you to define all types of clear cables in record time and to edit both complete and meticulously presented measurement reports.

BRAIDO machines provide the perfect solution to the demanding production requirements of electromagnetic shields and mechanical protection for electrical harnesses. The quality and the precision of the braid are guaranteed by the machine's software, which also ensures the complete traceability of your operations.

ADVANTAGES OF BRAIDO:

• RAPID loading of carriers
• AUTOMATICALLY set overbraiding characteristics
• Complete TRACEABILITY of production
• REPEATABLE manufacturing process
• OPTIMISED Production

Electronic harness assembly board

An electronic harness assembly board allows different wiring harnesses to be produced without having to make a board for each harness. This eliminates the need for storage of harness assembly boards. Subsequent changes in the wiring harness can be implemented quickly. Installation instructions are displayed online, thus reducing faults in the manufacture of the cable harness.

Technical data

EasyWiring Additional functions

Touch mode
EasyTouch automatically detects when an operator touches the cable end. The cable identification as well as the routing and pinning information are transmitted and displayed directly to the EasyWiring wiring harness assembly board. This makes the operation of your electronic cable harness assembly board even faster and easier.

Continuity test mode
By connecting a plug connector to the test unit, the continuity test can be performed on a single connector during the cable harness assembly process. This way, errors are pointed out to the operator who can rectify them more quickly. But when you create all connections to the EasyTouch test unit, a final testing of the entire cable harness is performed. A comprehensible test report is delivered. It ensures a strict quality control. This function makes your production more efficient and boosts quality.

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

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

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

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

The flexible Exmore splicing machines make it possible to manufacture perfect and efficient connections. In one processing step the necessary piece of the continuous splice band is cut off without waste, the cut piece is formed and the connecting components are crimped to a durable and reliable crimping connection using the pre-formed piece of the splice band. These splice bands are made in a wide range of materials/alloys, sizes and profiles.

High dimensional accuracy, easy handling and tailor-made options: The KTR 10 CS (Control System) table machine offers an ideal introduction to program-supported taping. It has a combined length measuring and roll feed system and can store up to 20 production steps. This means that high-precision taped products can be created according to individual specifications. Whether simple cable sets or module cable sets for doors, mirrors or headlining:the powerful KTR 10 CS impresses with its speed and reliable performance.

When dealing with long cables and branches, optimal handling is vital. That is why KABATEC has developed the KTR 15 for cable sets, which can be conveniently inserted into the machine from the front or from the side. In addition, the open winding head allows maximum flexibility when long sets are being taped with different types of adhesive tape. There is no need to laboriously thread the cable through a closed winding head, it is simply passed through the open winding head. The process then starts at precisely the desired point. An advantage that certainly pays off when manufacturing trailer cable harnesses, for example. On the one hand, these are exceptionally long (up to 10 meters), while on the other, different types of adhesive tape are required for indoor and outdoor use.

Taping machine

Easy, quick and cost-effective taping solution. It is flexible and easy to use. This device processes any conventional adhesive tape.

Technical data

A model that is creating some excitement in the trade: The KTR 1800 is perfectly designed for processing high-voltage (HV) cables and cable sets with large diameters. Technically, the machine is based on the KTR 160 and, as an option, has two different lengths of the linear system: With a length of 750 mm and optionally 1,500 mm, it is ideally suited for taping long cables and branches. The open winding head is designed for easy handling and fast processing times. This allows long branches to be inserted and removed from the front. The KTR 1800 was also specially designed for taping cable harnesses that have up to 25 branches. The individual taping steps can be visualized on the 15-inch display.

Twisted cables require a secure fixing at the open ends so that the twist does not unravel. To protect such cables, KABATEC has developed the KTB E Twist Spot electric automatic bundling machine. It is based on the proven technology of the KTB E PLUS. The KTB E Twist Spot is used after the cables have been removed from the fully automatic or semi-automatic twisting machine. Using specifications defined by the user, the semi-automatic machine applies a spot tape to fix the open ends of the twisted-pair cables, ensuring the highest level of safety and quality. The KTB E Twist Spot is also the ideal solution for processing critical cable cross-sections.

Taping machine

Taping of simple and long cable kits as well as complex cable harnesses without length measurement. High rotational speed reduces processing time. This device processes any conventional adhesive tape.The KTB E9P is particularly suitable for integrating into a production line, thanks to its slim design.

Technical data

Bench top resistance welding unit

Appropriate for labs and small series. Compact design with integrated welding head. Controller offers a variety of adjustment options. Its HV inverter delivers a precise, controlled output current.

Technical data

Sequential compacting station

Compacting allows the further processing of a copper stranded wire without ferrules. The compact design of this unit makes it easy to use. The compacting width is adjustable using an electric motor.

Technical data

DC-L0600A and DC-L1000A Series Linear DC Resistance Welding Power Supplies

The DC-L Family of Linear DC Resistance Welding Power Supply are high performance 1,000 Amp precision Linear DC spot welding power supplies. Both models combine an easy-to-use touch panel interface, integrated database process control and monitoring with a high accuracy, zero ripple linear transistor output stage that delivers ultra-fast 10µs dynamic process response rates, with absolute closed loop 1amp incremental accuracy and repeatability.

Technical data

DC-H3000A and DC-H6000A High Performance DC Resistance Welding Power Supplies

The DC-H Family of HFDC Resistance Welding Power Supply are high performance 3,000 Amp and 6,000 Amp precision Inverter DC spot welding power supplies. Both models combine an easy-to-use touch panel interface, integrated database process control and monitoring with high duty, low ripple DC output.

Technical data

WH-M070A, WH-U070A and WH-L090A Resistance Welding Weld Heads

The WH Family of Weld Heads offers a flexible, simple and feature rich range of Weld Head solutions for Micro Joining Applications. Incorporating a precision ultra-low inertia mechanism, Weld Heads can be specified as modules for machine integration, standalone Weld Heads or fully integrated into bench solutions. Displacement monitoring and force setting options can be selected to suit application and process optimisation requirements.

Technical data

PA-H Series Pulsed Arc Power Supplies

The PA-H range of programmable pulsed arc power supplies are linear DC precision arc-welding units extensively used in contactless, high-speed solder-free coil and wire termination industries. Available for single output laboratory use and multi-output high-speed automation applications alike, these units employ state-of-the-art closed-loop electronic arc control circuitry to deliver output accuracies and repeatability better than 1% with currents up to 200 amps.

Welding currents and profiles are fully programmable with real-time graphical oscilloscope feedback that provides process monitoring and quality assurance.

Technical data

C16 and C25 Compacting Equipment

Resistance Welding Compacting is ideally suited for stranded wires, sensors and Y connectors. It applies an eve, intense and massive compression. As compared to ultrasonic methods the surface of a compacted Resistance Welding wire is even and uniform. There are no individual strands in the compacting areas. Compacting delivers an even and uniform wire surface. Combined with the brazing technique compacting is ideally suited to join cables of a large dimension in automotive applications such as the intelligent battery sensor application which allows for smart battery power management. The compacted wire diameter may be up to 16, 25 or 70 mm2.

Technical data

*Exact ranges depend on the application. AMADA WELD TECH is pleased to recommend a suitable configuration for compacting devices which meets the specific needs.

Soldering machine

The economic A300/400 is a universal, pc-controlled bench top soldering robot with three axes. This unit is especially suitable for process evaluation of new products or for manufacturing small and medium series.

Technical Data

Infrared Shrinking Tube Control System

The compact and lightweight STCS-CS14 is ideal for high production quantities. The touch display enables convenient operation. Networking is possible via an Ethernet interface. The ISAC14 is an add-on for the integration into the STCS-CS14 in order to have the heat shrink tube automatically centered on the sealing zone and check whether a tube with the correct length is being used. 

Technical data

Lightbeam: contactless heat transfer from tool to work piece; selective reflow soldering.

Hot iron soldering: automatic hot iron soldering with robot.

Induction soldering: automatic induction soldering with robot.

> Thonauer can supply the right soldering system for your application. 

Infrared: Shrinking Tube Control System

The evo500TS is the bestseller in the STCS Series. It is characterised by an extraordinarily high processing speed. The enclosure of the tube leads quickly to a constant temperature around the heat shrink tubing. A reasonable result is achieved within seconds. The STCS-RCM offers an additional centering function, which pushes the tube automatically above the uninsulated area.

Technical data

Infrared: Shrinking Tube Control System

The CS19 shrinking system is the ideal choice for processing medium or high volumes. It is designed for workbench applications and can process several parts at the same time. The system has a conveyor with two sets of timing belts that grips the wires with the sleeves and feeds them into an infrared oven for the shrinking process. The assemblies are then carried through a cooling zone and deposited in a collection bin. The parameters can be easily set and controlled.

Technical Data

Infrared: Shrinking Tube Control System

The RT und CRT versions hold and position the cable, connector and heat shrink tube. Due to the dual chamber, the operator can load and unload one side whilst the other is processed. A variety of products can be processed at the same time.

Technical Data

Hot air: Shrinking Tube Control System

The aim of automated shrinking of heat shrink tubing is to reduce processing time and increase quality. To achieve this, our hot air products are a good starting option. They are produced and installed according to customer-specific requirements.

Technical Data

Hot air: Shrinking Tube Control System

The VM and BWT Series with customer-specific product holder enables the processing of several products at the same time. This leads to a time reduction of 50 to 70 %. During processing time an operator can load and unload the product holder.

Technical Data

The Exmore Infrared Mobile Device is an Infrared (IR) processing device for product diameters up to 16 mm. The Infrared processing appliance allows efficient and reliable processing of the following components: Heat shrink tubing, Adhesive coated heat shrinking tubes, Label sleeves, Solder sleeves, Heat shrinkage caps, Related heat-shrink materials and products.

An additional Infrared Digital Control Unit IRDC-2000 is required for the operating of the processing appliance.

Technical Data

The Exmore Infrared Single Shrink Device is an Infrared (IR) processing device to process multiple shrinking sleeves in one action, depending on the dimensions of heat shrink tubing and cable. Multiple cables or wires can be held in different holders, which gives the Single Shrink Device a wide range of applications. By sliding the movable unit between the emitters, the shrinking process is started.

Technical Data

The newest Exmore IR Digital Control Unit, is a digital controller with ergonomic design and a clear display with touchscreen, for controlling the Exmore Infrared appliances. There are different versions available, so that we can offer the most suitable device for every wish or application. Both versions can also be operated via a PC, tablet or smartphone.

Technical Data

The STCS-BLTTS is a test equipment to check sealed splices. Based on touchscreen technology, it can perform two independent tests: bubble test, to check if the splice is waterproof; and leakage test, to measure the splice’s insulation resistance or current

Mäder is one of the leading German manufacturers of hand-operated and compressed air presses. mäder presses are extremely versatile and can be used for assembly, pressing, joining, bending, crimping, riveting, punching, gluing and much more. Our presses cover the capacity range from 30 N to 100 kN. Customer-specific offers on request.

Technical Data

Print jobs for the Wraptor printer applicator are created on a PC with Brady's easy-to-use, Brady Workstation™ labelling software. Brady Workstation™ software eliminates the material handling cost of manual identification, and also optimises wire identification with variable, serialized and graphical information as well as multi-legend marking and barcode.

Technical Data

Mobile label printer / Bench top label printer

The BMP™41 Label printer is a rugged, portable solution that gives you the versatility to create die-cut or continuous labels up to 25 mm wide, anywhere, anytime!

The mobile Label printer BMP™71 is Brady's newest high performance printer for wire and cable marking. The versatile printer BMP™71 is especially suitable in the telecommunication and electronic industry.

Technical Data

Wiedenbach offers one of the widest portfolios of inks, covering all types: dye based, lightly pigmented and highly pigmented. Our inks are known for their bright colours, fast drying time and excellent adhesion on a range of different substrates.

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

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

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

Stripping force tester

The new Micropull 10 tension and compression testeris equipped with an intuitive user interface and, thanks to its various modes, makes it possible to carry out the correct verification at all times. Verifications involving both individual and a series of measurements are possible, with or without standard specifications. For standard specifications, the usual standards can be selected or the customer’s own standards can also be stored.

Technical data

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

Manual test device

Electronic force test devices for checking the clamping force in cable tie guns. Suitable for both manual and pneumatic cable tie pliers. The device has a rugged and low-maintenance mechanism and can be used with a large number of cable tie guns thanks to a variety quick-change tools. Optionally available as “CGT” with dot matrix touch display or as “CGT-Touch” with color touch screen and a higher display resolution.

Technical data

Manual test device

Electronic force test device with hand lever operation and digital display for the measurement of tensile forces, e.g. on pre-assembled lines with crimped, soldered, welded, glued and similar connections on flat plugs, cable lugs, wire end sleeves, etc. Thanks to the simple and precise handling by means of the hand lever and parallel load carriage, the device is ideal for use in production plants as well as in test laboratories and similar test facilities. Optionally available as “FT” with dot matrix touch display or as “FT-Touch” with color touch screen and a higher display resolution.

Technical data

Manual force measuring device

Force display with compatible force transducers to check tensile and compressive forces in mobile and stationary applications. Up to 8 force transducers with maximum power ranges between 50 N and 10,000 N can be registered at the same time. The detection of the respective connected force transducer takes place automatically. Due to its compact design, the device is also suitable for the calibration at production locations directly on site. Furthermore, the force measurement device is characterized by its high measurement resolution and simple operation via color touch screen.

Motorized Tester Models

Re-designed model series for tensile and compressive force measurements with a high level of measurement accuracy and a simple control concept and durable construction. High internal measurement frequency and resolution to ensure the highest degree of accuracy.

Technical data

The storage system has been designed exclusively for reels and provides optimum use of storage and production space. The absence of warehouse pallets allows not only the best utilisation of storage height, but also reduces operating costs. Our storage system offers the possibility to connect several production lines, such as cable cutting/stripping lines or cable rewinding systems. The integrated double de-reelers make for high productivity through fast exchange of cables (within max. 60 seconds).

Technical data

Cable storage requirements for are well known! They should be easy to build, cost effective and space saving. Above all, they should be safe. De-reeling has to work smoothly, quickly and easily. These requirements are also applicable to the change-over of the reels.

Technical Data

Coiling machine

The task of the OE-VE10/BA is to pull the cable from the drum and the wind it up in precise layers. The length measuring system and the automatic cutting function make for a complete system, which is transported on rollers to the respective drums.

Technical data

Manual coiler-uncoiler

Easy, manual coiling of cables. By using a built-up measuring unit in combination with the compact shears, the entire cut to length and winding process can be carried out simply and economically.

Technical data

One spindle winding machine

The WH 751 is a single spindle bench top coil winding machine with tailstock and digital control for semi-automatic operation. This coil winding machine can be fitted with a wide selection of accessories and provided with variable drive ratios, and it is suitable for winding all types and sizes of coil including transformers, chokes and motors. An all-round performer and highly versatile workhorse.

Technical data

Two spindle small inductor winding machine WH 800i

Four spindle small inductor winding machine WH 764

WH 800i and the WH 764 are high speed, semi-automatic bench top coil winding machines with digital controller for winding small inductors with fine wire. The high speed of up to 6,000 rpm enables short cycle times. Applications include the manufacture of ignition coils, motors, relays, solenoids and many forms of sensor coil in small and medium batch quantities.

Technical data

Toroid Winding Machine

The WH 900 is a digitally controlled toroid winding machine, ideally suited to the manufacture of toroidal power transformers, isolation transformers, inductors, chokes and other toroidal devices of up to 60 mm finished outside diameter. The machine can be equipped with either 4 or 6-inch toroid winding heads, both of which are available in belt and side slider versions.

Technical data

Electronic Tensioner

The TH3 is a floor-model heavy-duty tensioner and is suitable for wires of 0.5 to 3 mm in diameter. Soft wire guiding and electronically controlled brakes make this tensioner perfectly suitable for all heavy duty winders.

Technical data

Mixing and dispensing system

This mixing and dispensing system delivers 2-component material and adhesives based on polyurethane, epoxy and silicone quickly and accurately.

Technical data

3-axis working table

The ROBO-DOS in combination with the mixing and dosing system 2-K-DOS forms a robot system for fully automatic dispensing and application of electronic assemblies, sensors, seal tracks, etc.

Technical data

Linear unit

LIN-DOS is a three axis linear unit for the automatic sealing of rails, in particular LED strip light, in combination with the mixing and dispensing units 2-K-DOS or 2 K MiniDOS.

Technical data

Dispensing cell

Compact and flexible - the new dispensing system for dynamic sealing, bonding and encapsulating. Features: 2K-material conditioning on carriage for easy maintenance; servo-driven high-precision gear pumps; integration into existing production lines possible, etc.

Technical Data

Dispensing robot

Variable X-Y-Z strokes enable the three-dimensional dispensing of sealants, adhesives, and encapsulates. The DR-CNC is equipped with the highest standards in CNC technology to combine the mixing and dispensing system with maintenance-free CNC linear axis.

Technical Data

Compact dispensing system

The C-DS dispensing system is highly versatile and can be used as a manually operated unit, an automated partial solution, or a fully automated robot system. The system consists of a material conditioning, metering, and mixing unit, and PLC controls. The modular design simplifies integration into existing production lines.

Technical Data

Mixing systems

Mixing systems, as diverse as your applications. A solution for every task: selection of the mixing system is according to material and application.

Technical Data

The contact strips made from beryllium copper are offered in a wide variety of shapes, sizes and mounting options. To avoid problems with the compatibility of the material, contact strips are supplied with different surface finishes.

Electrically conductive elastomers (EcE) are available in many different elastomer compounds, fillers and shapes. Common variants are gaskets made from silicone filled with carbon or silver-plated glass or silicone foam with a silver-plated surface. Very good environmental sealing (IP65-IP68) is also guaranteed with this seal.

These highly conductive gaskets are available in different material combinations and profiles and are widely used in cabinet construction.

Metal housings offer the best shield against electromagnetic radiation. Non-conductive plastics such as polyurethane foam, ABS, ABS/PC etc. are becoming more common for enclosures for electrical and electronic devices. Since these materials cannot resist electromagnetic interference, the function of these devices will affect or interfere with disturb other devices. This requires the use of conductive coatings to achieve electromagnetic compatibility and shielding. The Celerol-EMI coating contains a high proportion of conductive particles for metallization and thus provides a very good attenuation.

Recesses in enclosures which contain electronic components often produce EMI problems. The PSC products Solaris-Shield™, an optical filter with resin hardened metal mesh, and Combi-Shield™, a metal mesh stretched over a part, are the solutions offered.

We can solve all winding problems.

Send us your request, and we will provide the appropriate winding machine.

Electrically conductive silicone-based gaskets offer protection against electromagnetic radiation and prevent electrostatic charges. Customized EMI gaskets for complete sealing of housing parts and assembly segments are the main fields of application. Especially in lower quantities, the use of EMI gaskets offers a price advantage over other customised solutions and offers great flexibility. These seals adhere very well to aluminium, stainless steel, copper or nickel plating plastics.

Protection against pollution, moisture, liquids, environmental influences, unintentional changes or contact plays a major role in the entire electrical and electronics industry. Our services cover selective coating, casting plugs and electro-mechanical and electronic components, modules and sensors, as well as the applying of seals. We handle almost every 1-component material, time and UV-curing.

Digital product – production control system

The cloud-based version of the Komax MES gives customers quick access to a professional production control system and does so without financial risks, since cloud technology holds customer investments to a minimum. Production data, which is uploaded to the system as Excel files, can be efficiently planned and then sent onto the machines. All advantages of an MES, such as increased productivity, assured quality and planning flexibility are 100% guaranteed.

Depending on the contact type and cross-section, the right WDT-branded die for hand tools or machines can be used, easily and at low cost. The widest range of contact types can be processed in this way, from wire end ferrules to tube cable lugs or twisted contacts. Further dies and tool heads are available for almost all types of loose contact.

Technical Data

Set 441 red/blue/yellow	Set 66 (D)	Set RM 4	CSV 10 - F 4,8
0.5 - 6.0mm2 dies for insulated press cable lugs	0.1 - 10.0mm2 dies for insulated crimp cable lugs (mandrel crimp)	0.14 - 4.0mm2 dies for twisted contacts incl. RM positioner	0.5 - 1.0/1.5 - 2.5mm2 tabs + receptacle for 4.8mm width tabs to DIN 46247 Sheet 2

Laser Stripping Device

The ILC Bench Top laser stripping device is equipped with advanced features, making your cable processing both rapid and uncomplicated. A variety of cable types can be processed extremely cleanly, thanks to its high-precision infrared laser rotary cut. Depending on the model, the device accepts a wide range of cable diameters. The modern program supplied ensures quick mechanical changes between cables with different characteristics and external diameters. The ILC Bench Top can handle the majority of insulation materials and the most difficult types of cable, even processing intermediate insulation.

Technical Data

	ILC-20/8 BT	ILC-20/8 BTS	ILC-30/20 BTS
Outside diameter	from 0.5 to 7.8 mm	from 0.5 to 7.8 mm	from 1 to 20 mm
Stripping length	3-115 mm	3-115 mm	3-115 mm
Laser type and strength	Infrared CO2, 20 watt	Infrared CO2, 20 watt	Infrared CO2, 30 watt
Laser cut	Circumferential cut	Circumferential, longitudinal, and spiral cut	Circumferential, longitudinal, and spiral cut

The STCS-SYX is a heat shrink system based on infrared technology capable of processing up to six meters long harnesses. The equipment can be supplied only as onesingle main module suitable to process products up to one meter long and extension modules are available to enlarge the machine’s production area.

The ISAC14 (Integrated System Automatic Centering) is a newly developed system to integrate to the existing STCS-CS14 to guarantee the centering of the heat shrink tube on the splice. It’s an automatic system, developed as an addon for STCS-CS14 and it’s compatible with all the previous versions of this model.

Stripping and crimping machine for loose, insulated ferrules

Electro pneumatically driven stripping and crimping machine. Crimp quality according to DIN 46228. Special feature: Two cross-sections of any lengths can be processed at the same time. You can switch between preset cross-sections at the push of a button. Thonauer can also supply you with the right ferrules.

Technical data

	AM 04 Duomatic
Ferrules
Conductor cross-section	4– 10 mm²
Crimp length	8–12(18) mm

Battery Crimp Tool EHC 13

EHC 13 Battery Crimp Tool is designed for the crimping of loose piece contacts in small and medium volumes. Small and larger cross sections can be crimped in areas especially difficult to access. The ergonomic design and wide range of crimping profiles provides flexibility and efficiency to your manufacturing environment. The “Quick Connect System” combines the ability to change tool heads and die sets easily to provide several industry standard and custom crimp solutions. An additional benefit is offered with the cutting tool head, which provides the capability to cut cables up to a diameter of 54 mm.

Inkjet printer

The Ax family can be operated stand-alone or in-line. The simple installation and operation together with the easy ink tank change minimize your operating costs. The Ax family is designed to be integrated into a production line and prints on the products in defined positions.

Technical Data

The M611 is very popular with customers who want to print labels quickly with smartphones and who are fond of technology. Easy operation for spontaneous printouts. The portable BradyPrinter M611 can be operated via a smartphone and is suitable in combination with the Brady Workstation app “Express Labels” for the identification of cables, components and laboratory samples as well as for complex identification in the electrical field. Using a smartphone, you can easily create 1D and 2D codes and barcodes, serialize data and benefit from a comprehensive image library.

Technical data

The BMP61 is also available with WLAN function and as a bundle with the WS, etc. It is a state-of-the-art printer and very popular in switch cabinet construction and outdoor applications. The BMP™61 label printer offers several user interfaces, a touch screen, different connectivity options and various options for managing and storing data. The printer prints extremely quickly pre-cut and continuous labels as well as labels in bulk with a width of up to 50.8 mm. Customized labels can also be printed. The BMP™61 comes with the Brady Workstation Suite for product and cable identification, so you can start designing professional labels immediately.

Technical data

Heavy cable wire cutting and stripping

The Artos CS-370 cutter can strip and cut heavy wires with a diameter of up to 35 mm and a length of just 50 mm with high performance and precision.

The robust wire leveler guides the product on the Artos CS-370 to the precise cutting device. The servo feed drive takes over the additional driving force to enable hands-free and safe working. Optionally, a rotary blade can also be upgraded to make even more accurate cuts without damaging the wires. This cutting module enables several alternatives to stripping for multi-layer and shielded wires. In addition, the Artos CS-370 can be equipped with inkjet wire marking and a wire slitter in order to combine further wire processing steps in one machine.

Technical Data