Komax AG

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.

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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.

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Web-based training

Thanks to the Komax On.Line training courses, employees can be trained at any time without any great effort.Various training courses on machines are available but also courses on the basic knowledge of cable processing. Further information under Solutions --> On.Line Training

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.

High voltage – stripping and crimping machine

The Lambda 240 SC combines three different cable processing steps: stripping, crimping and block loading of 2-pin HV connectors, Class 1 and 2. Simple operation by touch panel and a fast product change thanks to recipe management are other hallmarks of the product.

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Lambda 440 HV cable assembly machine

The Lambda 440 offers a modular cable processing system for the automated processing of high-voltage cables. Depending on the process, 6-15 modules can be used. Each cable is assembled in a continuous process from preparation to housing assembly.

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High voltage – semi-automatic shield processing machine

The Lambda 240 SP is a compact, semi-automatic solution for processing the shielding braid and inner conductors of HV cables in the field of electric mobility. Serial processing of two individual lines in parallel is possible. The touch panel ensures the simple storage and downloading of process parameters as well as a fast product change.

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High voltage – shield fixation machine

The compact, semi-automatic machine fixates and secures the shielding braid of high-voltage lines using tape. This solution was designed especially for applications in the electric mobility sector. The taping process meets the requirements of the Hirschmann PowerStar 40-2 connector system. This process is part of an overall solution, because the preparation is done on a Lambda 240 SP (see previous machine).

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Stripping machine

The Mira 32 electrical stripping machine is the ideal entry-level model for semi-automated cable processing when hand tools are no longer up to the job. This model is designed for cables used in the automotive and industrial sectors that can be stripped with V-blades. The machine, which can be adjusted with rotary knobs, processes cables with external diameters up to 4 mm and stripping lengths up to 25 mm. Single cables and the cores in sheathed cables can be fully or partially stripped. 

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Stripping machine

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

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

Stripping machine

The Mira 230 Q has all the functions of the Mira 230 plus the ACD electronic cut-in monitoring (Automatic Conductor Detector). This monitoring system detects and signals the slightest contact between the blade and the conductor. This function can be activated during cutting and/or removal for quality assurance purposes. The Mira 230 Q also uses ACD technology as an aid to making adjustments automatically. The cut-in values are set based on the measured conductor diameter.

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

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.

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Rotary stripping machine

Exceptional high-performance due to 4 rotary X-blades. Perfect cut even with critical insulations such as Teflon®, Kapton® or silicone. Sequence processing enables stripping of multi-layer cables. Easy operation by 5” touch screen. State-of-the-art and flexible.

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Stripping machines for coaxial and semi-flexible cables

Highly precise processing of multi-layer cables.

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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.

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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.

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Kappa 340 with RIU / without RIU

The Kappa 340 handles the precise processing of uneven cable surfaces, battery, multicore, HV and sensor cables as well as hard, tough, thick and thin insulation.

The versatile Kappa 340 stripper and cutter is equipped for all current and future wire processing requirements: The dual head double cutting head with various V, V-radius and form blades processes wires with a thickness of 0.22 to 70 mm² and ribbon cables up to a width of 16 mm. The device is also available with a RIU (rotating incision unit) for even more precise and careful stripping and cutting. Thanks to the 4 m/s belt drive, even complex sequences are processed efficiently. The integrated two-stage length measurement enables precise incision positioning as well as length correction and detects slip. In addition, the optional quality assurance with optical sensor minimizes cutting losses.

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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.

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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. 

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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.

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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.

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.

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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.

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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.

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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.

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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.

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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

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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Wire delivery system

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

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Cable feed system

The Komax 106 is an active feed system that is especially suitable for the processing of a wide range of different lines at high speed. The feed takes place from loose rings, from cable drums, Conipacks or central cable storage systems. The device can be operated both as a “stand alone” unit and in combination with all cable processing machines. A compatible interface is available for Komax machines in particular.

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Cable feed system

The motorized feed system F1150 is the latest in the Komax product range for the automatic processing of low-tension cable reels up to 300 kg. The device can process a wide range of round cables and is particularly suitable for tension-sensitive cables, e.g. coaxial cables. This cable feed system is highly compatible and can easily be integrated into a complete cable processing line.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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Micrograph laboratory

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

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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.

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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.

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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.

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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.

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