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Alpha 488 S – Economical processing of twisted pairs
Introduction
Alpha 488 S produces fully automatically Twisted-Pairs out of two single bulk wires
completely cut-to-length and terminated, with all quality controls included. The modular composition
of the system provides superb flexibility. Four processing stations at the wire beginning and two at
the wire end offer extensive processing possibilities.
Key features:
- Complete processing of two single bulk wires into twisted pairs with processed ends
- Fully automatic twister featuring well-proven as well as innovative quality monitoring systems (DLA, TFA, SPM, CFA/CFA+ etc.) for maximum process control
- Gentle and precise wire handling for the best quality of the final product
- Highly reliable and proven TopWin graphical user interface on touch screen for efficient machine use
- Simplified machine design for the greatest ease of operation and maintenance
- Networking possibilities with reliable WPCS and KomaxCAO
- Excellent value for the money for the economical production of Twisted-Pairs
Function
Highest flexibility
The machine layout accommodates up to six
processing stations. Wires with cross sections ranging from 2×0.13mm2 (AWG26) to 2×2.5mm2 (AWG14) may
be processed in the highest quality.
The system can also be used for the processing of two untwisted isometric single wires. Alpha488S is available in the versions of four, seven and ten meters.
In combination with the Komax crimping modules mci 722 or mci 712 and the Komax seals module mci 765 C as well as with the quick-change systems and the integrated quality monitoring systems
Alpha 488 S ensures maximum process reliability and extremely short changeover times.
The system can also be used for the processing of two untwisted isometric single wires. Alpha488S is available in the versions of four, seven and ten meters.
In combination with the Komax crimping modules mci 722 or mci 712 and the Komax seals module mci 765 C as well as with the quick-change systems and the integrated quality monitoring systems
Alpha 488 S ensures maximum process reliability and extremely short changeover times.
Outstanding user-friendliness
The system is characterized
by a remarkable user-friendliness. Accessibility to all stations is optimal due to a large swivel radius
and an upwards opening protection cover.
In addition, long and fold-up wing-doors allow the operator an excellent and quick access to the upper wire deposit tray as well as to the twisting area.
A pivoting operator console allows an improved machine operation, since the wire deposit tray is freely accessible at all times.
The touch screen which combines visual output and data input in the same spot, also contributes to a more efficient operation of the machine. It is included in the standard configuration.
The graphical user interface is based on the well-proven TopWin and allows the easiest control of the Alpha 488 S.
The compact design of the wire feed-in unit provides central and fast access to daily used guiding parts and tools.
In addition, long and fold-up wing-doors allow the operator an excellent and quick access to the upper wire deposit tray as well as to the twisting area.
A pivoting operator console allows an improved machine operation, since the wire deposit tray is freely accessible at all times.
The touch screen which combines visual output and data input in the same spot, also contributes to a more efficient operation of the machine. It is included in the standard configuration.
The graphical user interface is based on the well-proven TopWin and allows the easiest control of the Alpha 488 S.
The compact design of the wire feed-in unit provides central and fast access to daily used guiding parts and tools.
Maximal ease of maintenance
Thanks to a sophisticated, highly innovative, wireless
electrical transmission system - ICS (Inductive Communication System) in combination with an autonomous
air-pressure storage system allows the suppression of the drag chain at the wire-puller
carriage. The highly simplified guiding concept for the linear carriages, the compact deposit cells and some automated adjustments greatly simplify the installation and maintenance of the system.
A single control cabinet and the simplified hardware architecture further facilitate the maintenance work.
carriage. The highly simplified guiding concept for the linear carriages, the compact deposit cells and some automated adjustments greatly simplify the installation and maintenance of the system.
A single control cabinet and the simplified hardware architecture further facilitate the maintenance work.
Technology
The
twisting head with AC servo-drive is the heart of Alpha 488 S and delivers the required dynamics. The
integrated Twist Force Analyzer (TFA) monitors the forces during twisting and regulates the subsequent
adjustment movements of the twisting head.That ensures a steady and ultra-precise twisting.
The linear wire-puller with integrated Delta Length Analyzer (DLA) ensures that wires are drawn-in gently and with great accuracy of length. The high output of the system results from the parallel processing of two wires and the division of the overall processing cycle into three perfectly synchronized main processes.
A further central element of the Alpha 488 S is the transfer bridge with motorized axes. It allows wires to be handled gentler and more precise than ever while enabling the automation of some adjustment procedures.
The linear wire-puller with integrated Delta Length Analyzer (DLA) ensures that wires are drawn-in gently and with great accuracy of length. The high output of the system results from the parallel processing of two wires and the division of the overall processing cycle into three perfectly synchronized main processes.
A further central element of the Alpha 488 S is the transfer bridge with motorized axes. It allows wires to be handled gentler and more precise than ever while enabling the automation of some adjustment procedures.
Applications
| Cutting |  |
|---|---|
| Cut pulled strands / Precision cut |  |
| Full strip |  |
| Half strip |  |
| Twisted pair (also with different open wire ends) |
 |
| Crimping |  |
| Hot stamp marking |  |
| Ink-Jet marking |  |
| Split cycle |  |
| Seal insertion |  |
Technical data
| Length range | 700mm–4000mm (27.6in–157.5in) 700mm–7000mm (27.6in–275.6in) 700mm–10000mm (27.6in–393.7in) Optional from 150mm (5.9in) Final length of twisted pairs |
|---|---|
| Length accuracy | ±(0.3% +1.5mm(0.06in.)) |
| Stripping lengths | Side 1: 0.1mm - 18mm (0.004in. - 0.7in.) Side 2: 0.1mm - 35mm (0.004in. - 1.4in.) |
| Wire cross sections* | 2×0.22mm2–2×2.5mm2 (AWG24–AWG14) Optional from 0.13mm2 (AWG26) |
| Open wire ends | 30mm - 99mm (1.2in. - 3.9in. (optionally 30mm - 125mm (1.2in. - 4.9in.) on side 1)), depends on pitch, cross section, and end processing |
| Pitch length | 5mm - 80mm (0.2in. - 3.2in.) programmable accuracy: ±10%, max. 5mm |
| Wire draw-in speed | max. 5m/s (16.4ft/s) |
| Noise level | <75dB (no crimping module) |
| Electrical connection | 3×208–480V/50–60Hz; 10kVA |
| Pneumatic system | 5 - 6bar (73 - 87psi) 12Nm3/h (424ft3/h) |
| Weight | incl. two crimping modules and two seal loading modules Alpha 488 S / 4m: approx. 2800kg (7502lb.) Alpha 488 S / 7m: approx. 3400kg (9109lb.) Alpha 488 S / 10m: approx. 4000kg (10717lb.) |
*
Extremely hard and tough wires may not be able to be processed even if they are within the above cross
section range. If you are in doubt about your wires, we are happy to process your samples.
Software
TopWin 使用方便,同时保证数据安全.它采用Windows界面,它是KOMAX全自动压接机的操作界面.
可选装的 WPCS 软件在Topwin界面下将机器相互联接.在这开放的界面下,机器可以方面地融入到现有的生产中去..
TopNet 是一个管理软件,可以集中创建部品号,工艺卡,生产工单,帮助您优化生产.
TopConvert 可以转换现有生产工单,工艺卡为WPCS格式数据,然后由全自动压接机直接生产..
Processing modules
The Alpha 488 S can be customized with various modules to meet specific
customer needs:
- mci 712/722 crimping module
- mci 765 C seal module
- mci 792 sleeve module
- mci 782 twisting module
- Fluxing/Tinning ioc 785
- other processes on request
Accessories/options
There are a number of
different accessories available with which you can adapt the
Komax Alpha 488 S to your own specific needs and expand its capabilities as desired.
Preliminary wire processing
- Ink jet marker
- Hot stamp marker
- Wire feed systems
Crimping module accessories
- Paper winder
- Carrier strip chopper
- Valve set for pneumatically operated advance
- Pressure regulation set
- Monitoring of length-wise and cross-wise transport of terminals
Process monitoring
- Twist force analyzer (TFA)
- Delta length analyzer (DLA)
- Crimp force analyzer (CFA/CFA+)
- Seal position analyzer (SPM)
- Splice detection
- Quality assurance Komax 331, 341, 371, Generic Barcodescanner
Deposit systems
- Deposit cells 4m, 7m or 10m
Further accessories
- Short lengths (starting from 150mm)
- Different open ends up to 125mm in length on side 1
- Tower light
- Wire measurement band
- Magnifying glass
- Keypad
- Uninterruptible power supply (USV)
- Set for small gauges
- Set for non-halogen wires
