Alpha 356 – Multifunctional automatic crimping machines

Introduction

With its extra large mounting surface, the Alpha 356 has room for up to seven processing modules. This machine is ideal if you need increased flexibility or have complex processes.

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Key features:

Highly flexible with up to five or seven processing stations
Integration of standard and customer-specific processes possible
Many processing configurations to choose from
High productivity thanks to the latest technology
Integrated quality measurements
Create the next job while the machine is running
Can be integrated in a network with WPCS interface

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Function

Along with the most frequent standard processes of crimping and seal loading, you can obtain a large variety of processing modules such as: fluxing/tinning, twisting the ends of wires, fitting with insulating sleeves and crimping modules for the widest variety of contacts types, ultrasonic or resistance welding modules. You can integrate customer-specific processing stations easily with the ultra-flexible TopWin software.

High productivity

With the reliable TopWin software you can record and edit jobs while the machine is running. The quick wire selector, quick tool-change system and other options ensure excellent productivity especially if there are frequent changeovers.

Maximum quality control

Crimp-height measurement and fully automatic pull-out force measurement are integrated in the process sequence. Optional material-change detection and the optional barcode scanner help to prevent materials from getting mixed up.
The processes are constantly checked against the specified values during production with functions that monitor crimp force, seals, splices, end of wire supply, and length. Any cables with processing defects are removed and an appropriate number of cables are post-processed automatically to replace them.

User friendly

The drive unit for the blade head is placed underneath, giving the machine a neat and ergonomic layout. All processing stations have safety covers that open vertically for optimum access, and application-specific parts like applicators and contact rolls can be changed without tools. Controls are placed at decentralized positions, allowing the necessary machine functions to be triggered during setup. All setting and adjustment procedures can be controlled from the TopWin graphical user interface in the operator’s choice of over 20 different languages.

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Applications

Cutting
Cut pulled strands / Precision cut
Full strip
Half strip
Flat cable / Notching
Inner conductor processing
Double sheath cables
Coaxial and triaxial cable
Intermediate strip
Crimping
Hot stamp marking
Ink-Jet marking
Sequence
Double crimping
Split cycle
Seal insertion
Twisting/Tinning
Sleeve insertion
Ferrule crimping
MIL-Crimping
Wire end solidifying

Cutting

Cut pulled strands / Precision cut

Full strip

Half strip

Flat cable / Notching

Inner conductor processing

Double sheath cables

Coaxial and triaxial cable

Intermediate strip

Crimping

Hot stamp marking

Ink-Jet marking

Sequence

Double crimping

Split cycle

Seal insertion

Twisting/Tinning

Sleeve insertion

Ferrule crimping

MIL-Crimping

Wire end solidifying

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Technical data

Length range	60mm - 65000mm (2.36in.-213ft.) Optional 30–60mm (1.18in.–2.36in.)
Length accuracy(Repeat)	+- (0.2% +1.0mm (0.04in.))
Stripping lengths	0.1 - 35mm (0.004in.-1.38in.)
Stripping lengths with partial strip	47mm (1.85in.) on side 1 35mm (1.38in.) on side 2 Optional up to 80mm (3.15in.)
Wire cross-sections*	0.22 - 6.0mm2 (AWG24 - AWG10) Optional up to 0.13mm2 (AWG26)
Wire draw-in speed	max. 12m/s (39ft/s)
Noise level	<75dB (no crimp module)
Electrical connection	3x208 - 480V 50/60Hz 5kVA
Pneumatic connection	5 - 8bar (73 - 116 psi)
Air consumption	9m3/h (318ft3/h)
Weight	approx. 1400kg (3090lb.)

Length range

60mm - 65000mm (2.36in.-213ft.)

Optional 30–60mm (1.18in.–2.36in.)

Length accuracy(Repeat)

+- (0.2% +1.0mm (0.04in.))

Stripping lengths

0.1 - 35mm (0.004in.-1.38in.)

Stripping lengths with partial strip

47mm (1.85in.) on side 1
35mm (1.38in.) on side 2
Optional up to 80mm (3.15in.)

Wire cross-sections*

0.22 - 6.0mm2 (AWG24 - AWG10)
Optional up to 0.13mm2 (AWG26)

Wire draw-in speed

max. 12m/s (39ft/s)

Noise level

<75dB (no crimp module)

Electrical connection

3x208 - 480V 50/60Hz 5kVA

Pneumatic connection

5 - 8bar (73 - 116 psi)

Air consumption

9m3/h (318ft3/h)

Weight

approx. 1400kg (3090lb.)

*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 samples of them.

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Software

TopWin .

The optional interface WPCS (Wire Processing Communication Stand-ard) allows Komax machines to be networked under TopWin. With this open interface, the machine is easy to integrate into existing production sequences.

TopNet is a clearly arranged mana-gement software with functions for the centralized creation and management of parts, articles and jobs that help you to optimize your production operations.

TopConvert can be used to convert already existing job and article lists to WPCS format. This data can then be directly processed by fully automatic crimping machines.