crimp to crimp
EN
THE ROBUST DURABLE
ALL-ROUNDER INVESTMENTS
Stable, tried-and-tested technology combined ARE MORE
with innovative solutions secures and increases
the added value of your company. Alpha 530 – PROFITABLE
the fully automatic wire processing machine for
crimping and loading of seals – on both sides –
meets these criteria with its solid, powerful
technology. In addition, double crimp, sleeve
assembly and ferrule assembly can also be
efficiently processed and the strands twisted
and tinned. The quick set-up and changeover
times of Alpha 530 contribute to high productiv-
ity. High process capability and retrofittable
quality options such as Q1250 scalable and
ACD meet the highest quality requirements.
Unrivaled robustness and durability
– Reliable processing of wire cross sections
ranging from 0.13 to 6 mm²
– Production of special and complex
applications thanks to flexible machine
configurations
– Solid and reliable processes with powerful,
durable technology
– Reduced maintenance costs thanks to the
unique approach to wearing parts
– Designed for demanding ambient conditions
Precise and outstanding quality
– First time right – perfectly synchronized
machine processes enable excellent
CpK results
– Highly robust machine configuration
– Can be retrofitted with unique quality
monitoring systems such as Q1250 scalable
and ACD
– Wires handled carefully, gently during
processing
Productive due to fast changeover
– High productivity performance thanks to
ultra-fast machine setup and operation
– Q uick and highly efficient changing of
cables, crimp tools, terminal rolls
– New deposit system for maximum output
Absolutely precise
processing with
single-line blade
holder.
Maximum productivity in no time at all and ergonomic to operate via touch intervention and ensures quality control of
ROBUST AND Short distances for the operator between
crimping, cable and cutting stations, as
screen, keyboard and mouse. The intuitive
user interface makes it possible to load
even the finest wires. The ACD detects the
slightest contact between the blade and
HIGHLY well as LED-illuminated work zones in- the next job on the fly – as well as prepare the conductor strand during the stripping
PRODUCTIVE
crease productivity. The user interface is material and tools. Control displays and process.
clearly structured and can be expanded. LED-illuminated work areas optimize and
The user guidance is sequence-controlled enhance user guidance. Gentle wire guidance
and can be individually adapted. The pneumatic wire straightener enables
Changeovers with the Alpha 530 can be First-time-right approach – high feed-in speed and excellent deposit
even faster using the optional linear wire minimal rejects quality even with difficult conductor mate-
quick changer and the stationary (STC) Top precision, even at maximum system rial. With the actively controlled roller pres-
terminal quick change system. performance and excellent CpK results – sure, any changes in the cable containers
the machine processes and the functions and draw-in speed are compensated. To
Quick changeover; set up in parallel for quality assurance are perfectly attuned avoid indentations on the cables during
Simple, fast set-up and changeover to each other. The reliable EtherCAT tech- machine stops, the roller pressure is auto-
concepts enable short distances and nology guarantees optimum processes. matically reduced.
speed up the processes for changeover The speed of the deposit conveyor belt
and set-up. The Alpha 530 is time-saving Quality assurance by Komax is automatically adjusted, assuring neat
Komax develops and produces its own and gentle wire deposit. The deposit tray
quality assurance technology. This QA features a smooth surface to prevent any
technology meets the highest standards of cable damage.
the automotive industry. Also available are
the integrated optical stripping, seal and The market leader’s quality
crimp monitoring function (Q1250 scalable) and expertise
and crimp force monitoring (CFA+/CFA) for Komax assures the maximum performance
detecting missing strands and other crimp capability of the Alpha 530 by delivering ho-
faults. The optional Automatic Conductor listic, comprehensive quality. It considers all
Detector (ACD) reduces operator components and rounds out these efforts
with local services globally.
01
Quick and reliable setup directly
on the crimp module.
02
The tools are within reach at any time
in the practical, lockable drawer
situated directly under wire draw-in.
03
Quick change of the guide tubes
without tools. Processing of cables
with seals and crimp with the same
guide tube (one guide tube length).
01 02 03
AUTOMOTIVE
CONFIGURATION
Crimp modules C1370 / C1360 / C1340
Shortest setup and conversion times are
Q1250 SCALABLE achieved thanks to efficient user guidance
OPTICAL QUALITY MONITORING with wire positioning directly on the mod-
ule. CFA+ assures the highest level of
quality and the lowest possible rate of
rejects. In combination with time savings
productivity can be increased considera-
bly. Functions such as stroke and split
cycle are easily programmed.
The C1370/C1360 adjusts the crimp hight
automatically during the teaching process.
C1370/C1360/C1340 The C1370 also offers maximum position-
CRIMP MODULE ing accuracy and sequencing capability.
S1441
SEAL MODULE
S1441 seal module for maximum
flexibility
The module automatically fits wires with
common seals and mini-seals. The combi-
nation of precision mechanics and the
Q1250 scalable seal position monitoring
function guarantees a high degree of
process safety and maximum productivity.
The module can be simply and quickly
switched from one seal variety to another.
Optical quality control Q1250 scalable
for maximum quality
The quality tool visually checks the
stripping quality and automatically rejects
faulty products. A seal monitoring function
is also available that monitors the seal
position and orientation. Thanks to the
high-performance color camera, any crimp
defects such as crimped-on strands or
insulation in the crimp can be monitored.
Easy to integrate into the production pro-
cess. Product quality can be seamlessly
tracked using statistics, image saving and
network feedback.
INDUSTRIAL
CONFIGURATION
CM03
MIL-CRIMP MODULE X1585
TINNING MODULE
AEH-LS
FERRULE MODULE C1340
Shortest setup and conversion times are
C1360/C1340 achieved thanks to efficient user guidance
CRIMP MODULE with wire positioning directly on the mod-
ule. CFA+ assures the highest level of
quality and the lowest possible rate of
rejects. Functions such as stroke and split
cycle are easily programmed.
SLEEVE MODULE C1360
Crimp height programmable crimp module.
Efficient user guidance. Integrated crimp
force monitoring CFA+/CFA.
AEH-LS
The AEH-LS ferrule module is a flexible
solution for controlled crimping of bulk
ferrules on stripped conductors.
Double gripper module
DC With the double gripper module, two wires
DOUBLE GRIPPER MODULE can be connected in one crimp.
Sleeve module
The sleeve insertion module mci 792
marks up with an efficient and reliable in-
sertion of different sleeve types on one
device. By an application set the device
quickly can be converted to other sleeve
types.
X1582 X1585
TWISTING MODULE The X1585 fluxing/tinning module enables
versatile, lead-free tinning of strand
ends. Constant tin flow allows for consis-
tent quality.
X1582
The X1582 twists stripped wire ends and
offers the ideal basis for optimum tinning
processes.
CM03
The MIL-Crimp module CM03 processes
turned pin and socket contacts reliably
and precisely.
Basic wire deposit module 2 m: 3825 mm (150.6 in)
Basic wire deposit module 4 m: 5770 mm (227 in)
The finished cables
are placed in the
smooth deposit unit
made of stainless
steel.
1525 mm (60 in)
Height with cover closed: 1790 mm (70.5 in)
Height with cover completely open (maximum opening): 2790 mm (109.8 in)
Output rate Technical data
6000
FLRY conductors 0.5 mm² (AWG 20) Wire cross sections 0.13 – 6 mm² (AWG 26 – 10)*
5000 Pressure 6 bar (87 psi) Wire draw-in speed max. 9 m/s (29 ft/s) belt drive
Wire feed speed 9 m/s Outer diameter of conductor max. 5.1 mm (0.20 in.)
4000
Crimp module C1370 Length range 60 – 65’000 mm (2.35 in. – 213 ft.)**
optional 30 – 60 mm (1.18 – 2.36 in.)
3000 Seal module S1441
pcs/ h
Full stripping 0.1 – 18 mm (0.004 – 0.71 in.)
Crimp force monitoring Active
optional up to 29 mm (1.14 in.)
2000
ACD, Q1250 scalable Inactive
Half stripping 15.5 mm (0.6 in.)
1000 Deposit gripper Active optional up to 35 mm (1.38 in.)
Crimp / Crimp The actual output rate can vary Crimp force 1 – 22 kN (224 – 4’946 lbf.)
0 with application and machine
0 500 1000 1500 2000 2500 3000 3500 4000 Crimp-Seal / Crimp-Seal configuration.
Process modules side 1 / 2 2/2
Wire length [mm]
Noise level < 80 dB (without crimp tool)
Electrical connection 3 × 208 – 480 V / 50 – 60 Hz / 5.6 k VA The efficient belt drive
Options and accessories reliably draws in the cable
Compressed air connection 5 – 8 bar (73 – 116 psi.) at a speed of up to 9 m/s.
Automatic delivery F1110 • F1150 • Komax 106 • ads 119 • ads 123 Air consumption Crimp / Crimp < 7 m³/h (247 ft³/h)
systems Seal crimp / Seal crimp < 11 m³/h (388.5 ft³/h)
Wire drive Belt drive Weight (incl. 2 crimp modules) 1.3 t (2866 lbs.)
Marking systems Komax 26 hot-stamp marker • Komax IMS inkjet marking systems • * Very hard or tough wires may not be able to be processed under certain circumstances although they are within the specification.
Komax offers feasibility tests for testing the wires in advance. The processing of larger wire cross sections is possible on request.
Laser marking on request ** Wire length tolerance ±(0.2% + 1 mm (0.039 in))
Blade holders Single-blade line for V blades • Double-blade line for V blades and special blades
Process modules C1370 /C1360 /C1340 crimp module • S1441 seal module • X1582 twisting module •
X1585 tinning module • Sleeve module • Double gripper module • Processing examples
AEH ferrule module • MIL crimp module • Welding module • Ultrasonic compaction
Quality control Komax 341 Integrated crimp height measurement • Q1210 Integrated pull-out force Cutting to length Intermediate stripping Sleeve insertion
measurement • ACD automatic conductor detection • Q1250 scalable optical
stripping- and crimp monitoring • Material change detection • Material verification • Cutting pulled strands Crimping Ferrule crimping
Splice detection • Q1140 spark tester • Terminal end detection
Deposit systems Basic module 2 m (78.7 in) or 4 m (157.5 in) • Extension module 2 m (78.7 in) or 4 m Full stripping Double crimping MIL crimping
(157.5 in) • Deposit gripper
Split cycle Wire-end compaction,
Half stripping
for closed barrels splicing, welding
Accessories STC Crimp tool quick-change system • Wire quick-change system •
Bar code scanner • Intermediate stripping Core processing Seal insertion Hot-stamp marking
Software Komax HMI • Komax MES • MIKO networking interface • WPCS/MIKO Converter • Double casing, coaxial
Twisting / tinning Inkjet marking
TopConvert data conversion and triaxial cables
Komax – leading the field now and in the future
As a pioneer and market leader in automated wire processing,
Komax provides its customers with innovative solutions. Komax
manufactures series and customer-specific machinery, catering to
every degree of automation and customization. Its range of quality
tools, test systems, and intelligent software and networking
solutions complete the portfolio, and ensure safe, flexible, and
efficient production.
Komax is a globally active Swiss company with highly qualified
employees and development and production facilities on several
continents. It provides local support to customers worldwide
through its unique sales and service network and offers services
that help them get the most out of their investments.
Komax AG
Industriestrasse 6
6036 Dierikon, Switzerland
Phone +41 41 455 04 55
[email protected]
Alpha 530 V11 02-2023
Subject to change
komaxgroup.com
