Cars, airplanes, appliances and electrical equipment have changed considerably in the past few years, and so has the wiring that goes into them. The equipment needed to cut, strip, crimp and assemble that wiring is changing, too. Here’s a look at some of the latest technology.

System Brazes Bus Bars

This flexible manual welding system is designed for brazing connections in the power distribution sector. Connections from bus bars to high-voltage contacts, cables and pigtails are possible. The slim design and quick-change tools enable the production of bus bars with difficult geometries. A flexible servo brazing feeder with integrated monitoring can be connected at various angles on the right and left sides. At an angle of 0 degrees, it allows the feeding of different brazing widths through the welding unit. A conversion kit for compacting cables and pigtails up to 120 square millimeters is also available. Complete traceability is ensured via camera or DMC. The system can also be connected to Strunk’s MES or other MES software.

See this company at The ASSEMBLY Show South April 16-17 in Nashville, TN.

Strunk Connect Automated Solutions
https://strunk-connect.com

Image courtesy of Komax

Spot-Taping Machine for Wire Harnesses

The KTB 50 E-Plus is a semiautomatic spot-taping system for wire harness assembly. It applies tape or labeling material to wire bundles in just 1.8 seconds. An intelligent gripper fixture automatically detects the cross-section of the inserted wire set and adjusts the required belt length, minimizing setup time during changeovers. Individual process parameters can be set via the machine’s control panel. The machine stores five programs in memory. The machine applies tape 60 percent faster than manual application. Maintenance intervals are displayed automatically, and oiling of the cutting blade is automatic.

See this company at The ASSEMBLY Show South April 16-17 in Nashville, TN.

Komax
www.komaxgroup.com

Image courtesy of Daniels Manufacturing Corp.

Heavy-Duty Crimping Tool

The 120 Series of hydraulic crimping tools are designed for attaching heavy-duty lugs and terminals onto large-gauge wire. The tools produce 12 tons of crimp force and cover a wide wire range from 8 to 4/0 AWG. They are available in manual hydraulic, battery hydraulic, and remote hydraulic versions. 

All models accommodate interchangeable dies for crimping insulated and uninsulated lugs and terminals for aerospace and other high-reliability applications. MS23002-xx dies secure insulated lugs and terminals with a confined crescent type crimp. MS90485-xx dies produce hex-type crimps on  uninsulated copper lugs and terminals. MS25442-xx dies crimp uninsulated aluminum lugs, terminals and splices.

The manual tool features a two-stage hydraulic system that reduces the number of handle closures required, making it easier and faster to crimp large components. The tool includes an automatic pressure relief valve that prevents over-compression, while the automatic die retraction indicates when the crimp cycle is complete. This means no second-guessing when the job is finished.

The tool’s 340-degree rotating head provides flexibility in confined spaces, making it highly functional in tight work areas. Padded handles add an extra layer of comfort, reducing strain on the operator during extended use. Plus, the hydraulic pump is factory-filled with biodegradable hydraulic fluid, eliminating the need for priming or bleeding.

The HDE120C is the battery-powered hydraulic tool in this series. This tool enhances productivity with a quick full cycle of just 2 seconds. The tool can complete an average of 150 crimps per charge. Built-in technology tracks tool performance, usage and crimp data, which can be accessed via an LED display or downloaded through an app. This level of data tracking allows for better management of tool maintenance and performance. 

Like the manual tool, the battery-powered tool features a two-stage hydraulic system, a 340-degree rotating head, and biodegradable hydraulic fluid. 

For more specialized applications, there’s the TBHD1M remote hydraulic crimp head. This tool is QPL approved and Mil-Qualified to MS25441-1 standards. The TBHD1M can be handheld or mounted on a BM-2A bench mount. It features a retractable spring plunger and is compatible with several hydraulic pumps. When bench mounted, this tool is virtually hands-free allowing operators to easily position components while actuating the tool with a foot-operated pump.

See this company at The ASSEMBLY Show Oct. 21-23 in Rosemont, IL.

Daniels Manufacturing Corp.
https://dmctools.com

Image courtesy of ETCO Inc.

Flame-Retardant Insulated Terminals for Appliances

These fully insulated electric terminals come in right angle (flag) and straight styles. They are constructed from a high-temperature alloy and flame-retardant nylon insulator and feature an open barrel “F” crimp connector to withstand the appliance assembly process. They are produced to UL and NEMA specifications.

The terminals are available in 10- to 22-gauge wire sizes to mate with NEMA male tabs in sizes 0.110 by 0.02 inch, 0.187 by 0.02 inch, and 0.250 by 0.032 inch. They are designed for automated wire processing equipment. Housings are rated to 150 C. If there is a malfunction, the nylon insulator collapses on itself and safely holds until the appliance completes an automatic shutdown. They are V-O rated per UL94 and RoHS compliant.

ETCO Inc.
www.etco.com

Image courtesy of Metzner Maschinenbau GmbH

Cut and Strip Thick Cable

The Metzner AM 3000 series is designed to cut and strip thick cables. Both the AM 3800 and AM 3850 offer maximum flexibility. The patented double blade enables different cutting techniques and can handle cables with cross-sections from 0.5 to 70 square millimeters. Operators can change the blades and guides without tools.

The conveyor belt protects the material and, thanks to pneumatics, guides it to the knife with the lowest possible slippage. Accuracies of ±1 millimeter are possible at a feed rate of 180 meters per minute. The motor generates up to 40 percent more cutting force than the motors of many other machines.

The machines also offer a complete range of software features, with both MES and PC integration included as standard. The parts list program is also included at no extra charge. Both models are also prepared for all types of pre- and post-processing. An interface for a printers is also included as standard.

Metzner Maschinenbau GmbH
www.metzner.com

Image courtesy of Icotek Corp.

Split Cable Entry Saves Space

The Modular Interface System (MIS) combines a split cable entry with the option of integrating 3A or 4A connectors directly into the frame. The cable entry enables the entry, sealing and strain relief of cables with and without connectors, with cable diameters from 1 to 15 millimeters, in accordance with DIN EN 62444. Both 3A and 4A industrial connectors are plugged directly onto the frame.

The complete system consists of a frame with an add-on housing for the socket insert, a cover, two screws and a locking element. The set also includes the counterpart, a housing for 3A or 4A pin insert, and a cable gland (M20 or M25).

The frame is CE compatible with numerous manufacturers, including Harting, Ilme, Phoenix Contact, TE Connectivity, Weidmüller, Lapp, Amphenol, Molex and RS Pro.

Unused connectors can be covered with an optional protective cover to ensure IP54 protection.

Icotek Corp.
www.icotek.com