The WireTerminal C3010 produces fully automatic assembled wires for control panel manufacturing. Up to 36 different wires can be processed without retooling. The wire cross-section ranges from 0.5 mm² to 6 mm².
The wires are cut to length, labelled and different end processings can be applied to both ends. The wires can then be placed in a WireRail, fixated between adhesive tape one behind the other or simply dropped.
The WireTerminal C3010 comprises a proprietary ten-way crimper with ten vibrating conveyor bowls in which loose ferrules ranging from 0.5 mm² to 6 mm² can be assembled. The vibrating conveyor bowls can be individually configured to meet customer requirements.
Standard equipment
Wire feed casette
During the production process, the WireTerminal can process up to 36 wires with a cross-section of 0.5 mm² to 6 mm² without retooling. To process other wires, you only have to replace one of the wire feed cassettes, which can be equipped with up to 12 wires, in one of the three positions.
The change can be carried out easily and without tools using a quick release. This is opened and the current wire cassette is replaced with another one. Each wire cassette is fitted with an RFID chip so that it can be clearly assigned.
Reading the RFID chip makes the WireTerminal recognise which wires are equipped at the machine and these are simultaneously released for production. If the wire assignment on the wire cassette is changed, this can simply be updated on the display. The wire assignments of the different wire cassettes are shown on the WireTerminal. All fine copper wires according to DIN VDE 0295 class 5 can be processed.
Wire labelling
The labelling of the wires produced by the WireTerminal is applied with an inkjet printer. This is used to print an individual text on the wire in the colours black or white.
The WireTerminal is equipped with up to two printers, which can be used alternately without waiting time. This means that the wires for the control panel manufacturing are clearly labelled and easy to assign.
The positioning of the labelling on the wire can be selected individually or printed continuously.
Crimper
The ten-way crimper developed in-house comprises ten vibrating conveyor bowls in which loose wire-end ferrules from 0.5 mm² to 6 mm² can be prepared.
All ferrules that comply with DIN 46228 are approved. Ferrules with a length of 8 to 18 mm can be processed, as well as different ferrule lengths on the same wire.
All ferrules with all cross-sections are crimped using a cross crimping tool.
Output in WireRails
When dispensing in WireRails, the wires are deposited individually. The WireRail magazine can be individually equipped with up to 15 WireRails.
Each cross-section between 0.5 mm² and 6 mm² is stored in a separate WireRail. The wires are sorted in such a way that they correspond to the sequence used for control panel wiring. All wires that have a ferrule crimped onto at least one end can be stored in the WireRail magazine.
Due to the high capacity of the WireRails, it is possible for the WireTerminal assembles wires over several hours without the need for manual intervention. The WireRails with the produced wires can be removed from the WireRail magazine once the job has been completed and immediately provided at the workstation for the control panel wiring.
The wires can be removed individually from the WireRails according to the predefined sequence and wired straight away without having to remove any adhesive tape residue.
Output in tape chains
When outputting in tape chains, wires are fixated using adhesive tape according to the wiring sequence.
Wires with different cross-sections of
0.5 mm² to 6 mm² can be arranged one behind the other. All wires can be deposited here, regardless of the end processing.
The finished tape chains are collected in a collection tray. Once the job has been completed, they can be removed from the tray and made available for the control panel wiring at the workstation.
Wire end processing
With the WireTerminal, the following end processings are possible on both ends:
> Continuous partial stripping from 6 to 20 mm
> Continuous full stripping from 2 to 22 mm
> Crimped-on ferrules 0.5 | 0.75 | 1 | 1.5 | 2.5 | 4 | 6
> Length of ferrules from 8 to 18 mm
> Ferrules in accordance with DIN 46228
It is also possible to crimp ferrules of different lengths on the same wire at each end.
Operation and interfaces
A swivelling 24" touch display is used for production-optimised operation of the WireTerminals.
The order data for the wire sets can be loaded onto the WireTerminal in many file formats. Possible examples include export files from ECAD software as well as XLSX, CSV, or TXT files.
In addition, the production status of the WireTerminal can be monitored and controlled at any time from different workstations
(e.g. work preparation, workshop management) via a network connection.
