Splice crimping machines by SM Contact

Splice crimping

Splice crimping equipment

SM Contact designs and produces splice crimping machines for a wide range of electrical components: wire, PCB, coil frame, metal tab, capacitor, sensor, diode, transformer, lead frame, resistor, textile, filament, etc.

We start each project with a profound connection and tooling qualification to define its optimal parameters, to adapt machine specification, and to match industry norms. Depending on the configuration, equipment performs insulation stripping, single or multiple splice crimping, inline quality control, and defective products removal.

Choose one of SM Contact equipment configuration to manufacture gastight, vibration resistant, compact connection with low electrical resistance.

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SM Crimp V8Splice crimping with manual components positioning

SM Crimp V8 operation includes components manual positioning, when operator holds components within the splice area, and splice crimping by pressing the pedal.

Touch screen control panel (instead of manual buttons in the earlier models):

– displays information about tooling and connection,

– lets choose connection with preadjusted heights,

– detects position of main shaft by encoder,

– transmits picture from camera in the cassette and data from the built-in CFM.

Tool cassette can be designed for a wide range of wire cross-sections, e.g. 0.5-1.5 mm². What is more, changing only the cassette it is possible to perform various connections with the same splice band.

SPECIFICATIONS:

– automatic crimp height adjustment with position controlled by encoder

– built-in CFM

– built-in component position video verification

– easy punch return to zero position

– plug-and-play fixture installation

– сan be integrated into automatic production line

Learn more about splicing

Watch SM Crimp V8 on YouTube

DOWNLOAD SM Crimp V8 PDF

Technical characteristics

Power supply	230 V / 50 Hz
Absorbed power	500 watts
Motor rating	300 watts
Cycle time	300 ms
Noise level	< 75 dB
Weight	app. 50 kg
Dimensions including handwheel (WxDxH):	292 x 508 x 340 mm
CE conformity	✔
Apave (TÜV) certification	✔

STANDARD FEATURES

OPTIONS

CONNECTION EXAMPLES

STANDARD FEATURES

Cast iron frame
In contrast to machines assembled from separate parts by screws, SM Crimp cast iron frame warrants perfect stability during crimping.

Crimping tooling set
Tooling set includes clincher, anvil, punch, punch guide, and cutting block.

Such parameters as clincher type, clincher size, and punch tip shape are customized for the application.

Inclined clincher surface, smooth cutting surface, quick-change tooling cassette, and finger guard lighting cap guarantees efficient and safe operation.

Data memory in each tooling cassette stores its own tooling list (PN’s) and connection data for up to 10 connections with independent crimp height settings. It enables automatic correction of crimp height when the cassette is installed.

Crimp height adjustment
Crimp height adjustment is realized via touch screen with buttons +- (increment of 0.01 mm) or by selecting among preadjusted connections parameters (automatically).

Motorized splice band feeding system
Rubber surface of a feeding wheel prevents damages of the splice band. Special sensor controls the length of each splice.

Touch screen control panel
All controls except the power switch are located at the display. It is possible to control the quantity of products, inputs and outputs, return punch to zero position, check CFM and component position, tooling technical data and feeding system, choose interface language and activate emergency stop.

Hand wheel
Hand wheel is used to perform manual cycle for testing the system before production, e.g. centering the clincher, change of tooling. Wheeling moves the punch down and allows to monitor splicing process in general as well as positioning of the tooling.

Splice band
Splice band is defined according to the type of application and environment temperature range: splice band type and material (brass, brass with tin coating, cupronickel,cupronickel with tin coating, stainless steel), thickness (0.2 – 0.53 mm), width (1.5, 2, 3, 4, 6, 7 mm), and length.

Splice band is engineered with serrations for magnet wire and standard wire types. It is suitable for multi-strand and solid core copper and aluminum wires.

Our splice materials meet the following standards:

UL 486C
MIL – STD 202
IEC 60352-2
IPC/WHMA-A -620
REACH & RoHS

SPLICE MATERIAL	APPLICATION
Brass CuZn30	General purpose, -80..+120°C
Brass with tin coating CuZn30 tinned	General purpose, -80..+120°C, corrosion resistant, pre-soldered components
Cupronickel CuNi9Sn2	High reliability, -80..+400°C, perfect corrosion resistant, weldable
Cupronickel with tin coating CuNi9Sn2 tinned	High reliability, -80..+120°C, perfect corrosion resistant, weldable
Stainless steel 2 mm: 2.4867, 4.6 mm: 1.4567	Special purpose, -80..+900°C, for aggressive environments
Customer specified	On request

Built-in Crimp Force Monitor (CFM)

CFM captures, calculates and evaluates force-time curve and detects any deviation from the quality tolerances.

System works with many types of splicing and crimping machines and suites well to any application requiring inline monitoring of forces.

The reference curve of CFM corresponds to crimping force, but in fact it can reflect such quality deviations as:

missing wire strands,
missing terminal,
inaccurate components positioning,
inaccurate crimp height,
inaccurate wire gauge,
insufficient insulation strip length,
insulation in wire barrel,
wire partially inserted in wire barrel.

CFM allows to adjust automatic cutting and/or rejection of defective items.

Options

Force sensor for CFM

Piezo sensor detects force at the moment of splicing, transmits information to CFM for data processing and displaying force-time curve corresponding to crimp force.

Component position video verification

Camera shoots the clincher area and sends video to the HMI screen in real time. Thus, operator can view the components being crimped and is capable to position them in the clincher precisely.

There are two options for the camera placement:

1, built into the tooling cassette,

2, mounted on the left wall of the tooling cassette and connected via USB cable.

Cutting unit

Cutting unit cuts components after splice crimping so that their ends protruding out of the splice band from one side are of equal length. It suits wires of up to 1.5 mm² diameter.

CFM and cutting unit can be integrated to cut defective parts in halves.

Quality control equipment

Laboratory equipment allows to control whether the splice quality matches industry norms or any other special requirements. Check our micrograph laboratories, pull force and crimp height control tools, as well as specialized measurement software.

Need more automatic features? Please check advanced versions:

SM Crimp V8 Advanced with automated table
SCS for automatic stripping and splice crimping of various components
HSCS for semi-automatic stripping and splice crimping for plastic connector and wires

SM Crimp V8 AdvancedSplice crimping with automated table

SM Crimp V8 Advanced operation involves components manual positioning to the jig. Each jig is customized to the certain components. Jig is placed in the special support (fixture).

Fixture moves between loading and work positions automatically (by servomotor). These positions are predetermined to guarantee highly reliable connections.

Splice crimping is performed by pressing the pedal or automatically.

SPECIFICATIONS:

– digital crimp height adjustment with position controlled by encoder

– built-in CFM

– built-in component position video verification

– punch return to zero position by one touch

– using of several jigs for different components in one fixture

– possibility to mount high resolution external camera for components position, presence, colors, etc.

Learn more about splicing

Watch SM Crimp 2000 Advanced on YouTube

DOWNLOAD BROCHURE

Technical characteristics

Power supply	230 V / 50 Hz
Absorbed power	500 watts
Motor rating	300 watts
Cycle time	300 ms
Noise level	< 75 dB
Weight	app. 60 kg
Dimensions including hand wheel (WxDxH)	420 x 585 x 461 mm
CE conformity	✔
Apave (TÜV) certification	✔

STANDARD FEATURES

OPTIONS

CONNECTION EXAMPLES

STANDARD FEATURES

Built-in Crimp Force Monitor (CFM)

CFM captures, calculates and evaluates force-time curve and detects any deviation from the quality tolerances.

System works with many types of splicing and crimping machines and suites well to any application requiring inline monitoring of forces.

The reference curve of CFM corresponds to crimping force, but in fact it can reflect such quality deviations as:

missing wire strands,
missing terminal,
inaccurate components positioning,
inaccurate crimp height,
inaccurate wire gauge,
insufficient insulation strip length,
insulation in wire barrel,
wire partially inserted in wire barrel.

CFM allows to adjust automatic cutting and/or rejection of defective items.

Splice band is engineered with serrations for magnet wire and standard wire types. It is suitable for multi-strand and solid core copper and aluminum wires.

Our splice materials meet the following standards:

UL 486C
MIL – STD 202
IEC 60352-2
IPC/WHMA-A -620
REACH & RoHS

SPLICE MATERIAL	APPLICATION
Brass CuZn30	General purpose, -80..+120°C
Brass with tin coating CuZn30 tinned	General purpose, -80..+120°C, corrosion resistant, pre-soldered components
Cupronickel CuNi9Sn2	High reliability, -80..+400°C, perfect corrosion resistant, weldable
Cupronickel with tin coating CuNi9Sn2 tinned	High reliability, -80..+120°C, perfect corrosion resistant, weldable
Stainless steel 2 mm: 2.4867, 4.6 mm: 1.4567	Special purpose, -80..+900°C, for aggressive environments
Customer specified	On request

Crimp height adjustment
Motorized crimp height adjustment is realized via touch screen with buttons +- (increment of 0.01 mm) or by selecting among preadjusted connections parameters (automatically).

Motorized splice band feeding system
Rubber surface of a feeding wheel prevents damages of the splice band. Special sensor controls the length of each splice.

Touch screen control panel
All controls except the power switch are located at the display. With 5 buttons and 1 display it is possible to control the quantity of products, inputs and outputs, interface language, tooling technical data, feeding system and activate emergency stop.

It indicates the process of each crimp in a jig.

Hand wheel
Hand wheel is used to perform manual cycle for testing the system before production, i.e. centering the clincher, change of tooling. Wheeling moves the punch down and allows to monitor splicing process in general as well as positioning of the tooling.

Crimping tooling set
Tooling set includes clincher, anvil, punch, punch guide, and cutting block.

Such parameters as clincher type, clincher size, and punch tip shape are customized for the application.

Inclined clincher surface, smooth cutting surface, quick-change tooling cassette, and finger guard lighting cap guarantees efficient & safe operation.

Automated YZ fixture table

Enables shifting the jig with components to the zone of crimping with Y and Z axes capability. High movement accuracy is achieved through programmable actions. Control over the YZ table is provided at the HMI screen, including control of stepper motor drives of the table.

Operator is protected by safety covers.

Support for the jig precisely carries the jig to the crimping zone.

Jig
Removable part of a fixture that perfectly fits components and thus enables its precise positioning. Jig can be adapted to components depending on its quantity, shape, materials.

If machine has two jigs, while one is processing, second can be reloaded by another operator.

Cast iron frame
In contrast to the machines assembled from separate parts by screws, SM Crimp cast iron frame warrants a perfect stability during crimping.

Options

HMI

On the touch screen display HMI system shows complete work algorithm, indicating the current step and step when the failure occurred if any. It can be displayed as an algorithm graphics or product visualization.

HMI provides intuitive process control. It is possible to readjust all sensors including CFM to another product by choosing the corresponding program in the interface. HMI displays pictures of connections kept in memory when the tooling cassette is installed and the corresponding connection selected for processing.

Within the password protected area one can switch machine subfunctions on/off. Different access levels (operator and technician) are available at HMI touch screen.

Component position video verification

Camera shoots the clincher area and sends video to the HMI screen in real time. Thus, operator can view the components being crimped and is capable to position them in the clincher precisely.

There are two options for the camera placement:

1, built into the tooling cassette,

2, mounted on the left wall of the tooling cassette and connected via USB cable.

Protection of operation area

Safety covers can be installed on the side panels to detect foreign object presence and stop the machine.

Bimanual cycle start

Requires two hands touch to start the cycle to eliminate hands presence in the work zone.

POKA YOKE

Allows controlling utilization of NG/NOK components. If CFM detects quality deviation and estimates connection as NG/NOK, then machine stops operation and waits until NG/NOK component is placed to POKA YOKE bin.

Components camera control

According to the selected program, high/low definition camera takes pictures and controls components` presense, position, color and stripping length. High or low definition is selected depending on size of components.

Force sensor for CFM

Piezo sensor detects force at the moment of splicing, transmits information to CFM for data processing and displaying force-time curve corresponding to crimp force.

Frame & cabinet

Machine and all its components can be integrated into the floor mount frame for products needs.

Quality control equipment

Double crimping

Two machines are used: one set up for one splicing type, another – for the second. This solution speeds up the process and perfectly fits if the product consists of different sized crimping.

Need basic version? Please check here:

SM Crimp 2000 Standard for splice crimping with manual components positioning

Need more automatic features? Please check advanced versions:

SCS for automatic stripping and splice crimping of various components
HSCS for semi-automatic stripping and splice crimping for plastic connector and wires

SCS (Splice Crimping Station)Automatic stripping and splice crimping

SCS (Splice Crimping Station) allows all required manipulations for customized splice connection: straightening, cutting, stripping, twisting, splicing. All the steps could be controlled by camera. Electrical setting of machine height allows sitting and standing position of operator.

Each fixture is customized to the corresponding components. Fixture is moved between loading and work positions automatically. Thus all the processes run fast and precisely.

The tool cassette can be designed for a wide range of wire cross-sections, e.g. 0.5-1.5 mm². To perform another connection on the same machine it is necessary to change cassette and tooling.

Learn more about splicing

Watch SCS on YouTube

DOWNLOAD BROCHURE

Technical characteristics

Power supply	220 V. 50 Hz 240 V AC / 2400 W / 10 A
Absorbed power	500 watts
Motor rating	300 watts
Cycle time	300 ms
Noise level	< 75 dB
Weight	approx. 56 kg
Overall dimensions including hand wheel (W x D x H)	291 x 490 x 340 mm
CE conformity	✔
Apave (TÜV) certification	✔

STANDART FEATURES

OPTIONS

CONNECTION EXAMPLES

STANDART FEATURES

Splice band
Splice band is defined according to the type of application and environment temperature range: splice band type and material (brass, brass with tin coating, chrome-nickel, chrome-nickel with tin coating, stainless steel), thickness (0.2 – 0.53 mm), length (1.5, 2, 3, 4, 6, 7 mm), and height.

Crimping tooling set
Tooling set includes clincher, anvil, punch, punch guide, and cutting block.

Such parameters as clincher type, clincher size, and punch tip shape are customized for the application.

Inclined clincher surface and smooth cutting surface guarantees efficient operation.

Integrated memory keeps application parameters, recommended settings and spare parts list.

Automatic fixture
Allows accurate positioning of the components being adapted to its quantity, shape and size. Fine adjustment of the height position of components. Fixture moves between loading and work area automatically with servomotor.

Automatic manipulators
Automatic manipulators transfer components automatically in three axis from one unit another: straitening, cutting, stripping, twisting, splice crimping and unloading.

Each manipulator is customized to fit the application. It prevents damage and guarantees precise & safe operation.

Sitting and standing position of operator
Electrical setting of machine height allowing sitting and standing position of operator. Ensures a comfortable way of working for the operator (from 850 to 1050 mm).

Safety cover
Polycarbonate cap covers work zone of SCS, dividing it from the loading area. It provides operator`s safety and allows loading of components while the previous connection is being processed.

Final products container
Container for operator to collect proper parts fast.

Options

Crimp Force Monitor (CFM)

CFM captures force-time curve and detects any deviation from the quality tolerances. System works with many types of splicing and crimping machines and suites well to any application requiring inline monitoring of forces.

The reference curve of CFM corresponds to crimping force, but in fact it can reflect such quality deviations as: missing wire strands, inaccurate components positioning or crimp height, insufficient insulation strip length, insulation in the splice area, etc.

CFM also allows to adjust automatic cutting and/or rejection of defective items.

Straightening, cutting, twisted and stripping station

Wires straightening is proceed by combing.

Cutting unit cuts the wires after splice crimping in order to get wires of a same length. It suits wires of up to 1,5 mm2 diameter.

Stripping length (until 7 mm) and knives penetration into insulation is set by micrometer. Waste removal in cutting and stripping area is performed by a vacuum cleaner.

Movements of all the stations are driven by a step motor.

POKA YOKE

High/ low definition camera

According to the selected program, camera takes picture and controls components` position, color and stripping length. High or low definition is selected depending on size of components.

Quality control equipment

Need basic version? Please check here:

SM Crimp 2000 Standard for splice crimping with manual components positioning
SM Crimp 2000 Advanced with semi-automatic positioning of various components

Need more automatic features? Please check advanced versions:

HSCS for semi-automatic stripping and splice crimping for plastic interface and wires

HSCS (High-Speed Splice Crimping Station)Semi-automatic stripping and splice crimping for plastic interface and wires

HSCS is designed for high-speed automatic connection of wires and connectors. Feeding of all the components are synchronously performed by motorized manipulators.

Various additional options are available on demand: straightening, cutting, stripping, twisting, etc. Such quality features as components presence, stripping length, and crimp force could be assured by camera and laser control, CFM and other systems.

The tool cassette can be designed for a wide range of wire cross-sections, e.g. 0.5-1.5 mm². To perform another connection on the same machine it is necessary to change cassette and tooling.

Learn more about splicing

Watch HSCS on YouTube

DOWNLOAD BROCHURE

Technical characteristics

Power supply:	240 V AC single phase / 2400 W / 10 A
Cycle time (manual wires loading and connector unloading):	6-7 sec.
Cycle time (automatic wires loading and connector unloading):	5 sec.
CE conformity	✔
Apave (TÜV) certification	✔

STANDART FEATURES

OPTIONS

CONNECTION EXAMPLES

STANDART FEATURES

Frame & cabinet
Machine and all its components can be integrated into floor mount frame with PLC and HMI units for operation control.

Automatic connector manipulator
If plastic connectors are supplied in embossed carrier tape, then the tape is automatically unreeled, the cover film is removed and the connectors are transferred by special manipulators to the clincher in the splicing area.

Connector manipulator is customized to fit the component perfectly. It prevents damage and guarantees precise positioning.

Automatic wire manipulator
Automatic wire manipulator transfers wires to the stripping unit and then to the clincher in the crimping area.

Wire manipulator is customized to fit the component perfectly. It prevents damage and guarantees precise positioning.

CNC stripper
CNC stripper is equipped with two brushless servomotors, one is for blade motion, and the second is for transfer of wire manipulator to splice clincher.

Stripper could be adjusted by HMI for precise jog mode. Stripping length is managed by mechanical stopper equipped by micrometer screw from Mitutuyo.

Wires could be cut before stripping to get the equal length.

Crimping tooling set
Tooling set includes clincher, anvil, punch, punch guide, and cutting block.

Such parameters as clincher type, clincher size, and punch tip shape are customized for the application.

Inclined clincher surface and smooth cutting surface guarantees efficient operation.

Integrated memory keeps application parameters, recommended settings and spare parts list.

Crimp Force Monitor (CFM)
CFM captures force-time curve and detects any deviation from the quality tolerances. System works with many types of splicing and crimping machines and suites well to any application requiring inline monitoring of forces.

CFM also allows to adjust automatic cutting and/or rejection of defective items.

Options

Vibrating feeder

Option for connectors fed in-bulk. A bulk supply hopper automatically doses parts into the vibratory bowl and inline vibrating conveyor.

Lighting & safety beams

Safety beams can be installed on the frame to detect foreign object presence and to stop the machine. This feature as well as work area lighting guarantees operator’s safety.

Cutting unit

Cutting unit cuts unused metal leg of the connector if necessary.

HMI

HMI system shows the complete work algorithm, indicating the current step and step when the failure occurred if any. It can be displayed as an algorithm graphics or product visualization.

HMI provides intuitive process control. It is possible to readjust stripping cutting depth and all the sensors, including CFM to the other product by choosing the corresponding program in the interface.

Within password – protecting area one can switch machine sub functions on/off.

High/ low definition camera

According to the selected program, camera takes picture and controls wires color and presence as well as final assembly . High or low definition is selected depending on size of components.

Laser control

Laser control allows to monitor tape and interface presence.

Quality control equipmenta