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SM Contact Corporation developed custom electrical connection, designed and manufactured an appropriate connectors’ assembly equipment: Sm Crimp 1000 & Pininsert 2100.

2014-09-24T00:00:00
Splice crimping

SM Crimp 2000 StandardSplice crimping with manual components positioning

SM Crimp 2000 Standard operation includes components manual positioning, when operator holds components within the splice area, and splice crimping by pressing the pedal.

The 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.

Learn more about splicing

Watch SM Crimp 2000 Standard on YouTube

 

DOWNLOAD PDF

Technical characteristics

 

Power supply 220 V. 50 Hz
Absorbed power 500 watts
Motor rating 300 watts
Cycle time 300 ms
Noise level < 75 dB
Weight approx. 56 kg
Max pin’s cross section 1,5 mm
Overall dimensions including handwheel (W x D x H): 291 x 490 x 340 mm
CE conformity ✔
Apave (TÜV) certification ✔
STANDART FEATURES
OPTIONS
CONNECTION EXAMPLES

STANDART FEATURES

Cast iron frame
In contrast to the machines assembled from separate parts by screws, SM Crimp 2000 cast iron frame warrants a perfect stability during crimping.

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.

Crimp height adjustment
Crimp height adjustment panel contains a dial and an alphabetical indicator to set up an appropriate crimp height if necessary.

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.

Control panel
All the controls except the power switch are located at the control panel. 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.

Interface is available in different languages.

Hand wheel
Hand wheel is used to perform manual cycle for testing the system before production, i.e. centering the clincher. 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.

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

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.

Component position video verification

Built-in camera shoots the clincher area and transfers the image to the monitor in real time. Thus operator is capable to position components precisely.

Cutting unit

Cutting unit cuts the 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 could 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.

READ MORE

SM Crimp 2000 AdvancedSplice crimping with semi-automatic positioning

SM Crimp 2000 Advanced operation includes components manual positioning to the fixture.

Each fixture is customized to the corresponding components.  Fixture is moved  between loading and work positions manually by operator  or automatically. In both cases these positions are predetermined to guarantee precise splice crimping.

Splice crimping is performed by pressing the pedal or automatically.

The 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.

Learn more about splicing

Watch SM Crimp 2000 Advanced on YouTube

 

DOWNLOAD

Technical characteristics

Power supply 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

Cast iron frame
In contrast to the machines assembled from separate parts by screws, SM Crimp 2000 cast iron frame warrants a perfect stability during crimping.

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), type, thickness (0.2 – 0.53 mm), length (1.5, 2, 3, 4, 6, 7 mm), and height.

Crimp height adjustment
Crimp height adjustment panel contains a dial and an alphabetical indicator to set up an appropriate crimp height if necessary.

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.

Control panel
All the controls except the power switch are located at the control panel. 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.

Interface is available in different languages.

Hand wheel
Hand wheel is used to perform manual cycle for testing the system before production, i.e. centering the clincher. 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.

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

Manual/ automatic fixture
Allows accurate positioning of the components. Fine adjustment of the height position of components. Prevents double crimps in same position. Machine has a sensor detecting jig presence on a fixture.

Manual fixture is moved by operator between loading and work positions manually. Automatic fixture moves between loading and work positions automatically with servomotor.

Jig
Removable or build-in part of a fixture that perfectly fits the shape of components and thus allows its precise positioning. If machine has 2 jigs, while one is processing, second can be reloaded by another operator. Jig could be adapted to the components depending on its quantity, shape, materials.

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.

Component position video verification

Built-in camera shoots the clincher area and transfers the image to the monitor in real time. Thus operator is capable to position components precisely.

Cutting unit

Cutting unit cuts the 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 could be integrated to cut defective parts in halves.

Bimanual cycle start

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

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.

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 all the sensors, including CFM to the other product by choosing the corresponding program in the interface. Within password protected area one can switch machine subfunctions on/off.

Frame & cabinet

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

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.

Double crimping

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

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.

READ MORE

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

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

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.

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

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.

READ MORE

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

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.

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.

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.

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

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.

READ MORE

APPLICATION FIELDS

ALTERNATIVE ENERGY

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AUTOMOTIVE

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CIVIL ENGINEERING

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ELECTRONICS

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LIGHT INDUSTRY

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MASS MARKET

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MEDICAL

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RAILWAY

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COMPONENTS TYPES

CORDS

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DIODE & RESISTOR

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FILAMENT

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WIRE & CAPACITOR

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WIRE & COIL

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WIRE & DIODE

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WIRE & LEADFRAME

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WIRE & METAL TAB

WIRE & METAL TAB

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WIRE & PCB

WIRE & METAL TAB

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WIRE & SENSOR

WIRE & METAL TAB

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WIRE & RESISTOR

WIRE & METAL TAB

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WIRE & WIRE

WIRE & METAL TAB

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PCB & COAXIAL CONNECTOR

WIRE & METAL TAB

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WIRE & PIN

WIRE & METAL TAB

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WIRE & PLASTIC CONNECTOR

WIRE & METAL TAB

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WIRE & PLUG ADAPTER

WIRE & METAL TAB

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WIRE & THERMAL FUSE

WIRE & METAL TAB

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RELATED TOPICS

SPLICE TECHNOLOGY

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