crimp to crimp
EN
The compact, fully automatic Gamma 450 pro- BEST-IN-CLASS
cesses crimps and seals on both sides and SETUP AND CHANGEOVER
takes up minimum space. It guarantees high
production availability and traceable quality.
The wire processing machine has all the nec-
essary key functions and can also be extended
for specific purposes using an extensive range
of options. High-performance modules ensure
seamless quality monitoring. Optimized quick-
change systems reduce set-up and change
over times. Handling is intuitive and ergonomic
– easy and error-free thanks to the Komax HMI
operating software. This combination contrib-
utes significantly towards achieving stable and
optimal productivity.
High level of process stability and
comprehensive monitoring
– New machine platform based on tried-and-
tested Alpha technology
– Complete quality monitoring, thanks to a
fully integrated quality concept
Fast setup and changeover
– Q uick manual wire change
– Short replacement times for tools and 01 02
terminals thanks to STC
– Reduced changeover times thanks to
machine operation at the crimp module
Compact machine design and 01
efficient operation Fast cable insertion without
cross section-dependent guide
– Simple and user friendly elements.
02
– T he machine design meets global ergonomic The stationary quick terminal
requirements changer STC (optional) reduces
changeover times.
– Komax HMI software with Green Button
for error-free and efficient production
– Comprehensive transparency across the
entire production process
Cost-effective maintenance
– Conveyor belt can be used on both sides
– Good machine access for short
maintenance times
– Common-parts strategy with Alpha 530/550
reduces complexity and costs for spare parts
MAXIMUM
QUALITY ASSURANCE
AND EFFICIENCY
C1370 / C1360 / C1340
CRIMP MODULE
Q1250 SCALABLE
OPTICAL QUALITY MONITORING
S1441
SEAL MODULE
Ergonomic working conditions, logical
workflows and the simplest possible user
guidance all promote a cost-effective
production process. Maintenance costs
have been optimized by having a common-
parts strategy. This makes the machinery
less complex, brings down costs for spare
parts and reduces training requirements.
Maximum availability and efficiency
Gamma 450 – exceptionally The Gamma 450 processes crimps and
economical seals with cross sections of 0.13 to 4 mm²
The Gamma 450 fulfills all the requirements on both sides. The proven, robust technol-
of future-proof, cost-effective wire produc- ogy ensures continuous machine availabili-
tion. The precise modules and functions ty with minimal downtimes. Shorter routes
required can be customized individually and stringent processes between work
on four stations. With these supplementary zones improve the workflow and the pro-
options, the compact machine provides ductivity. Operation of the machines is aid-
the required functional scope, powerful ed by optimal lighting in the work areas
performance and seamless quality moni- and dimensions that are adapted to suit
toring. global standards.
REDUCED TO
THE MAX
01
02 03
01 Fast setup and changeover tool Q1250 scalable offers the possibility to
Intuitive, correct operation thanks
to Komax HMI operating software The optional STC tool and terminal reel monitor both the stripping quality as well
02
quick-change system enables the terminal as the contact and seal assembly, and
Q1250 scalable, optical quality
monitoring rolls and crimp tools to be changed during automatically sort out faulty products.
03
Quick, secure set-up directly on operation. The time-saving insertion of the
the module wire into the belt drive takes place without Simple and flawless operation
the need for additional cross-section de- with Komax HMI
pendent guide elements. The option to use Supported by the user guidance in the
both sides of the drive roller ensures it has HMI operating software, the Gamma 450
an above-average service life. can be set up in just a few steps. The
large touchscreen makes operation of the
Full quality assurance and traceability HMI user interface easy. The use-case-
All integrated and optional modules and driven design of HMI also ensures error-
functions ensure seamless quality control. free data input while the Komax Green
Perfectly coordinated with each other, they Button guides the user through the wire
meet the high demands of the automotive processing step by step.
industry. Integration with the MES manu-
facturing execution system provides docu-
mented traceability. The integrated CFA+/
CFA crimp force monitoring detects miss-
ing individual wires and crimped insulation.
The optional automatic conductor detector
(ACD) ensures quality, even for the finest
conductors. It detects the slightest contact
between the blades and conductor strands
during cutting and stripping. The quality
Wire deposit basic module 2 m: 3388 mm (133.4 in)
Wire deposit basic module 4 m: 5333 mm (210 in)
Q1250 scalable
1445 mm (56.9 in)
The Q1250 scalable enables users to
adjust the level of checks according to their
specific requirements, ranging from basic
to advanced levels of quality control. This
quality tool also allows for the individual
monitoring and configuration of critical
components such as stripping, seals, and
terminals to ensure that they meet the Height with closed hood: 1775 mm (69.9 in)
Height with cover completely open (maximum opening): 2775 mm (109.3 in)
necessary standards.
Lower wire lines of 90 mm compared to Alpha 530/550
Technical data
Tried and tested C1370/C1360/C1340
crimp modules with CFA+/CFA
The efficient user guidance and wire posi- Wire cross-sections 0.13 – 4 mm² (AWG 26 – AWG 12)
tioning directly on the module allows the
Wire draw-in speed max. 8m/s (26ft/s) belt drive
shortest setup and changeover times.
CFA+/CFA- guarantees the highest quality Wire outer diameter max. 3.9 mm (0.15 in)
and minimal rejects. Combined with the Length range 60 – 65 000 mm (2.35 in – 213 ft)**
time savings, this can increase productivity optional 33 – 60 mm (1.3 in – 2.36 in)
considerably. Features like the stroke and
Full strip 0.1 – 16.5 mm (0.004 – 0.65 in)*
split cycle can be programmed easily. With optional double blade up to 35 mm
The C1370 and C1360 modules automati-
cally adjust the crimp height during teach- Partial strip 0.1 – 16 mm (0.004 – 0.63 in)*
With optional double blade up to
in.
21 mm (S1) and 34.5 mm (S2)
Crimp force 1 – 22 kN
S1441 seal module for maximum
Process modules Side 1 and side 2: 2 stations
flexibility
The module automatically fits wires with Noise level < 75 dB (without crimp tool)
conventional seals and mini-seals. The Electrical connection 3 × 208 – 480 V; 50/60 Hz; 2.5 kVA or
combination of precision mechanics and 3 × 400 V, 50/60 Hz, 2.5 kVA
the new seal position monitoring function
Compressed-air connection 5 – 8 bar (73 – 116 psi)
guarantees a high degree of process safety recommended operating pressure 6 ± 0.5 bar (87 ± 7.25 psi)
and maximum productivity. The module
can be simply and quickly switched from Air consumption of crimp / < 6 m³/h (212 ft³/h)
crimp seal crimp / seal crimp < 9 m³/h (318 ft³/h)
one seal variety to another.
Weight (incl. 2 crimp modules 920 kg (20828 lbs.) 01
+ 2 seal modules)
* Depending on the nature of the cable material
** Repeat accuracy ± (0.2 % + 1 mm [0.04 in])
Deposit length > 8 m on request
01
Absolutely precise processing thanks
to the double blade holder and auto-
02 matic conductor monitoring (ACD).
02
Tools are always available in the
practical, lockable drawer.
Options and accessories
Prefeeder Prefeeder
Wire drive Belt drive
Marking systems Komax inkjet printing systems
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 •
Double gripper module • X1582 twisting module •
X1585 tinning module
Quality assurance Integrated crimp height measurement • Integrated pull-out
force measurement • ACD automatic conductor detector •
Q1250 scalable optical stripping- and crimp monitoring •
CFA+/CFA crimp force monitoring • Material change
detection • Material verification • Splice detection •
Terminal end detection
Deposit systems Base module 2 m (78.7 in) or 4 m (157.5 in) • Extension
module 2 m (78.7 in) or 4 m (157.5 in) • Deposit gripper
Accessories Stationary tool and terminal reel quick-change system •
Wire quick-change system
Software MIKO networking interface • Komax HMI
Processing examples
Cutting to length Wire draw-in
Double-ended crimping and seal insertion. Cutting pulled strands Wire deposit
Full stripping Incision monitoring
Stripping, terminal and
Half stripping
seal monitoring
Output rate Crimping Crimp force monitoring +
CFA
5000 Crimp height measurement
FLRY conductor 0.5 mm² (AWG 20) Double crimping
integrated
4500
Pneumatic pressure 6 bar (87psi) Split cycle function for Pull-out force measurement
4000 closed terminals integrated
3500 Crimp module C1370
Seal insertion Wire length correction
3000 Seal module S1441
Twisting / tinning Splice monitoring
pcs / h
2500 Crimp force monitoring Active
2000 Material change detection Good/bad separation
ACD, Q1250 scalable Inactive
1500 Crimp tool – terminal –
Deposit gripper Active quick-change system
Production in sequences
1000
Crimp / Crimp Wire changer Batch separation
500
Crimp-Seal / Crimp-Seal
Programmable crimp
0 The actual piece output may vary Networking
0 500 1000 1500 2000 2500 3000 3500 4000 depending on the application and
height
machine configuration
wire length [mm] Customer-specific
Inkjet marking ➝
I
PROG
processes * ➝
O
* Available on request
Prefeeder/dereeler
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]
Gamma 450 V1 03-2023
Subject to change
komaxgroup.com
