Smart Factory by Komax – a vision becomes reality 

With the new generation of Alpha machines, we are reaching another milestone in our “Smart Factory by Komax” vision: Intuitive – Automated – Networked – Self-adjusting. For the first time, we are presenting our solution for autonomous production of single wires.

The most important innovation is the new, fully automatic tooling- and crimp change system that enables a highly efficient plug-and-produce production concept.

The combination of this new, fully automatic tooling change and crimp-cassette system is the result of a joint development between TE Application Tooling and Komax. The crimp-cassette system combines the terminal reel and crimping die. The production relevant data is created and stored centrally. This enables an unique identification. One substantial benefit is that operator influence of the quality is minimized, improper adjustments during production are prevented and the lifespan of the perishable tooling is increased.

With the help of the intelligent, fully automatic tooling change system, a material change takes less than a minute, whereas today it still takes up to 15 minutes. The tooling change is completely automatic and ensures the highest precision and process quality.

Due to the interchangeability of the crimping cassette, it can be universally loaded onto any new generation Alpha machine and achieves the same precise crimp results.

An extensive field test under real conditions showed up to 50% higher production output per shift.

High-voltage, data- and sensor cables with extra high quality requirements

In recent months, the sale of electric- and vehicles with convenience and assistance systems has increased enormously and with it, the demand for high-voltage (HV) wire harnesses as well as data cables. As different as their areas of application may be, an unprecedented degree of precision in the wire assembly is required. Because when the tightly defined tolerance fields are not adhered to, it may lead to a system failure and results in a standstill of the car. A major challenge for manual production. In addition, the already multifaceted connector systems are constantly evolving, which means that it is always necessary to adapt to a new situation.

Assembly systems that automate individual process steps or even the production of complete wire harnesses is vastly superior to us humans in terms of speed and accuracy. By offering solutions that specifically automate quality-relevant processes, Komax makes it easier for its customers to get started with the automated assembly of HV and data cables.

Komax is therefore presenting its enhanced machines at this year’s productronica. With them, users boost their competitiveness by further automating their production with optimized and new process modules. The new Komax standard modules for MES integration improve traceability.

Komax Services 

With our broad range of service packages, we enable you to work even more productively and achieve higher quality with the Komax Group products. Komax has the most comprehensive service network in the industry and is always at your service, wherever and whenever you need us.

The 19 different Komax services are strongly geared towards the needs of our customers and offer measurable, effective added value – The increase of efficiency of your Komax systems.

Thereby, you will find for every task the exact right service.

With our existing technical services, we ensure that your production machines are correctly installed, set up, operated and maintained, which results in high availability. You work more productively with machines and testing systems that are always at the latest technology level and thus have a longer lifespan. Perfectly trained through the Komax Academy, your employees operate the systems optimally and get the best possible performance out of them. Digital products and services help organize your production as well as monitor and improve the efficiency of the machines.

With Komax Care, your personal service level agreement, we put together your individual service package. Around the globe, our perfectly trained experts accompany you throughout the entire lifespan of your equipment, on site or remotely.

Comprehensible proof of high precision 

Our smart quality monitoring systems can be individually integrated into each specific process steps. The processing parameters are entered via Komax HMI, the control software for fully automatic crimping machines, which equally minimizes operator influence and changeover times.

With the Q1250 scaleable, Komax peruses the philosophy of parameterization. In addition to the optimized optics and deep machine integration, parameter-based image evaluation with a specially developed evaluation algorithm, is the decisive step towards intelligent and efficient quality assurance.

For special orders with very small batch sizes, multi-conductor cables and pre-assembled wires, the new Bench Top Crimper generation is the right solution. Thanks to integrated crimp force monitoring CFA/CFA+, quality verification and an open interface, the products are also specially designed for the networked production environment.

Our fully automatic twisting machine with integrated spot taping, Sigma 688 ST, helps meet the increasing demand for taped UTP (unshielded twisted pairs) wires in an economical way. With the unique ACD (Automatic Conductor Detector) system, the machine detects the slightest contact between stripping blades and conductor strands during incision and automatically sorts faulty wire ends. Another quality feature is the consistently low torsion force despite high rotation speed during twisting and taping.

Crucial aspects of high productivity and optimized overall performance are the minimization of scrap, quick changeover, and the reduction of downtimes. For strategic machine control, Komax Connect delivers the best transparency and serves as the basis for intelligent production analysis.

Find out more by visiting us at booth 263 in hall B4. We look forward to seeing you there!

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