Omega 750 S: New benchmark for output, efficiency and flexibility
Technology & Innovation
Following the introduction of the Omega machines for twisted wires and splice applications, the Komax Group is now closing another gap for its customers with the Omega 750 S: The new wire assembly machine sets standards in terms of performance and flexibility in the fully automated insertion of complex wire harnesses and enables even higher precision and consistency in the wire assembly process. Thanks to the newly developed double insertion head, the application area for short cables was reduced to 240 millimeters. This opens up new application areas such as the processing of double-sided jumper connections. Product manager Matthias Felder explains how the Omega 750 S can be adapted to customer-specific production requirements and the unique selling points with which it helps to achieve competitive advantages for customers.
Over the past few years, the Komax Group has closed two gaps for its customers in fully automatic wire processing in a targeted way: The Omega 840/50 wire assembly machine made the insertion of twisted wires possible for the first time and a machine for automatic creation of splice nodes was successfully launched on the market with the Omega 740/50 Autosplice. Komax is now doubling up in two respects with the Omega 750 S and its little sister the Omega 740 S. On the one hand, because the new wire assembly machine expands the options of automation by enabling double-sided insertion of significantly shorter cables, and on the other hand because «the parallel insertion of both cable ends results in faster cycle times and thus increases the output», explains product manager Matthias Felder. «The Omega 750 S can also increase precision, consistency and flexibility in the wire assembly process.»
«A core component of the new development of the Omega 750 S is double insertion head, which enables simultaneous insertion of both cable ends in the majority of cases. This improves the cycle time and significantly increases productivity», continues Felder. «The machine typically works with a speed of 1.2 seconds per insertion with double-sided processing, making it particularly efficient. In addition, we have reduced the application area for short cables to around 240 millimeters, which also enables processing of jumper connections, i.e. usually short connections of two plug housings.» The supply of the housing for insertion takes place via the familiar carousel with pallets which the machine shares with the other models from the Omega series.
Advanced functions and modern software
«To react more flexibly to changing cable types and adapt to the production requirements of our customers, the Omega 750 S can be equipped with up to 10 modules and the Omega 740 S with six modules», explains Matthias Felder. The wire assembly machine is also equipped with a highly developed software: «Our software offers an intuitive user interface, which enables simple programming and operation and shortens the inductions times and increases productivity. As a unique selling point on the market, it also monitors the insertion force during the entire process and checks the correct clamp locking, guaranteeing a high reliability of the connections.»
A central feature of the Omega 750 S is the optical terminal position measuring system (TPMS), which enables precise insertion with different terminals and keeps the error quotas low. «It also supports a comprehensive wire changer for up to 36 different wires or the production of different products on one pallet for more flexible production and shorter changeover times. The software of the Omega 750 S furthermore makes the production of complex wire harnesses easier through the management of the integrated wire store for immediate reproduction in the event of defective wires – automatically, without intervention from the machine operator.»
Short development time enables fast delivery
«We began with the development of the new Omega 750 S at the start of 2023 and were able to deliver the first machines within just one and a half years», reports Senior Project Manager Martin Stocker. This was fast, but intentional, because the main goal with the development was to launch the machine on the market as quickly as possible. «We wanted to offer our customers a competitive advantage as quickly as possible with the increased cycle time and higher flexibility», continues Stocker. One challenge with the development of the Omega 750 S and 740 S was to provide a solution for the customer requirements all over the world. «To offer an ideal solution for all our customers, the parallel development of a sister model for the Asian market was also pushed forward in close cooperation with the Product Management at the Komax site in Shanghai», says Stocker.
The new Omega 750 S will be presented for the first time in Europe at the WirePro Expo in Switzerland from 19 to 21 November. Interested parties can discuss their production requirements in person with our wire processing specialists and product managers and receive concrete solution suggestions. Free tickets, including attractive prices for nearby hotels, can be reserved here.
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Matthias Felder’s career at Komax began in 2014. After starting out in assembly, he first became Product Support Manager of Harness Machines division and has fully embraced this product group since 2022.
