Fully automatic machine Zeta 620: Huge opportunity for smaller control cabinet builders
Technology & Innovation
Almost half of the work involved in control cabinet construction takes place during the wiring stage. Komax's most advanced wire processing machines allow for the full automation of the most labor-intensive processes. With the new compact Zeta 620, even smaller control cabinet builders can now enter the world of automation at a reasonable price.
Key insights
The Zeta 620 automatically produces entire parts lists and deposits the cables sorted and labeled.
Without changeover, it produces up to 24 different cables in the cross-section range from 0.5 to 6 mm² with up to 7 different ferrules in any order.
Depending on the requirements, the cables are bundled by lots using adhesive tape or are bundled sequentially in the ideal wiring sequence for installation on request.
According to a study by the University of Stuttgart, manual wiring accounts for 49% of the total effort involved in control cabinet construction. With an average creation time of 157 seconds per cable, wire assembly - i.e. cutting and stripping, crimping and marking - accounts for the largest share of this work. With typically 500 cables, that's about 22 hours per control cabinet.
The Zeta series from Komax: leading the way in sequential wire assembly
The models in our Zeta series for sequential wire assembly are the most advanced on the market, automatically producing entire parts lists and depositing the cables sorted and labeled. This also reduces the time required for reading and analyzing the diagram and for laying the wire, which corresponds to a total time reduction of around 80%.
With this new entry-level model in the Zeta series, even smaller control cabinet builders can automate their wiring. With a footprint of 2150 × 1545 mm, the Zeta 620 fits into any space and produces 360 cables per hour fully automatically, with ferrules on both sides.
Zeta 620: cost-efficient just-in-time production from batch size 1
The previous top models Zeta 630, Zeta 640 and Zeta 650 are designed to meet the high performance requirements of larger manufacturers and specialized wire assemblers. With the simplified and extremely compact Zeta 620, we were systematically focused on the conditions and demands of small and medium-sized control cabinet builders. Full automation allows for cost-efficient just-in-time production from batch size 1, while at the same time guaranteeing continuously high quality.
However and whatever you produce. Whether batch or sequence production, chain or round bundles: The choice is yours.
Compact, nimble and hugely versatile
With a footprint of 2150 × 1545 mm, the Zeta 620 fits into any space and produces 360 cables per hour, with ferrules on both sides. Without changeover, it produces up to 24 different cables in the cross-section range from 0.5 to 6 mm² with up to 7 different ferrules in any order.
The end product is cables that are ready-labeled and bundled, which makes it much easier and quicker to install them in the control cabinet because it’s clear from their ends which components they need to be connected to.
Clearly labeled cable ends make wire laying quicker and easier. Two inkjet printers can be completely integrated into the Zeta 620 without the need for any additional space. Having two printers is practical when it comes to printing light and dark cables with corresponding contrasting colors.
As an alternative or addition to printing on the cable, you can also apply tube labeling with the M1650 Tube Module. These tubes can be rotated and are easier to read in the control cabinet.
Bundled ready for assembly on request
Depending on the requirements, the cables are bundled by lots using adhesive tape or are bundled sequentially in the ideal wiring sequence for installation on request. All of this increases efficiency: No more labeling, searching for the right wire, reading diagrams, changing tools, accidentally wiring incorrectly etc.
Jobs can be programmed directly on the machine or using an Excel spreadsheet created on a PC, converted to a WPCS file using TopConvert software and sent to the machine. Once the control cabinet builder starts working with ECAD, the workload is reduced enormously because the production data can be exported directly.
This entry-level model offers a real breakthrough
The Zeta 620 offers you a great opportunity to streamline your production and offer a service package that was previously reserved for larger manufacturers. We would be happy to advise you on how you can automate this previously laborious process and strengthen your position in the market, taking into account your infrastructure and product range.
We have developed the CM F20 ferrule module especially for users of the Zeta 620. It sequentially processes five different taped ferrules with cross sections from 0.5 to 2.5 mm² and crimp lengths of 8 or 10 mm, and can be easily integrated into the Zeta 620. The CM 1/5 GS, AEH-LS and CM04 Duo ferrule modules are also available.
Data preparation is particularly convenient with our simple and flexible DLW (Digital Lean Wiring) software. This process involves the skilled worker completing the wiring virtually based on a photo or drawing on the screen. DLW calculates the cable lengths, converts the manufacturing data and sends it to the machine.
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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.
