Wire Processor
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The Model 45-774 Wire Processor measures, cuts, strips and counts a variety of insulation, from 30 to 8 AWG (0.05 to 6.0 mm2). The machine performs a full or semi strip on one or both ends of the wire. Ten programmable processing speeds are available. The "wire out" electromechanical sensing is said to provide unattended, real-time wire feeding monitoring capability. The battery back-up memory stores up to 99 batch jobs and an RD-232 serial communication interface allows for connection to PCs. Ideal Industries Inc., Sycamore, Ill.
Ultrasonic Splicer
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The Raptor Wire Splicer is designed to operate in rough production environments. It is encased in a heavy metal shell, reportedly to dampen vibrations, eliminate bends and deflections, and maximize the efficiency of vibration energy. The system is said to be easy to maintain with "drop-in" and "take-out" subassemblies that fit into the side and center cavities of the shell. It splices wires ranging from 22 to 4 gauge; splice sizes ranges from 0.7 to 40.0 mm2. Self-diagnostics and built-in controls reportedly ensure the quality and integrity of each weld. Stapla Ultrasonics Corp., Wilmington, Mass.
Wire Cutter/Dereeler/Coiler
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The Wire-3 is a combination wire and cable machine that can be used to prepare wire, flexible tubings and small cables. It consists of the medium-duty DE600 dereeler, the WMI (inches) or WMM (metric) measuring meter with stand, the FC10 foot-operated cutter with stand, and the CW20 coiler. Coils of material containing up to 1,200' of 0.25" or equivalent material may be prepared, and the system accommodates wire and cable reels up to a maximum diameter of 29.0" and weight of 200 lb. The Eraser Co. Inc., Syracuse, N.Y.
Crimping Machine
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The SuperSplice CS-1500 Crimping Machine is designed to provide an alternative to soldering for a range of applications, including wire-to-wire, wire-to-component, wire-to-PCB or wire-to-subassemblies. Average cycle times of less than 500 ms and throughput rates as high as 800 to 1,000 splices per hour can reportedly boost production output by as much as 500 percent over hand soldering. The machine is said to produce up to 75,000 crimps from a single reel of splice band with no wasted material. Standardized tooling is available to handle wiring sizes from 32 to 12 AWG. Autosplice Inc., San Diego, Calif.
Dereeler
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The Motorized Dereeler (AMTI-2158) interfaces with all of the company's Slice cutting machines, as well as other manufacturers' cutting equipment. The maximum reel weight is 100 lb and the maximum reel diameter is 2'. It allows cutting at 20" per second when used with one of the Slice machines. It has an adjustable micro-switch to prevent material jam on heavy loads, an adjustable torque, and an all stainless-steel and aluminum construction. It operates at 115/230 V, 50-60 cycles. American Mfg. & Technologies Inc. (AMTI), Addison, Ill.
Wire Processing Machines
The Uno, Duo and Primo Wire Processing Machines are said to be designed to serve the entire spectrum of the wire processing industry. The Primo is a fully automatic, dual-end wire processing system. The Uno features fully automatic wire processing with up to four process stations. The Duo is designed for the high-end user. Megomat USA Inc., Marietta, Ga.
Stripper/Crimper
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The Kirsten K750ASC Stripper/Crimper comes with a pneumatic stripping unit and cable clamp and covers wire ranges of 30 to 11. Stripping parameters are digitally selectable with up to 200 programs stored. Standard features include a suction unit for insulation debris and a precutting device with stripping knives. All machines are sensor-operated and do not use a foot pedal. Once the wire touches the sensor, the wire is clamped and reportedly remains in position during the entire process. The crimped contact is automatically ejected. Tomken Industries Inc., Norwalk, Conn.
Wire Wrapping Tool
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The Model WG-350L Wire Wrapping Gun is said to offer many features, including ease of use; smooth, reliable operation; fast insertion and removal of bits and sleeves; and durability. It is reportedly precision-manufactured. Jonard Industries Corp., Tuckahoe, N.Y.
Termination Machine
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The Entry Level Terminator (ELT) is designed for use by wire harness manufacturers in various industries. The machine exerts 3,000 lb of crimping force and cycles in less than 0.4 seconds. It is said to accept mini-style applicators for both end- and side-feed product. A DC drive is said to allow operation at less than 76 DbA. It reportedly features the removal of guards and applicators without the use of tools, and operates on 100/240 VAC 50/60 Hz. Options include precision crimp-height adjustment, batch counting and crimp quality-monitoring capability. AMP, a part of Tyco Electronics Corp., Harrisburg, Pa.
Applicator Press
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The TM-2000 Universal Press is designed for mid-volume, semiautomatic bench operations. It accepts most industry-standard applicators, and is factory-set to an industry-standard shut height of 135.8 mm. It is electrically controlled and features a single-cycle, fly-wheel design and an automatic counter. A quick-release base plate is said to make applicator changeover fast and simple, requiring no tools. It meets OSHA safety and noise requirements. Molex Inc., Lisle, Ill.
Stripping Machine
The MX-5025 Center Stripping Machine is designed to remove or displace a section of insulation along the length of an insulated wire. The machine can remove 8 to 25 mm of insulation from 20 to 8 AWG stranded or solid conductor wires. It is said to interface with virtually any automatic wire processing machine. Maximum speed of the machine is about 3,500 center strips per hour, depending on wire and wire processing machine. Mechtrix, Menomonee Falls, Wis.
Cutting and Stripping Machine
The Model MCS 135BC is a heavy-duty production machine for cutting and stripping heavy wire as large as 4/0 AWG or as light as 16 AWG. It is also capable of cutting multiconductor cable as large as 1.125" OD. The control system features a touch screen. A partial strip attachment is optional. Accessories such as prefeeders and collectors are also available. Kut-Rite, Milwaukee, Wis.
Cut and Strip Machine
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The Compu-Strip 96 is a fully programmable, bench-top measure, cut and strip machine capable of processing 32 to 10 AWG, multiconductor up to 7 mm OD, flat cable up to 0.52" wide. It comes with user-friendly, menu-driven software; a wire straightener and seven wire guides; and a one-year warranty. Carpenter Mfg. Co. Inc., Manlius, N.Y.
Wire Cutting and Stripping Machine
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The PowerStrip 9500 RSL combines power and stripping capabilities with rotary cutting capabilities. It offers a pneumatically driven guide tube concept that is said to assure positive slug removal from the cutting head area. The multiple-blade system on the cutting head allows the use of up to three pairs of blades.
Additional features include programmable rotating cutting blades with cable centering system, a rotary blade system, a belt feeding system, and standard wire and cable processing with the rotary unit disabled. Schleuniger Inc., Manchester, N.H.
Ribbon Cable Separator
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The Separator 3250 is a motor-driven ribbon cable separator available with a variable speed (DC) drive option. It reportedly provides separation speeds of 0 to 20" per minute. It is said to be capable of separating all types of ribbon cable at widths of up to 3". Features include an infinite-length, motor-driven separation; removable and interchangeable tooling; and 110 VAC, 60 cycles (220 VAC, 50 cycles, on request). It has the ability to separate individual, groups or combinations of conductors with optional tooling. AG Devices of Colorado Inc., Cedaredge, Colo.
Wire Stripper/Cutter
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Model 11049 is suitable for stripping, cutting and gauging stranded wire. The six stripping holes are designed for 8, 10, 12, 14, 16 and 18 AWG stranded wire. Metric sizes are available in 6.0, 4.0, 2.5, 1.5 and 0.75 mm2. Features include a spring-loaded, self-opening action and cushion-ridged and plastic-dipped handles. Manufactured of hardened steel, the product is finished with black oxide to provide corrosion resistance. Klein Tools Inc., Chicago, Ill.
Wire Stripping Machine
The Model C High-speed Wire Stripping Machine is a bench-type that includes stripping blades; adjustable wire diameter bushings; a safety switch; a foot treadle; and a 1/6 HP, 115 V, single-phase, 60-cycle motor, installed and wired. It is suitable for the stripping of leads on the ends of various sizes and types of wire. Three knives center the wire and are said to assure a clean strip every time. Knife maintenance and replacement is reportedly kept to a minimum with special alloy steel knives. High Speed Hammer Co. Inc., Assembly Equipment Div., Rochester, N.Y.
TECHNOLOGY UPDATE
By Tom Peterson
The wire processing equipment industry as a whole is experiencing three major trends. The first is the move toward contract manufacturing — original equipment manufacturers (OEMs) utilizing outside suppliers for their wire processing operations. Contract manufacturing firms are consolidating and getting larger in scale, both in their number of employees and their technological capabilities. This trend has shifted bargaining strength from the OEMs to the contract manufacturers, yet has also forced the contract manufacturers to become more cost-effective to remain competitive.
To that end, it is the contract manufacturers that are leading the surge in demand for wire processing equipment that offers the proverbial "more for less." Machines that a few years ago would have cost $10,000 or more now cost half that amount. Today's wire processing machines boast additional features and capabilities at much lower price points — advantages that benefit all customers.
The second key trend in the industry is globalization. There is a growing influx of international flavor in the wire processing equipment arena. European companies are partnering in the United States in an effort to spur faster growth by offering a wider breath of products and taking advantage of existing distribution infrastructures.
The third trend is the continuing strength of the corporate aircraft market, both domestically and internationally, where France, Brazil, England and Italy have heightened their market share in both military and commercial aerospace products. The military and commercial aerospace industries continue to represent a large share of the market that needs wire processing.
Keeping these three trends in mind, wire processing equipment manufacturers would be smart to maintain their strategic focus on the under-$10,000 commercial wire processing marketplace. Additionally, manufacturers should target the new, smaller corporate aircraft manufacturers, as well as their traditional domestic and international aircraft customers.
TOM PETERSON is director of sales and marketing, Ideal Industries Inc., Wire Processing Div., Becker Place, Sycamore, IL 60178; (815) 895-1384; Fax: (815) 899-7712; E-Mail: ideal@wirenut.com; Web site: www.idealindustries.com.
Wire Termination Technology Improves Production
By Vernon Smith and Bob Grenke
With printed circuit board (PCB) space at a premium, it seems components cannot be small enough. This trend toward miniaturization presents challenges to original equipment manufacturers (OEMs) and wire harness houses when it comes to crimping small-gauge terminals. The major challenge arises in setting up the crimping press. Operators spend a lot of time adjusting the shut height of the press and shimming the crimp applicator to meet the tight tolerances required.
Along with being labor-intensive, these set-up procedures can have a negative effect on crimp quality. A typical crimp applicator operates in three steps. In the first step, the terminal is contained on the down stroke of the ram, in position over the anvil. In the second and third steps, the carrier strip(s) is cut and the terminal is crimped to the required specifications. The timing of these three steps — containment, cut and crimp — has to be precise to produce a proper crimp termination. Continuous adjustments to the crimping press or applicator can, and usually do, disrupt the timing of applicator operation.
OEMs and wire harness houses can minimize these wire termination problems with a fine-adjust-style crimp applicator. This style of applicator can be adjusted in increments as low as 0.015 mm, meeting tight crimp tolerances and eliminating the need for shimming. The crimp height and insulation diameter are adjusted independently of one another — meaning that changing one does not affect the other. When using this applicator type, the shut height of the crimping press can be preset to the industry standard 135.80 mm, with no need to adjust it. Any adjustment that is needed is done on the crimp applicator.
Maintaining the standard shut height of all crimping presses helps to ensure repeatability. There is a crimping press that addresses this issue. It is factory-set to the industry shut height and does not require any adjustment, which minimizes operator error and reduces set-up time. Companies with wire crimping operations that want increased productivity and profitability along with lower costs are finding that fine-adjust-style crimp applicators and presses with a factory-set shut height are helping to meet their needs.
VERNON SMITH is manufacturing manager, and BOB GRENKE is product marketing specialist, Application Tooling Div., Molex Inc., 1150 Diehl Road, Naperville, IL 60563; (630) 527-4521; Fax: (630) 969-0049; Web site: www.molex.com.
