Alpha 565

Crimp to Crimp

Overview

The Alpha 565 wire processing machine is suitable for special processing with up to seven process stations and conductor cross-section 0.13 – 6 mm²

With seven process stations, the Alpha 565 wire processing machine offers plenty of space for special processing and individual processes. Customer-specific applications are easily and effectively integrated. Thanks to the modular machine design, even complex assembly processes such as dual core wire processing, ultrasonic solidifying or welding processes are possible. Elements such as the X1582 twisting unit, the X1585 fluxing and tinning module, the DC double gripper module, the AEH-LS ferrule module, the S1441 seal module and the selection of various crimp modules can be individually integrated. This means that the machine also meets changing and complex requirements. Accurate processing is ensured thanks to the CFA+/CFA, ACD and Q1250 quality process monitoring.

Features

Variety of process combinations due to additional applications

Various crimp, seal, twisting and tinning modules, sleeve loaders or ferrule modules as well as a welding module are possible with the Alpha 565– individual solutions are possible.

No damage to strands on the twisting unit, even with thin wires

The optional X1582 twisting unit twists quickly and flawlessly stripped wire ends– without damaging strands– even on the thinnest wires.

High-quality tin plating thanks to constant flow of tin

The X1585 flux/tinning module for Komax fully-automatic machines enables versatile, lead-free tinning of stranded ends. Constant flow of tin ensures consistent quality.

Optional double gripper module for processing two wires

Two wires are brought together with the ingenious rotary gripper. The wire gripper then takes over the two wires and swivels them on to the crimp module.

Technical Data

ALPHA 565SPECIFICATIONS
Specification name	Specification value
Wire cross section min.	0.13 mm²
Wire cross section max.	6.0 mm²
Wire length, single-sided processing min.	60 mm
Wire length, processing on both sides min.	60 mm
Wire length, processing on both sides (optional from) min.	30 mm
Wire length max.	12000 mm
Strip length side 1 min.	0.1 mm
Strip length side 1 max.	29.5 mm
Strip length side 2 min.	0.1 mm
Strip length side 2 max.	29.5 mm
Strip length, full stripping side 1 with wire outer diameter 1mm/0.4 inch (blade in wire line) max.	15 mm
Strip length, full stripping side 1 for wire outer diameter 2mm/0.08 inch (blade in wire line) max.	14.9 mm
Strip length, full stripping side 1 for wire outer diameter 4mm/0.16 inch (blade in wire line) max.	14.5 mm
Strip length, full stripping side 2 for wire outer diameter 1mm/0.04 inch (blade in wire line) max.	15 mm
Strip length, full stripping side 2 for wire outer diameter 2mm/0.08 inch (blade in wire line) max.	14.9 mm
Strip length, full stripping side 2 for wire outer diameter 4mm/0.16 inch (blade in wire line) max.	14.5 mm
Strip length, full stripping side 1 for wire outer diameter 1mm/0.04 inch (blade next to wire line) max.	29.5 mm
Strip length, full stripping side 1 for wire outer diameter 2mm/0.08 inch (blade next to wire line) max.	29.4 mm
Strip length, full stripping side 1 for wire outer diameter 4mm/0.16 inch (blade next to wire line) max.	29.2 mm
Strip length full stripping side 2 for wire outer diameter 1mm/0.04 inch (blade next to wire line) max.	29.5 mm
Strip length, full stripping side 2 for wire outer diameter 2mm/0.08 inch (blade next to wire line) max.	29.4 mm
Strip length, full stripping side 2 for wire outer diameter 4mm/0.16 inch (blade next to wire line) max.	29.2 mm
Strip length, partial stripping side 1 (blade in wire line) max.	15.5 mm
Strip length, partial stripping side 2 (blade in wire line) max.	15.5 mm
Strip length, partial stripping side 1 (blade next to wire line) max.	35 mm
Strip length, partial stripping side 2 (blade next to wire line) max.	35 mm
Wire outer diameter max.	5.1 mm
Wire cross section (optional) max.	10 mm²
Number of process modules side 1	4
Number of process modules side 2	3
Wire draw-in speed max.	12 m/s
Length accuracy	Repetition accuracy: ± (0.2% + 1.0mm)
Noise level (without crimp modules) max.	80 dB
Electrical connection	3 × 208 – 480V 50/60Hz; 5.6kVA
Electrical connection (optional)	3×400V, 50/60Hz, neutral required, 5.6kVA
Minimum permissible cross section of connection lines	5 x 4 mm²
Compressed-air connection	5 – 8 bar
Wire protection/ground	32
Compressed-air pressure quality according to DIN/ISO8573-1:2010	Pressure dew point: Class 6 (<=+10°C) Max. oil concentration: class 4 (5mg/m3)
Air consumption with wire length of 500mm (19.7inch) (Crimp/Crimp)	7 m³/h
Air consumption with wire length 500mm & 19.7 inch (Seal Crimp/Seal Crimp)	11 m³/h
Recommended operating pressure ±0.5bar/7.25psi	6 bar
Operating pressure	5.5 bar
Operation outside the recommended operating pressure	Non-compliance with the recommended operating pressure can restrict the proper functioning of peripheral devices. Please also observe the technical data for peripheral devices.
Maximum permissible operating pressure depending on the ambient temperature	6.125 bar
Weight (approx.)	1400 kg
Weight (including 2 crimp modules) approx.	1400 kg
Length	4080 mm
Length with basic module 2m/78.74 inch	4080 mm
Length with basic module 4m/187.48 inch	6025 mm
Width	1990 mm
Height (with safety cover closed)	1790 mm
Height (with safety cover open)	2790 mm
Ambient temperature min.	10 °C
Ambient temperature max.	45 °C
Humidity, non-condensing	30 - 90 %
Processing outside the specifications	Processing outside the specifications upon request. In case of doubt, we will be happy to provide processing samples for your wires.
Hard, tough wires	In the case of extremely hard, ductile or thick-stranded wires, processing might not be possible even within the cross section range. In case of doubt, Komax will be happy to provide processing samples of your wires.