Harness Manufacturing

Overview

The Omega 740/750 wire assembly machine can be used to produce wire harnesses of various complexity and to equip them with terminal housings on one or both sides.

Depending on the design, five (Omega 740) or eight (Omega 750) modules can be installed. This means that autonomous wire harnesses can be created in a short production time. The Omega series is manufactured for automated wire harness production. Regardless of the operator, the quality of the end product is ensured: A high-precision force sensor monitors the insertion process of up to 36 different wires and the precise locking of the terminal part in the housing. The individual parameters are automatically compared. Supported by a spindle drive, even the smallest components are loaded that could hardly be connected in by hand. The optionally available ACD incision monitoring additionally ensures quality.

Features

Optical terminal measuring system for insertion of various terminals

The optical terminal measuring system enables insertion of a wide variety of terminals into terminal housings, on one side as well as on both sides.

Extensive wire changer for up to 36 different wires

The automatic wire changer provides up to 36 wires from the entire cross-sectional area. This covers, for instance, the wide variety of control cabinet designs.

Three pairs of blades with optional ACD incision monitoring

The already integrated three blade pairs with optional incision monitoring (ACD) cover a cross-section range of 0.13 to 2.5 mm² (AWG 26–14).

Special untwisting module for neutralizing twisted wires

Unwound wires always have a twist. The untwisting module removes the twist from the wires, which is important for subsequent fully automatic loading.

Integrated wire storage for more efficient production

Two-sided wire harnesses with a high level of complexity can be easily produced with the help of the wire storage. It also enables the immediate post-production of defective wires.

Technical Data

OMEGA 740SPECIFICATIONS
Specification name	Specification value
Shortest wire length for one-sided processing	240 mm
Shortest wire length, double-sided jumper connection	300 mm
Shortest wire length, double-sided jumper connection max.	540 mm
Shortest wire length, complex loading min.	300 mm
Shortest wire length, complex loading max.	760 mm
Wire length (standard tray) max.	3000 mm
Strip length side 2 max.	25 mm
Strip length side 1 max.	25 mm
Wire outer diameter max.	4 mm
Wire cross section min.	0.13 mm²
Wire cross section max.	2.5 mm²
Wire draw-in speed max.	10 m/s
Wire acceleration	50 m/s²
Cycle time per loading	1.8 – 2.6 s
Length accuracy	± 1mm or < 0.2% (depending on cable length)
Electrical connection	3 × 208 - 480 V 50/60 Hz, 4 kVA (base machine)
Compressed-air connection	5 – 8 bar
Air consumption (without modules)	15 m³/h
Network connection	Ethernet
Exhaust connection	Upon request
Recommended operating pressure ±0.5bar/7.25psi	6 bar
Compressed-air quality in accordance with DIN/ISO 8573-1	Compressed air, dry, filtered (10 μm), oil-free
Minimum permissible cross section of connection lines	DN 15
Recommended size of compressed-air storage per machine	50 l
Weight (approx.)	1900 kg
Floor load capacity	500 kg/m²
Maximum permissible operating pressure	6.5 bar
Length	4785 mm
Width	2050 mm
Height (with safety cover closed)	2060 mm
Height (with safety cover open)	2870 mm
Minimum clearance around equipment for maintenance work	1500 mm
Floor conditions	Level, stable, clean and vibration-free bearing surfaces. Bearing surface for machine bearing points, made from a continuous base plate of concrete. No expansion joints between machine bearing points. Bearing surface is slip-proof. No plastic or asphalt coatings.
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.

Downloads

Omega 740