Harness Manufacturing

Overview

In contrast to Omega 740/750, the Omega 745/755 machines are also equipped with a fully automatic conveyor system for depositing the wire harnesses.

As with all models in the Omega series, automatic wire assembly can be individually adapted with the Omega 745/755. The machines differ only in the number of modules (five module options for the Omega 745 and eight for the Omega 755). Subsequent processes can also be integrated thanks to the conveyor system already available from the factory. Thanks to the elimination of manual steps and precise processing technology, these fully automatic wire processing machines are the answer to high demands, constantly evolving requirements and continuous miniaturization. This ensures long-term cost-effectiveness and quality independent of the operator.

Features

Additional functions such as automatic secondary locking

An individually developed tool automatically closes the secondary locking mechanism of the plug housing. The tool can be integrated as an additional function.

Uninterrupted production thanks to flexible housing track system

Up to four different housing types can be fed at the same time. This ensures the efficient loading and unloading of the housings and finished wire harnesses while the machine is running.

Monitoring of the insertion process using force sensors

The terminal housing is fed into a track. The insertion gripper monitors the insertion force and checks that the terminals are correctly locked.

Careful interim storage of wire harnesses before further production

The finished wire harnesses are collected in a custom-made track of any length until they are unloaded by the operator for further processing.

Technical Data

OMEGA 745SPECIFICATIONS
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 outer diameter of bundled wires max.	6 mm
Wire outer diameter of inserted wires 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 745

Omega 745