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SCS (Splice Crimping Station)

SCS (Splice Crimping Station) provides all required manipulations for customized splice connection: straightening, cutting, stripping, twisting, splicing. All the steps can be controlled by camera. Electrical setting of machine height allows sitting and standing position of operator.

Each fixture is customized to the corresponding components. Fixture is moved between loading and work positions automatically. Thus, all the processes run fast and precisely.

Tool cassette can be designed for a wide range of wire cross-sections, e.g. 0.5-1.5 mm2. To perform another connection on the same machine it is necessary to change cassette and tooling.

Technical characteristics

Power supply
220V / 50Hz / 2400W / 10A
Absorbed power
500 watts
Motor rating
300 watts
Cycle time
300 ms
Noise level
< 75dB
Weight
approx. 56 kg
Dimensions including hand wheel (WxDxH)
291x490x340mm
CE conformity
Apave (TÜV) certification

STANDARD FEATURES
OPTIONS
CONNECTIONS EXAMPLES

STANDARD FEATURES

Built-in Crimp Force Monitor (CFM)
CFM captures, calculates and evaluates force-time curve and detects any deviation from the quality tolerances.
System works with many types of splicing and crimping machines and suites well to any application requiring inline monitoring of forces.
The reference curve of CFM corresponds to crimping force, but in fact it can reflect such quality deviations as:
- missing wire strands
- missing terminal
- inaccurate components positioning
- inaccurate crimp height
- inaccurate wire gauge
- insufficient insulation strip length
- insulation in wire barrel
- wire partially inserted in wire barrel
CFM allows to adjust automatic cutting and/or rejection of defective items.
Splice band

Splice band is defined according to the type of application and environment temperature range: splice band type and material (brass, brass with tin coating, chrome-nickel, chrome-nickel with tin coating, stainless steel), thickness (0.2 – 0.53 mm), length (1.5, 2, 3, 4, 6, 7 mm), and height.
Crimping tooling set

Tooling set includes clincher, anvil, punch, punch guide, and cutting block. Such parameters as clincher type, clincher size, and punch tip shape are customized for the application. Inclined clincher surface, smooth cutting surface, quick-change tooling cassette, and finger guard lighting cap guarantees efficient & safe operation.
Automatic fixture

Allows accurate positioning of the components being adapted to its quantity, shape and size. Fine adjustment of the height position of components. Fixture moves between loading and work area automatically with servomotor.
Automatic manipulators

Automatic manipulators transfer components in three axes from one unit to another to provide straitening, cutting, stripping, twisting, splice crimping and unloading. Each manipulator is customized to fit application. It prevents damage and guarantees precise and safe operation.
Sitting and standing position of operator

Electrical setting of machine height allows sitting and standing position of operator. Ensures a comfortable way of working for the operator (from 850 to 1050 mm).
Safety cover

Polycarbonate cap covers work zone of SCS, dividing it from the loading area. It provides operator`s safety and allows loading of components while the previous connection is being processed.
Final products container

Container for operator to collect proper parts fast.
Splice band

Splice band is defined according to the type of application and environment temperature range: splice band type and material (brass, brass with tin coating, cupronickel, cupronickel with tin coating, stainless steel), thickness (0.2 – 0.53 mm), width (1.5, 2, 3, 4, 6, 7 mm), and length.

Splice band is engineered with serrations for magnet wire and standard wire types. It is suitable for multi-strand and solid core copper and aluminum wires.

Our splice materials meet the following standards:

UL 486C

MIL – STD 202

IEC 60352-2

IPC/WHMA-A -620

REACH & RoHS

SPLICE MATERIAL APPLICATION

Brass CuZn30 General purpose, -80..+120°C

Brass with tin coating CuZn30 tinned General purpose, -80..+120°C, corrosion resistant, pre-soldered components

Cupronickel CuNi9Sn2 High reliability, -80..+400°C, perfect corrosion resistant, weldable

Cupronickel with tin coating CuNi9Sn2 tinned High reliability, -80..+120°C, perfect corrosion resistant, weldable

Stainless steel 2 mm: 2.4867, 4.6 mm: 1.4567 Special purpose, -80..+900°C, for aggressive environments

Customer specified On request
Crimping tooling set

Tooling set includes clincher, anvil, punch, punch guide, and cutting block.
Such parameters as clincher type, clincher size, and punch tip shape are customized for the application.
Inclined clincher surface, smooth cutting surface, quick-change tooling cassette, and finger guard lighting cap guarantees efficient and safe operation.
Data memory in each tooling cassette stores its own tooling list (PN’s) and connection data for up to 10 connections with independent crimp height settings. It enables automatic correction of crimp height when the cassette is installed.

OPTIONS

Crimp Force Monitor (CFM)

CFM captures force-time curve and detects any deviation from the quality tolerances. System works with many types of splicing and crimping machines and suites well to any application requiring inline monitoring of forces.

The reference curve of CFM corresponds to crimping force, but in fact it can reflect such quality deviations as: missing wire strands, inaccurate components positioning or crimp height, insufficient insulation strip length, insulation in the splice area, etc.
CFM also allows to adjust automatic cutting and/or rejection of defective items.
Straightening, cutting, twisted and stripping station

Wires straightening is proceed by combing.

Cutting unit cuts the wires after splice crimping in order to get wires of a same length. It suits wires of up to 1,5 mm2 diameter.

Stripping length (until 7 mm) and knives penetration into insulation is set by micrometer. Waste removal in cutting and stripping area is performed by a vacuum cleaner.

Movements of all the stations are driven by a step motor.
POKA YOKE

Allows controlling utilization of NG/NOK components. If CFM detects quality deviation and estimates connection as NG/NOK, then machine stops operation and waits until NG/NOK component is placed to POKA YOKE bin.
Camera quality control

According to the selected program, high/low definition camera takes picture and controls components` position, color and stripping length. High or low definition is selected depending on size of components.
Quality control equipment

Laboratory equipment allows to control whether the splice quality matches industry norms or any other special requirements. Check our micrograph laboratories, pull force and crimp height control tools, as well as specialized measurement software.
Component position video verification

Camera shoots the clincher area and sends video to the HMI screen in real time. Thus, operator can view the components being crimped and is capable to position them in the clincher precisely.

There are two options for the camera placement:

1, built into the tooling cassette,

2, mounted on the left wall of the tooling cassette and connected via USB cable.