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Komax Alpha 530

Komax Alpha 530 – The robust all-rounder

Unrivalled robustness and durability

  • Reliable processing of wire cross sections ranging from
    0.13 to 6 mm2
  • Solid and reliable processes with powerful, durable technology
  • Reduced maintenance costs thanks to the unique approach to wearing parts
  • Designed for demanding ambient conditions

Precise and outstanding quality

  • First time right – perfectly synchronised machine processes enable excellent CpK results
  • The Komax Alpha 530 has a highly robust machine configuration
  • Can be retrofitted with unique quality monitoring such as ACD, Q1240, Q1250
  • Wires handled carefully, gently during processing

Productive due to fast changeover

  • High productivity performance thanks to ultra-fast machine setup and operation
  • Quick and highly efficient changing of cables, crimp tools, terminal rolls
  • New deposit system for maximum output
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Solid, reliable technology coupled with innovative solutions ensures and increases your company’s ability to add value. The Komax Alpha 530 – the fully automatic wire processing machine for one and two-sided crimping and seal loading – meets this criteria with solid, powerful technol­ogy. In addition, double crimp, sleeve insertion, ferrule crimping, strand twisting and tinning can be processed efficiently. The fast setup and conversion times of the Alpha 530 contribute to a high level of productivity. The highest quality requirements are met with its high degree of process capability and retrofittable quality options such as ACD and Q1240.

Attains maximum productivity in no time at all

The work flow is enhanced by short paths for the operator between crimp and wire and cutting stations, all with LED-illuminated work zones. With the help of the optional linear quick wire changer and the quick mobile (MTC) or stationary (STC) terminal changer, the Alpha 530 can be converted even more quickly.

Lightning-quick to convert, parallel set-up procedures

Simple, fast setup and conversion approaches allow short travel paths while accelerating the conversion and setup pro­cedures. With the touch screen, keyboard and mouse, the Alpha 530 can be operated in a time-saving and ergonomic fashion. The TopWin software allows the next job to be loaded without halting operations and the material and the tool to be prepared. Indicator lamps and LED-illuminated work zones optimize and expand user guidance.

First-time-right approach – minimal rejects

Top precision, even at maximum system performance and excellent CpK results – the machine processes and the functions for quality assurance are perfectly attuned to each other. The reliable EtherCAT technology guarantees optimum processes.

Quality assurance by Komax

Quality production means quality products: Komax develops and produces the elements of quality assurance itself. The highest requirements of the automotive industry are satisfied. The optional available automatic conductor detector (ACD) reduces operator influence and ensures quality monitoring even for the finest wires. The ACD detects the slightest contact between blade and conductor strands during stripping. Other available options include integrated strip moni­toring (Q1240), crimp force analysis (CFA+/CFA) and seal position monitoring (SPM).

Gentle wire guidance

The pneumatic wire straightener enables high feed-in speed and excellent deposit quality even with difficult conductor material. With the actively controlled roller pressure, any changes in the cable containers and draw-in speed are compensated. To avoid indentations on the cables during machine stops, the roller pressure is automatically reduced.

The speed of the deposit conveyor belt is automatically adjusted, assuring neat and gentle wire deposit. The deposit tray features a smooth surface to prevent any cable damage.

Automotive Configuration

Available processing modules

  • Crimp modules C1370/C1360/C1340
  • Seal modules S1441
  • Seal and strip monitoring Q1240
  • Seal-, strip- and crimp quality monitoring Q1250

Industrial Configuration

Available processing modules

  • Crimp modules C1360/C1340
  • Ferrule modules AEH-LS/ AEH-G
  • Double gripper module
  • Sleeve module mci 792
  • Tinning module X1585
  • Twisting module X1582

The market leader’s quality and expertise

Komax assures the maximum per­formance capability of the Alpha 530 by delivering holistic, comprehensive quality. It considers all components and rounds out these efforts with local services globally.

Processing Applications and Functions

Cutting
Cutting pulled strands
Full stripping
Half stripping
Core processing
Coaxial and triaxial cable processing
Double sheath cable processing
Intermediate strip
Crimping
Double crimping
Split cycle for closed barrels
Seal insertion
Twisting / tinning
Sleeve insertion
Ferrule crimping
MIL crimping
Wire end solidifying, splicing, welding
Hot stamp marking
Inkjet marking
Wire cross sections 0.13 – 6 mm2 (AWG 26 – 10)*
Wire draw-in speed Max. 9 m/s (29 ft/s) belt drive
Max. 6 m/s (19 ft/s) roller drive
Outer diameter of conductor Max. 5.1 mm (0.20 in)
Length range 60 – 65 000 mm (2.35 in – 213 ft)**
optional 30 – 60 mm (1.18 – 2.36 in.)
Full stripping 0.1 – 15.5 mm (0.004 – 0.6 in)
optional up to 29 mm (1.14 in.)
Half stripping 15.5 mm (0.6 in)
optional up to 35 mm (1.38 in.)
Crimp force 1 – 22 kN (224 – 4946 lbf.)
Process modules side 1 / 2 2 / 2
Noise level < 80 dB (without crimp tool)
Electrical connection 3 × 208 – 480 V / 50 – 60 Hz / 5.6 k VA
Compressed air connection 5 – 8 bar (73 – 116 psi)
Air consumption Crimp / Crimp
Crimp-Seal / Crimp-Seal		 < 7 m3/h (247 ft3/h)
< 11 m3/h (388.5 ft3/h)
Weight (incl. 2 crimp modules) 1.3 t (2’866 lbs.)

* Very hard or tough wires may not be able to be processed under certain circumstances although they are within the specification. Komax offers feasibility tests for  testing the wires in advance. The processing of larger wire cross sections is possible on request.
** Wire length tolerance ±(0.2% + 1 mm (0.039 in))

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