Komax Alpha 477 with three crimping modules and three seals modules plus the optional 4-meter

basic conveyor belt module Parallel gripper systems for both wires Two crimping modules and two seals modules on side 1

Straight-forward setup menu Production menu with all relevant information mci 722 crimping module with mci 712 crimping module mci 761 seals module with Batch sorting with head separation
programmable crimp height optional seal presence
analyzer (SPA-iL)SPA-iL (Seal
Presence Analyser)

Unbeatable ergonomics and flexibility

Alpha 477

The Alpha 477 fully automatic double
crimping machine allows you to process two
different wires simultaneously to produce
your choice of double crimp or single wires.
With four processing stations at the lead
termination and two at the trailing end,
you have a large number of possible proces-
ses at your command.
Maximum flexibility
The machine is laid out to
accommodate up to six processing
stations. When combined with
the double gripper module,
integrated as part of the standard
equipment, and the double wire
drive, the Alpha 477 can produce
V connections out of two different
wires with two different seals and
three different crimp contacts. It
can handle cross section ratios
from 1:4 onward with no trouble at
all as well as total cross sections
as large as 6mm2. With a mere
click of your mouse, you can
choose between double crimp and
single wire processing or switch
from one job to another.
Technology
The two wire drives are fitted
with highly dynamic AC-servo
axes and an integrated anti-slip
system. With this sophisticated
handling technology, two wires
can be fed in parallel and their
ends cut to length and terminated
in a controlled process. Wires
are handled gently throughout.
For example, the gripping force
exerted on the two wires can be
programmed separately and saved
for each wire.
The two wires are brought together
in the double gripper module,
where double crimps can be
produced either side by side or
one above the other.
Maximum ease of operation
The machine has a large swivel
radius of 400mm and an upward
opening safety cover, making it
highly accessible to the operator.
An expandable wire deposit
system plus the TopWin user
interface are two further user
friendly features that assure great
ease of operation.
Wire deposit system
The standard configuration of
the Alpha 477 includes a wire
deposit system with batch sorting.
This deposit system assures
a reliable transition from one
batch to the next, even when the
machine is producing double
crimp connections. An integrated
head separation feature is also
now featured in the deposit
system. It allows the two wires
to be separated at the end with
the double crimp. If placed
in a portable deposit tray, the
processed wires can then be
removed easily and conveniently
outside the safety zone.
TopWin
TopWin is a Windows®-based
graphical user interface designed
for quick, easy data input.
Thanks to its simple and logical
structure, users can fully master
the machine in no time at all. All
the important parameters can be
conveniently set and saved. Error
messages are presented in clear,
uncluttered graphics. A special
editor (Permission Editor) can be
used to manage access rights
for all entry parameters. With the
optional WPCS (Wire Processing
Communication Standard)
interface, Komax machines can
be networked together and easily
integrated into existing production
processes. The supplemental
networking software known
as TopNet is the ideal tool for
achieving optimum production
management.
mci 722 crimping module
Press with programmable crimp
height, integrated crimp force
analyzer (CFA) for crimping forces
up to 20kN (short conversion
times)
– Just one teach crimp required
– Controls for the most important
functions, e.g. creep speed, are
right on the press.
– Split-cycle function
mci 712 crimping module
Press with integrated crimp force
analyzer (CFA) for crimping forces
up to 20 kN
– Just one teach crimp required
– Controls for the most important
functions, e.g. creep speed, are
right on the press.
– Split-cycle function
mci 761 seals module
Changeover times are ultra-short
thanks to two great features:
the consistent use of quick-
release locks for all seal-related
application parts and a software-
assisted function for approaching
special setup positions. Setup
and adjustment work is eliminated
entirely. The mci 761 seals
module can be tipped back on its
height-adjustable module base,
allowing ready access. An optional Cost-optimized total solutions
seal presence analyzer can be Modern wire processing requires
integrated directly into the mci 761 cost-optimized total solutions.
seals module and the TopWin user Komax offers you just the
software. technologies you need to achieve
this goal.
Terminal feed
The swiveling terminal roll holder
allows the use of applicators with
right or left infeed. It is as easy as
can be to switch from side feed
to back feed. The tidy disposal of
carrier strips is assured by a paper
winder and a carrier strip chopper.
 4268mm (168.03in)

Subject to change /gu

1780mm (70.08in)

0054380 Version 3
Height with cover closed: 1790mm (70.5in)
Height with cover open: 2670mm (105.1in)
Processed samples Blade blocks with two V stripping blades

Set values
Conductors: FLRY 1.0mm2, 1.5mm2
Reference values for piece output of Alpha 477 Pressure: 6bar

4. Alpha 477
Piece number [pieces/h] Speed: 10m/s
Acceleration: 50m/s2
Crimping module: mci 722
Seals module: mci 761
Quality monitoring: cfa, SPA-iL active

Same cross sections

Different cross sections

Same cross sections

Double wire draw-in and feed Wire length [mm]

– Ferrule module
Technical data
Length range
Accessories
There are a number of different Wire deposit systems
– Conveyor belt, basic module, 2 m
Efficient production of
60mm–80000mm (2.36in–3149.61in) accessories available with which
Optional from 35mm (1.38in)
Length accuracy
you can adapt the Komax Alpha
477 to your own specific needs and
or 4m
– Conveyor belt, extension module, double crimp connections
4m
Alpha 477
±0.2% (min. ±1mm) expand its capabilities as desired.
Stripping lengths Preliminary wire processing Options
Both ends 0.1–35mm – Ink jet marker – Wire measurement table
Wire cross sections* – Hot stamp marker – Tower light
0.22mm2–4mm2 – Wire feed systems – Magnifying glass
Your benefits
AWG24–AWG12 Crimping module accessories – Keypad
Cross section ratio >1:4 – Height adjustable lift pedestals – Deposit table with control cabinet
– No conversion required when switching from
Double crimp (wire A+B) <6mm2 – Paper winder – Uninterruptible power supply
double crimp to single wire production
Wire feed speed – Carrier strip chopper (UPS)
– Double crimp connections can be produced side-
max. 10m/s – Valve set for pneumatically – WPCS networking and TopNet
by-side or one above the other
– Integrated head separation and batch sorting Noise level operated advance Services
– Active good/bad wire sorting <75dB (without applicators) – Pressure regulation set Komax also provides superb after-
– An ergonomic layout assures the operator optimum TopNet
Electrical connection – Monitoring of length-wise and sales support:
accessibility and minimal walking/reaching distanc- 3×208–480V/50–60Hz; 7kVA cross-wise transport of terminals – Commissioning
es. Pneumatic connection Process monitoring – Training courses for different
– mci 722 /mci 712 assure superb flexibility and 5–6bar – Anti-slipping system (ASS) levels of users
shorter changeover times. Air consumption – Crimp force analyzer (CFA) – Production coaching and
– Integrated quality monitoring (CFA, SPA-iL) with 22m3/h – Seals presence analyzer (SPA-iL) assistance
automatic post-production of defective parts Weight – Splice detection – Worldwide customer service
– Accommodates up to six processing stations Approx. 1900kg (including 2m conveyor belt, two – Quality assurance network with complete range of
– Great ease of operation thanks to TopWin software crimping modules and two seals modules) Komax 331, 341, 351, 371 spare parts
– Networking possibilities with reliable WPCS and * Certain extremely hard, tough wires may not be able to be processed Further modules – Professional consulting services
even if they are within the indicated cross section range. In case of
TopNet – Sleeve module
doubt, we are happy to produce samples of your wires.
– Twisting/fluxing/tinning
– MIL crimp module
Komax AG, Industriestrasse 6, CH-6036 Dierikon/LU
Tel. +41 41 455 04 55, Fax +41 41 450 42 66, info@komax.ch, www.komax.ch

Professionals in Advanced Automation