Producing wire harnesses reliably with high process stability. The Zeta 656 performs this task with speed and precision. This block loader is also compelling for its great flexibility and short changeover times.

  • Fully automatic harness production even when miniature components are involved
  • Seamless quality monitoring of all process steps
  • Fully automatic post-production
  • Manufacture of different kinds of harnesses on a single machine
  • High availability thanks to minimal work involved with changeover

Function

The Zeta 656 is designed for double sided block loading. Teamed up with the Zeta 633 basic machine, it creates a standardized total solution for the automatic production of wire harnesses.

Mini-components

With its ultra-precise insertion technology, the Zeta 656 can process wire cross sections of 0.13mm² (AWG26) and multi-row housings featuring a grid element spacing of 1.5mm (0.059in) without any trouble.

Manual insertion of these miniaturized components is difficult and prone to error. 

Technology

The housings are mounted on a pallet system to permit very flexible production of the widest range of harness configurations. It is easy to implement any changes in the wire harness or to set up completely new harnesses.

Precise movement axes powered with a spindle drive allow highly dynamic and fast insertion processes.

From preinsertion and actual insertion to final insertion and interlock testing, the complete insertion process is monitored by the integrated precise force sensor so top quality is guaranteed.

User friendly

The pallets are loaded and unloaded with the machine running while the machine is producing a harness on the other pallet. A safety light curtain protects the user from the hazardous area during this work. Operations can be expanded to a third pallet to increase machine autonomy to an even greater extent.

The «post production» option is used to replace incorrectly crimped conductors and fit them with components automatically. No operator intervention is required.

Software

The software add-on for the Zeta 656 block loader covers the automatically calculated insertion sequence and helps to simplify the setup of new wires. The software calculates the management of individual holder grippers in the rotary storage unit for «chaotic» harnesses.

The optional interface WPCS (Wire Processing Communication Stand-ard) allows Komax machines to be networked under TopWin. With this open interface, the machine is easy to integrate into existing production sequences.

TopNet is a clearly arranged mana-gement software with functions for the centralized creation and management of parts, articles and jobs that help you to optimize your production operations.

TopConvert can be used to convert already existing job and article lists to WPCS format. This data can then be directly processed by fully automatic crimping machines.

Accessories/options

The Zeta 656 can be tailored to a customer‘s specific requirements by adding various types of accessories, e.g. block closing, secondary interlocking, etc. We are happy to send you a quotation for your specific request.

Services

Komax offer to you an optimal support by individual Service offers. 

  • After-Sales Service
  • Production Assistance
  • Certified Training Courses
  • Feasibility Test

Piece number output*                            One- and Two-ended loading 1.8s per loading operation

* Piece number output depends on wire length and block/terminal combinations. 

Shortest wire length                               With one-ended loading 85–110/240mm
                                                               For jumper connections at both ends 300mm–480mm**
                                                               For complex loading operations 300mm–680mm**

** Depends on wire harness structure 

Cable cross sections                                 ***0.13mm²–2.5mm² (AWG26–AWG14)

Outside cable diameter                            Maximum of 4mm

Wire end storage unit                                Rotary storage unit with a maximum of 30 storage slots

Process monitoring (integrated)              Collision monitoring (block cavities)

                                                              Monitoring of loading force

                                                              Monitoring of terminal interlocking

Block feed                                             Carousel with pallets Customerspecific solution on request

Pallet system                                             Loading field (WxHxD) 64x200x120mm

Electrical/pneumatic connections         Directly from Zeta 633

*** Wires outside the indicated cross section range can also be processed on the Zeta. In case of doubt, we are happy to produce samples of your wires for you.

Cutting
Cut Pulled Strands
Full Strip
Half Strip
Double Sheath Cable
Inkjet Marking
Sequence
Crimping
Double Crimping
Split Cycle For Closed Barrels
Seal İnsertion
Ferrule Crimping
Twisting And Tinning
Sleeve Insertion
Solidifying, Splicing, Etc.
Mıl Crimping
Block Loading