La SM Crimp V8 Advanced de SM Contact es una máquina semiautomática de engaste de empalmes de alto rendimiento diseñada para fabricantes que requieren la máxima precisión, flexibilidad y fiabilidad en el proceso. Al combinar la automatización inteligente con la carga manual de componentes, el sistema ofrece conexiones de empalme repetibles y de alta calidad para una amplia gama de componentes eléctricos, al tiempo que mejora significativamente la productividad y la seguridad del operario.
Diseñada para aplicaciones industriales exigentes, la SM Crimp V8 Advanced es la solución ideal para los sectores de la automoción, la electrónica, la medicina, el ferrocarril, las energías renovables y la fabricación industrial.
Engastado semiautomático de empalmes para una máxima eficiencia
La SM Crimp V8 Advanced combina el posicionamiento manual de los componentes con el movimiento automatizado de los soportes, lo que da lugar a un proceso de producción eficiente y altamente repetible.
Los componentes se colocan manualmente en plantillas específicas para cada aplicación, mientras que un dispositivo de sujeción accionado por servomotor los transfiere automáticamente entre las posiciones de carga y de engaste. Esto elimina la variabilidad en el posicionamiento, acorta los tiempos de ciclo y garantiza conexiones eléctricas precisas y uniformes.
El engaste de empalmes puede activarse mediante un pedal o mediante un ciclo totalmente automático, en función del proceso de producción y de los requisitos de la aplicación.
Automatización inteligente con plantillas intercambiables
A diferencia de los equipos de engaste convencionales, la SM Crimp V8 Advanced admite múltiples plantillas intercambiables dentro de un mismo dispositivo de sujeción. Esto permite a los fabricantes procesar diferentes componentes sin necesidad de sustituir todo el sistema de herramientas.
La mesa de fijación automatizada Y-Z posiciona cada plantilla con una precisión excepcional, lo que garantiza una alineación fiable de los componentes antes de cada ciclo de engaste. Mientras una plantilla está en funcionamiento dentro del área de trabajo protegida, se puede preparar otra fuera de la máquina, lo que minimiza el tiempo de inactividad y aumenta el rendimiento de la producción.
Este concepto modular hace que la máquina sea ideal tanto para la fabricación de volúmenes medios como para entornos de producción flexibles.
Control de calidad avanzado integrado en cada ciclo
La fiabilidad de las conexiones eléctricas depende de una supervisión continua del proceso. La SM Crimp V8 Advanced integra tecnologías avanzadas de garantía de calidad directamente en el ciclo de producción.
Las características de calidad de serie incluyen:
- Monitor de fuerza de engaste (CFM) integrado
- Ajuste digital de la altura de engarzado con control por codificador
- Verificación por vídeo de la posición de los componentes integrada
- Retorno automático del punzón a la posición cero
- Alimentación de bandas de empalme servocontrolada
Los sistemas de inspección opcionales incluyen:
- Inspección por visión de alta resolución
- Verificación de la presencia de componentes
- Reconocimiento del color del cable
- Inspección de la longitud de pelado
El sistema integrado de control de la fuerza de engaste analiza continuamente la curva de fuerza durante cada engaste, lo que ayuda a detectar la falta de hilos, un calibre incorrecto, un posicionamiento inadecuado, defectos en el aislamiento y otras desviaciones del proceso antes de que los productos defectuosos salgan de la estación de trabajo.
Características técnicas
| Fuente de alimentación | 220-240 V (110 V available) / 50 Hz / 2A |
| Potencia absorbida | aprox. 500 vatios |
| Potencia nominal del motor | 300 vatios |
| Tiempo de ciclo | Depende del producto |
| Carrera | 35 mm |
| Rango de engarzado | 35 mm |
| Nivel de ruido | < 75 dB |
| Peso | 80-90 kg |
| Dimensiones (An x Pr x Al) | 375 x 660 x 490 mm |
| Conformidad CE | ✔ |
| Certificación Apave (TÜV) | ✔ |
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, 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 |
Crimp height adjustment
Motorized crimp height adjustment is realized via touch screen with buttons +- (increment of 0.01 mm) or by selecting among preadjusted connections parameters (automatically).
Motorized splice band feeding system
Rubber surface of a feeding wheel prevents damages of the splice band. Special sensor controls the length of each splice.
Touch screen control panel
All controls except the power switch are located at the display. With 5 buttons and 1 display it is possible to control the quantity of products, inputs and outputs, interface language, tooling technical data, feeding system and activate emergency stop.
It indicates the process of each crimp in a jig.
Hand wheel
Hand wheel is used to perform manual cycle for testing the system before production, i.e. centering the clincher, change of tooling. Wheeling moves the punch down and allows to monitor splicing process in general as well as positioning of the tooling.
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.
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.
Automated YZ fixture table
Enables shifting the jig with components to the zone of crimping with Y and Z axes capability. High movement accuracy is achieved through programmable actions. Control over the YZ table is provided at the HMI screen, including control of stepper motor drives of the table.
Operator is protected by safety covers.
Support for the jig precisely carries the jig to the crimping zone.
Jig
Removable part of a fixture that perfectly fits components and thus enables its precise positioning. Jig can be adapted to components depending on its quantity, shape, materials.
If machine has two jigs, while one is processing, second can be reloaded by another operator.
Cast iron frame
In contrast to the machines assembled from separate parts by screws, SM Crimp cast iron frame warrants a perfect stability during crimping.
HMI
On the touch screen display HMI system shows complete work algorithm, indicating the current step and step when the failure occurred if any. It can be displayed as an algorithm graphics or product visualization.
HMI provides intuitive process control. It is possible to readjust all sensors including CFM to another product by choosing the corresponding program in the interface. HMI displays pictures of connections kept in memory when the tooling cassette is installed and the corresponding connection selected for processing.
Within the password protected area one can switch machine subfunctions on/off. Different access levels (operator and technician) are available at HMI touch screen.
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.
Protection of operation area
Safety covers can be installed on the side panels to detect foreign object presence and stop the machine.
Bimanual cycle start
Requires two hands touch to start the cycle to eliminate hands presence in the work zone.
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.
Components camera control
According to the selected program, high/low definition camera takes pictures and controls components` presense, position, color and stripping length. High or low definition is selected depending on size of components.
Force sensor for CFM
Piezo sensor detects force at the moment of splicing, transmits information to CFM for data processing and displaying force-time curve corresponding to crimp force.
Frame & cabinet
Machine and all its components can be integrated into the floor mount frame for products needs.
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.
Double crimping
Two machines are used: one set up for one splicing type, another – for the second. This solution speeds up the process and perfectly fits if the product consists of different sized crimping.
SM Crimp V8
Splice crimping with manual
components positioning
SCS (Splice Crimping Station)
Automatic manipulation of components
in X-Y-Z and exchangeable jig concept
HSCS (High-Speed Splice Crimping Station)
Semi-automatic stripping of cables and fully automatic feeding of components in tape / reel / vibrating bowl format for splice crimping