Lead Makers and
Harness Makers
Lead Makers and Harness Makers
Application Tooling and Equipment Portfolio
■ Applicators
■ MOST Equipment
■ Crimp Machines and Equipment
■ Pin Insertion and Press-Fit Machines
■ Electrical Test Equipment
■ SOLARLOK Equipment
■ FFC-FPC Equipment
■ Tooling for Raychem
Heat Shrink Products
■ Hand Tools
■ Wire Preparation Equipment
■ IDC Machines
■ Lead Makers
■ Magnet Wire Equipment
■ Installation, Inspection and Service
as well as Training and Short Term
Rental Crimp Applicators within
EMEA region
MOST is a trademark of SMSC Europe GmbH.
For more detailed information please refer to our website at
www.tooling.te.com www.tooling.te.com/europe
Lead Makers and Harness Makers
Efficiency and Flexibility
in Cable Production
High quality demands are placed on modern cable
production. Small batch sizes and just-in-time
production are the order of the day.
Fast and easy retooling of the machines is an
increasingly important consideration. For this reason
fully automatic crimping machines have been
designed to meet all these requirements.
TE Connectivity offers a wide range of fully automatic
crimping machines.
From compact and flexible fully automatic machines to
linear transfer systems. Every fully automatic machine
is on state-of-the-art technologies and designed to
produce a wide range of wire applications from simple
crimp to crimp applications to complex insertions from
terminals in housings.
The modular design and integrated quality controls
with good/bad andling enable maximum flexibility
and process reliability.
Due to the multi-lingual user software the fully
automatic crimping machines can be used almost
everywhere in the world.
For more information please contact your
TE Application Tooling (AT) representative.
For more detailed information please refer to our website at
www.tooling.te.com www.tooling.te.com/europe
1
Lead Makers and Harness Makers
Table of Contents
Page
Lead Makers
Gamma 255
3
Fully Automatic Crimping Machine
Gamma 263
4
Fully Automatic Crimping Machines
Gamma 333 PC and Gamma 333 PC-B
5
Fully Automatic Crimping Machines
Alpha 355 / Alpha 355 S
6
Fully Automatic Crimping Machines
Alpha 356
7
Fully Automatic Crimping Machine
Alpha 433 H
8
Fully Automatic Crimping Machine
Alpha 477
9
Fully Automatic Crimping Machine
Alpha 488 S
10
Fully Automatic Crimping Machine
Zeta 633 and Zeta 633 L
11
Fully Automatic Crimping Machine
Harness Makers
Zeta 651
12
Fully Automatic Wire Harness Manufacturing Machine
Zeta 656
13
Fully Automatic Wire Harness Manufacturing Machine
2
For more detailed information please refer to our website at
www.tooling.te.com www.tooling.te.com/europe
Lead Makers
Gamma 255 Fully Automatic Crimping Machine
The Gamma 255 lead maker is a
flexible fully automatic crimping
machine for efficient wire processing.
It processes cross sections in a range
from 0.0123 mm2/AWG 36 to 2.5 mm2/
AWG 14. It is compatible with all commercially available applications. It also
handles double-sided crimped wires as
short as 20 mm.
The entire cross section is processed
using programmable, highly dynamic
servo-drives and V stripping blades.
As part of its standard equipment, the
machine has a prefeeder, splice, wireend and knot detection, as well as two
wire straightening units. A bad wire
handling system with automatic postproduction is also integrated in the
Gamma 255 lead maker. To verify
quality, you can also integrate devices
for measuring crimp height and pull-out
force right into the production process.
The compact layout is carefully
thought-out and allows you to change
over from crimping to twisting, fluxing
and tinning very fast.
With its vertically opening safety cover,
the Gamma 255 lead maker is readily
accessible from all sides. Operations
and material handling are convenient
and simple. The reliable TopWin software user interface adds to this high
level of user convenience in over
20 different languages.
Key features:
Reliable processing of a larger range
of cross sections
Double side crimping or twisting,
fluxing and tinning (even lead-free)
Can handle double side crimped
wires as short as 20 mm
Minimal footprint thanks
to a compact design
High equipment standards
TopWin software with
graphical user interface
Readily accessible
Over 20 different languages
available
Technical Data:
Length range
15.0–10,000 mm
Length accuracy
Up to 500 mm: ± 1 mm
> 500 mm: ± 0.2% of the wire length
Stripping lengths
0.1–15.0 mm
Wire cross section*
0.0123–2.5 mm2 (AWG 36–AWG 14)
Wire draw-in speed
max. 3 m/s
Noise level
<75 dB (without crimp module)
Electrical connection
3x 208–400 V 50/60 Hz
1x 230 V 50/60 Hz
Pneumatic connection
5–6 bar / 500–600 kPa (73–87 psi)
Air consumption
3 m3/h
Weight
870 kg gross (with packaging)
* The Gamma 255 lead maker may also be able to
process wires outside the indicated cross section
range. Certain types of extremely hard, tough wires
may not be able to be processed even though they
are within the indicated cross section range.
In case of doubt, we are happy to produce samples
of your wires.
TopWin is a trademark of Komax AG.
Gamma is a trademark.
For more detailed information please refer to our website at
www.tooling.te.com www.tooling.te.com/europe
3
Lead Makers
Gamma 263 Fully Automatic Crimping Machine
Technical Data:
Length range
40.0–20,000 mm
Length accuracy
(0.2% +1.0 mm)
Stripping lengths
0.1–20.0 mm
Stripping lengths with partial strip
1.0–30.0 mm
Wire cross section*
0.13–4.0 mm2 (AWG 26–AWG 12)
Wire draw-in speed
max. 6.0 m/s
Noise level
<75 dB (no crimp module)
Electrical connection
3x 208–400 V 50/60Hz 5 kVA
Compressed air connection
5–8 bar / 500–800 kPa (73–116 psi)
Air consumption
3.0 m3/h
Weight
870 kg (1,918 lbs)
* Extremely hard and tough wires may not
be able to be processed even if they are within
the above cross section range. If you are in
doubt about your wires, we are happy
to process samples of them.
Although compact in size, this fully
automatic crimping machine combines
simplicity and functionality with
economy and process reliability to
deliver a high piece output. It is a real
hit when it comes to obtaining excellent value for money. Whether you
opt for the roller or belt drive, you can
adjust the use of this device to your
individual needs and be doing so
yourself in no time at all.
The machine is designed for one and
two-sided crimping and for one-sided
seal loading. The wire transport system
ensures gentle processing of varying
conductors with cross-sections ranging
from 0.13–4.0 mm2 (26–12 AWG).
Proven quality monitoring systems
are integrated. A second integrated
encoder ensures maximum length and
repetition accuracy for stripping and
wire length.
In spite of its compactness, this model
ensures that all processing stations are
highly accessible. Fitted with safety
covers that open vertically, the modules
are readily accessible from all sides.
All controls are modules are arranged
in a neat and orderly manner.
The new touch screen control based
on the TopWin graphical user interface
is designed for fast and easy equipment
operation. The layout is logical and
easy to understand so user training
can be kept quite short.
The optional WPCS (Wire Processing
Communication Standard) interface
allows Komax machines to be
networked and easily integrated into
existing production processes.
Key features:
Small investment for high
production output
Belt or roller drive in one machine
for gentle wire handling
Well known and proven crimping
press technology
Compact and user friendly on
small floor space
Highly ergonomic thanks to the
touch screen control
Gamma is a trademark.
4
For more detailed information please refer to our website at
www.tooling.te.com www.tooling.te.com/europe
Lead Makers
Gamma 333 PC and Gamma 333 PC-B
Fully Automatic Crimping Machines
Technical Data:
Length range
60.0–65,000 mm
Optionally from 30.0 mm
Length accuracy (Repeat)
(0.2% + 1 mm)
Stripping lengths
Side 1: 0.1–15.0 mm
Optionally from 28.0 mm
Side 2: 0.1–15.0 mm
Wire cross section*
0.22–5.0 mm2 (AWG 24–AWG 10)
Optionally from 0.13 mm2 (AWG 26)
Wire draw-in speed
6 m/s – Gamma PC
10 m/s – Gamma PC-B
Noise level
<75 dB (without crimp module)
Electrical connection
3x 208–480 V 50/60 Hz
Pneumatic connection
5–6 bar 500–600 kPa (73–87 psi)
Air consumption
6.5 m3/h
Weight
1,200 kg (2,649 lbs) gross
The Gamma 333 PC lead maker is a
flexible fully automatic crimping
machine for efficient wire processing.
It processes cross sections in a range
from 0.13–5.0 mm2 (AWG 26–AWG 10).
Short conversion times, additional
applications and a user-friendly user
interface with multiple-language
capability. The Gamma 333 PC and
Gamma 333 PC-B lead makers
(B-version with beltdrive) makes it all
possible! With its third processing station and state of the art control software, you are provided high flexibility
and an even more efficient way of
meeting your wire processing needs.
With an additional processing station
on side 1, the Gamma 333 PC lead
maker enables you to crimp both ends
of the wire, to create double crimp
connections with three different
contacts, to carry out one-ended seal
application, tinning or ink-jet marking.
Dimensions (W x D)
3,137 x 1,377 mm
Height with cover closed:
1,790 mm
Height with cover open:
2,670 mm
In addition, process monitoring is all
integrated to ensure that the wire is
cut to length and stripped perfectly.
Key features:
Exact reproducible settings for
processing stations
Maintenance-free step and servo
motor of top quality
Very short conversion times thanks
to integrated processing modules
Highly comfortable and convenient
to operate thanks to graphic-based
TopWin software
User specified language – more
than ten different languages to
choose from
Integrated good/bad sorting
Can be networked with additional
WPCS (Wire Processing Communication Standard) software
TopWin is a trademark of Komax AG.
Gamma is a trademark.
* Certain extremely hard, tough wires may not be able
to be processed even if they are within the indicated
cross section range. In case of doubt, we are happy
to produce samples of your wires
For more detailed information please refer to our website at
www.tooling.te.com www.tooling.te.com/europe
5
Lead Makers
Alpha 355 and Alpha 355 S Fully Automatic
Crimping Machines
Alpha 355 Lead Maker
Alpha 355 S Lead Maker
The Alpha 355 lead maker is designed
for one and two-sided crimping and
seal loading. It even handles doublecrimp connections involving varying
lengths and the same wire types
without any problem. The precise
dual-channel blade system allows for a
large range of wire sizes without blade
changes. With options like the manual
wire selector and/or the quick-change
system for crimping tools, materials
and tools can be prepared for the next
job while the machine is running.
The Alpha 355 fully automatic crimping
machine is a proven performer and
now available in a model offering the
flexible selection of modules. The high
safety cover and the flat table design
is the most striking difference between
this version and the Alpha 355 lead
maker. It allows processing modules
not specifically designed for certain
machines to be mounted. One of the
two module slots on each processing
side is fitted with special mounting
tables to accommodate the various
mounting methods. Combined with the
ingenious open-ended software interface, the flexibility of the Alpha 355 S
lead maker can be increased.
Key features:
Short changeover times
Reliable process monitoring
High production output
Setup of next job while production
of current job is underway
WPCS (Wire Processing
Communication Standard)
Integrated quality measurement
with quality monitoring,
CFA+ (Crimp Force Analyzer),
SPM (Seal Position Monitor)
Key features:
Flexibility in module selection
Reliable basic machine
Open-ended software interface
WPCS
Q-monitoring, CFA+ (Crimp Force
Analyzer), SPM (Seal Position Monitor)
Technical Data:
Length range
60.0–65,000 mm
Optionally from 30 mm
Length accuracy (Repeat)
(0.2% +1.0 mm)
Stripping lengths
0.1–35.0 mm
Stripping lengths with partial pull-off
Beginning of wire: 47.0 mm 1 mm
End of wire: 35.0 mm 1 mm
Wire cross section*
0.22–6.0 mm2 (AWG 24–AWG 10)
Optionally from 0.13 mm2 (AWG 26)
Wire draw-in speed
max. 12 m/s
Noise level
<75 dB (without crimp module)
Electrical connection
3x 208–480 V 50/60 Hz, 5 kVA
Pneumatic connection
5–8 bar / 500–800 kPa (73–116 psi)
Air consumption
9 m3/h
Weight
1,300 kg (2,866 lbs) including two crimp
and seal modules
* Extremely hard, tough wires may not be able to be
processed even if they are within the indicated
cross section range. In case of doubt, we are happy
to produce samples of your wires.
Alpha is a trademark.
6
For more detailed information please refer to our website at
www.tooling.te.com www.tooling.te.com/europe
Lead Makers
Alpha 356 Fully Automatic Crimping Machine
Technical Data:
Length range
60.0–65,000 mm
Optional 30.0–60.0 mm
Length accuracy (Repeat)
(0.2% +1.0 mm)
Stripping lengths
0.1–35.0 mm
Stripping lengths with partial pull-off
47.0 mm on side 1
35.0 mm on side 2
Optionally up to 80.0 mm
Wire cross section*
0.22–6.0 mm2 (AWG 24–AWG 10)
Optionally from 0.13 mm2 (AWG 26)
Wire draw-in speed
max. 12 m/s
Noise level
<75 dB (without crimp module)
Electrical connection
3x 208–480V 50/60 Hz, 5 kVA
Pneumatic connection
5–8 bar / 500–800 kPa (73–116 psi)
Air consumption
9 m3/h
Weight
approx. 1,400 kg (3,090 lbs)
The Alpha 356 fully automatic crimping
machine has room for up to seven
processing stations.
A wide variety of configurations are
possible, in fact, almost any combination of crimping, seal loading, fluxing/
tinning, twisting, fitting with insulating
sleeves and end sleeves for strands
as well as bulk turned contacts and
customer-specific processes. In a
configuration featuring three crimping
presses, for example, you can crimp
the three wire ends for double-crimp
connections with different contacts
or select different articles without a
machine changeover.
With the rotating wire selector and
the TopWin user software, you can
complete most of the preparations for
the next job while the current one is
still being produced on the machine.
Crimping tools, contact rolls and other
application-specific parts can be
* Certain extremely hard, tough wires may not be able
to be processed even if they are within the indicated
cross section range. In case of doubt, we are happy
to produce samples of your wires.
For more detailed information please refer to our website at
www.tooling.te.com www.tooling.te.com/europe
changed without tools. Thanks to the
use of the modern technology, the
production output – and the degree of
process control – is extremely high in
this machine generation.
Key features:
High flexibility with up to seven
processing stations
Both standard and customerspecific processes can be integrated
Wide choice of different processing
configurations
High productivity thanks to the
latest technology
Integrated quality measurements
Next job can be prepared while
machine is processing current job
Combinable in networks using
WPCS (Wire Processing Communication Standard) interface
TopWin is a trademark of Komax AG.
Alpha is a trademark.
7
Lead Makers
Alpha 433 H Fully Automatic
Crimping Machine
Technical Data:
Length range
60.0–65,000 mm
Length accuracy
1.0 mm or <0,2%,
depend of the wire length
Stripping lengths
0.1–18.0 mm
Stripping lengths with partial strip
Side 1: 35.0 mm 1 mm (optional 50.0 mm)
Side 2: 35.0 mm 1 mm
Wire cross section*
0,22–16.0 mm2 / AWG 24-6
Wire feed speed
max. 10 m/s
Noise level
<75 dB (without crimp module)
Electrical power
3x 208–480 V 50/60 Hz, 5 kVA
Pneumatic pressure
5–6 bar / 500–600 kPa (73–87 psi)
The Alpha 433 H lead maker is a
flexible fully automatic crimping
machine for efficient wire processing.
Large wires no longer pose a problem.
The machine is capable of processing
large wires from 0.20–16 mm2 / AWG
24-6 (fine-wire conductors). The P104
crimping press delivers the requisite
force to process large terminals.
Terminals can be crimped on both ends
but seals can also be loaded at one end.
Wire processing to very exacting
standards – great versatility without
conversion. The Alpha 433 H fully
automatic crimping machine is based
on state of the art technology and
is designed for processing single
conductors as well as double crimp
connections.
Key features:
Safe and trouble-free processing of
large cross-sections up to 16 mm2
The know-how of the staff, which
has been acquired on the Alpha 433,
can be used
Crimp press P104 with
40 kN (8’992 lbf) crimp force
Integrated crimp force monitoring
(cfa 326)
Easy handling by TopWin
Wide range of accessories
TopWin is a trademark of Komax AG.
Alpha is a trademark.
Air consumption
9 m3/h
Weight
1,200 kg
(with 2 presses and lifting pedestal)
* Fine-stranded wires possible (FLY 16; 16 mm2,
128 single wires, PVC insulation) => For coarse
stranded wires prior feasibility test recommended
8
For more detailed information please refer to our website at
www.tooling.te.com www.tooling.te.com/europe
Lead Makers
Alpha 477 Fully Automatic Crimping Machine
Technical Data:
Length range
60,0–80,000 mm
Optional from 35.0 mm
Length accuracy (Repeat)
(0.2% +1.0 mm)
Stripping lengths
Both ends 0.1–35.0 mm
Optional 50,0 mm on side 1
Wire cross section*
0.22–4.0 mm2 (AWG 24–AWG 12)
Optionally from 0.13 mm2 (AWG 26)
Cross section ratio > 1:4
Double crimp (wire A+B) < 6 mm2
Wire draw-in speed
max. 10 m/s
Noise level
<75 dB (without crimp module)
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. 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.
With four processing stations at the
lead termination and two at the trailing
end, you have a large number of
possible processes at your command.
Electrical connection
3x 208–480 V 50/60 Hz, 7 kVA
Pneumatic connection
5–8 bar / 500–800 kPa (73–116 psi)
Air consumption
22 m3/h
Weight
Approx. 1,900 kg (including 2 m conveyor
belt, two crimping modules and two seal
modules)
* Certain extremely hard, tough wires may not be able
to be processed even if they are within the indicated
cross section range. In case of doubt, we are happy
to produce samples of your wire.
Key features:
No conversion required when
switching from double crimp to
single wire production
Double crimp connections can be
produced side-by-side or one above
the other
Integrated head separation and
batch sorting
Active good/bad wire sorting
An ergonomic layout assures the
operator optimum accessibility and
minimal walking/reaching distances
mci 722/mci 712 module assure
superb flexibility and shorter
changeover times
Integrated quality monitoring
– CFA (Crimp Force Analyzer),
– SPM (Seal Position Monitor)
with automatic post-production of
defective parts
Accommodates up to six processing
stations
Great ease of operation thanks to
TopWin software
Networking possibilities with
reliable WPCS and special software
TopWin is a trademark of Komax AG.
Alpha is a trademark.
For more detailed information please refer to our website at
www.tooling.te.com www.tooling.te.com/europe
9
Lead Makers
Alpha 488 S Fully Automatic Crimping Machine
Technical Data:
Length range
700–4,000 mm
700–7,000 mm
700–10,000 mm
Optional from 150.0 mm
Final length of twisted pairs
Length accuracy (Repeat)
(0.3% +1.5 mm)
Stripping lengths
Side 1: 0.1–18.0 mm
Side 2: 0.1–35.0 mm
The Alpha 488 S produces fully automatically twisted-pairs out of two single
bulk wires completely cut-to-length
and terminated, with all quality controls
included. The modular composition of
the system provides superb flexibility.
Four processing stations at the wire
beginning and two at the wire end
offer extensive processing possibilities.
The machine layout accommodates
up to six processing stations.
The system can also be used for the
processing of two untwisted isometric
single wires and is available in the
versions of four, seven and ten meters.
In combination with the crimping
modules mci 722 or mci 712 and the
seals module mci 765 C as well as
with the quick-change systems and
the integrated quality monitoring
systems the Alpha 488 S ensures
high process reliability and extremely
short changeover times.
The optional interface WPCS (Wire
Processing Communication Standard)
allows the machine to be networked
under TopWin. With this open interface,
the machine is easy to integrate into
existing production sequences.
Open wire ends
30.0–99.0 mm
optionally 30.0–125.0 mm on side 1,
depends on pitch, cross section
and end processing
Pitch length
Programmable from 5.0–80.0 mm
programmable accuracy: 10%, max. 5 mm
Wire draw-in speed
max. 5 m/s
Key features:
Complete processing of two single
bulk wires into twisted pairs with
processed ends
Fully automatic twister featuring
well-proven as well as innovative
quality monitoring systems for
maximum process control
Highly reliable and proven TopWin
graphical user interface on touch
screen for efficient machine use
Networking possibilities with reliable
WPCS
TopWin is a trademark of Komax AG.
Alpha is a trademark.
10
Wire cross section*
2x 0.22 mm2–2x 2.5 mm2 (AWG 24–AWG 14)
Optionally from 0.13 mm2 (AWG 26)
Noise level
<75 dB (no crimping module)
Electrical connection
3x 208–480 V 50/60 Hz, 10 kVA
Pneumatic connection
5–6 bar / 500–600 kPa (73–87 psi)
Air consumption
12 m3/h
Weight
Including two crimping modules and
two seal loading modules
Alpha 488/4 m: approx. 2,800 kg (6,173 lbs)
Alpha 488/7 m: approx. 3,400 kg (7,496 lbs)
Alpha 488/10 m: approx. 4,000 kg (8,818 lbs)
* Extremely hard and tough wires may not be able to be
processed even if they are within the above cross section
range. If you are in doubt about your wires, we are happy
to process your samples.
For more detailed information please refer to our website at
www.tooling.te.com www.tooling.te.com/europe
Lead Makers
Zeta 633 and Zeta 633 L Fully Automatic Crimping Machine
Technical Data:
Length range
240–3,000 mm standard tray
240–10,000 mm optional
Length accuracy
1.0 mm or <0.2% depending
on wire length
Stripping lengths
0.1–25.0 mm with full strip
0.1–42.0 mm with partial strip
Wire cross section*
0.22–6.0 mm2 (AWG 24–AWG 10)
Optionally from 0.13 mm2 (AWG 26)
Useable transfer length
1.800 mm – Zeta 633 (basic machine)
2.880 mm – Zeta 633 L (basic machine)
1.720 mm – Zeta 633/Zeta 633 L extension
Wire draw-in speed
max. 10.0 m/s
Noise level
<75 dB (without crimp modules)
Electrical power
3x 208–480 V 50/60 Hz,
10 kVA (basic machine)
Pneumatic pressure
5–6 bar / 500–600 kPa (73–87 psi)
Air consumption
12 m3/h
Weight
Approximately 1,560 kg (3,440 lbs)
Zeta 633 is a highly flexible fully automatic crimping machine used for just-intime production. With its flexible
machine concept, the Zeta 633 lead
maker opens up an almost unlimited
number of possibilities for handling
small jobs and wire sequences.
Up to 36 conductors are available for
wire feed without changeover. Wire
transport can be adapted to the specific
properties of each conductor. Applying
the loop transfer principle, the device
feeds the two wire ends of the loop
individually one after the other to the
appropriate processing station.
Key features:
Up to 36 different conductors can
be processed without changeover
Station layout can be defined
as desired
Full integration of existing
processing stations
High processing quality
TopWin software:
Existing user expertise can be
applied immediately.
Excellent accessibility and safety
Expandable
Modules can be configured as desired
Prepared for Zeta 651 and Zeta 655
along the entire length of the Zeta 633
machines
lead maker. That means total flexibility
Fully
integrated quality monitoring
for each area of application. The Zeta
with
good/bad
sorting
633 standard machine accommodates
up to five processing stations, the Zeta
Customer specified special
633 L Version even 8 processing station.
applications possible
If needed, both Zeta versions can be
successively expanded and still have
TopWin is a trademark of Komax AG.
Zeta is a trademark.
space for additional processing stations.
The wires can be bundled or deposited
in predefined order as a chain.
* Certain extremely hard, tough wires may not be able
to be processed even if they are within the indicated
cross section range. In case of doubt, we are happy
to produce samples of your wires.
For more detailed information please refer to our website at
www.tooling.te.com www.tooling.te.com/europe
11
Harness Makers
Zeta 651 Fully Automatic Wire Harness Manufacturing Machine
Technical Data:
Wire cross section
0.22–4.0 mm2 (AWG 24–AWG 6)
Together, the Zeta 633 and Zeta 651
harness makers offer a reliable and
attractively priced complete solution
for the single-sided loading of single
and double row blocks.
The Zeta 633 fully automatic crimping
machine applies the loop transfer
principle to feed the two wire ends of
the loop individually one after the other
to the appropriate processing station.
With the Zeta 651 harness maker, the
contacts are mechanically centered
prior to loading and optionally rotated,
if need be. The use of the reliable
loading head and the process monitoring
systems of the Zeta 656 harness maker
ensure optimum loading. The entire
loading process is monitored, from
insert in chamber to correct locking.
Blocks are fed automatically and can
be replenished while the machine is
running.
Feed and deposit can be adapted to
meet the respective needs of the
specific customer.
The long deposit system with batch
separation and integrated bad part
cutter is used for producing harnesses
with long conductors up to 3000 mm
in length.
Key features:
Fully automatic block loading
Full integration into TopWin software
Integrated process monitoring with
good/bad separation
Automatic block feed
Blocks can be replenished while
machine is running.
Economical production of harnesses
undergoing single-sided loading
Outside cable diameter
4.0 mm
Lengths of processed cables
Single-sided processing
85.0–3,000 mm
Double-sided processing
85.0–110.0 mm / 240.0–3,000 mm
Loadable blocks
Single and double row blocks
Piece output
Cycle time: 1.5 s per loading operation*
Block loading time: 1.5 s*
Monitoring of loading process
Collision
End force for loading
Contact locking
Block feed
Vibratory bowl feeder
Linear rail
Customer-specific solution on request
Wire deposition
Simple deposition for wires
up to 1,000 mm long
Deposition for wires
up to 3,000 mm long
Customer-specific solution on request
TopWin is a trademark of Komax AG.
Zeta is a trademark.
Electrical/pneumatic connections
Directly from Zeta 633 harness maker
Accessories
The Zeta 651 harness maker can be fitted
with various accessories to meet specific
customer requirements such as block
closing, secondary locking, etc.
* Piece output depends on wire length and
block/contact combination.
12
For more detailed information please refer to our website at
www.tooling.te.com www.tooling.te.com/europe
Harness Makers
Zeta 656 Fully Automatic Wire Harness Manufacturing Machine
Technical Data:
Piece number output*
One-ended loading 1.5 s per loading
operation
Two-ended loading 1.5 s per loading
operation
Shortest wire length
With one-ended loading 240.0 mm
For jumper connections at both ends
280.0–440.0 mm**
For complex loading operations
280.0–640.0 mm**
Wire cross section**
0.13–2.5 mm2 (4.0 mm2)
(AWG26–AWG 13/AWG11)
Outside diameter of cable
Maximum of 4.0 mm
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 customer specific
solution on request
Pallet system
Loading field (W x H x D)
164.0 x 200.0 x 120.0 mm
The Zeta 656 harness maker is a block
loading robot designed to taken into
account the ever smaller sizes of production batches. Thanks to its machine
design, the Zeta 656 harness maker
allows investment costs to be amortized in parallel on different types of
wire harnesses, markedly reducing
the cost per lead set. The Zeta 656
harness maker allows new applications
to be subsequently incorporated. With
the flexible pallet carousel, the most
varied types of wire harnesses can be
produced just-in-time and changeover
times are very short. All the operator
has to do to change over to a new type
of block is switch the two pallets. The
loading of each and every block is
monitored and controlled by a force
sensor.
The Zeta 633 basic machine has a
36-wire changer and several crimping
stations with automatic crimp height
adjustment, allowing far more than 300
different wire/terminal variations to be
processed without any changeover at
Connection electrical/pneumatic
Directly from Zeta 633 harness maker
all. In combination with a machine
extension, another four processing
stations can be accommodated.
Moreover, wire marking systems can
be connected, allowing different wires
within the same harness to be marked
with the operator’s choice of black or
colored text.
Key features:
Extremely broad variety of
harnesses on one machine –
no application-specific parts
New applications can be easily
added later on
Economical even for tiny
production batches
Non-contact position recognition
for the terminals
Uniform top quality processing –
high degree of process reliability
Integrated quality monitoring
with good/bad sorting
Short amortization period
Zeta is a trademark.
*** Piece number output depends on wire length and
block/terminal combinations.
*** Depends on wire harness structure
*** 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 more detailed information please refer to our website at
www.tooling.te.com www.tooling.te.com/europe
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FOR MORE INFORMATION PLEASE REFER TO
www.tooling.te.com
FOR REGIONAL ASSISTANCE PLEASE REFER TO
www.te.com/support-center
While TE Connectivity has made every reasonable effort to ensure the accuracy of the information in this catalog, TE Connectivity does not guarantee
that it is error-free, nor does TE Connectivity make any other representation, warranty or guarantee that the information is accurate, correct, reliable or
current. TE Connectivity reserves the right to make any adjustments to the information contained herein at any time without notice. TE Connectivity
expressly disclaims all implied warranties regarding the information contained herein, including, but not limited to, any implied warranties of merchantability or fitness for a particular purpose. The dimensions in this catalog are for reference purposes only and are subject to change without notice.
Specifications are subject to change without notice. Consult TE Connectivity for the latest dimensions and design specifications.
Tyco Electronics Corporation
PO Box 3608, 161-09
Harrisburg, PA 17105, USA
Phone: 1-888-777-5917 or 171-810-2080
Email: toolingsales@te.com
www.te.com
© 2013 Tyco Electronics AMP GmbH, Germany
All rights reserved.
Raychem, SOLARLOK, TE Connectivity, TE connectivity (logo)
are trademarks.
Other products, logos and company names mentioned herein
may be trademarks of their respective owners.
5-1773444-9 Revised 10-2013