Wire Processing Products
New Technology Ensures Fast, Accurate Harness Assembly
New products include a pneumatic banding tool and a motorized pull-force tester.
Like all manufacturers today, wiring harness shops are faced with challenges ranging from supply chain issues and rising material costs to finding and retaining workers. Fortunately, a variety of manual, semiautomated and fully automated tools and equipment are available to cut, strip, crimp, and assemble cable and wire
Here’s a look at some of the latest products.
Taping Machine Can Process Complex Wire Harnesses
The Rotar 500 Series taping machine can process complex wire harnesses used in applications such as automotive batteries, doors and mirrors. Programming is intuitive and can be done either directly on the machine or at a remote workstation. For maximum safety, the right-flush winding head prevents the wire from being blocked. The processor hood opens and closes automatically and detects handling errors. The machine can accept tape rolls up to a 220 millimeters in diameter.
Komax Group
www.komaxgroup.com
Image courtesy of Daniels Manufacturing Corp.
Pneumatic Banding Tool Is Operator-Friendly
The DBS-1200 is designed to install 0.25-inch M85049/128 welded buckle bands. It can be used with either M85049/128-5 flat or M85049/128-6 coiled bands. The tool tensions and cuts the band, leaving an extended cut-off tab. Cut-off blades are replaceable. The PBT1200 pneumatic banding tool is also available for improved ergonomics in high-volume production environments. The DBS-CG1 laboratory calibration instrument allows operators to measure the exact tension produced by the tool.
Daniels Manufacturing Corp.
https://dmctools.com
Image courtesy of Brady Worldwide Inc.
Cordless Desktop Label Printer Is Lightweight
The i4311 transportable industrial desktop label printer features an all-day battery and an ergonomic carrying handle. It can process labels ranging from 0.25 to 4 inches wide. The device weighs only 13 pounds and uses a fast-charging battery that can print up to 5,000 labels on a single charge. LabelSense technology automatically detects and calibrates materials to eliminate manual setup, trial and error, and material waste. The portable device enables users to print labels from phones, tablets or laptops.
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Brady Worldwide Inc.
www.bradyid.com
Image courtesy of DIT-MCO International
Benchtop Tester Is Compact and Portable
The Model 2115 delivers a full 1500-volt isolation and 2-amp continuity test stimulus. An optional AC breakdown test provides a 1,000 VAC test stimulus, meeting all test requirements. The unit’s compact size makes it ideal for many benchtop or portableapplications. The heart of the system is the master switching unit (MSU), which contains all the control and instrumentation electronics, and up to 1,000 test points of switching. This single chassis is an entire test system. If more test points are needed, expansion switching units (ESUs) can be added. Each MSU and ESU fits into a standard rack mount enclosure.
DIT-MCO International
www.ditmco.com
Image courtesy of Schleuniger Inc.
Motorized Pull-Force Tester Is Highly Accurate
The motorized PullTester 320 can be used with automatic crimping machines to measure pull-off forces for wire terminations. The versatile machine has three individually calibrated measuring ranges of 100, 200 and 1,000 newtons, and pulling rates of 25-, 50- and 100-millimeters per minute. A speed-controlled motor ensures consistent pull rates that can’t be guaranteed with hand-actuated or pneumatic pull-test devices. A standard 12-position holder accommodates a wide variety of terminals.
Schleuniger Inc.
www.komaxgroup.com
Image courtesy of ETCO Inc.
Insulated Terminals Are Flame-Retardant
Flame-retardant, fully insulated terminals can be color-matched to meet unique branding, safety, assembly or field service requirements. The disconnects are stamped from a high-temperature alloy and feature a nylon insulator that comes in standard black or white colors. If there is a malfunction, the insulator collapses on itself and safely holds. All products are made to UL and NEMA specifications, and supplied in strip form with an open barrel “F” crimp connector. They are rated up to 150 C.
ETCO Inc.
www.etco.com
Image courtesy of Weidmuller USA
Versatile Tool Cuts and Strips Wire
The swifty CS is a compact, all-in-one tool for cutting and stripping wire. It slides onto any uninsulated screwdriver with a 3.5-millimeter blade diameter. End users cut wire on one side of the attachment and strip it on the other side. The tool strips PVC-insulated fine-stranded and solid conductors up to 14 AWG. It can cut copper conductors that are single-stranded up to 16 AWG and fine-stranded up to 14 AWG. An ergonomic grip is versatile for use with either right- or left-handed users. The tool is ideal for screw and spring clamp terminals, ensuring a fast and efficient workflow.
Weidmuller USA
www.weidmuller.com
For more information on wire processing, read these articles:
‘Volunteer’ Engineers Tackle Wire Harness Automation | ASSEMBLY
Testing Wire Harnesses for Defense Systems | ASSEMBLY
Zonal Wiring Architecture Will Make EVs Easier to Assemble | ASSEMBLY
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