Alpha 477

Efficient production of double crimp connections

THE WAY TO MAKE IT | FLEXIBLE

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 modular system design provides maximum flexibility. With four
processing stations at the wire beginning and two at the wire end, the machine
offers extensive process possibilities.

Maximum flexibility
The machine is laid out to accommodate up to six contacts. It can handle cross section ratios from
processing stations. Combined with the double 1:4 onward with no trouble at all as well as double
gripper module, integrated as part of the standard crimp connections with total cross sections as large
equipment, and the double wire drive, the Alpha 477 as 6mm2. With a mere click of your mouse, you can
can produce V connections out of two different wires choose between double crimp and single wire pro-
with two different seals and three different crimp cessing 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 pro-
grammed separately and saved for each wire.
The two wires are brought together in the double
gripper module, where double crimps can be pro- Double wire Draw-in and feed

duced either side by side or one above the other.

Blade blocks With two V-stripping lines

 Parallel gripper systems For both wires

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 de-
posit system plus the TopWin user interface are two
further user friendly features that assure great ease
of operation.

Up to six processing stations



Wire deposit system

The standard configuration of the Alpha 477 in-
cludes 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 produc-
ing 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 por-
table deposit tray, the processed wires can then be
removed easily and conveniently outside the safety
zone.
Batch sorting With head separation


TopWin
TopWin is a Windows®-based graphical user inter-
face designed for quick, easy data input. Thanks
to its simple and logical structure, users can fully Your benefit
master the machine in no time at all. All the important • No conversion required when switching from
parameters can be conveniently set and saved. Error double crimp to single wire production
messages are presented in clear, uncluttered graph- • Double crimp connections can be produced
ics. A special editor (Permission Editor) can be used side-by-side or one above the other
to manage access rights for all entry parameters. • Integrated head separation and batch sorting
With the optional WPCS (Wire Processing Communi- • Active good/bad wire sorting
cation Standard) interface, Komax machines can be • An ergonomic layout assures the operator
networked together and easily integrated into exist- optimum accessibility and minimal walking/
ing production processes. The supplemental net- reaching distances.
working software known as KomaxCAO is the ideal • mci 722/mci 712 assure superb flexibility
tool for achieving optimum production management. and shorter changeover times.
• Integrated quality monitoring
(CFA/CFA+, SPM etc.) 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 KomaxCAO
Application sample Alpha 477

Cutting Double sheath / Coaxial

and triaxial cables
Half strip
Cut pulled strands /
Full strip Precision cut

Intermediate strip / Sleeve insertion

Intermediate slitting
Ferrule crimping
Crimping
MIL-Crimping
Twisting / Tinning
Wire end solidifying /
Crimping Splicing / Welding

Split cycle Hot stamp marking

for closed barrel
Ink-Jet marking

Double crimping

Options and Accessories

Feeding systems Komax 106 | ads 119

Marking systems Komax 26 hot stamp marking | Komax Inkjet marking system IMS

Wire infeed Belt drive

Processing modules Crimping module mci 712 (mit CFA/CFA+) | Crimping module mci 722 (with programmed
crimp heights and CFA/CFA+) |
Seal loading module mci 765 C (with seal position monitoring SPM) | Double gripper
module in standard

Quality control Integrated crimp height measurement | Integrated pull-off force measurement |
Crimp force analyzer CFA/CFA+ | Material change detection | Material verification |
Wire length correction | Splice check | Spark tester | Seal position monitoring (SPM) |
Strip- and terminal control

Deposit systems Basic module 2m (78.7in.) or 4m (157.5in.) |

Extension module 4m (157.5in.)

Accessories Manual tool changer | Manual wire changer | Manual roll-holder changing system |
Barcodescanner PM8300 | Software: Networking WPCS | Data conversion TopConvert |
Production control center KomaxCAO
 Made in Switzerland
Machine layout Alpha 477

4268mm (168in.)

Subject to change /gu

1780mm (70.1in.)

0054380 Version 4
Heigth with cover closed: 2000mm (78.7in.)
Heigth with cover open: 2900mm (114.2in.)

Reference values for piece output of Alpha 477 Single wires

Pieces/h
Same cross sections

CC. Alpha 477

Different cross sections

Same cross sections

Conductors FLRY 1.0mm2, 1.5mm2

Pneumatic pressure 6bar (87psi)
Speed 10m/s (32.8ft/s)
Acceleration 50m/s2 (164ft/s2)
Crimping module mci 722
Seal loading module mci 765 C
Wire length [mm]

Technical data

Length range 60mm–80000mm (2.36in.–262.5ft.)

Optionally from 35mm (1.38in.)

Length accuracy Repeat accuracy: ±(0.2% +1.0mm (0.04in.)) More information about

Stripping lengths 0.1mm–35mm (0.004in.–1.38in.) our products:

Wire cross-sections* 0.22mm2 –4mm2 (AWG24–AWG12)

Optional from 0.13mm2 (AWG26)
Cross section ratio >1:4
Double crimp (Kabel A+B) <6mm2 (AWG10)

Wire infeed speed max. 10m/s (32.8ft/s)

Noise level <75dB (no crimping module)

Electrical connection 3×208 –480V / 50–60Hz 7kVA

Pneumatic system 5– 6bar (73– 87psi) | 22Nm3/h (777ft3/h) www.komaxwire.com

Weight 1900 kg (2866lb.) including 2m conveyor belt,

Komax Wire is a division
two crimping modules and two seal loading modules
of Komax Holding AG,
* 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. Switzerland.

THE WAY TO MAKE IT