Crimp center 62-electrical cable wire cut,strip

and crimp machine:

The crimp centre 62 is called wire cut, strip and terminate machine, which belongs to CNC.It is a
fully systemized and automated machine,the features are

• High performance and short setup times

• Simple operation with state-of-the-art software and touchscreen
• Easy network integration in existing infrastructure (no proprietary technology)
• Low maintenance costs due to use of standard components
• Wide range of options and accessories available
• Fully Automatic Crimping Machine

The CrimpCenter 62 is a fully automatic swivel arm crimping machine with up to 2 crimping
stations specially suited for crimp to crimp applications. At a maximum feed rate of 12 m/s
(39.37 ft/s), the CrimpCenter 62 allows high-quality crimping of wires from 0.15 to 6 mm² (26 -
10 AWG) at maximum productivity.
The specifications are,

 Cable cross-section 0.15 - 6 mm²

 Transport speed 12 m/sec.

A. Technical specifications

• Machine CrimpCenter 62 Wire Length

• standard: • 60 mm - 65 m (2.36'' - 213.25 ft)
• optional: • 35 mm - 99 m (1.38'' - 324 ft)
• Wire Size Range
• standard: • 0.15 - 6 mm² (26 - 10 AWG)
• optional: • 0.05 - 6 mm² (30 - 10 AWG)
• Stripping Length
• side 1: • 0.1 - 18 mm (0.004 - 0.71'') standard
• side 2: • 0.1 - 18 mm (0.004 - 0.71'')
• Transport Speed 1 - 12 m/s (3.28 - 39.37 ft) Power Supply 3L / N / PE AC 400 / 230 V
50 / 60 Hz; 16 A
(transformer for different voltages optionally available) Air Supply min. 6 bar, not oiled,
dried and filtered compressed air Dimensions (L x W x H) 3'640 x 1'300 x 1'830 mm
(143.3" x 51.2" x 72.1'')
incl. Stacker 2 m (78.74") Weight
• base machine: • approx. 470 kg (1'036 lbs)
• with 2 processing stations: • approx. 743 kg (1'638 lbs)
 Self centering belt feed

Fig1.4.2 end bit crimping

Top view of crimp center

Machine power source: Electro-pneumatic source

Machine working procedure:

This machine is used for cable cutting,stripping and crimping. Also the cutting and
swivel mechanism are based on servo motor drives. The control panel of the
machine side is mainly based on plc,called b &r automation plc. Also five
servo drives are incorporated for giving the controlled signal to their motors.
Moreover the controlling of full unit which is based on plc,the inputs are received
from some sensors like position,speed,encoders.

It is a fully automatic machine,the operator is allowed only to give the requirements

like depth to cut,stripping length,wire feed rate,crimping length. Actually the
working is,after entering the datas in the ouch screen monitor,the system
automatically stats their process.the wire input is primarily fed with front side, by
self centering belt feed. This wire is passed through belts with rollers. The encoder
measures their length to cut,the cutting process is done with four cutting blades
up/down.

After it cutted,the wire is fed to the left side of the crimp center through gripper
mechanism. The end bit is crimped with pneumatic force,after that the other end of
wire is fed to the right side crimp center,likewise the bothe ends of the cutted wire
at fixed length is crimped. This is fast process. After both end crimps the wire is put
in the conveyor belt.

PLC-main controller:

The over all plc control is called system 2005. The System 2005 is the high-
performance controller from B&R. Its large amount of bandwidth for the input and
output of signals from peripherals covers all of the requirements of machine
manufacturing, plant manufacturing, and process engineering. Together with I/O
systems, industrial PCs, and controllers from B&R, automation solutions are created
that meet the highest demands. Modern interfaces, together with fieldbus systems,
networks, and peripheral devices, provide optimal data throughput.

In this machine,the plc modules are CPU, analog i/o,digital i/o,

CPU

MODEL NO 7CP476-020.9
DIGITAL I/O:

MODEL NO 7DI 135.70

PROBLEM DESCRIPTION:

Actually the problem is while giving short length(62mm) wire requirements the final
output is well. But while giving longer length for ex.( 85 mm or 20 m) the final
output will be wastages that means after it crimped the copper strands will come
out at the end. So this is the problem,but it is not technical fault,it occurred due to
the reasons of deflection.

PROPOSED METHOD:

In my proposed technique, by creating one external module we can eliminate the

wastages. That is this module is comprised of sensor and controller(normal pi)the
final control element will be one roller,this roller is used for precompress the
incoming copper stands at some light dia.

So the main thing is to interface my external module controller with the main plc
controller. Also u have to develop a plc program for this interfacing via main
controller(which including the machine basic operations). The additional controlling
is based on the sensor signal the timer will be on,so the roller is on thus by main plc
give command to this slave controller to reduce the input gripper
pressure(<0.001bar)light reduce.

For this method the wastages will be reduced by proper alignment of copper
strands in the crimp guard.

Moreover that plc is programmed with automation studio software from b&r
automation.