The Q1140 spark tester is a fully integrated system for testing cable jackets and conductor insulation. The cable to be tested is fed through a high-voltage electrode. If the insulation is damaged, the voltage drops and the control unit detects the fault. The corresponding wire section is automatically cut off without production downtime. The insulation tester operates at a maximum speed of 40m/s and is suitable for wires with a diameter of up to 30mm. Reliable detection of even the smallest insulation faults and automatic sorting increase quality and prevent lost production time. The spark tester cannot be used with the ACD incision monitoring.

Miniaturization and new technologies are making increasingly stringent demands on the quality of wire processing. To meet this demand, Komax has developed the fully automatic ACD incision monitoring. The ACD is integrated in the blade holder and can be operated with standard stripping blades. The standard working spectrum covers the cross section range from 0.13 to 6 mm². Any desired wire length can be stripped in full or partial stripping. The desired parameters can be set on the machine. Faulty wire ends are detected and sorted out fully automatically in the process. The ACD thus ensures consistently high quality, prevents time-consuming follow-up checks and enhances cost-effectiveness.

The Q1250 test module can be upgraded from a basic monitoring tool to a high-quality monitoring system. The BASIC unit monitors fully automatically if the stripping has worked and whether the seal and crimp are present. The device can be scaled on request: Should the requirements change, the Q1250 can be expanded with licences and/or a dome light. This means that with the integration of just one tool, comprehensive quality testing can be carried out and responses to later requirements can also be made without major changeovers. The specified parameters are monitored during operation by an algorithm independently of the user. There is no need for visual checks and time-consuming changeovers, which saves a considerable amount of time.

The measurement device ensures quality even before production: The crimp height is measured before the start, transmitted to the base machine and compared with the setpoint. If the values do not match or if the measurement is not performed, production cannot be started. This prevents incorrect processing. The Komax 341 crimp height measurement device perfectly complements the mci 721/722 and C1370 crimp modules with integrated crimp height adjustment: Based on the measured value, the correction to achieve the target crimp height is calculated. The crimp modules then automatically correct the height; there is no need to adjust the crimp height by hand. This means that the changeover and downtime of the machine can be significantly reduced.

The Q1210 is extremely versatile thanks to the wide range of measured pull-out forces of up to 1000 N and a wide range of applications for small and large cross sections. It has a control loop that keeps the pull-out speed constant. The measured value is transferred directly to the base machine and compared with the target value. The measured pull-out forces can also be output via the WPCS interface. Easy operation is ensured thanks to ergonomic handling for left- and right-handed users as well as simple integration into the TopWin or HMI software of the base machine. The sensor-controlled clamping protection function also enables safe handling.

The precision measuring device generates reproducible measurements and is suitable for very small to medium cross-sections of < 4 mm². It operates at a constant pull-out speed thanks to an embedded control loop. The pull-out forces are collected, transferred and compared with the setpoint. Seamless integration into the software of the base machine guides you step-by-step through the workflow. A test unit to check the accuracy of the Q2205 is available as an option: A series of measured values are recorded over the entire measurement range and automatically compared with the values of the test unit. A calibration certificate is created at the end of the process. The Q2205’s robust design makes it suitable for harsh conditions in the industrial sector.

Increasing miniaturization makes quality control with the naked eye difficult. Komax developed a digital microscope to meet the needs of qualified personnel. With the testing device, even the smallest terminals and wires are clearly displayed on a monitor and can therefore be easily checked. Thanks to the adjustable focus and various measuring supports, it is possible to test wires and terminals of widely differing dimensions. The integrated LED light provides perfect illumination. The software not only operates the light, but also zooms into the digital recording of the pattern and saves it with a date and time stamp.

The crimp height measurement device, MicroHeight 10, consists of an anvil to support the crimp and a measuring tip on a dial gauge to determine the height of the crimp. The patented centering aid positions the terminal accurately, minimizing operator-induced errors. Moreover, the device comes equipped with a camera and LED illumination to provide a clear view of the work area. The included software allows the configuration of the virtual keyboard and buttons, controlling the lighting and capturing snapshots of the work area whilst visually aiding the user to hold the crimp straight by means of a correct measuring zone indication. The optional tool set includes an extra wide anvil of 1.0 mm (0.0394 in) and a measuring tip of 0.8 mm (0.0315 in). The device can be used as a stand-alone tool or integrated into certain Komax machines for quality verification.

Whether a quick and easy check of the pull-out force or a complete measurement series is needed, the MicroPull 10 has a range of options available. Its modern touch interface guarantees an easy and intuitive operation. The MicroPull 10 enables single measurements or measurement series according to the specified requirements. Live viewing of the measurements and accessing measurement data is also easy. Generating reports and Onsite calibration is possible using the Pull Tester Verification Unit (PTVU). In summary, the MicroPull 10 is a reliable and versatile tool that ensures accurate pull-off force measurements. Its various features and user-friendly interface make it a suitable option for quality control purposes across different industries.

With SmartOptic, everything needed to capture color images is provided in one module: Image capture is sharp and precise thanks to digital zoom, 18 megapixel resolution and integrated illumination. It also offers high measurement accuracy and realistic colors and can be used after a short calibration time. The all-in-one device comes with a tripod, integrated ring light, camera, extender, lens and Teflon sample holder. An additional lens for detecting very large objects is available as an option.

The MicroLab 10 enables quick quality assessment of crimp connections regardless of location thanks to the easy creation of micrographs. For this purpose, samples are clamped in the sample holder of the case system and the cutting, grinding, etching and visualization can be carried out without reclamping. Useful micrographs are created, thus uncovering quality defects at an early stage to prevent expensive failures. A USB digital camera with microscope is integrated for visualization and complete documentation. The user-friendly SmartVision software supports precise and fast evaluation. This enables reliable and quick production approval on site.

The MicroLab 11, despite its compact size, delivers flexibility and mobility. It comes equipped with a high-resolution camera and the Smart Vision v.3 evaluation module, offering impressive micrograph analysis capabilities with minimal investment. Furthermore, the system is adept at handling small wires and accommodating modest production capacities. It achieves precise wire positioning and alignment through a multi-directional panning and micro-adjustment X-Y table, ensuring accuracy in operations.

In comparison with its predecessor, the MicroLab 20 can cut a broader range of wires, spanning from 0.05 mm² to 80 mm². Additionally, it offers the convenience of all-in-one cutting and polishing at the press of a button, along with a double-claw sample holder for precise perpendicular alignment of crimps. The micrograph laboratory MicroLab 20 can also be integrated with other Komax quality tools, such as Crimp Force Monitors, Pull Testers, and Micrometers, to provide a more comprehensive quality report.

MicroLab 30 is an all-in-one device for the creation of micrographs of terminals in copper and aluminum up to a maximum diameter of 10 mm. Thanks to the combined cutting and grinding process, the sample is optimally prepared for the subsequent etching process. An integrated line laser facilitates the positioning of the micrograph plane. The device operates fully automatically, independent of the operator, and with a short processing time: No need to reclamp the sample. It is also self-adaptive: No settings need to be made. The MicroLab 30 can be used for a wide range of applications and offers not only high-quality images with realistic colors but also high measurement accuracy.

MicroLab 45 is designed for fast micrograph preparation of specimens up to a maximum diameter of 6 mm. The fully automatic transport system and the proven technology enable a short processing time. Parallel processes allow continuous micrograph preparation. Samples can be clamped quickly and the cut surface can be determined easily and accurately. Without reclamping, the MicroLab 45 cuts and grinds the samples independently.

The MicroLab 55 micrograph laboratory is ideally suited for a wide range of applications. It enables the creation of micrographs of B-crimps, MIL-crimps, hex-crimps, IDC connectors, etc. made of copper or aluminum. The MicroLab 55 is also ideally suited for creating micrographs of products such as circuit boards or housings outside the automotive sector. The SmartEtch module is self-adaptive, so no adjustments are needed. It is not necessary to reclamp the sample for the individual processing steps. SmartOptic with digital zoom produces high-quality micrographs with high measurement accuracy. The device enables short processing times thanks to the optimal arrangement of the individual modules. It can be used both as a sitting and standing workstation.

The MicroForce 85 is a crimp monitoring device that reliably detects all faulty crimps and contributes to improving the crimping process using data analysis. The MicroForce 85 is designed to monitor the quality of each and every crimp. Based on these results, processes can be optimized, faulty crimping can be minimized, and traceability in the production process can be ensured. Sensor installation is quick and easy. The MicroForce 85 combines reliable and proven technology with high processing quality.

The QpLite’s simple touch display allows for intuitive operation. The user is guided through the quality validation including measurement of the crimp height, crimp width and pull-out force. The validated data is automatically stored in the database. The QpLite can be used with the Ethernet network adapter with other quality tools. Material testing with the barcode scanner is therefore possible as an option. The scanned data is compared with the QpNet database and the process is blocked if the materials do not comply with the specifications. This also helps to avoid production errors. The device can be upgraded with additional software licenses without upgrading the hardware.

The QpLite2 redefines crimping processes, setting new standards for precision and efficiency. It is designed to adapt seamlessly to evolving requirements, allowing function upgrades without hardware replacements. With optional software licenses, you can unlock advanced functionalities like headroom analysis and material verification. Even in challenging production environments, the QpLite2 is able to maintain production efficiency by processing crimp force curves with its noise filtering capability. The device offers optional remote accessibility to manage processes on-the-go. For added convenience, its capacitive touchscreen interface makes operations intuitive and user-friendly.

The crimp module analyzer allows the stability of the module stroke (STSA, Stroke Stability Analysis) to be measured for mci 7x1, mci 7x2, bt 7x2 and C13x0. A PC or laptop with at least Windows® 10 (64 Bit) is required to perform the test on a device with mci interface. On modern wire processing machines with EtherCAT interface (C13x0 crimp modules), the test is carried out directly via TopWin or Komax HMI. The measured values can be saved after quality control and loaded again later. It is also possible to generate and print out a clear report. In order to ensure the constant precision of the test equipment, the test case must be sent to Komax Switzerland annually for recertification.

The CPA PRO is a convenient, portable device that is universally used for testing crimping machines. A real-time graphic display shows the CPK index and standard deviation for shut height and crimp force. This measurement device can be used to perform regular preventive maintenance on crimping presses. Reports are generated directly in production and data analysis can be carried out on site. The shut height and pre-tensioning force are immediately shown on the LCD display. In addition, up to 20 crimp module data can be stored in the device. A timer and cycle counter controls the automatic triggering of the crimp module– ideal for quality control of crimp module manufacturers.

The CFAlab software graphically displays all results of the crimping process and thus allows easy analysis and fast optimization of the CFA/CFA+ parameters – and this during operation! Various settings can be simulated in the software. This provides prompt and clear results. After successful optimization, the parameters of the module are updated to further increase quality and throughput. CFAlab can read data from all modules with CFA or CFA+ crimp force monitoring. The connection is made via a serial communication interface. All recorded crimp results are clearly displayed and stored in databases. The CFAlab is therefore a powerful tool for optimization and increased efficiency.