The customizable and powerful fully automatic wire processing machines are complex– but not the operation: The Komax HMI strives for maximum simplicity of use. The clearly structured user guidance is very simple: Workflows are customized, and then the software guides the user step-by-step through the production process. The Komax HMI is based on use case-driven design. The most common use cases are mapped and all process data is displayed clearly and in a sequence-oriented manner. The Green Button, which is pressed during each work step, guides the machine operator through the production process without errors. This means that each work step is automatically carried out correctly and consistently logged.

TopWin offers maximum ease of use: Smart data linking requires only a little input when setting up articles. Saving ensures easy repeatability: For example, the strip length is linked to a terminal and the values are simply loaded and processed during reprocessing. The sample window makes a significant contribution to efficiency: Settings can be easily adjusted when setting up the article. If, for example, the crimp position needs to be changed, it is sufficient to operate a position slider. The setup times are reduced, which increases the machine's availability. The person responsible for the system can block individual input fields or even make them invisible based on their own criteria.

The Komax Cloud MES offers efficiency advantages in particular for small and medium-sized enterprises (SMEs), as the software ensures full control over the production process in the cutting room. The system provides all production data and prevents errors caused by manual entries. It displays all production data in real time and thus creates a high level of transparency. Implementation of the Komax Cloud MES requires only a small initial investment and little organizational effort. A monthly license fee gives you full access to a professional, high-performance MES. Upgrades and support are included. The MES is hosted in the cloud by Microsoft Azure. High data security and availability of the system is always ensured.

In the “Crimp to Crimp” or “Cut and Strip” area, cutting lists in electronic form are often only available as CSV files. In many cases, the raw data is different: One customer specifies the wire type in column B, the next one combines the wire type with cross section and color in several columns. Komax offers the TopConvert software as a solution to this challenge: Installed on any PC, data in CSV format can be translated into machine-readable files in WPCS format. An Excel specification sheet is used to define a converter for the data in CSV format. You can create as many converters as you like and thus process a wide variety of cutting lists.

WPCS is used to send production orders, article and material specifications to crimping machines. Orders are often managed together with material specifications by an ERP (Enterprise Resource Planning) system or MES (Manufacturing Execution System). They are sent to the desired wire processing machine via a network in the standardized WPCS format. Sources of error are reduced, product quality is ensured, and valuable time is saved as there is no need for manual data entry at the machine. Material consumption, quality and statistics data, machine errors, order and production status are also reported back via the WPCS interface for evaluation.

The program includes all the features of professional quality assurance metrology software: Existing standards and software-supported, guided measurement processes ensure fast and reliable quality control. Crimp height, crimp width, cross section and calculations such as compression or vacuum rate can be measured and evaluated. The automatic detection of B-crimp contours ensures that even large quantities per day are precisely controlled. SmartVision is therefore a time-saving, economical element of quality assurance. The software fits perfectly into the production system: The management of rights, report templates, various language variants and other standards can be individually configured.

With manual wire production, skilled personnel need around half the production time for wiring a control cabinet. With highly automated prefabrication, up to 80 % of the wiring time is reduced in comparison. To achieve this efficiency in wiring, Komax offers various optimal solutions for flexible wire production. The data is prepared with the DLW (Digital Lean Wiring) software or via ECAD systems, which export wire lists with all relevant parameters. Under these conditions, the wires are prefabricated fully automatically and ready for installation. From one-off to series production, tailor-made economical solutions are possible from the first automation steps all the way up to full automation.

The MIKO interface monitors the parameters for product and process quality in real time and ensures complete traceability. The operating sequence can be adapted to the specific order requirements and contributes to productivity and quality with seamless integration into the peripheral systems. In accordance with Industry 4.0, MIKO enables communication between ERP or MES and machine – for the implementation of individual production flow. This maximizes process reliability and minimizes manual input – and hence sources of error. Progress and quality are tracked thanks to storage and provision of all production and measurement data. This forms the basis for the OEE (Overall Equipment Effectiveness) analysis.

With QCenter, costly production errors are avoided because manual data entry is no longer necessary and production only starts when the measured values are within the required tolerances. Thanks to a simple identification function and the optional integration of a barcode scanner, measurement devices for checking crimp heights and pull-out force, such as Komax 341 or Q1210, can be used together on up to 20 crimpers. The measurement data can be transferred to an MES (Manufacturing Execution System) in real time via the MIKO interface, where it can be stored and evaluated. Alternatively, Komax Print is available, with the help of which a measurement report is automatically generated during production release and saved locally.