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Automatic twisting machine with integrated spot taping

Sigma 688 ST from Komax enables automatic processing with twisting and simultaneous taping of both open wire ends. The integrated taping function simplifies logistics and ensures high quality for downstream operations.

For UTP wires for applications with high data transfer such as CAN FD, OEMs demand the spot taping of open wire ends for quality reasons (Source: Komax)
Optional “short lengths” processing set for twisted wires from 150 mm (with activated spot taping modules from 300 mm) (Source: Komax)

Manual work takes time, costs money, and is prone to error. A situation that has, ultimately, only one solution: full automation of all processes. As the first fully automatic twisting machine, the Sigma 688 ST now facilitates the entire process, from processing and twisting to spot taping open wire ends, said the company. Thanks to spot-taped UTP wires (unshielded twisted pairs), it fulfills OEM (original equipment manufacturers) quality requirements when wires need to be fixed on a fully automatic twisting machine in a single process. This move to automation enhances both process security and stability.

For UTP wires used in applications with high data transfer speeds such as CAN FD, OEMs require open wire ends to be spot taped for quality reasons. This prevents ends from opening up unintentionally during downstream logistical steps or manual loading. The Sigma 688 ST now permits fully automatic processing including double-sided spot taping at the first intersection point.

Taped unshielded twisted pairs that fulfill OEM quality requirements (Source: Komax)
Double-sided spot taping of wire ends (Source: Komax)

The Sigma 688 ST allows economical parallel processing of two single wires (bulk goods) in one go. Automatically spot-taped UTP wires no longer need to be moved on to a manual spot taping station. This cuts out one step of the process and reduces the need for floor space and resources, scaling down the cost of logistics overall. The spot taping modules can be activated or deactivated on both sides or on one side, depending on the article.

The WPCS interface can be used to save time by communicating stored taping parameters between the machine and ME system. Processing sets are available for “short open ends” and “open ends standard”. Three others are also available as an option: for long and unequal length open ends, for short lengths, and for small cross sections. A variety of different options are ideal for marking, optimized loading thanks to the terminal pre-orientation module X2880 and quality assurance.

When starting, the wire pull-out carriage with integrated delta length analyzer (DLA) guarantees gentle feed-in of two wires as well as high length accuracy and symmetry. The wires are processed via the dynamic twisting head featuring an AC servo drive. In the process, the integrated twist force analyzer (TFA) checks forces, regulates corrective motion, and guarantees twisting. A wireless ICS power transmission system and autonomous air-pressure storage system allow the omission of the drag chain at the wire-puller carriage. A pivoting operator console ensures ergonomics and takes up minimal space. Operation is enabled by sophisticated handling, assisted by: touchscreen with graphical user interface, two-hand operation directly at the crimp modules, easy-access stations as well as quick tape changes and bar code verification. What’s more, the simplified hardware architecture and oil-free compressed air supply keep maintenance to a minimum.


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