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.