Komax Semi-automated Control Cabinet Wiring Automation System Instruction Manual
- May 15, 2024
- Komax
Table of Contents
Komax Semi-automated Control Cabinet Wiring Automation System
Specifications
- Manufacturer: Komax
- Automation Level: Semi-automated to fully automated
- Processing Options: Labels, Wire production in sequences, Process wire ends (ferrule, crimp, weld, etc.), Ink Jet TopWin X60/A4 X60/A5, Tube marking
- Features: Fully integrated inkjet labeling or tube marking systems, Greater flexibility in wire end processing, Consistent data flow for efficient data preparation
Data Preparation
Efficiently prepare data using Komax software DLW or ECAD from exported Wire
lists. Ensure consistent data flow for optimized quality and reduced input
errors.
Wire Assembly
Process wire ends by attaching ferrules, crimp contacts, MIL crimps, or
compacting through ultrasonic welding. Use the Zeta machine for assembling
wires based on the wiring scheme.
Labeling and Marking
Utilize fully integrated inkjet labeling or tube marking systems to label
wires accurately according to the diagram. This ensures easy identification
during installation.
Cable Production
Produce wires fully automatically by cutting them to the correct length,
assembling them, and labeling them with inkjet or tubes. Bundle the wires
based on component type for easier management inside the control cabinet.
Instruction
It is very time-consuming to design and build control cabinets manually and is dependent on specialists. To slash the throughput time and make production processes more flexible and ideal, Komax offers a range of optimum automation solutions. These are designed to improve the process, increase efficiency, and reduce the throughput time for switch cabinet production. As a result, they generate major time and cost savings while simultaneously boosting quality and economic efficiency. These perfectly coordinated solutions cover all your needs from entry-level automation right through to fully automated wire assembly – whether you are producing a single control cabinet or manufacturing small or large series.
Save with
automation
- Reduce your production costs
- Production times reduced by up to 50% and more
- The savings start from a batch size of one
Flexibly increase efficiency
- Wide processing area for wire ends
- Optimized logistics
- Greater workforce flexibility, due to intuitive guidance in work processes and through optimal use of the available expertise.
Achieve top quality
- Most efficient use of resources
- Low effort to achieve high production data quality
- Consistently high quality throughout
SHORTER PRODUCTION TIMES –MAXIMUM EFFICIENCY
Cut time and costs
Trained specialists need around 157 seconds to manually assemble a wire, with
an average of 500 wires per switch cabinet. To read a connection from the
schematic with 300 pages, an average of 67 seconds is required. Mounting of a
wire requires an average 42 seconds. Depending on the degree of automation,
this processing time can be significantly reduced. With full automation, the
production time, compared to manual wire assembly, can be reduced by up to
64%.
Consistent data flow
Data preparation is efficient using the Komax software DLW (Digital Lean
Wiring) or via ECAD from exported Wire lists. Automation that relies on
consistent data flow optimizes quality and reduces input errors. Within this
framework, ready-to-install wires can be produced fully automatically: by
cutting them to the correct length, assembling them, and labeling them and
with inkjet or tubes.. What‘s more, you can even produce the cables
sequentially in the correct order of installation and tie them.
Greater flexibility
You can process the wire ends in a whole host of ways: by attaching ferrules,
crimp contacts, or MIL crimps, or compacting them through ultrasonic welding.
The solutions feature fully integrated inkjet labeling or tube marking systems to ensure that everything is always labeled in accordance with the diagram. This simplified approach means that control cabinet wiring can be carried out by less specialized personnel.
Perfectly coordinated automation
By offering solutions to match any requirements, the market leader Komax is
opening up the huge potential for automation in control cabinet construction.
Its semi- and fully automatic state-of-the-art machines ensure maximum
efficiency on any scale: from individual units through to small and large
series.
Manual Wiring
Average values
- 500 wires per cabinet
- 300 pages schematic
Digital Lean Wiring
Data preparation
Cable processing
Wire laying
IDEAL FOR ANY LEVEL OF AUTOMATION
Cut and strip Low level of automation
Semi-automated production sorted according to cross-section
Processing options 
Crimp to Crimp Moderate level of automation
Fully automated production sorted according to cross-section
Processing options 
Harness manufacturing High level of automation
- Fully automated production sorted according to assemblies (sequential production)
- Tied with tape
Cable bundling based
on component type makes it easier to manage the wiring inside the control
cabinet.
EASIER DATA PREPARATION WITH DLW
The simple
alternative
In order for the control cabinet construction process to be automated, the
first step is to collect the production data, including the cable length. The
DLW (Digital Lean Wiring) software developed by Komax offers the ideal
solution for this with its clear focus on simplicity and flexibility. It
offers various options for importing and preparing the data. For instance, you
can use existing wire lists to define how the connections should be marked.
You can also import 2D drawings in a variety of formats with ease. If you want
to avoid the high costs involved with maintaining a component database of
standard ECAD systems, virtual wiring can be carried
out based on a high-resolution photo. This keeps product maintenance to an
absolute minimum.
Photo with Roundshot or 2D drawing for wire length determination
A high-resolution photo of the control cabinet or a trustworthy 2D drawing is
a really easy way of dimensioning the lengths of the cables. The photo is
captured by the optionally available Round-shot camera. This takes several
individual images and combines them to create one dimensionally accurate
overall image, which is then imported into DLW.
Virtual wiring
In the DLW software, the technician uses this image or a 2D drawing to wire
the cables virtually on the screen. This is a highly efficient method of
determining the cable length per connection. After that, the production data
is converted and uploaded to the wire processing machine, which produces the
ready-to- install cables.
DLW Viewer – Guided assembly
The DLW Viewer features a streamlined, touch-operated interface. This guides
the operator along the wiring path as they lay the pre-assembled strands
virtually on the screen. As a result, this processing step can be carried out
by less highly specialized personnel.
Komax – leading the fi eld now and in the future
As a pioneer and market leader in automated wire processing, Komax provides
its customers with innovative solutions. Komax manufactures series and
customer-specifi c machinery, catering to every degree of automation and
customization. Its range of quality tools, test systems, and intelligent
software and networking solutions complete the portfolio and ensure safe,
flexible, and efficient production.
Komax is a globally active Swiss company with highly qualifi ed employees and
development and production facilities on several continents. It provides local
support to customers worldwide through its unique sales and service network
and offers services that help them get the most out of their investments.
Komax AG Industriestrasse 6
6036 Dierikon, Switzerland Phone +41 41 455 04 55
[email protected]