TransferModule 6000
Due to increasing cost and quality requirements, the demand for automated, flexible and reliable processing solutions for coaxial, sensor, ABS, FFC, POF, as well as multi-conductor cables is continuously increasing. The Schleuniger TransferModule 6000 closes the gap between existing standard cable processing machines used for single wire processing steps and fully automated production systems, used for multiple processing steps and specifically built as unique machines, to produce complete and specific cable assemblies. Thus, it offers a valuable alternative between both processing methods.
The central element of the TransferModule 6000 is the ability to configure individual processing steps according to specific production needs. The equipment consists of the following assembly groups: Cable loading, cable transport (chain transfer), cable unloading and application specific processing stations which consist of either standard or custom-designed units. These can be combined to form a semi- or fully automated system. As standard, the following machining processes can be integrated: Schleuniger units for the processing of cable ends, weather seal assembly, fluxing/tinning, twisting, mounting of loose connector components and connector housings, performance and quality testing/checking, wire marking/printing (laser/ink jet, hot stamp) and coiling/binding. Other additional processes can be made available upon request.
Very high process reliability is achieved by broadly implementing Schleuniger standard units. The complete installation is very compact, requires a minimum of production space and can, if necessary, be extended using further modules. Despite its compact design, each station of the installation can be monitored and accessed easily. Cables up to 8 mm in outer diameter, stranded wires up to 25 mm², solid conductors up to 6 mm² and cable lengths ranging from 150 mm up to 5 m (without coiling binding option) can be processed.
The TransferModule 6000 operation is controlled through a PC which is directly integrated into the machine, or off line via LAN. An SPS control coordinates the process activities and ensures a constant reproducible quality. Each processing unit is equipped with its own control.
Chain transfer with cable clamping
Virtually Unlimited ApplicationsParallel processing allows for high productivity with maximum precision and accuracy. The transfer chain conveys the cable gently from processing station to processing station. Depending on the processing requirements, the transfer chain can be equipped with specific transfer shuttles. The shuttles differentiate themselves by the number of individual, very precise fine movement capabilities towards and within the single processing stations. This allows processing of Coaxial-, Sensor-, Airbag- ABS-, FFC-, POF- and multi-conductor cables throughout an extended range of diameters and lengths. Therefore, the application range of the TransferModule 6000 is almost unlimited.
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Coaxial conector assembly |
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Coaxial conector assembly |
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Coaxial conector assembly |
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Multi-conductor / sensor cable assembly |
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Multi-conductor / sensor cable assembly |
Application examples
Automated FAKRA – Coaxial Connector Assembly
For automatic assembly of coaxial connectors, according to FAKRA norm, various single processing steps have to be carried out. These steps can be automated on the TransferModule 6000 and will run in parallel (simultaneously) for maximum production output.
Processing sequences:
| 1) |
Coaxial cable stripping |
| 2) |
Metal sleeve mounting |
| 3) |
Shield flaring |
| 4) |
Inner conductor crimping |
| 5) |
Inner conductor mounting |
| 6) |
Metal sleeve assembly and crimping |
| 7) |
Electrical connection testing (for example: short circuit test of shield to inner conductor) |
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Example: Cable end after processing step 4 |
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Example: Cable end after processing step 6 |
On the TransferModule 6000 the seven processing steps are carried out as follows:
Schematic layout of coaxial cable assembly on the TransferModule 6000 (Section cut-out from the complete machine layout, without cable feeding and cable stacking devices)
In case of Low Loss cable processing, such as a RTK-031, the foil under the shield's meshwork has to be cut back first. Furthermore, when using 90° angled connectors, the inner conductor often has to be tin-plated first. These processing steps can also be integrated into the TransferModule 6000.
During parallel processing operations, the speed and capacity of the line is given by the slowest single processing unit. In the example shown, the most time consuming production step is the rotary stripping of the coaxial cable. Approximately 5 to 8 seconds are needed for clean and accurate stripping of both cable ends, hence the production output, including transfer time, will be approximately 300 – 600 pieces/h.
The Most Important Advantages
- High productivity through parallel processing of different processing steps
- High flexibility in reconfiguring the equipment to changing production needs
- High process reliability through the use of standard equipment for each individual processing step
- Modular design that allows for upgradeable (expandable) degree of automation (partial- or full automation)
- Ability to re-use standard equipment in the event of production changeovers
The TransferModule 6000 offers highly improved economical efficiency and a short return on investment. The system has the strong potential to optimize competitiveness and costs per piece in the wire harness industry.
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