Alpha 355 S / Alpha 356

Multifunctional automatic crimping machines

With their open architecture, the Alpha 355S and Alpha 356 have a wide vari-
ety of applications. Besides Komax standard processing modules, many cus-
tomer-specific modules can be easily integrated.

Alpha 355 S Areas of application

You can mount up to five processing modules on the Along with the most frequent standard processes
Alpha 355 S. In spite of its compactness, it offers of crimping and seal loading, you can obtain a large
excellent accessibility. variety of processing modules such as: fluxing/tin-
ning, twisting the ends of wires, fitting with insulating
Alpha 356 sleeves and crimping modules for ferrule crimping
With its extra large mounting surface, the Alpha 356 and MIL-crimping, ultrasonic or resistance welding
has room for up to seven processing modules. This modules. You can integrate customer-specific pro-
machine is ideal if you need increased flexibility or cess modules easily with the ultra-flexible TopWin
have complex processes. software.
 Alpha 356 With three crimp modules and two seal modules


Alpha 355 S Basic module 4m with crimp tool quick-change system



High productivity
The quick wire selector, quick tool-change system
and other options ensure excellent productivity
especially if there are frequent changeovers. With
the reliable TopWin software you can record and edit
jobs while the machine is running.

Alpha 356 With crimp modules and seal module



User friendly Maximum quality control

The drive unit for the blade holder is placed under- Crimp-height measurement and pull-out force mea-
neath, giving the machine a neat and ergonomic surement are integrated in the process sequence.
layout. All process modules have safety covers that Optional material change detection and the optional
open vertically for optimum access, and application- barcode scanner help to prevent materials from
specific parts like applicators and contact rolls can getting mixed up. The processes are constantly
be changed without tools. Controls are placed at de- checked against the specified values during produc-
centralized positions, allowing the necessary machi- tion with functions that monitor crimp force, seals,
ne functions to be triggered during setup. All setting splices, end of wire supply, and length. Any cables
and adjustment procedures can be controlled from with processing defects are removed and an appro-
the TopWin graphical user interface in the operator’s priate number of cables are post-processed auto-
choice of over 20 different languages. matically to replace them.
Conductor detector sensor ACD
Miniaturization and new technologies are making the
quality requirements on cable processing tougher
all the time. To satisfy the current automobile crim-
ping standard for solder-free electric connections,
Komax has developed the fully automatic conductor
detection (ACD). This product recognizes even the
slightest contacts between blades and conductor
strands in the course of production. ACD is based
on a capacitive measuring principle and integrated in
the blade holder. It uses the regular stripping blades.
The work range covers the entire spectrum of cross ACD Conductor detector sensor

sections, any conductor length and stripping with full
strip or partial strip. There are setup parameters to
set the limits of monitoring desired. Defective con-
ductor ends are removed fully automatically during Your benefit
production. • Highly flexible with up to five or seven
process modules
Strip Quality Check SQC • Integration of standard and customer-specific
The stripping quality check (SQC) entails visually processes possible
monitoring the stripping quality during the swivel mo- • Conductor detector sensor for highest quality
vement. It measures the stripping length and checks in cutting
the wire for projecting or splayed wires. The use • Integrated quality measurements
of the SQC instead of the CPS option („cut pulled • Create the next job while the machine is
strands“) boosts the output by an average up to running
10 percent. The actual figure depends on conductor • Can be integrated in a network with
length and quality.Defective products are automati- WPCS interface
cally removed.

Choice of standard configurations

Alpha 355 S Alpha 356

Stat. 1 (22°) Stat. 1 (22°)

mci 765 C mci 765 C

mci 792 mci 792

Stat. 8 (77°)
Stat. 2 (47°) Stat. 2 (44°)
mci 712
mci 712 mci 712
mci 722
mci 722 mci 722
AEH-G
AEH-G AEH-G
CM03
CM03 CM03

Stat. 5 (47°)
mci 712 Stat. 3 (78°) Stat. 7 (51°/60°)

mci 722 mci 712 mci 712

AEH-G mci 722 mci 722

CM03 AEH-G AEH-G

CM03 CM03

X1585

Stat. 6 (35°)
Stat. 4 (35°)
Stat. 4 (110°) mci 765 C
mci 765 C
mci 712 mci 792
mci 792
mci 722 X1585
Stat. 3 (21°) AEH-G Stat. 5 (21°)
Double gripper CM03 Double gripper
module module
Application sample Alpha 355 S/356

Cutting Core processing

Half stripping Double sheath / Coaxial

and triaxial cables
Full stripping
Ferrule crimping
Intermediate strip
MIL crimping
Alpha 356
Twisting / Tinning
Wire end solidifying /
Crimping Splicing / Welding

Seal insertion Hot stamp marking

Split cycle for closed barrels Inkjet marking

Alpha 355 S

Double crimping
Alpha 356

Alpha 355 S

Alpha 356
Sleeve insertion

Options and Accessories

Feeding systems Komax 106 | ads 119 | ads 123

Marking systems Komax 26 hot stamp marker | Komax Inkjet marking system IMS | Laser marking on
request

Wire infeed Belt drive

Processing modules Crimp module mci 712 | Crimp module mci 722 (with programmed crimp heights) |
Seal module mci 765 C (with seal position monitoring SPM) |
Twisting module mci 782 | Tinning module X1585 | Sleeve module mci 792 |
Double gripper module | Ferrule module AEH | MIL-crimping module | Welding module |
Ultrasonic compaction

Quality control Integrated crimp height measurement | Integrated pull-off force measurement |
Conductor detector sensor ACD | Strip quality check SQC |
Crimp force analyzer CFA/CFA+ | Material change detection | Material verification |
Wire length correction | Splice detection | Spark tester |
Seal position monitoring SPM/SPA | Terminal end detection

Deposit systems Basic module 2m (78.7in.) or 4m (157.5in.) |

Extension module 2m (78.7in.) or 4m (157.5in.) | Deposit gripper

Accessories Crimp tool quick-change system (355S) | Automatic guide tube changer (355S) |
Barcodescanner

Software Networking WPCS | Data conversion TopConvert |

Manufacturing execution system Komax MES
 Made in Switzerland
Machine layout Alpha 355 S Machine layout Alpha 356

4125mm (162.4in.) 4125mm (162.4in.)

1485mm (58.5in.)

1964mm (77.3in.)

Subject to change /fim

Heigth with cover closed: 2000mm (78.7in.) Heigth with cover closed: 2000mm (78.7in.)
Heigth with cover open: 2900mm (114.2in.) Heigth with cover open: 2900mm (114.2in.)

0320020 Version 5
Reference values for piece output of Alpha 355 S Reference values for piece output of Alpha 356
Pieces/h Pieces/h
5000 5000

4000

CC. Alpha 355 S & 356

4000

3000 3000

2000 2000

1000 1000

0 0
0 500 1000 1500 2000 2500 3000 3500 4000 0 1000 2000 3000 4000 5000 6000 7000 8000

Wire length [mm] Wire length [mm]

Conductor FLRY 0.50mm2 (AWG20) Conductor FLRY 0.75mm2 (AWG19)

Pneumatic pressure 6bar (87psi) Pneumatic pressure 6bar (87psi)
Speed 12m/s (39ft/s) Speed 10m/s (33ft/s)
Acceleration 60m/s2 (197ft/s2) Acceleration 50m/s2 (164ft/s2)
Crimp module mci 722 Crimp module mci 722
Seal module mci 765 C Seal module mci 765 C
Quality monitoring active Quality monitoring active

Technical data

Length range 60mm–65000mm (2.36in.–213ft.)

Optionally 30–60mm (1.18in.–2.36in.)

Length accuracy Repeat accuracy: ±(0.2% +1.0mm (0.04in.)) More information about
our products:
Stripping lengths 0.1mm–35mm (0.004in.–1.38in.)

Stripping lengths with partial 47mm (1.85in.) on side 1 | 35mm (1.35in.) on side 2
strip Optionally up to 80mm (3.15in.)

Wire cross-sections* 0.22 mm2– 6mm2 (AWG24–AWG10)

Optionally 0.13mm2 (AWG26)

Wire infeed speed max. 12m/s (39ft/s)

Noise level <80dB (no crimping module)

Electrical connection 3×208 – 480V / 50 – 60Hz 5kVA www.komaxwire.com

Pneumatic system 5 – 8bar (73 –116psi) | 9m /h (318ft /h)
3 3

Komax Wire is a division

Weight incl. crimp and seal Alpha 355 S: ca. 1300kg (2866lb.)
of Komax Holding AG,
modules Alpha 356: ca. 1400 kg (3090 lb.)
Switzerland.
* Extremely hard and tough wires may not be able to be processed even if they are within the above cross section range.
If you are in doubt about your wires, we are happy to process samples of them.