This fully integrated system is built for precision: now approved to German VDE and automotive standards, it automates wire cutting, dual-end crimping, and low-temperature tin dipping with exceptional accuracy.
Munich Factory Result: BMW Tier1 Case Study
At a Continental plant in Ingolstadt, this machine replaced three manual stations. The outcome:
- 38% faster cycle times
- 02% crimp rejection rate
- 3 FTE labor saved per shift
Why It Meets European Standards
- VDE-compliant terminations with full RFID traceability
- Cold tin dipping to automotive-grade specs
- Sub-millimeter stripping, ISO 6722 Class B
- Flux-free zones for IP 67-rated connectors
Key Engineering Highlights
- Automotive-grade cutting/scoping:dual-stage stripping of Teflon/XLPE insulation, ±0.1 mm tolerance.
- Zero-defect crimping:6 axis servos, supports Schlemmer-type terminals, 40 mm stroke.
- Cold tin dipping:includes Stuttgart-tested thermal controls, nozzle adjustments for optimal results.
Case–Flux Contamination Fix (Audi Q6)
Problems like dendritic growth on harnesses were traced to:
- Dip temp too high (255 °C → 245 °C per VW TL 824)
- Purging time too short (2.8 s → 3.1 s)
- Nozzle angle misaligned (22° → 18°)
With these adjustments—and an integrated Menzel preheater—the system meets DIN 8518 standards.
Technology Breakdown: BMW Tier1 (Continental Ingolstadt)
Before deployment, the team used oscilloscopes, thermal imaging, and force profile data. Key tune-ups included:
- Stripper delay: 0.25 s → 0.18 s
- Crimp dwell: 0.40 s → 0.35 s
- Flux viscosity: 38 cP → 42 cP (Loctite F640)
Results: just 0.12% force deviation, passed VW 60330 humidity test.
“Send 10 samples. We deliver DIN compliant strip/crimp force diagrams and salt spray reports.” – Dr. Weber, Process Lead
German-Grade Service & Support
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Challenge |
Innovation |
Outcome |
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VDE audits |
RFID process logging |
100% traceability |
|
Scratch damage |
Step-depth stripping |
0% micro-scratch rate |
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Flux crystallization |
Heated delivery lines |
600+ hrs uptime |
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Factory space limits |
Compact footprint (1900×760×1500 mm) |
55% smaller than typical EU footprint |