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Automated Wire Processing Machine | Cut&Crimp&Tin System (16–32 AWG)

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

  1. Automotive-grade cutting/scoping:dual-stage stripping of Teflon/XLPE insulation, ±0.1 mm tolerance.
  2. Zero-defect crimping:6axis servos, supports Schlemmer-type terminals, 40 mm stroke.
  3. 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 forceprofile 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 DINcompliant strip/crimp force diagrams and salt spray reports.” – Dr. Weber, Process Lead

German-Grade Service & Support

Challenge

Innovation

Outcome

VDE audits

RFID process logging

100% traceability

Scratch damage

Step-depth stripping

0% micro-scratch rate

Flux crystallization

Heated delivery lines

600+ hrs uptime

Factory space limits

Compact footprint (1900×760×1500 mm)

55% smaller than typical EU footprint

Want EU Grade Automation?

Book your automated wire processing demo or request optimization settings by visiting our website: