Multi-Core Wire Terminal Crimping & Connector Insertion Machine | KK-Insert
The KK-Insert Multi-Core Wire Terminal Crimping & Connector Insertion Machine is a fully automated wire harness assembly solution that integrates wire payout, wire alignment, cutting, stripping, terminal crimping, connector insertion, and finished wire collection into one continuous production process.
Designed for automotive wiring harnesses, electronic assemblies, appliance wiring, and industrial cable manufacturing, this machine significantly reduces labor requirements while improving consistency and production efficiency. With output reaching 2,200 pieces per hour, it is an ideal solution for manufacturers seeking to automate complex connector assembly operations.
Explore our complete range of Wire Processing Machines for additional automation solutions.
Fully Automated Wire Harness Assembly Process
The KK-Insert combines multiple manufacturing steps into a single automated workflow:
Wire Payout → Wire Aligning → Cutting → Stripping → Terminal Crimping → Connector Insertion → Finished Product Collection
This integrated design minimizes manual handling, reduces production errors, and ensures stable product quality across high-volume manufacturing environments.
Key Features & Advantages
- ✔ Fully automated wire harness processing and connector insertion
- ✔ Production capacity up to 2,200 pcs/hour
- ✔ Automatic wire payout and take-up system
- ✔ Precision conductor and sheath stripping
- ✔ High-speed terminal crimping and housing insertion
- ✔ High-precision OTP applicator system
- ✔ Compatible with multiple die standards including OTP, JAM, Korean-style, and 2000-type dies
- ✔ Touchscreen control system with user-friendly interface
- ✔ Stable operation for multi-core wire processing
- ✔ Reduced labor costs and improved productivity
Optional Quality Inspection Systems
To meet demanding automotive and industrial quality standards, the machine can be equipped with advanced inspection modules:
- CCD visual color sequence inspection system
- Connector insertion verification system
- Crimp force monitoring system
- Defective product detection and rejection system
- Production traceability functions
These optional systems help prevent defective products from reaching the next production stage and improve overall manufacturing quality.
Applicable Wire Types
- AV Wire
- AVS Wire
- AVSS Wire
- CAVUS Wire
- KV Wire
- KIV Wire
- UL Wire
- IV Wire
- Teflon Wire
- Fiber Lines
- Multi-Core Cables
Technical Specifications
| Parameter | Specification |
|---|---|
| Model | KK-Insert |
| Power Supply | AC 220V / 50-60Hz |
| Production Capacity | 2,200 pcs/hour (≤100 mm wire length) |
| Wire Diameter Range | 0.8 – 2.5 mm |
| Cutting Length Tolerance | ±0.05 – 0.1 mm |
| Conductor Strip Length | 0.5 – 10 mm |
| Sheath Strip Length | 2–5 Core: ≥40 mm 6–12 Core: ≥50 mm |
| Crimping Force | 1.5T / 2T / 3T |
| Terminal Type | Open-End Continuous Terminal (Horizontal) |
| Applicator Stroke | 30 mm (40 mm Optional) |
| Applicator System | OTP / JAM / Korean Style / 2000 Type |
| Dimensions | 1750 × 900 × 1400 mm |
| Machine Weight | Approx. 348 kg |
Main Components
- Wire Payout System
- Wire Aligning / Combing Unit
- Precision Stripping Module
- Terminal Crimping Station
- Connector Insertion Unit
- Manipulator / Robot Arm
- Touchscreen HMI Interface
- Emergency Stop Safety System
- High-Precision OTP Applicator
Why Manufacturers Choose Automated Connector Insertion Machines
Traditional wire harness assembly often requires multiple operators performing stripping, crimping, and connector insertion separately. This process increases labor costs and introduces variability into production quality.
The KK-Insert automates the complete assembly sequence, helping manufacturers improve throughput, maintain consistent assembly quality, and reduce operational costs.
Many automotive wire harness factories use automated connector insertion systems to meet strict quality requirements while maintaining competitive production efficiency.
For additional automation equipment, explore our Terminal Crimping Machines and Wire Cutting Machines.
Why Buy From Cable Machineries?
- Factory-direct pricing
- More than 10 years of manufacturing experience
- Custom automation solutions available
- Worldwide technical support
- Global shipping services
- Spare parts and maintenance support
- Professional engineering consultation
Learn more about our manufacturing capabilities on our About Us page.
Request a Free Quote
Looking for an automated solution for wire harness terminal crimping and connector insertion? Contact our team today for machine specifications, pricing, and customized production solutions.
Frequently Asked Questions
What is the production capacity of the machine?
The KK-Insert can produce up to 2,200 assembled wires per hour when processing wire lengths of 100 mm or less.
Can the machine process multi-core cables?
Yes. The machine is specifically designed for multi-core wire processing and connector assembly applications.
What terminal types are supported?
The machine supports open-end continuous terminals and can be configured for different applicator systems.
Can visual inspection systems be added?
Yes. CCD color sequence inspection, insertion verification, and crimp force monitoring systems are available as optional configurations.
Is customization available?
Yes. We can customize tooling, applicators, connector types, and inspection systems according to your production requirements.
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