Precise processing of cables

Our company is currently processing wires in a wide range of cross-sections from 0.22 mm², through 10 mm², to 50 mm². However, our machinery stock allows us to work with a much broader scope. We also cut, crimp contacts with wire sealing, twist, and weld wires. In addition to standard cables, we also process jacket or coaxial cables.
We use two technologies of joining wires – the so-called splices, using ultrasound, or with SMCrimp machines (using metal band). We place great emphasis on the quality of the semi-finished product by utilizing all kinds of inspections such as checking the crimp height, checking the braking force, and inspecting the cross-section. Our machines will not start production until the crimp height is within the tolerances specified by the tool manufacturers and the breaking force complies with the standard. These two factors are crucial for us to green-light mass production of the product.

Our company currently carries out a very wide range of cable processing:
• Automatic cutting of cables up to 70 mm², but we are capable of cutting cables with a much higher cross-section
• Cable crimping up to 625 mm²
• Overprints on wires from 0.22 to 6 mm²

We use the Schleuniger CrimpCenter 36 S for cable processing. The centers can be equipped with stations for crimping, sealing, tin plating, and a double gripper. Much of our production is performed on these machines, in the configuration of simultaneous cutting and crimping of contacts together with seals. By using a special printer, we make custom prints on wires.

Our quality control of cable processing takes advantage of the most modern equipment available on the market. The wires are tested for breaking force and crimp geometry. Thanks to the Schleuniger MicroGraph System, we can perform analyses of the microsection of the crimped contacts.
Large cross-sections and multi-wire cables are made on the Schleuniger PowerStrip 9550 machine. The machine is extended by a rotating head, which enables the processing of complex jacket cables. This machine cuts cables with a maximum diameter of 70 mm².

Twisted wires are made on Schleuniger WireTwister 3300AD machines. The unique guide system allows quick twisting of long products. It has a double spindle, which speeds up work. Our equipment is adapted to products with a length of 9 m, but there is a possibility of expansion.

The solution we use for crimping large cross-sections is the WDT UP60 press. The machine is suitable for cross-sections up to 185 mm². In addition, we have an ERKO hydraulic aggregate with a wire crimping head. By selecting the right tools, you can successfully crimp cross-sections of up to xxx mm².

Our company makes connections of cables using two methods: ultrasonic splicing and mechanical splicing. The method of ultrasonically welded joints is carried out by the Branson 2032S machine, which handles cross-sections up to 32 mm². We also have SM Crimp 2000 mechanical presses. Our dies allow for the joining of cross-sections from 0.3 to 10 mm².