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Harnessing in insulation displacement technologygg iiiiiinn insulllllllaaaaaattttttiiiiioooooonnnnnn ddddddddiisssssssssssppppppppppllllaaccccccceeeeeeeeemmmmmmmmeeeeennntttt tttteeecccchhhh
2
35
Connector series
State of delivery of connectors
Processable conductor
Stroke capacity, discrete conductorper hour
Harnessing of bus cables
Cable color detection 7 + 1 (CA)
Verification of insertion pattern and line end position
Storage of insertion patterns
High-voltage test (HV)
Cutting and vacuum extractiondevice for connector chain inter-links (RK)
Key cutting (KC)
Key test (KT)
Automatic feeding of connectors
in chain (HZ35 to be decollated)
discrete conductor, ribbon cable
ca 240 ca 370
in chain
discrete conductor, ribbon cable
ca 450
in chain
discrete conductor, ribbon cable
ca 1,200
• • • • • • • •
• • • • • • • • • • • •
• • • • • • • • • • • •
• • •
• • • • •
• • • • • • • •• • • • •
• • • • • • • • • • • •
in chain
discrete conductor, ribbon cable
ca 1,200
• •
• • • •
• • • •
• •
• • • •
in chain, to be decollated
discrete conductor, ribbon cable
•
RAST 2.5
Kind
Type
HZ...35...
Manual tongs· HZ35 up to 10 poles· HZ-M35 up to 20 poles,with cutting knife
HZ35
HZ-M
35
M
od
ula
r m
anu
al t
on
g
HZ35-K
Ton
g f
or
keyi
ng
KHP35
Knuckle-joint press
351...352...
(not including RAST 2.5 plus™)
HA35e... HA35f...
Semiautomatic harnessing machines, modular set-up
small base machine· limited upgrading possible
larger base machine· individual upgrading possible
HA
35e
...-R
K
...-C
A
...-R
K-C
A
...-R
K
...-R
K-C
A
...-R
K-C
A-K
C
...-R
K-C
A-K
C-K
T
...-R
K-C
A-K
C-K
T-H
V
...-C
A
....-
CA
-KC
...-C
A-K
C-K
T
...-C
A-K
C-K
T-H
V
...-K
C
...-K
C-K
T
...-H
V
HA35e-DC
Semiautomatic harnessing machine· for production of daisy chain harnesses
Series 97
Tools and harnessing machines
3
354...
on bulk
discrete conductor, ribbon cable
ca 370
on bulk
discrete conductor, ribbon cable
ca 400
in bar stock carrier
discrete conductor, ribbon cable
ca 1,000
•
•
•
•
357...(not including RAST 2.5 Power plus™)
in chain
discrete conductor, ribbon cable
ca 370
in chain
discrete conductor, ribbon cable
ca 450
RAST 2.5 Power
in chain, to be decollated
discrete conductor, ribbon cable
ca 450
352...00(RAST 2.5 plus™)
in chain
discrete conductor, ribbon cable
ca 1,200
•
•
•
double-sided
•
RAST 2.5 plus™
HZ354
Manual tong
KHP354
Knuckle-joint press
HA354e-ST
Semiautomatic harnessing machine
KHP35 plus
Knuckle-joint press
HA35 plus
Semiautomatic harnessing machine· multiple chain feeding
HZ-M357
Modular manual tong
KHP357
Knuckle-joint press
detailed information www.lumberg.com
4
35 35
357...(not including RAST 2.5 Power plus™)
in chain
discrete conductor, ribbon cable
ca 1,200
• • •
• • • • •
• • • • •
• • •
double-sided
• • •
• • • • •
357...00(RAST 2.5 Power plus™)
in chain
discrete conductor, ribbon cable
ca 1,200
•
•
•
double-sided
•
in chain, to be decollated
discrete conductor
ca 450
RAST 2.5 Power RAST 2.5 Power plus™
in chain
discrete conductor, ribbon cable
ca 1,000
•
• •
• •
• •
7335...
in chain
discrete conductor,ribbon cable
ca 1,200
•
• •
• •
• •
SmartSKEDD
HA7335e...
Semiautomatic harnessing machines
small base machine· limited upgrading possible
HA
7335
e
...-
CA
KHP357 plus
Knuckle-joint press
HA357 plus
Semiautomatic harnessing machine· multiple chain feeding
HA357e... HA357f...
Semiautomatic harnessing machines, modular set-up
small base machine· limited upgrading possible
larger base machine· individual upgrading possible
HA
357e
...-
CA
...-
KC
-KT
...-
CA
-HV
...-
CA
-KC
-KT
...-
CA
-KC
-KT-
HV
...-
HV
Connector series
State of delivery of connectors
Processable conductor
Stroke capacity, discrete conductorper hour
Harnessing of bus cables
Cable color detection 7 + 1 (CA)
Verification of insertion pattern and line end position
Storage of insertion patterns
High-voltage test (HV)
Cutting and vacuum extractiondevice for connector chain inter-links (RK)
Key cutting (KC)
Key test (KT)
Automatic feeding of connectors
Kind
Type
Series 97
Tools and harnessing machines
5
36
362...,363...
in chain
discrete conductor, ribbon cable
ca 370
in chain
discrete conductor, ribbon cable
ca 450
in chain
discrete conductor, ribbon cable
ca 1,200
•
• •
in chain
discrete conductor, ribbon cable
ca 1,200
• • •
• • • • •
• • • • •
• • •
• • •• • •
• • • • •
3647, 3647-1, 3648
in bar stock carrier(separate)
discrete conductor, ribbon cable
ca 450
in bar stock carrier
discrete conductor, ribbon cable
ca 1,000
•
•
•
•
RAST 5
HZ...36...
Manual tongs
HZ-M
36
M
od
ula
r m
anu
al t
on
g
HZ36-K
Ton
g f
or
keyi
ng
KHP36
Knuckle-joint press
KHP364
Knuckle-joint press
HA364e-ST
Semiautomatic harnessing machine
HA36e... HA36f...
Semiautomatic harnessing machines, modular set-up
small base machine· limited upgrading possible
larger base machine· individual upgrading possible
HA
36e
...-
CA
...-
KC
-KT
...-
CA
-HV
...-
CA
-KC
-KT
...-
CA
-KC
-KT-
HV
...-
HV
detailed information www.lumberg.com
6
36 30RAST 7.5 Power
3690
in chain
discrete conductor
ca 450
Micromodul™
...30 MICA
...M30 MICA, MICAL, MICALD
MICA (MICA VP3 HA30e-R), MICAL, MICALD
on bulk
ribbon cable
ca 450
•
on bulk
ribbon cable
ca 600
optional
on reel, to be taken off manually
ribbon cable
ca 300
•
MICA VP3
on reel, versions A and C
ribbon cable
ca 900
optional
•
302299
on reel, to be taken off manually
ribbon cable
ca 450
•
HZ30 · HZ-M30
Manual tongs
HZ30
HZ-M
30
M
od
ula
r m
anu
al t
on
g
KHP369
Knuckle-joint press
KHP30
Knuckle-joint press
PP30
Electropneumatic harnessing machine
HA30e-R
Semiautomatic harnessing machine
HZ-M3022
Modular manual tong
KHP3022
Knuckle-joint press
on bulk
ribbon cable
ca 240 ca 300
•
Connector series
State of delivery of connectors
Processable conductor
Stroke capacity, discrete conductorper hour
Harnessing of bus cables
Cable color detection 7 + 1 (CA)
Verification of insertion pattern and line end position
Storage of insertion patterns
High-voltage test (HV)
Cutting and vacuum extractiondevice for connector chain inter-links (RK)
Key cutting (KC)
Key test (KT)
Automatic feeding of connectors
Kind
Type
Series 97
Tools and harnessing machines
7
3...
on reel, to be taken off manually
ribbon cable
ca 600
optional
on reel
ribbon cable
ca 1,000
optional
•
302299302299, MICA,
351..., 352..., 354..., 357..., 362..., 363...
optional
•
PP3022
Electropneumatic harnessing machine
HA3022e-R
Semiautomatic harnessing machine
HA3...e
Processing modules· for use with suitable fully automatic har-nessing machines (Komax Alpha 356)
· individual customer solutions
· camera test· distruction of reject parts
detailed information www.lumberg.com
Abbreviations within of the type desig-
nations of the Semiautomatic harnessing
machines HA...
CA: Color Approval
CT: Camera Test
DC: Daisy Chain
HV: High-Voltage Test
KC: Keying Cutting
KT: Keying Test
RK: Removal Kit
SC: Scrap Cutting
8
VARICON 7000-RD · ...-CR*VARICON 7000
in chain (354... in bar stock carrier)
discrete conductor
ca 16,200 contacts per hour ca 8,400 contacts per hour ca 5,200 contacts per hour
2 different RAST systems loadable in parallel (3 optional), loading modules exchangeable
Detaching of connectors and cutting of RAST keyings
Number of cable barrels that can be mounted in parallel
24 12 6
Number of parallel loadable cables (6 different types, sections, colors)
8 4 2
1-to-n (U-type) and 1-to-1 (Z-type) harnesses
Crossed cables, bridged contacts and varying pitches in one harness
Multiple cable lengths in one harness, min. 200 mm, max. 2,500 mm min. 60 mm, max. 2,500 mm (special solution 30 mm)
Precise IDT termination
Mechanical testing units including RAST keying and cable position tests
Electrical testing units, including continuity, high-voltage/short-circuit tests
Distruction of reject parts
Cable bending unit for RAST 2.5 Power, RAST 2.5 Power plusTM and RAST 5
Produced harnesses hanging straight or in loop for manual unloading
Especially short changeover times
Main process units duplicated for maximum performance and output
*-CR Termination of crimp contacts as specifi ed by customer Up to 3 crimping stations possible With crimp force analyzer Double crimp possible Block loader station optionally
VARICON 7000-Eco · ...-CR*
Versatile, fully automatic harnessing machine for termination of RAST connectors, for flexible harness configurations
Series 97
Fully automatic harnessing machine
The complete application tool-
ing equipment for insulation
displacement technology (IDT)
connector systems, for high
volume production.
State of delivery of connectors
Processable conductor
Stroke capacity
Specifications
Additional specifications
RAST
RAST 2.5 (351..., 352..., 354...)
RAST 2.5 plusTM (352...00)
RAST 2.5 Power (357...)
RAST 2.5 Power plusTM (357...00)
RAST 5 (362...,363...)
35 · 36
9
VARICON 1000VARICON 7000-Inline · ...-CR* VARICON 7000-DC · ...-CR*
ca 4,300 contacts per hour ca 20,000 contacts per hour
1 RAST system loadable (changeable module)
6 6
2 8
–
–
Daisy chain harnesses with up to 6 connec-tors per cable
Common harnesses also possible
VARICON 1000-Eco
Fully automatic harnessing machine for termination of Micromodul™ connectors
302299
MICA
MICAL
MICALD
on reel, in bar stock carrier
ribbon cable
ca 1,200 contacts per hour ca 750 contacts per hour
4 feeder modules included 2 feeder modules incl., additional ones optional
Processing modules for mass termination
Test station for color detection
Type U, type Z, hybrid
Multiple cable lengths min. 35 mm, max. 1,000 mm
Mechanical testing units for cable position detection
Electrical testing units
Distruction of reject parts
Produced harnesses for manual unloading
Especially short changeover times
Micromodul™RAST
RAST 2.5 (351..., 352..., 354...)
30
detailed information www.lumberg.com
10
Harnessing Technology – Service Worldwide
From manual tongs to knuckle-joint presses, semi-
automatic harnessing machines to our top prod-
ucts, our versatile fully-automatic harnessing ma-
chines of the VARICON line: We offer our harness
makers every option from a single source, to ter-
minate cables efficiently with our connectors –
be it for small, medium or high volume production.
A quality promise we afford ourselves for your
products is the high internal vertical range of
manufacture: the design, construction and soft-
ware programming of harnessing machines for
connector systems using crimp and insulation
displacement technology (IDT) are essential core
competences of our company.
Our specialized in-house mechanical engineering
department keeps a close eye on the reasonable
degree of automation as well as the highly devel-
oped testing techniques after the cable assembly.
The demands on our own processing machines are
high – all in the interest of the quality of your
product.
For initial operation, training, maintenance as
well as upgrading or conversions, our service
technicians are available to you on site at short
notice worldwide.
11
Our Team of SpecialistsOur Team of Specialists[Potent Knowledge][Potent Knowledge]
| at Lumberg| at Lumberg
Bernhard BurkardSales Manager Harnessing Machines
Walter SprockHead of Mechanical Engineering
Philipp SchulteTechnical Sales Engineer
Jürgen BergemannService
Dai LiService
Stephan ChristensenProject Team Mechan-ical Engineering
Christian HenselProject Team Mechan-ical Engineering
Michael MöllerProject Team Mechan-ical Engineering
Frank MüllerProject Team Mechan-ical Engineering
Martin RuhlProject Team Mechan-ical Engineering
Rainer SchwinefotProject Team Mechan-ical Engineering
Alex StillerProject Team Mechan-ical Engineering
Christian WesselsProject Team Mechan-ical Engineering
