Wire comes in a multitude of sizes and configurations and is used in a vast number of electrical and electronic devices and assemblies. In recent years, efforts to reduce overall weight of a wire harness mean smaller wire gauges and thinner wire insulation are being used. At the same time electrical demands of some products have increased the requirement for larger cable, able to handle a higher current load. The automotive industry is a prime example of the demands to address both ranges; smaller to bring weight down for more fuel efficiency and larger for emerging applications such as electric car batteries and hybrid fuel cells.
This article will focus on processes and components used in assemblies with large cables.
Defining Large Cable Processing.
For the purposes of this article, we will discuss processing (cut, jacket strip and wire end process assembly) on wire 6 awg and larger. Also multi-conductor cables with individual insulated wires encased in an outer insulation jacket or sheath. In general, as the wire size increases, the production volume decreases. Production volumes typically dictate whether single or multi stage processing solutions are deployed. We will outline single and multi stage processing solutions.
Single Processing Tools
Processing tools that perform a single function.
Wire Cut
The Wezag SH Series Hand cutter series features a ratchet action and can cut wire up to 350 mm in diameter.
The Model 31 from Carpenter Mfg is a lever style wire cutter designed to cut wire and other materials. Featuring a guillotine blade, and adjustable wire guides, the model 31 can cut material 1″ in diameter and 4″ wide. Wire up to 0 awg can be cut and (material dependent) up to 2/0.
Wire Strip
The Carpenter 72C is a dual blade rotary wire stripper. The 72C processes a wide range of single and multi-conductor wire. Quick change wire guides center the wire for nick free processing.
The Carpenter 77E wire stripper is a pneumatic heavy cable wire stripper. The large wire grippers provide high pulling power for tightly bound insulation and large cross sections. The 77E uses fully adjustable V blades and quick change wire guides for accurate and repeatable processing. Form blades can also be used where V blades do not provide the desired results.
The Beri.Co.Megamax is a heavy duty programmable wire stripper capable of multi-stage precision wire stripping for cable up to 25.00 mm wire diameter. The Megamax can process large OD coaxial wire. The Megamax is one of three high capacity multi-stage wire strippers available through our partner Schaefer Megomat.
Wire Crimp
Wire Process Specialties supplies crimp technology for loose and reel fed contacts. The WDT (Wezag) UP60 shown at the left is a pneumatically activated crimping press that can crimp large terminals such as battery lugs up to 180 square mm. Interchangeable adaptors with a wide range of die sets provide maximum flexibility.
Multi-Stage Wire Processing
Process machines that perform more than one function during a single machine cycle.
Measure/Cut
The Compu-Cut 42B is a heavy duty wire and tubing cutter with a 4″ wide blade and 1″ opening. Flat cable and tubing as well as round wire and multi-conductor cable can be processed using the 42B. Add additional wire separators and multiple rows of material can be processed to maximize production quantities. The cutter head is pneumatically operated and the feed unit is electrically motor driven for accurate cut lengths.
The Compu-Cut 36A is an additional option for cutting heavy duty wire. With a special guided blade holder and a standard utility knife blade, the 36A makes precision cuts on large gauge wire as well as semi ridgid tube.
Terminals and Connectors
ETCO is a supplier of terminals and connectors. ETCO has two manufacturing facilities in the USA for processing reel fed and loose piece heavy duty terminals. ETCO terminals are manufactured to exacting quality requirements using state of the art fabricating equipment.
The connector at left is a top post battery terminal. This is one of many terminal styles for heavy cable and power cords. ETCO can also supply custom fabricated connectors to your design.
Special Processes
The Judco FLG2 processes heat shrinkable tube around large cable, battery lugs or other connector systems. The FLG2 is energy efficient and shrinks tube fast with low cost quartz halogen bulbs and mirrors to focus light energy around the material being processed.
These are a few solutions for processing wire and cable harnesses available from Wire Process Specialties, your authority in wire processing, connectors and terminal crimp technology. Connect Your Way to WPS to see how we can help your company reduce cost and improve the efficiency of your wire assembly processes.
