Schaefer Megomat | WireProcess Specialties

Archive for Schaefer Megomat

Global Technology Partners in Focus: Schaefer Megomat

October 21, 2016 wireprocess Application Illustrations, Schaefer Megomat Comments Off

Schaefer Megomat has been part of the WireProcess Global Technology Partners Group for over 20 years. We have had a long and successful partnership in supplying wire processing solutions to our valued customers. And our customers have benefited by reducing their processing costs and improving their production efficiency in wire processing assembly.

We have seen a revolution in wire processing over the past 20 years or so. From pneumatic processing machines requiring time consuming set up to servo based systems incorporating advanced micro-processors and motion control. Set up time has been drastically reduced with the introduction of these advanced system technologies.

I am pleased to introduce Todd Miller of Schaefer Megomat. Todd is the Assistant General Manager of Schaefer Megomat and oversees the automation assembly operations out of Pewaukee Wisconsin, a suburb of Milwaukee.

WPS: Todd, thank you for speaking to us and to our WireProcess Global Community. How long have you served at Schaefer Megomat.

TM: Thank you for giving me the opportunity to talk with you today. I started my career here with Schaefer Megomat (or just Megomat at that time) back in 1997. I have been lucky enough to hold many different titles and positions through the course of my employment, with the most recent being the AGM since 2014. Growing up in this company has given me a unique perspective of what it takes to bring our customers a quality product from all sides of the business.

WPS: Schaefer Megomat is part of the Schaefer Group. Can you expand on the company’s operations and global product offering.

TM: The Schaefer Group purchased Megomat USA back in 2005. We feel this partnership gave us an instant global presence and added to the stability and variety of products and services that we are able to offer to our customers. With the acquisition, the Schaefer group can offer our customers everything from small hand held wire stripping devices, all the way up to multi-function, autonomous special machines designed specifically for a customer’s applications and needs. Some of the other products that Schaefer now offers include applicators, stripping and crimping modules, hot stamp marking, tinning, crimp quality monitoring systems, twisting, seal application units, injection molding, and even testing and laboratory equipment. Chances are if you are in the wire industry and have a need, we can help you!

WPS: As mentioned in the introduction, Schaefer Megomat is based in Pewaukee, Wisconsin. Can you describe the operation and activities at this location?

TM: Schaefer Megomat was started in 1990 to be a direct sales and service company for all the Megomat products. Over the years, as we gained market share, we faced the need to expand our operations and facilities. In 1995 we built a 30,000 square foot facility on 4 acres of land in Pewaukee, WI which has served as our North American base of operations ever since. We have added mechanical and electrical engineering ability over the years, so we are able to design, build, service and support all of our equipment from this location. We currently have 26 active assembly bays in-house, with the ability to add more as demand would dictate. Our facility also offers the space to hold thousands of parts, in stock, to assure our customers’ needs are always met. In addition, we have a sales and service location in El Paso, Texas as well to serve our customers in the south and Mexico.

WPS: How does Schaefer Megomat service their customer base domestically (in the United States) as well as Internationally (North America and beyond).

TM: Schaefer Megomat prides itself on our ability to service our customers and we rely on the small business customer service mantra that our customers have come to expect over the years. Even though we have grown with the Schaefer acquisition, we have never gotten too big to provide our customers with the personal level of service that they require and expect. We have many well trained service technicians based out of Wisconsin, El Paso, and around the world that insure the equipment we sell stays on-line and in production. Locations in Germany, Switzerland, Brazil, Mexico, Romania and Asia, to name a few, help to assure we can service what we sell, no matter where it is located.

WPS: What machine platforms are assembled at the Pewaukee facility?

TM: Our Pewaukee facility is currently home to the assembly of our fully automatic wire processing equipment line. We are now building the next generation of fully automatics using our recently updated WireStar20 software and electronics package. Our base model M500, newly updated 4-station M600, and flexible, 6-station capable M800 machine are all currently built in this facility. We have also recently started the production of select applicators in our Pewaukee facility as well to insure our customers can have a one-stop shop type experience for all of their wire applications.

WPS: How does the corporate Schaefer organization support the Schaefer Megomat operations?

TM: The Schaefer Group provides us with a global presence, technical and engineering resources, as well as adding additional expertise and real-world experience in many different areas of the industry. Thank you for talking with me Terry. Schaefer Megomat values the relationship we have built over the years with Wire Process Specialties.

Thank you Todd for your time today. For more information on Schaefer Megomat, please visit the Global Technology Page of www.WireProcess.com or www.Schaefer.biz.

You Asked: “When should we automate?”

September 5, 2016 wireprocess Application Illustrations, Schaefer Megomat Comments Off

Automation is a big step most manufacturing companies consider at one point in time. There are a distinct advantages which include improved quality and more accurate piece to piece consistency.

This question to automate is frequently asked. Is there a trigger that pushes you to make a decision to invest in automation? Are there signs leading to that decision? We will address these topics in this post. First a short answer and following some points to consider.

The short answer is no. There are no defined rules to move you into automation. Every company and their business conditions are different. Some will move quicker to automate while others integrate automation much slower. Volume per batch is less of a consideration. Annual production volume is a greater consideration.

There is a sliding scale to automation. In general, any production above manual hand tool processing can be considered automation. For a perspective on a migration path from manual to automated processing, consider Methods of Processing Wire Assemblies. For the basis of our discussion, we are focusing on the migration from semi automating processing of wire (measure, cut and strip using single or multi-stage bench top machines) to an automated work center.

Elements of wire processing automation

The most basic of processing automation is the measure, cut and strip of wire and crimp of terminals on one or both ends. But automation allows for other processing possibilities. Typical secondary processing options include:

Tin tipping of wire
Ultrasonic tipping of wire
Weather seal application.
Wire doubling.

Ultrasonic wire tipping

Weather Seal Application

Current or future processing should include an evaluation of processing wire leads using the above secondary processing. This makes justification easier to achieve and gives the company an indication of the scope of machine solution needed.

Set up time and job lot sizes.

In the past, automation was justified based on one or several large production runs. That was due to the time it took to change from one set up to the next. Pneumatic motions and bolted in production tooling gave way to programmable servo motors and quick change tooling bases. Therefore it is easier to run smaller lots with less machine down time than in the past.

With production rates in excess of 3,000 pieces per hour on short wire lengths, there still needs to be a reasonable lot size. Providing a recommended lot size would not be useful as companies consider a range of minimum lot sizes. You just need to balance the set up time with the lot size and the acceptable number of set ups per day.

Labor Savings.

There is a potential for significant labor savings when moving to automation. But consider that the personnel that operate the automation systems need to be trained in the machine operations, the software and use of a micro processor communication interface. Also consider maintenance resources.

Conditions Triggering a move to Automation.

Typically there are two conditions that we see when companies migrate to automation.

Business Growth. This is a slower movement towards the point where the decision to automate occurs. Available resources in capital funding, facility floor space space and the need to reduce direct labor content will converge to make a seamless decision to automate.
New Contract. When the company receives a substantial contract for a specified duration, the decision is quicker.

Floor space can be a factor that speeds up or slows down the decision to automate. Limitation of floor space to accommodate the new machine installation can be an issue. Re-locating to a larger facility may be part of a larger business strategy that includes new automation investment. Often it is a balance between the distribution of labor, overall direct labor costs and the availability of floor space.

Summary.

As stated from the beginning, automation is a big step in any company large or small. Considering global annual production of wire assemblies that are processed is more important than large lot sizes due to the reduced set up time with newer technology processing machines. Redeployment of labor, training personnel in set up operation and maintenance are critical factors. Where a decision to automate is made from a new large volume contract, the duration of the contract is also an important factor.

When these elements are considered and in conjunction with good advice from outside sources, the migration to automation is a low risk proposition. WireProcess can provide the direction you need and the solutions required to fulfill your automation requirements. Connect Your Way to WireProcess.

Wire Processing Solutions for Communication Cables

July 16, 2015 wireprocess Application Illustrations, Carpenter Manufacturing, Judco Mfg, Schaefer Megomat, Wezag Tools Comments Off

Wire Processing Techniques span a number of assembly categories. In this posting we cover some of the processing methods used in assembling a communication cable.

We will focus on a few cable types that represent the wider variety of communications cable assemblies and share processing methods.

Coaxial Cable

Coax cable generally has several layers including an outer jacket, woven metal shield and dielectric insulation over a center conductor. Most applications require two or three stage stripping. This wire is normally crimped into a round coaxial connector. Stripping specifications are specified by the connector manufacturer to match the connector. The connectors are loose piece and have a pin that is crimped to the center conductor and the housing is placed over the wire and crimped on. The trend of coaxial cable is consistent with other wire, that is the range is increasing. We are seeing micro coax cables and at the other end large cable such as LMR400 for large telecomm installations such as cell towers.

Wire Cut to Length.

As this wire is typically stripped in two or three stages in an offline process (see Wire Strip), wire is separately cut to length.

Model 31 manual cutter from Carpenter Manufacturing

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Wire Strip

As mentioned above, this wire is normally stripped in two of three stages in a fixed strip length that is specified by the connector manufacturer. These multiple stages are processed using a programmable unit which can process multiple strips in sequence. Or separating the two or three processes onto separately adjusted stripping heads. See illustrations below.

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Carpenter Model 74

Schaefer ST730 Coaxial Wire Stripper

Rittmeyer Beri.Co.Max Coaxial Wire Stripper for large cable.

Crimp

Crimping coaxial connectors is also a two step process. A terminal is crimped to the center conductor. The connector housing is assembled over the wire and crimped to the insulation. The crimp is normally hex shaped. Hand or bench equipment for loose piece terminals is used to crimp both the center conductor and connector housing.

Wezag CS30 Hand Crimp Tool

Wezag CS300 Electric Crimper for Loose Piece terminals.

Automated processing of coaxial wire is possible for high volume applications.

RJ11 and RJ45 Cables

Cut and Strip

Cut and strip of RJ11 or RJ45 is possible. This wire is either flat (as pictured below) or round. Flat or radius blades are required to provide the desired nick and scrape free results.

RJ11 Parallel Wire Stripped on Carpenter Compu-Strip 97A.

Strip

Inner conductors and the outer jacket (round cable) can also be stripped stripped using rotary or blade style of wire strippers as illustrated below. Results are application dependent as some wire is irregular in shape.

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Carpenter Model 72C

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Carpenter Model 78

Crimp

Modular plugs are loose piece and require a linear action crimp head to crimp (Insulation displacement) modular plugs. The crimp heads are designed to process all leads at one time. Crimping can be done on the CS300 as pictured above or a pneumatic powered crimper like the SSC below.

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Multi-Conductor Cables

Cut and Strip

A cut and strip machine as described for the RJ11/45 wire above can also be used to remove the outer jacket of a multi-conductor wire. Radius blades may be required for some applications. For larger volume applications, wire processing machines are available where the outer jacket and inner conductors are processed at the same time.

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Strip

In addition to the outer jacket stripping using a bench top rotary as described above, larger cross sections and longer strip lengths may require a heavy duty wire stripper as illustrated below.

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Crimp

Crimping can be loose piece using the CS300 or SSC as described above or reel form terminals on strip.

Side Feed applicator from Applitek.

Summary

As shown by the above applications, there are cross over techniques to these three examples. And by extension, other similar communication wire types. Finding the proper mix of processing methods is important to optimize a specific customer requirement. And that requires a partner that has the broad application knowledge and connections to produce the desired result. WireProcess Specialties is that partner. We have the resources and partnerships you need. Connect Your Way to WireProcess Specialties.

Methods of Marking Wire and Cable

March 19, 2015 wireprocess Application Illustrations, Carpenter Manufacturing, Judco Mfg, Schaefer Megomat Comments Off

Marking wire with an identifying number or character has been a necessary part of wire assembly for as long as anyone can recall. Most electrical standards require a mark identifying a specific electrical circuit for tracability in assembly and service

Methods of marking a wire continue to evolve as processing technology improves. New methods are being introduced to compliment existing processing methods which continue to be effective. The result is a wide range of processing options to meet virtually all applications and production volumes.

We will outline some of the more common processing methods and how they are applied in a production environment.

Labels

Adhesive labels are an effective method of applying an alpha numeric mark to wire. Processing methods include manual from a box or card, labeling guns and semi automatic systems. Label adhesion can be affected by the type of wire insulation and quality of the label itself. Permanence can be affected by the above plus the operating environment of the wire. The operating environment can include temperature, humidity and the presence of chemicals or contaminants). Cost of application equipment can range from zero (manual) to high (semi-automated, integrated with a cut only or wire cut and strip machine).

Hot Stamp

Stamprite Machine Hot Stamp Marker

Hot stamp marking is a wire marking process that dates back to World War II. Hot Stamp marking uses heat type and thermal marking foil to place a mark to the surface of a wire. The wire is fed through a guide or anvil and the guide assembly lifts up to contact the heated type surface with the foil sandwiched between the type and the wire. There are two types of hot stamp markers, separate marking type and wheels. The separate marking type are arranged in the desired number sequence and mounted into a type holder. In the case of a wheel type of marker, each wheel represents one character and includes the characters generally used (0-9, A-Z, blank and special marks: right and left arrow and hyphen). Wheel type are quicker to change over and lend themselves better to manual or automatic processing. Actuation is by lever or foot pedal for manual (offline) processing and integrated into a semi or fully automated solution with actuation controlled by the automation system.

Hot stamp marking is less prone to environmental conditions that can affect the adhesion of a wire label. Some industries specify other marking methods as the mark is imprinted to the surface of the wire using heat and there are concerns about potential damage to the insulation. But the cycle time is limited and the heat applied is localized so this processing method is acceptable for the majority of applications.

End marking (same or different number on opposing ends of the wire) and continuous (along the length of the wire at a fixed distance) are normal processing types. Continuous marking does slow down a semi or fully automated wire processing machine as the wire feed must stop during the stamping process. The number of marks and distance between marks affects processing speed.

The type of thermal marking foil used, the temperature of the type and impression time are critical factors for a hot stamp mark. The insulation type and wall thickness normally determine the foil, temperature and cycle time. Marking foil normally comes in rolls and is white or black.

Ink Jet

Ink Jet marking is a newer technology relative to hot stamp. Ink droplets are sprayed onto the wire surface in a pattern to form a character or character string. Ink jet marking systems are fully programmable and offer more character options than other methods. These markers can also interface into the operating system of semi or fully automated processing systems. The interface provides programming and processing communication to the marker. End or continuous marking is possible but It is important to note that without a programming interface between the processing machine and marker, only continuous marking can be processed. Line speed is quicker than other processes as the process does stop to apply a mark to the wire.

There are a wide variety of pigmented and non-pigmeted inks available to suit a wide range of insulation types. In addition, chemicals to clean the ink jet head are required to prevent dried ink from clogging the jets. Special handling of ink and chemicals is required and maintenance personnel are normally trained how to properly apply and store chemicals. Ink jet markers are typically dedicated to one type or ink due to the cleaning process required to transition from one ink type to another.

Permanence to an insulation can be a factor as the ink normally does not penetrate below the insulation surface. The mark can rub off in some environments. Using pre or post treatment methods such as plasma or UV curing can improve the adhesion of the ink to the wire.

Heat Shrink

Marking to heat shrink and applying the marked heat shrink to a wire is another method. The heat shrink tube is marked and cut to length on a dedicated machine. The marked heat shrink tube is applied to the wire manually using the Judco Focus Lite or heat gun. The mark to the heat shrink is applied using methods such as hot stamp or ink jet.

Laser Marking

Laser marking is an emerging marking technology. Line speed is slower than ink jet but suited for continuous marking. Mark characters and character strings are programmable. A black mark is the primary color as the character is burned into the insulation surface. A marking method endorsed by military and aerospace.

Wire Process Specialties provides solutions for processing wire harnesses. Connect Your Way to WPS to see how we can assist your company in their processing problems.

Terminal Crimping Technology

June 25, 2013 wireprocess Application Illustrations, Applitek, C&S Technologies, Carpenter Manufacturing, Etco, Schaefer Megomat, Wezag Tools Comments Off

Crimping terminals is a common wire assembly process dating back several decades. Over the years processing methods and procedures were established and improved to assure optimum crimp quality and electrical conductivity of the wire to terminal connection. This article will cover the common crimp types, crimp methods used to provide a quality wire to terminal connection and migration path from manual processing to automation of the crimp process.

Crimp Types

Closed Barrel: Closed barrel terminals have a round crimp barrel that surrounds the wire being crimped. There are two typical open barrel configurations, formed by progressive stamping process with a seam where the two sides come together and form a circle and solid machines connector where the crimp barrel is seamless, normally produced on a screw machine. Closed barrel terminals come insulated or non-insulated and are in loose form or on a reel. Examples of closed barrel terminals include rings, quick connects, ferrules and solid pins used in aerospace applications.

Open Barrel: Open barrel terminals are generally U shaped prior to crimping and are crimped around the terminal in a B shape or overlapped. Open barrel terminals are generally available mounted on a reel but in some cases are available in loose form for lower volume processing. In addition to a barrel for the wire, some open barrel terminals include an insulation support for applications for additional strain relief (from vibration or wire movement). Open barrel terminals normally are un-insulated but in some cases have a partially loaded insulator pod which is inserted over the terminal during the crimp process.

An example of this terminal type is the ETCO pre-insulated terminal series.

Crimping Methods

Hand Tools: A hand tool is used in low volume or prototype crimp applications. Tooling in a hand tool can be fixed and non-removable from the hand tool frame or can be removable. Crimp dies are available for open barrel and closed barrel terminals A reliable method of crimping wire to terminals with good repeatability. As volumes increase, repeated processing of terminals with hand tools can cause strain on an operator.

Bench Top Crimping: Crimping terminals with bench top crimping equipment provides moderate volume processing of loose piece and reel mounted terminals.

With loose piece terminals, the terminal and wire are hand loaded to a crimp nest and the operator cycles the press using a foot pedal or palm button.

Wezag CS200 Carpenter Accu-Crimp 62

Reel mounted terminals are processed using a crimp press and applicator. The applicator has a mechanical or pneumatic feed which positions the terminal on the crimp anvil. The operator presses a foot pedal and the crimp press cycles, forming the terminal over the wire and advancing the next terminal for further processing. A wide range of applications can be processed with bench top crimping equipment by the utilization of different press tonnages and applicators/die sets (fixed and quick change).

Automated Crimp Processing: Automated processing adds a wire cut and strip element to the crimp process. The most basic form is the stripper-crimper which adds a wire stripping unit to a bench crimp press to strip the end of the wire and presenting the wire to the crimp nest for crimping.

Automated crimp centers process the wire from its source in a barrel or reel, cut and strip the wire to length and present it to a crimp press for crimping. Reel fed applicators are the same as the bench top type. In the case of loose piece terminals, a vibratory bowl is used to orient the terminals and present to the crimp press for crimp processing.

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An example of an automated processing crimp center is the Megomat Primo XLT .

Manual to Automated Crimp, a Migration Path

As volumes increase, the need to automated also increases. On occasion, the increase is dramatic, requiring a greater step through the automation migration path. But normally the increase is controlled and slower so migration can take a multi step approach over time.

Hand Tool to Bench Top Migration: Migrating from a hand tool to power assisted bench top crimping requires a bench top crimping platform like the Accu-Crimp 62 or electric powered CS200 from Wezag Tools (both pictured above).

Heavy Duty Applications use higher tonnage to provide the power needed toprocess large terminals. The Wezag UP60 is pneumatic powered and provides over 7 tons of crimp force.

Non-Fixed hand tool die sets may be removed and compatible with bench top crimping units. This reduces the overall cost of the migration from hand tools to powered bench top equipment.

Bench Top to Automated Process Migration: Migrating from a bench top to automated processing machine like the Primo XLT or Uno multi-station machines is simple and straightforward. Mini style applicators used in a bench press application as pictured above can be mounted directly from a bench top press to the press on the automation system. Some applications require a different feed cam to feed the terminal on the press downstroke to allow for the robotic arm to swing into position with no interference from the terminal.

However, in the case of loose piece terminals, separate presses with integrated vibratory bowl fed systems may be required as they are not a standard set up on an automated machine.

Loose Piece to Reel Mounted terminal Migration: Converting from loose piece processing to reel fed terminals requires a crimp press and applicator as described above. The first step is determining the compatible terminal on reel equivalent. If a quick change mini applicator can be used, then the crimp press can be quickly changed from one terminal type to another simply by switching out the terminal applicator.

Crimp Process Validation and Control

Assuring an adequate quality and repeatable crimp and crimp process is common among all crimping methods. Non Destructive and Destructive crimp testing is used as pre-process and in-process validation methods. For more information on crimp quality process and validation, please refer to our three part series which can be found on our News Channel: Part One (crimp validation), Part Two (In Process Crimp Monitoring) and Part Three (Machine Process Capability and Calibration).

Wire Process Specialties has over 30 years of experience in processing of wire and cable including crimp technology. Connect Your Way to WPS. Our vision is to help our customers reduce processing costs and increase production efficiency.

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Archive for Schaefer Megomat

Global Technology Partners in Focus: Schaefer Megomat

You Asked: “When should we automate?”