Archive for Applitek

Global Technology Partners in Focus: Appltek Technologies.

logo png

Continuing with our Global Technology Partners in Focus series, I am pleased to introduce Applitek Technologies Inc.   Applitek supply crimping solutions for strip form terminals mounted to reels.  At WPS we believe in longevity in business relationships.  There are no short cuts in establishing long trusted relationships.  Our partner associations span over three decades in some cases.  Applitek has been a trusted partner of WPS for over 15 years.  Our connection to the owners of Applitek go back further than that.  I am pleased to present the founding President of Applitek Tecnologies, Bruce Getchell.

WPS: Thank you for spending some time with us today Bruce.  To get started, how long has it been since you founded Applitek Technologies?

BG: Applitek was founded 27 years ago

WPS: Describe the business conditions when you started Applitek?

BG:  Every terminal company had their own format for applicators and presses.  We saw a need to offer a standardized format so companies could use common presses.  As an independent manufacturer we would tool our applicators for any brand of terminals.

WPS: Can you compare the business conditions back then with what we see today?

BG:  Companies back when we started had very limited choices when purchasing applicators.  Today they have numerous choices’ due to the accepted mini die format.

app_1700

WPS: Do you have customers who have been with you for a long time?

BG:  We still have customers with us from the start of the company.

WPS: Do they value your longevity in this business?

BG:  I believe they do.  Many long term relationships and friends have developed from the start of Applitek.  Having been involved in the terminal manufacturing business 15 years prior to the start of Applitek many of those relationships have continued with us.  Some of our customers I have known for over 35 years.

WPS: As a third party applicator supplier, do you meet the OEM specifications for crimp tool design and crimp height specs?

BG:  Yes we do.

WPS: Can you supply a complete solution including crimping presses?

BG:  Applitek supplies a number of presses in tonnage capacity and price range to complement our applicator supply.  This also includes stripper-crimper modules.

M-3000

On behalf of WireProcess Specialties and our customers, thank you for your long term service to the Wire Processing industry. For your vision and pioneering spirit when applicator supply was considerably different from what it is today. We value our business partnership and look forward to many years of service to our valued customers.

BG: We would like to offer our Thanks and appreciation to all our customer that have made our Company successful over the years. Please visit our website to see more.

WPS is proud to be associated with companies like Applitek, true partners in helping our customers improve their production efficiency and reduce their processing costs. Connect Your Way to WPS to start see how we can support your organization.

Electrical Wire Processing Technology Expo 2015 in Review: Part Two

This is part two of our Wire Processing Expo 2015 coverage. In part one, we covered a few of the products from ETCO, Schaefer Megomat and Wezag Tools. This issue will complete our coverage with product displays of new technology.

C&S Technologies

C&S a leader in quality validation and monitoring technologies had their whole lineup on display. C&S has a range of solutions available including press calibration, crimp monitoring, crimp cross sectioning and data collection.

Crimp Inspection Station

Crimp Inspection Station

 

Applitek Technologies

Applitek is a leader in mini style applicators. Side and rear feed applicators were on display as well as a number of special designs.

Side Feed applicator from Applitek.

Side Feed applicator from Applitek.

 Carpenter Manufacturing

In addition to the standard lineup of bench top measure, cutting and stripping solutions, Carpenter displayed the new single and dual coil pans. These coil pans can be integrated into the Compu-Cut or Compu-Strip series machines.

Model 58B pre-feed and 97A on new single bowl coil pan.

Model 58B pre-feed and 97A on new single bowl coil pan.

Carpenter Mfg

Carpenter Mfg Dual Bowl Coil Pan.

Control Laser

WPS’ most recent Global Technology Partner is Control Laser. Control Laser is celebrating 50 years in business in 2015. Control Laser is a leader in marking, etching, engraving and cutting.  On display was the No Nic series hand held and Bench top wire stripper.

The Control Laser No Nic Hand Held wire stripper.

The Control Laser No Nic Hand Held wire stripper.

Lakes Precision

Lakes supplies blades for wire processing machines. A well established supplier of choice to OEM suppliers for their requirements, Lakes provides a full range of blade designs for most OEM suppliers and their respective machines. All from the Lakes modern facility in Wisconsin.

Lakes Blade

We enjoyed the time meeting with customers, sharing ideas and discussing applications. Networking with the leaders in our industry is a valuable time for all. We are ready and able to deploy these solutions and many more to help improve productivity and reduce processing cost. Connect Your Way to WPS today.

Terminal Crimping Technology

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.

30160

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

 

Crimping Methods

Wezag Crimp Tool 1Hand 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.

Wezag CS 200With 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.

62

Wezag CS200                                                          Carpenter Accu-Crimp 62

applicators2Reel 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.

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).

Wezag UP60

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.

Processing Options for Transformer Manufacturing.

Wire Process Specialties serves many industries that require assembly processes for electrical and electronics.  One industry that WPS has served for a number of years is in Transformers and Magnetics.  WPS supplies a multiple of solutions for the processing of magnet wire and coil winding from simple wire end processing to complex automation for transformer assembly.

Magnet Wire Stripping

The Carpenter Magnet Wire Stripper series provide cost effective methods to remove the enamel from magnet wire.  Models include the conical wheel 88F shown above for stripping ultra-fine wire down to 48 awg, the 27F with a collet stripping head and available extension wand and the 14B for heavy duty round and rectangular wire.

 Material Cutting

 The Compu-Cut 42B is a heavy duty cutter for a multitude of uses.  Cutting heat shrink, pvc and fibreglass tube as well as wire and irregular shaped material can be processed with the 42B. The 42B is part of the Compu-Cut machine series which includes the 33 and 36A models.

All consumable and spare parts for Carpenter machines are available through WPS.  For more information on the Carpenter Compu-Cut machines and Magnet wire stripping line Connect Your Way to WPS or visit wireprocess.com/carpenter

 Heat Shrink Tube Processing

 

 The heat gun has been a standard method of processing heat shrink for decades.  The Judco Focus Lite line is a cost effective method of processing heat shrink of various sizes. The energy efficient halogen bulbs operate on demand for fast and efficient shrinking of heat shrink tube.   Several models are available to shrink tube from 5/8″ to 1.5″ OD to 15.5″ long.  Connect Your Way to WPS or visit wireproces.com/Judco for more information.

Other Processing Options

Applicators and crimping presses for reel fed terminals, terminals and connectors,  quality validating and monitoring systems for crimping, wire marking, wire cut and strip equipment for stranded and multi-conductor wire.

Connect Your Way to WPS to discuss your assembly processes for your products.  We have over three decades of experience serving our valued customers from coast to coast.