Index. P. 02 Your expertise and ours combined P. 02 Analysis of your application P. 02 Prototypes and pilot series

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Christine Tucker
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3 Index Your partner in design P. 02 Your expertise and ours combined P. 02 Analysis of your application P. 02 Prototypes and pilot series Cost reduction P. 04 Permanent reduction of structural costs P. 04 Reduction of labour-intensive activities P. 04 Integrated quality control P. 04 Test equipment and statistics Logistics P. 06 Forecasts and response P. 06 Timely and high-quality communication State-of-the-art production equipment P. 08 Fully automated wire and cable processing machines P. 10 Semi-automated assembly equipment Core competences P. 12 Wiring with small contacts and at fine pitches P. 14 Wire & cable harnesses P. 14 Complex cable harnesses P. 16 Connector assemblies P. 18 Moulded connector assemblies P. 18 Over-moulding of printed circuit boards

02. Your partner in design Your expertise and ours combined From the very start, we will closely collaborate with you to achieve a perfect balance between your specifications, efficient production

4 02. Your partner in design Your expertise and ours combined From the very start, we will closely collaborate with you to achieve a perfect balance between your specifications, efficient production methods, and the right choice of wires, cables, connectors and components. This procedure will result in optimum cost reduction. Analysis of your application Together with you, we will answer all questions involved in your application. What is the appropriate IP sealing level against dust and water? How to avoid misconnections and damaged contacts? What is the most reliable connect/disconnect system for this particular application? Will the connector be able to combine fibre optics, high current and/or low current? How can we realise space and weight reduction? What solutions are available for extreme environments? How can I protect my wiring harness from EMI? Prototypes and pilot series After in-depth analysis of your application, you want to be certain that the solution presented will perform. That is why we will make prototypes that will enable you to perform extensive tests. Feedback will often lead to a second, or even a third, version. And in the case of a pilot series for your product, we will be happy to provide the finishing touches.

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6 04. Cost reduction Permanent reduction of fixed costs Outsourcing your purchasing process and stock-control methods to us, allows you to realise considerable cost reductions. You can dedicate your people to carry out the core tasks of your operating process. By combining the purchasing for a large customer base, we are able to help you realise substantial savings on your purchasing budget. Reduction of labour-intensive activities A high-quality design is based on automated and semi-automated production technologies, allowing you to drastically reduce the labour component. By calling in our help from the very first start, you are able to benefit from our state-of-the-art production facilities. Integrated quality control Our Komax automated wire-processing machines combine high output with the integrated control of the quality of crimped contacts. Crimped contacts transfer current and signals and are, therefore, of vital importance to the quality of connector assemblies and wire harnesses. Test equipment and statistics Our test facilities are very complete. Not only do we test the quality of the connections and, by means of a high-voltage test, the integrity of the insulating material, we also test the functionality of the complete wire harness. Including the switching behaviour of relays and other components. Each test is stored digitally and a hard copy can be included in each delivery.

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Delivery on demand is geared to your requirements, carefully communicated to our network of suppliers, and continuously monitored.

8 06. Logistics Forecasts and response To plan our logistics process, we make use of regular prognoses or rolling forecasts. This is especially helpful to clients who use unique components for their connector assemblies or wire harnesses. Delivery on demand is geared to your requirements, carefully communicated to our network of suppliers, and continuously monitored. Timely and high-quality communication Timely and high-quality communication, in addition to ERP software, remains an important basis for perfect logistics. Especially if clients make unforeseen orders for which they request the usual delivery times. On the purchasing side, we make use of a network of qualified suppliers who are willing to help you fulfil unexpected requirements and meet sudden peaks.

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crimping contacts at both ends - even two wires in a single contact - and marking by means of inkjet printing.

10 08. State-of-the-art production equipment Fully automated wire and cable processing machines Our fully automated Komax machines combine the following operations in a single cycle: cutting the wire to the desired length, stripping and crimping contacts at both ends - even two wires in a single contact - and marking by means of inkjet printing. The quality of the crimping of contacts to the wire core is inspected during each cycle and the measured results are recorded for each batch.

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Crimping of heavy duty contacts up to 100 mm 2 Three-stage stripping of coaxial and triaxial cable in a single

12 10. State-of-the-art production equipment Semi-automated assembly equipment: Taping of wires Semi-automatic machines to apply tie-wraps Ultrasonic welding of the copper core Processing heavier cable up to 100 mm 2 Crimping of heavy duty contacts up to 100 mm 2 Three-stage stripping of coaxial and triaxial cable in a single cycle Cutting, stripping and coiling of heavy cable in a single cycle Overmoulding of printed circuit boards and connector outlets

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08 mm2) are cut to length, stripped and fitted with small crimped contacts on fully automated

14 12. Core competences Wiring with small contacts and at fine pitches Pitches of 1 mm or less allow for a very compact and reliable wiring design. Even thin wires with a flexible core of AWG 28 (0.08 mm2) are cut to length, stripped and fitted with small crimped contacts on fully automated wire-processing machines. And during the same cycle, the quality of each crimped contact is automatically tested.

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14. Core competences Wire and cable harnesses Connections and wiring transmit current and signals.

Final assembly is done on wiring boards with integrated test equipment.

Complex cable harnesses Cable harnesses for machines are characterised by a variety of control units and a wide range of machine modules to

16 14. Core competences Wire and cable harnesses Connections and wiring transmit current and signals. In fact, they represent the nervous system of your product. We produce all wires and cables of a harness on fully automated machines. Final assembly is done on wiring boards with integrated test equipment. Bundling of wires and other assembly operations are performed by means of automated tools. Complex cable harnesses Cable harnesses for machines are characterised by a variety of control units and a wide range of machine modules to be connected. Many different connector systems are required to transfer current and signals. Long cable lengths are often typical for machine harnesses. Special attention is given to the individual design of all of these cable modules, so that they can be produced efficiently, thereby minimising labour time.

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individual pieces. Subsequently, the inner conductors are stripped and simultaneously fitted with crimped contacts on electronic presses with integrated quality control.

18 16. Core competences Connector assemblies Our production methods will drastically reduce labour time. During a single cycle, our fully automated cable-processing equipment will cut multi-conductor cable to the desired lengths, remove the outer sheaths, and coil up the individual pieces. Subsequently, the inner conductors are stripped and simultaneously fitted with crimped contacts on electronic presses with integrated quality control. Moulded connector assemblies Obviously, the wiring in diesel engines of boats and yachts has to be watertight. We make use of a standard sealed automotive connector, which we over-mould for additional protection against dust, moisture and stress.

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18. Core competences Over-moulding of printed circuit boards Lorries travelling across Europe need to transmit important information to their home base.

Here, the printed circuit board and the cable outlets are perfectly overmoulded, leaving the indication LED at the centre of the PCB completely clear.

This way, the components are protected against dust, moisture and mechanical stress.

20 18. Core competences Over-moulding of printed circuit boards Lorries travelling across Europe need to transmit important information to their home base. This is done by means of a small SMT PCB, which amplifies the signals from a computer/gps system to be transmitted via GSM. Here, the printed circuit board and the cable outlets are perfectly overmoulded, leaving the indication LED at the centre of the PCB completely clear. Over-moulding To protect even the most sensitive and delicate components, our over-moulding process operates at relatively low pressures and temperatures. This way, the components are protected against dust, moisture and mechanical stress. The cost for aluminium tooling is low, allowing for even small series up to 3000 pieces per year to be processed efficiently. Typical cycle times are between 10 and 50 seconds. The different types of granulate are of high quality, do not contain any toxic substances, are environment-friendly, and comply with UL 94 V0, ROHS and WEEE. And the bonding strength on PVC is excellent.

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23 AGCO BV Freddy van Riemsdijkweg 7 P.O. Box 7154 NL-5605 JD Eindhoven The Netherlands Tel: +31 (0) Fax: +31 (0) sales@agco.nl

Save with automation Reduce your production costs Cut your production times by up to 50 % The savings start from a batch size of one

Save with automation Reduce your production costs Cut your production times by up to 50 % The savings start from a batch size of one EN It is very time-consuming to design and build control cabinets manually and is dependent on specialists. To slash the throughput time and make production processes more flexible and ideal, Komax offers