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Engineered for complex wire harness production, this multi-station automated system streamlines the entire workflow, from wire feeding to finished assembly. It seamlessly integrates wire cutting, dual-end stripping, number tube printing and insertion, wire twisting, and terminal crimping into a single, cohesive process. This machine is ideal for manufacturing harnesses used in electrical panels, control cabinets, and advanced automation systems.
All production parameters—such as wire length, labeling content, wire types, and terminal configurations—can be batch-configured via a user-friendly Windows 11 interface with Excel (.xlsx) import, enabling seamless mixed-model processing in a single run. Operators can define marking content and print direction for each wire directly in Excel, supporting multiple orientations like forward and reverse. This flexible software-driven approach provides maximum customization without hardware adjustments, significantly boosting production adaptability for varied wiring specifications.
A unique U-shaped wire bending design aligns both wire ends on the same side, allowing head and tail processing to occur at shared stations. This innovative layout minimizes the required number of crimping stations and optimizes the machine's footprint. The four independent crimping stations accommodate both reel-fed and loose-piece terminals, with vibration bowls for automated loose terminal feeding.
Quality assurance is paramount, with a dual CCD vision system to inspect number tube insertion and crimp quality. An integrated crimp force monitoring system analyzes the full force curve of every crimp, automatically rejecting non-compliant units and halting production if measurements exceed preset tolerances. This guarantees high-quality output, reduces rework, and significantly improves production yield.
| Wire Size Range | AWG10 – AWG24 |
| Supported Terminal Types | 4 loose + 4 reel (customizable) |
| Supported Tube Types | Round (flat tube customizable) |
| Wire Cutting Length | 350 – 5500 mm (customizable) |
| Stripping Length | 3–20 mm |
| Twisting Function | Supported (both ends) |
| Tube Printing | Ribbon printing (black, white, etc.), cartridge type |
| Number of Crimping Stations | 4 (customizable) |
| Crimping Station Type | Servo motor driven (crimping height programmable) |
| Loose Terminal Capacity | 4 types (via 4 vibration feeders) |
| Reel Terminal Capacity | 4 types |
| Crimping Force Monitor | Logging function (full crimp-force curve) |
| Vision Inspection | Tube insertion result + crimping result (dual CCD) |
| NG Product Handling | Automatic rejection with counting logic |
| Control System | Windows 11 + Office 2021 + KINGSING Software |
| Data Input Format | Excel (.xlsx) |
| Operation Interface | Software with physical buttons |
| Production Capacity | ≥ 500 wires/hour |
| Power Supply | 220 V 50 Hz (customizable) |
| Air Pressure | 0.5 – 0.8 MPa |
| Noise Level | ≤ 70 dB |
| Power Consumption | 5000W |
| Machine Weight | Approx. 1.2 tons |
| Dimensions | 3400 mm × 1360 mm × 1800 mm |
| Optional Configuration | Terminal crimp force monitor, CCD vision inspection system, conveyor belt for long wire processing, full safety enclosure (optional door-mounted emergency stop), automatic wire prefeeder, bulk terminal vibratory feeding system, customized solutions available upon request |
Product Updates: Images and videos displayed may differ from current products due to ongoing design improvements and updates. The actual delivered product shall prevail in case of any discrepancy.
Optional Accessories: Some accessories and components shown in product photos/videos are optional configurations and not included in the standard package. Please order these items separately if required.
Technical Parameters: Specifications are for reference only. Equipment suitability depends on actual working conditions, not just parameter comparison. Please consult us to confirm compatibility for your specific application.
