Process automation system SynchroLine INDIVIDUAL

for productionfor cablesPhotovoltaik

Product summary The system is designed for fully automatic manufacturing of electrical assemblies for solar technology (photovoltaics). An innovative shuttle-cart transfer system provides the basis for efficient production and is completed by dedicated modules for separation and feeding of required parts.

Preparations for cable production Nearly tension-free feeding of the two-core cable is handled by a specially developed dereeler. Unwinding speed can be regulated according to demand and cable length is buffered. In the first processing step, the insulation at the cable end is roughened inline. At another station, product-specific lengths are cut and the cables are stripped.

Production of assemblies The transfer system moves cable pairs from station to station using shuttle carts. Separation and feeding of terminals and components run in parallel with the preparation steps. On one side of the cable, connections are executed with high precision using 4-point crimps. The opposite side is compacted and joined to an electrical assembly by resistance welding.

Intuitive user interface The touchscreen control system offers an intuitive multilingual user interface for safe, straightforward operation. Selection of user roles and operating modes, together with machine networking functions, enable flexible, modern workflows.

High safety for the operator Operator protection is provided by a monitored safety device. Opening protective doors interrupts the safety circuit and stops all motors. The system complies with applicable European directives on mechanical and electrical safety and electromagnetic compatibility.

Overview of the entire process

• Inline insulation roughening
• Cutting to length and stripping
• Separation and feeding of terminals
• Feeding of electrical components
• Crimping with terminals and components (4-point crimp)
• Compacting and resistance welding
• Testing for quality assurance

Illustrations Illustrations are exemplary and may show options or specific equipment. Subject to errors and alterations.

Technical characteristics / specifications

• System type: SynchroLine INDIVIDUAL transfer automation system
• Application: Manufacturing of electrical assemblies for solar technology / photovoltaics
• Transfer: Shuttle cart based transfer system for paired cable transport
• Feeding: Special dereeler for nearly tension-free two-core cable feeding with buffer storage
• Inline processes: Insulation roughening, cutting to length, stripping
• Assembly processes: Separation and feeding of terminals/components, 4-point crimping, compacting, resistance welding
• Control: Touchscreen control system with multilingual UI, user roles, operating modes and machine networking
• Safety: Monitored protective device; opening doors interrupts safety circuit; compliant with European mechanical, electrical safety and EMC directives
• Documentation: Brochure (PDF) available