Automatic assembly machine IDC Line INDIVIDUAL

connectorfor wirefor cables

Overview With machines from the IDC-Line series, insulation-displacement connections (IDC) are automated with high precision. In the IDC process, insulated conductors are contacted with connectors without prior stripping, enabling fast and repeatable electrical contacts. The IDC Line INDIVIDUAL is configured for use on electric motor stators and similar assemblies.

Innovative connection technology Insulation-displacement contacts are formed by pressing insulated wires into shaped contact slots. Blades inside the slots cut through the insulation during insertion and establish a reliable metal-to-metal contact with the conductor core.

Advantages of the technology The IDC method avoids additional soldering or crimping components and is well suited to high-volume production. It supports simultaneous contacting of multi-core cables and reduces cycle time while ensuring consistent contact geometry.

Application example — electric motors The machine inserts and connects winding wires to the corresponding contacts or anchors on the stator, producing stable and durable connections that meet electrical and mechanical requirements of motor assemblies.

Quality assurance functions Integrated sensors monitor insertion depth and press parameters for each contact. Deviations from reference values are detected and reported to prevent defective parts from progressing in the line and to support traceability.

Operator safety A monitored safety device with interlocked doors interrupts the safety circuit when opened and stops all drive systems. The equipment is designed to comply with applicable European directives for mechanical and electrical safety and electromagnetic compatibility (EMC).

Production process

• Operator loads the stator
• Rotate stator to first contact position
• Feed contacts through the IDC station
• Cut contacts from the strip
• Insert contact into slot and press wire to form IDC
• Cut and vacuum-extract excess wire
• Rotate stator to next contact position
• Repeat connections until complete

IDC station (module) The IDC station automates insulation-displacement connections with repeatable accuracy and can be integrated as a module into production machines and systems. Illustrations are exemplary and may show optional equipment.

Technical specifications

• Process type: Insulation-displacement connection (IDC)
• Primary application: IDC connections on electric motor stators
• Contact formation: Insulated wire pressed into shaped contact slots; blades cut insulation to form electrical contact
• Suitable for series production and multi-core cables
• Integrated sensors for insertion depth and process monitoring
• Excess material handling: cutting and vacuum extraction of wire remnants
• Operator safety: monitored interlocked doors interrupt safety circuit and stop drives
• Compliance: designed to meet relevant European directives for mechanical/electrical safety and EMC
• Modularity: IDC station/module for integration into machines and systems