Force monitoring system CrimpWise

for crimpingcheckevaluation

Overview
To ensure quality in cable production, Schäfer offers the CrimpWise crimp force monitoring system as an optional extension. CrimpWise can be integrated into most Schäfer crimping machines or mounted as an external module. The system is fully integrated into machine control and operated via a browser-based interface accessible from networked devices, enabling centralized quality management and parameter configuration.

Functionality
The system monitors crimp quality by recording the crimp force curve and comparing measured values with a learned reference curve. Deviations can indicate issues such as missing strands or insulation in the crimp. On deviation the machine issues an error message or, if a bad-part cutter is installed, removes the defective cable to prevent further processing.

Retrofit capability
CrimpWise is available as an internal module (CrimpWise iS) for cabinet integration or as an external module (CrimpWise eM) for machine mounting. It is retrofit-capable for many presses, including third-party machines. Adjustable sensors and established measurement technology simplify setup and help maintain consistent measurement quality over the machine lifecycle.

Software & connectivity
The CrimpWise software provides documentation and detailed analysis of recorded crimp forces. The browser-based interface supports multi-user access, system configuration and integration into the customer network. The system supports OPC UA connectivity for centralized data handling and traceability.

Advantages for cable production

• Zone-based monitoring with time- or position-based analysis.
• Fully configurable measurement setups and monitoring zones.
• Browser-based interface with multi-user access.
• Complete data logging and OPC UA connectivity for 100% traceability.
• Easy software updates to add features and improvements.

Modules and product variants

• CrimpWise iS: internal module for cabinet integration.
• CrimpWise eM: external module for machine mounting.
• CrimpWise software: browser-based interface for configuration, monitoring and analysis.

Technical specifications

• Integration: internal (cabinet) or external mounting; retrofit-capable for many presses.
• Operation: integrated in machine control; browser-based UI accessible from networked devices; multi-user support.
• Monitoring method: crimp force curve measurement compared to learned reference curves; zone-based analysis.
• Quality actions: machine error signalling and optional bad-part cutting on deviation.
• Data & connectivity: complete data logging and OPC UA connectivity for traceability.
• Measurement: adjustable sensor technology to ensure consistent measurement quality.
• Software: configuration, detailed analysis and documentation; supports centralized data management.