Electronic automation system SynchroLine INDIVIDUALweldingfully automaticassembling
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Characteristics
- Options
- electronic, welding, fully automatic, assembling, automotive, fiber optics, high volume, sawing, Transfer production system, for PoF, Light wave cables
Description
Product overview
Fully automated production system for polymer optical fiber (POF) light wave cables. Enables laser welding of POF to ferrules and pigtail terminals, with integrated quality assurance and automatic sorting of non-conforming cables. Modular design and short set-up times make the system suitable for series production in medical technology, automotive and telecommunications.
Flexible Machine with Transfer System
Modular SynchroLine automation uses a transfer system with shuttles to transport wires between stations. Welding connections are performed fully automatically with high precision. The machine base includes a transfer system that moves wires to each processing station using shuttles.
Preparations for Cable Production
The optical fiber is fed nearly tension-free from a specially developed unwinder. Unwinding speed is controllable and fiber length can be buffered. Product-dependent wire lengths are cut at the first station; the cutting process produces a high-quality end face without additional machining. An internal vacuum cleaning system removes plastic particles in quality-relevant areas.
Overview of the Overall Process
Connecting the Polymer Optical Fibers
Welding stations perform connections between fibers and fiber optic terminals. System supports standard ferrule terminals and pigtail terminals (pins and sockets). Integrated fiber measurement monitors each welded connection and attenuation values during production. Out-of-tolerance cables are automatically separated and prevented from continuing in the process.
Control and Safety
Intuitive multilingual touchscreen control with selectable user roles and operating modes; networking functions allow flexible process sequences. Main control: WireStar; station control: STI. Monitored safety equipment with safety doors interrupts the safety circuit and stops all drives. Machine conforms to applicable European mechanical, electrical and EMC directives.
Technical Data
Processable materials: wires, ferrule lightwave cables, pigtail lightwave cables.
Ferrule lightwave cable: conductor core diameter 1 mm; sheath diameter 2.3 mm (colored).
Pigtail lightwave cable: conductor core diameter 1 mm; sheath diameter 1.5 mm (black).
Terminals: ferrule (standard); pigtail sockets and pins.
Performance and geometry: Ferrule lightwave cables (one cable per shuttle laid in a curve): 840 pcs/h at 1230 mm; 570 pcs/h at 4350 mm; 545 pcs/h at 8500 mm. Pigtail lightwave cables (two single cables inserted in shuttle): 800 pcs/h at 60–280 mm.
Number of stations: ferrule lines 7 stations; pigtail lines 9 stations. Number of shuttles: 37.
Control: HMI WireStar (main), STI (station). Display: touchscreen.
Supplies and interfaces: Power supply 400 V, 50/60 Hz; Compressed air 6 bar.
Dimensions and weight: W x D x H 4480 x 5925 x 2700 mm (approx., closed machine depending on equipment); Weight approx. 3500 kg.
Illustrations
Illustrations on product pages are exemplary and may show options and specific equipment.
Technical specifications
Fully automated production system for polymer optical fiber (POF) light wave cables. Enables laser welding of POF to ferrules and pigtail terminals, with integrated quality assurance and automatic sorting of non-conforming cables. Modular design and short set-up times make the system suitable for series production in medical technology, automotive and telecommunications.
Flexible Machine with Transfer System
Modular SynchroLine automation uses a transfer system with shuttles to transport wires between stations. Welding connections are performed fully automatically with high precision. The machine base includes a transfer system that moves wires to each processing station using shuttles.
Preparations for Cable Production
The optical fiber is fed nearly tension-free from a specially developed unwinder. Unwinding speed is controllable and fiber length can be buffered. Product-dependent wire lengths are cut at the first station; the cutting process produces a high-quality end face without additional machining. An internal vacuum cleaning system removes plastic particles in quality-relevant areas.
- Short fibers: transported in pairs by shuttles to stations
- Longer fibers: wound into loops so two wire ends can be processed simultaneously
Overview of the Overall Process
- Unwinding and printing
- Cutting to length and finalizing the end face
- Winding and binding
- Mounting of protective caps
- Laser welding with terminals
- Measuring core residue
- Measuring attenuation
Connecting the Polymer Optical Fibers
Welding stations perform connections between fibers and fiber optic terminals. System supports standard ferrule terminals and pigtail terminals (pins and sockets). Integrated fiber measurement monitors each welded connection and attenuation values during production. Out-of-tolerance cables are automatically separated and prevented from continuing in the process.
Control and Safety
Intuitive multilingual touchscreen control with selectable user roles and operating modes; networking functions allow flexible process sequences. Main control: WireStar; station control: STI. Monitored safety equipment with safety doors interrupts the safety circuit and stops all drives. Machine conforms to applicable European mechanical, electrical and EMC directives.
Technical Data
Processable materials: wires, ferrule lightwave cables, pigtail lightwave cables.
Ferrule lightwave cable: conductor core diameter 1 mm; sheath diameter 2.3 mm (colored).
Pigtail lightwave cable: conductor core diameter 1 mm; sheath diameter 1.5 mm (black).
Terminals: ferrule (standard); pigtail sockets and pins.
Performance and geometry: Ferrule lightwave cables (one cable per shuttle laid in a curve): 840 pcs/h at 1230 mm; 570 pcs/h at 4350 mm; 545 pcs/h at 8500 mm. Pigtail lightwave cables (two single cables inserted in shuttle): 800 pcs/h at 60–280 mm.
Number of stations: ferrule lines 7 stations; pigtail lines 9 stations. Number of shuttles: 37.
Control: HMI WireStar (main), STI (station). Display: touchscreen.
Supplies and interfaces: Power supply 400 V, 50/60 Hz; Compressed air 6 bar.
Dimensions and weight: W x D x H 4480 x 5925 x 2700 mm (approx., closed machine depending on equipment); Weight approx. 3500 kg.
Illustrations
Illustrations on product pages are exemplary and may show options and specific equipment.
Technical specifications
- Product: SynchroLine INDIVIDUAL automation system for POF light wave cables
- Processable materials: wires, ferrule lightwave cables, pigtail lightwave cables
- Ferrule cable conductor core diameter: 1 mm
- Ferrule cable sheath diameter: 2.3 mm (colored)
- Pigtail cable conductor core diameter: 1 mm
- Pigtail cable sheath diameter: 1.5 mm (black)
- Terminals: ferrule (standard); pigtail sockets and pins
- Production rates (examples): up to 840 pcs/h at 1230 mm (ferrule); 570 pcs/h at 4350 mm; 545 pcs/h at 8500 mm; up to 800 pcs/h for pigtails (60–280 mm)
- Number of stations: 7 (ferrule), 9 (pigtail)
- Number of shuttles: 37
- HMI / Control: WireStar (main), STI (station)
- Display: Touchscreen
- Power supply: 400 V, 50/60 Hz
- Compressed air: 6 bar
- Dimensions (W x D x H): 4480 x 5925 x 2700 mm (approx.)
- Weight: approx. 3500 kg
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