Automation increases wire processing machine increases throughput by 20%.

An integration solution from Mitsubishi Electric has assisted wire processing machine maker Schaefer Megomat USA improve the throughput of one of their wire processing machines by 20% whilst maintaining accurate motion profiles.  The system, which integrates a System Q PLC, motion controller and anti-vibration servos is also easier to use and service, whilst producing less waste.

CHALLENGE

In wire processing, speed is important, but not at the expense of accuracy. In order to meet the demands of automobile harness manufacturers, wire contract manufacturers and panel shops – all of whom need to increase production levels to stay competitive – wire processing machines must be fast, accurate and reliable.

Schaefer Megomat wanted to create a machine that would far exceed the industry best in speed, while providing a consistent, repeatable crimp every time. Before the company developed its newest system, the fastest wire processing machines in the market could produce 5200 pieces per hour.  Schaefer Megomat’s goal was to create a state-of-the-art, fully automatic wire processing machine that could not only surpass the highest production speeds in the industry, but would also offer unequalled accuracy, reliability and simplicity.

Integrated automation solution

After researching solutions from several automation product manufacturers, Schaefer Megomat chose Mitsubishi Electric integrated automation because the company met its requirements for product quality and real-time support.

“Our customers can’t afford to have a machine down, so real-time support was an important factor in choosing Mitsubishi Electric,” said Reggie Butler, General Manager, Schaefer Megomat USA, Inc. Mitsubishi Electric was also the only company to produce servomotors with anti-vibration technology, which helps to meet the high accuracy needs of wire processing.

The Megomat 2000 is not only fast, but provides consistent and repeatable wire processing. The compact, swivel arm system is suitable for multiple applications, including end stripping, crimping and seal loading of a single wire, and allows for a broad range of wire size and terminal combinations. It also includes a 22-inch wide touch screen for easy programming, and a dual-wire straightener. The Q Series PLC allows production data retrieval and integration with ERP systems–capabilities particularly prized by the automotive industry.

RESULTS

At 6100 pieces per hour, the Megomat 2000 can reach higher speeds than Schaefer Megomat’s previous generation machines and delivers the highest known speeds in the market. “The Mitsubishi Electric drives and controls allow for much greater speed and movement of the axes than before,” said Butler. “We also get an incredibly accurate motion profile even at amazingly fast speeds,” he added, explaining that inaccuracy in wire processing can result in loose strands that can create a malfunction or short.

Schaefer Megomat also customized the HMI. The interface is extremelyeasy to use, which reduces training time on the system. The intuitive HMI also includes real-time video, allowing for quick troubleshooting and remote fixes. Besides speed, accuracy, reliability and simplicity, other benefits of the Megomat 2000 include reduced wire scrap and fewer support calls, resulting in cost savings for the customer.

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