WIRE TO WIRE

Splicing / crimping is a proven technology that solves assembly challenges where soldering is inadequate mechanically due to vibration, susceptibility to pull forces, fatigue or other usability factors (heat sinking, wetting, flux restrictions).

Autosplice

Autosplice Spliceband provides the lowest applied assembly cost connection when compared to soldering or resistance welding.

Spliceband is compatible with solid and stranded wire types and is proven to be more than 50% faster than wire soldering connections.

As the industry leader, our vast tooling library provides solutions to the most challenging wire types and materials. These tooling options can crimp multiple wires, 3-way wires, strain relief, magnet wire, tinsel wire, litz wire, and coax wire, of virtually all gauge diameters.

Produced in a variety of material options and sizes, Spliceband offers greater reliability than soldering with faster throughput.

Spliceband is produced with or without serrations with tool options than create a variety of finished splice crimps including, standard, ferrule, and pigtail versions.

WIRE TO PCB

D-BIT (wire to PCB crimp connection) provides high quality mechanical and electrical connection to PCB’s, flex circuits and other substrate materials, without the need for solder or traditional connectors.

Used with Autosplice SAS/2, SAS/3 and ACS2000 machines, D-BIT offers significant applied assembly cost savings for interconnections to printed circuit boards, flex circuits and other substrate materials by reducing components and assembly time.

D-BIT direct wire to circuit board technology can be applied to both solid and stranded wire.

D-BIT solves height restrictive assemblies where traditional connector methods are too tall or cost prohibitive. D-BIT assembly provides an excellent solution to PCB assemblies where solder joints cold form due to heat sinking.

Direct to Board Interconnect Technology eliminates the need for costly connectors, while producing a high quality connection.

STRAIN RELIEF

Provides protection against cable failure caused from pulling, pushing, twisting.

Prevents mechanically applied forces from being transferred to the electrical conductor terminations

Supports a minimum of 10 lbs. pull force without slipping on jacket

Cable remains intact when crimped and when stressed by pulling, pushing or twisting forces

Works with over-molding, solid/smooth, and segmented wire grommets and bend reliefs

Small form factor saves space, fits most applications

Securely anchors and protects cable, reinforces mechanical strength

Manufactured from brass for durability and low cost, high volume applications

Works with Autosplice ACS2000 machines for efficient assembly (requires Strain Relief Tool Set)

MAGNET WIRE

Spliceband for magnet wire (M-Spliceband) provides a cost effective and reliable method for connecting wires to electric motors, transformers, speakers, coils, alternators, solenoids, inductors and small appliances.

M-Spliceband uses a proprietary serrated profile, penetrating the various varnishes and coatings used on copper and aluminum magnet wire, producing a strong, reliable gas-tight interconnection between wires.

Multiple wires can be spliced simultaneously, with no pre-stripping required. Supported by a variety of tool sets, M-Spliceband enables high productivity splicing connections with no wasted material.

Using magnet-piercing splice band, the splice system will produce a connection of an unstripped magnet wire directly to wire or component.

SAS/2

SAS/2 has unprecedented machine life; over 25 years of reliable service reported by many customers.

The SAS/2 splicing system consists of a semi-automatic machine and a reel of continuous Spliceband material. The machine feeds, cuts, and forms the Spliceband to create highly reliable connections without expensive pre-formed crimps.

SPECIFICATIONS

• Eliminates soldering
• Scrap free operation
• Can be integrated into automated system
• Excellent process reliability
• Comprehensive Toolset library
• Push action Spliceband feeding mechanism
• Functions with Spliceband material types and widths from 2 mm to 9 mm (Standard widths include 2 mm, 4 mm, and 6 mm)
• 110 V or 230 V available

ACS 2000

Designed and tested throughout Europe, this proven platform provides reliable repeatable performance across a wide spectrum of interconnect challenges, such as: wire to wire (solid or stranded);wire to switch or component lead to switch; wire or component lead to flex circuit; wire or lead to flex circuit; wire or lead to PCB; flex circuit to PCB.

SPECIFICATIONS

• Servo Motor Drive technology
• Five piece modular tooling for quick application set-up, changeover and maintenance
• LED illuminated work area
• Micro-adjust spliceband feed mechanism (increments of .05 mm, .002″)
• Digital Crimp Height adjustments (increments of .01 mm, .0004″)
• Dual plate feeder eliminates damage to spliceband by rollers
• Programmable splice preselect function counts down and stops at end of job
• CE Certified

ACS 2000 Global Splice System is the most advanced, adaptable splice interconnect applicator available for global manufacturing environments.

CFM 4000 CRIMP FORCE MONITOR

It is an optional feature for all our Splice Machines, where process monitoring is preferred.

Designed and tested throughout Europe, this proven platform provides reliable repeatable performance across a wide spectrum of interconnect challenges, such as: wire to wire (solid or stranded);wire to switch or component lead to switch; wire or component lead to flex circuit; wire or lead to flex circuit; wire or lead to PCB; flex circuit to PCB.

Production Quality Monitoring aids in the detection of:

• Incorrect wire cross-section
• Incorrect terminal
• Inconsistent terminal material
• Insulation in wire crimp
• Incorrect insertion depth

SPLICE MATERIAL

Spliceband material is engineered for a variety of applications and operating conditions.

It is suitable for multi-strand and solid core copper and aluminum wires.

Available in several widths, thickness and metal types, our Spliceband materials and machines provide reliable connections meeting and exceeding the following standards:

• UL 486C
• MIL – STD 202
• IEC 60352-2
• IPC/WHMA-A -620
• RoHS

Spliceband is manufactured with unique serrations for magnet wire or standard wire types.

PIN INSERTION MACHINES

As a global manufacturer of flexible PCB pin insertion machines and interconnect components, Autosplice offers a full range of automated assembly equipment tailored to your manufacturing requirements.

From fully automated dual-head inline systems to precision bench-top pin machine, our quick change module systems offer cost-effective, rapid-turn solutions for today’s dynamic manufacturing environments.

We have tooling available for solid press-fit, compliant solder less components; PCBs; plastic, ceramic and metal substrates. Additionally, all tooling is transferable across the entire range of PCB pin insertion systems, accommodating future growth needs.

Our pin insertion machines are available in single-head or dual-head configurations, offering electronics manufacturers an ideal combination of flexibility and throughput for both high-mix and high-volume production environments.

Our pin insertion solutions are supported by global customer service staff and factory trained technicians who are ready to assist you with both machine- and component-related design or service.

MicroSert

The MicroSert™ Bench Top Pin Insertion Machine is the most cost-effective automated platform designed for smaller production environments.

Its design allows one operator to run two machines simultaneously which significantly increases the production efficiency.

A single head stand-alone base incorporates a 12”x12” (304mm x 304mm) insertion area and is digital servo motor driven. Small but powerful, the MicroSert system inserts up to three components per second and is built for today’s fast-paced global manufacturing environment.

We carry more than a dozen of various insertion heads designed for each component. We also offer the development of unique heads and tooling specifically for your project. Our modular pin insertion head technology allows for quick application tooling changeover and maintenance.

SPECIFICATIONS

• Insertion rate up to 3 per second
• Repeatability: .001” (.0254mm)
• Insertion area: 12”x12” (304 mm x 304 mm) scalable to 14” Y axis (355 mm) and 18” X axis (457 mm)
• Large touch screen monitor: 10.4” (264 mm)
• Easy-to-program Windows XP
• Professional operating system
• Industrial digital 3-axis controller
• USB port
• Interchangeable modular component heads

MiniSert

This single head stand-alone platform comes complete with a 12” X 12” insertion envelope and servo driven head actuation.

Minisert XE comes complete with our standard vision system that detects and corrects board error and skew. Additionally, a scan-all function allows for complete sequencing through the entire program to verify and correct all programmed insertion locations.

Engineered and manufactured to internationally recognized quality standards ISO/TS16949-2002.

SPECIFICATIONS

• Insertion rate up to 12,000 per hour on 0.2” (5.08 mm) pitch12” X 12” insertion area
• Accuracy +/- 0.001”Vision system for PCB error correction
• Single head platform
• Component end of reel sensors
• Touch screen monitor
• Windows 7 operating system
• Safety enclosure with light curtain
• Inserts soldered and press-fit components

MiniSert is a cost-effective high-speed pin insertion system designed for smaller footprint applications.

MultiSert

Fast and simple multiple parts and tooling changeovers along with auto-adjustment conveyors allow significant flexibility of the pin insertion manufacturing process.

Multisert XS is the culmination of over 50 years experience, servicing the automotive, telecommunications, medical and industrial market needs for applied interconnects.

SPECIFICATIONS

• Insertion rates up to 3 per second on .2” (5.08 mm) pitch
• Up to 2 insertion heads
• 18” x 18” Insertion area (457 mm x 457 mm)
• Accuracy +/- 0.001”
• Vision system for PCB error correction
• PCB anvil supportTouch screen monitor
• Windows 7 operating system
• SMEMA interface
• Interlocked enclosure with light curtain
• Component end of reel sensors
• Optional continuity sensor
• Inserts soldered and press-fit components

SYSTEM OPTIONS

• Programmable rotary stage (0-360 degrees)
• Real time insertion force monitoring
• CE Compliant
• Top or bottom view bar code scanners

AIS 4500

For your high volume production needs, Autosplice offers the AIS 4500 high-speed pin insertion machine for both single PCBs and multiple boards

High speed insertion of through hole pins or stamped terminals into printed circuit boards can reduce the high cost of manual connector placement. Fast yet compact pneumatic heads can be quickly changed to insert different components.

SPECIFICATIONS

• Insertion Area in mm X 250 / Y 250
• Application Size in mm X 270 / Y 250
• Insertion Time: Pin 0.7 sec./component
• Tab 1.0 sec./component
• Interface Touch Screen Panel with industry PC
• Insertion Heads max. 1
• Compressed Air 6 Bar
• Power supply 400 V / 50 Hz / 16 A
• Level of noise: less than 75 dB
• Dimensions in mm (L x W x H) 1170 x 1010 x 1763Tool protection sensor
• CE compliant

OPTIONAL FEATURES

• Rotary table
• Insertion force measurement
• Auto correct function
• Barcode reader
• EMC protection
• Bending station
• Post pushing station
• Badmark detection
• Remote controll service

AIS 5000

High speed insertion of through hole pins or stamped terminals into printed circuit boards can reduce the high cost of manual connector placement. Fast yet compact pneumatic heads can be quickly changed to insert different components.

SPECIFICATIONS

• Insertion Area in mm X 300 / Y 300
• Application Size in mm X 320 / Y 300
• Insertion Time: Pin 0.7 sec./component, Tab 1.0 sec./component
• Interface Touch Screen Panel with industry PC
• Insertion Heads max. 2
• Compressed Air 6 Bar
• Power supply 400 V / 50 Hz / 16 A
• Level of noise less than 75 dB
• Dimensions in mm (L x W x H) 1400 x 1300 x 1500
• Tool protection sensor
• CE compliant

OPTIONAL FEATURES

• Rotary table
• Insertion force measurement
• Autocorrection function
• EMC protection
• Bending station
• Post pushing station
• Badmark detection
• Remote control service
• Barcode reader

For your high volume production needs, Autosplice offers the AIS 5000 high-speed pin insertion machine – a highly flexible platform

AIS 5000 inline

For your high volume production needs, Autosplice offers the AIS 5000 high-speed pin insertion machine – a highly flexible platform

The conveyorized version can be integrated into a fully automatic line. One or two heads can be incorporated and the “quick change” feature allows the freedom to insert different continuous components with the same machine.

SPECIFICATIONS

• Insertion Area in mm X 300 / Y 300
• Application Size in mm X 320 / Y 300
• Insertion Time: Pin 0.7 sec./component , Tab 1.0 sec./component
• Interface Touch Screen Panel with industry PC
• Insertion Heads max. 3Compressed Air 6 Bar
• Power supply 400 V / 50 Hz / 16 A
• Level of noise less than 75 dB
• Dimensions in mm (L x W x H) 3025 x 1650 x 1600Tool protection sensor
• CE compliant

OPTIONAL FEATURES

• Rotary table
• Insertion force measurement
• Autocorrection function
• EMC protection
• Bending station
• Post pushing station
• Badmark detection
• Remote control service
• Barcode reader

PRESS-FIT TECHNOLOGY

Press-fit solutions provide our customers with solderless, internally powerful, gas-tight connections. Press-fit terminals are assembled onto PCB via high-speed insertion machines.

STAMPED TERMINALS

Autosplice stamping products are ranging from .001″ (.0254mm) to .060″ (1.524mm) thick in the following alloys including, but not limited to Phosphor Bronze, Beryllium Copper, Copper, Nickel-Silver, Stainless Steel, Brass.

DRAWN WIRE PINS

Drawn wire pin technology is a total process solution that offers a large variety of end-to-end pin sizes, types and features along with a continuous packaging format compatibility with high speed automation.