Feature
● Software-Controlled Crimp Height — No Screw Adjustment Required
On conventional terminal crimping machines, the crimp height is adjusted by physically turning a mechanical screw in the applicator and measuring sample crimp height with a micrometer until the target dimension is achieved — a process requiring a skilled setup technician and 15–30 minutes per terminal changeover. On the EW-8075+L, crimp height is set directly in the machine program as a numerical value; the servo-controlled ram positions to the programmed crimp dimension automatically. This eliminates the mechanical adjustment step, reduces changeover time to a touchscreen entry, and removes the operator skill dependency from the setup process — a significant advantage on automotive harness lines with high terminal variety and frequent applicator changes.
● Integrated Crimp Force Monitoring on Every Cycle
The crimp force monitor (CFM) is integrated in the machine and checks every crimp cycle's force-displacement profile against the stored reference envelope during production. Crimps that fall outside the envelope — indicating worn tooling, incorrect wire gauge, or applicator misloading — trigger an immediate fault stop and alert before the defective wire can advance to the next station.
● FP2 RTX Real-Time Bus System for Production Line Integration
The EW-8075+L uses the FP2 RTX internet bus system — an industrial real-time communication architecture that integrates the machine's cutting, stripping, and crimping axes into a unified motion control network. This architecture provides deterministic cycle timing (no timing jitter between axes), enables MES/production management system integration via standard industrial protocols, and simplifies parameter synchronisation across the machine's multiple servo axes when wire specifications or batch parameters change.
● Optional Waterproof Seal Insertion — Single or Dual End
The machine supports an optional waterproof seal insertion module configurable for one or both wire ends, supporting the production of automotive connector assemblies requiring environmental sealing to IP67 or IP69K specifications — including door, engine bay, and exterior lighting connector assemblies. The seal is inserted before crimping in the same automated cycle, maintaining the machine's 4,500–5,000 pcs/h throughput with the seal option enabled.
Application Range
Automotive body harness and exterior lighting wiring
Body harness sub-assemblies — including door modules, exterior lighting, and power window actuator wiring — use AWG18–AWG14 / 0.75–2.5mm² wire with weather-seal connector assemblies at exterior mounting points. The EW-8075's 0.3–6mm² range, optional waterproof seal function, and 4,500–5,000 pcs/h throughput cover the wire variety and production volumes typical of body harness zone production in automotive Tier 1 facilities.
Engine management and powertrain harness production
Powertrain harnesses connect sensors, actuators, and ECU modules in the engine bay using wire gauges from AWG23 (sensor signal) to AWG9 (high-current feed) — the full range of the EW-8075+L. The software-controlled crimp height and integrated CFM address the zero-defect quality requirements of powertrain harness production, where a failed sensor connection causes immediate drivability issues and warranty costs.
EV battery management system (BMS) and auxiliary wiring
Battery management system wiring and auxiliary control harnesses in electric vehicles use AWG22–AWG18 signal wire and AWG14–AWG10 power feeds in the 0.3–6mm² range. The FP2 RTX bus system's MES integration capability supports the per-wire production traceability documentation increasingly required by EV OEMs for battery system component qualification.
ADAS sensor and camera harness sub-assembly
Advanced driver assistance system (ADAS) sub-harnesses use AWG22–AWG20 fine-gauge wire for camera, radar, and LiDAR sensor connections requiring seal-crimped connector assemblies at the sensor interface. The EW-8075+L's precision stripping tolerance (±0.002×L) and CFM-verified crimp quality meet the dimensional and electrical continuity requirements of ADAS harness qualification testing under automotive sensor supplier standards.
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Tell us your need by filling out the form below and we will contact you as soon as possible!.input_group label{ line-height:35px;} Interesting Products Name * Company Email * Tel/Mobile * Country Tell us your needs (as specific as possible)
Tell us your need by filling out the form below and we will contact you as soon as possible!.input_group label{ line-height:35px;} Interesting Products Name * Company Email * Tel/Mobile * Country Tell us your needs (as specific as possible)