Feature
● Force-Displacement Curve Comparison Against Stored Template
The EW-2565 captures the full force-displacement curve of every crimping cycle and compares it in real time against a stored reference (template) curve. Deviations in peak force, curve shape, or displacement at peak — indicating worn dies, incorrect terminal loading, or wire gauge mismatch — are detected immediately, before the defective crimp can proceed to the next production stage. This curve-comparison method identifies quality defects that pull-force testing alone cannot detect, since a crimp can pass a pull test while exhibiting an abnormal force profile that signals incipient tooling wear.
● Ethernet Communication with UDP Protocol for PLC/MES Integration
Unlike monitor systems that rely on USB networking for multi-unit data aggregation, the EW-2565 communicates over standard Ethernet using the UDP protocol — allowing direct integration into a factory's existing network infrastructure and PLC/MES quality data systems without a dedicated monitoring PC. This is the preferred configuration for automotive Tier 1 facilities consolidating crimp quality data into a centralised manufacturing execution system alongside other production line sensors.
● 5 Trigger Inputs with Automatic Press Disconnection on Fault
The EW-2565 provides 5 trigger inputs and an alarm reset function, with a result output signal that can be wired directly as the disconnection (foot pedal) signal input on a semi-automatic crimping press. When a crimp cycle falls outside the reference tolerance, the EW-2565 can automatically interrupt the press cycle — preventing the operator from producing a second defective crimp before the alarm is acknowledged. This closed-loop interlock function is a significant safety and quality advantage over monitor systems that only log defects without controlling the press.
● 1 or 2 Channel Configuration — EW-2565-1 / EW-2565-2
The EW-2565-1 monitors a single crimping station; the EW-2565-2 monitors two stations simultaneously from one unit — useful for double-head crimping machines or adjacent single-head presses sharing one monitoring and PLC integration point. Both configurations share identical communication, IO, and power specifications.
Application Range
Automotive Tier 1 PLC/MES-integrated quality control
Automotive harness manufacturers operating centralised manufacturing execution systems require crimp quality data to flow directly into the plant's existing network infrastructure for real-time OEE and defect tracking dashboards. The EW-2565's Ethernet/UDP communication integrates without a dedicated USB monitoring PC, fitting directly into IATF 16949-compliant production data architectures already built around standard industrial Ethernet protocols.
Semi-automatic press safety interlock applications
Bench crimping presses operated by foot pedal benefit from the EW-2565's disconnection signal output, which halts the press cycle automatically when a crimp falls outside the reference tolerance — preventing an operator from completing a second defective cycle before the fault is reviewed. This interlock function is specifically valuable on manually-fed semi-automatic presses where the operator's attention may be divided between wire positioning and quality monitoring.
Double-head crimping machine quality monitoring
Double-end terminal crimping machines that crimp both wire ends simultaneously require independent quality verification on each crimping station. The EW-2565-2 dual-channel configuration monitors both crimp heads from a single unit, providing per-channel curve comparison and fault detection without doubling the monitoring hardware.
Multi-press production floors with centralised data collection
Production floors running multiple crimping presses that report into a central quality database benefit from the EW-2565's network-based architecture, which scales more naturally with standard Ethernet infrastructure (switches, VLANs) than point-to-point USB connections when the press count grows beyond what a single monitoring PC can practically manage.
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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)