Wire harnessing and processing with Rittal Automation Systems

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Cutting to length, stripping and crimping – the faster and more accurately you perform these routine tasks, the more efficient you become. Automated solutions for wire machining and processing are available to assist you. Accelerate your processes by up to 80% with fully automated wire assembly with the Wire Terminal WT. Investing in a crimping machine is financially worthwhile from just 90,000 crimping operations.
 
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Touch display

Integral touch display for data processing.

Label printer

Label printer for wire magazine identification.
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Wire storage

The modular, space-saving wire store and wire routing system for the Wire Terminal. Six wire drums are stored on each of the two levels in a space-saving design. Depending on the number of wires used, the fully automatic wire processing machine may be fitted with additional wire stores (central, left, right), each with space for 12 wire containers.
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24 or 36 wires

The Wire Terminal may be fitted with wire guides for 24 or 36 wires. Wires are fed in via a 24-/36-wire feed magazine which is horizontally adjustable and controlled via a servo-motor NC axis. Wires are held in a spring-assisted clamp which is pneumatically released during the wire feed process.
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Wire labelling and processing

To ensure optimum positioning of the origin/destination on the processed wires, the Wire Terminal may be fitted with marking systems in black, white or both. Multiple insulation stripping and crimping machines may also be integrated via an optional lift.
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Selection of wire magazines

The processed wires are sorted into their individual orders by the handling system in the removal unit, with up to 13 wire rails inserted in the removal magazine. A servomotor-controlled linear guide monitored by a limit switch positions the removal magazine horizontally on the rail.
Wire_storage

Wire storage

The modular, space-saving wire store and wire routing system for the Wire Terminal. Six wire drums are stored on each of the two levels in a space-saving design. Depending on the number of wires used, the fully automatic wire processing machine may be fitted with additional wire stores (central, left, right), each with space for 12 wire containers.

Touch display

Integral touch display for data processing.

Wire labelling and processing

To ensure optimum positioning of the origin/destination on the processed wires, the Wire Terminal may be fitted with marking systems in black, white or both. Multiple insulation stripping and crimping machines may also be integrated via an optional lift.

Label printer

Label printer for wire magazine identification.
Wire_terminal_draehte

24 or 36 wires

The Wire Terminal may be fitted with wire guides for 24 or 36 wires. Wires are fed in via a 24-/36-wire feed magazine which is horizontally adjustable and controlled via a servo-motor NC axis. Wires are held in a spring-assisted clamp which is pneumatically released during the wire feed process.
Wire_terminal_drahtmagazine

Selection of wire magazines

The processed wires are sorted into their individual orders by the handling system in the removal unit, with up to 13 wire rails inserted in the removal magazine. A servomotor-controlled linear guide monitored by a limit switch positions the removal magazine horizontally on the rail.
Wire_terminal-1 Wire terminal_mobil

Fully automated wire processing machine
Wire Terminal

The compact Wire Terminal 24 or 36 fully automated wire processing machine ensures efficient, cost-effective wire processing. Up to 36 different wires in cross-sections ranging from 0.5 mm² to 6 mm² may be processed fully automatically without retooling.

 

The optional print system prints the wires in black or white, then transfers them to downstream process stages via a controlled ordering system capable of accommodating up to 1300 processed wires.

 

All production data can be read and processed via suitable interfaces. Manual logging of wire lists is likewise possible.

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Note

Please talk to your Rittal sales consultant about a bespoke machine configuration.
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Benefits of the
Wire Terminal

  • Faster processes because of the fully automated wire processing with individual wire printing and order-picking

  • Fully interlinked, from the E-CAD tool through to the production processes

  • Wire processing that is 8 times faster

  • Consistently high quality

  • Investment amortisation period of 2.5 years from a minimum of 300 enclosures per annum

  • Assembled wires from the ordering system can be processed in the downstream enclosure wiring process stage with the “Smart Wiring” tool from Eplan
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Wire processing centres

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More and more workshops are turning to wire processing centres from Rittal, which combine accelerated processes with excellent repetition accuracy.

 

Discover our product portfolio and establish a competitive advantage.

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Manual tools

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Wire harnessing and processing in control engineering with machines, equipment and accessories from Rittal:

High-quality hand tools for professional industry and trade use.

These practical tools feature ergonomically styled handles for fatigue-free, non-slip working. Special tool-grade steel ensures a long service life and optimum protection against corrosion and means that it is really easy to crimp even cables with large cross-sections.

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Wire end ferrules

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Accessories for manual and semi-automatic cable processing:

 

Reap the benefits from our range of accessories and consumables,e.g. for collaring wire end ferrules with plastic, certified to CSA-US and UL of course.

 

Our accessories may be used for manual wire processing and with Rittal crimping machines. The wire end ferrules are available to DIN and Rittal colour codes, heat-resistant to 105 °C, and suitable for all standard cables and special ferrules (AWG).


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Length-cutting machine C8+

The C8+ length-cutting machine is sure to impress with its simple, reliable handling. Wires of up to 8 mm or 10 mm² diameter may be cut to an individually set length, for more efficient operating processes. This also guarantees excellent repetition accuracy thanks to the precise servo DC drive.

 

Cutting jobs can also be managed, documented and transmitted from your PC via a USB interface or via the CAE data interface (EPLAN Pro Panel). In this way, the C8+ length-cutting machine additionally supports the cable labelling and wiring of cables by displaying the relevant source/target code.

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Stripping machine S22

The electrically powered stripping machine S22 accurately and carefully strips the insulation from your wires. The stripping length can be easily controlled and adjusted accordingly.

 

The stripping machine also features a pre-integrated spare blade inside the enclosure. Other benefits include a running total counter and daily counter, which are easily read from the touch display.

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Crimping machine L8

The electro-pneumatic wire stripping and crimping centre L8 eliminates the need for tool changes. Linear adjustment of the blades and the high forces generated by the pneumatic crimping unit support the processing of standard cables as well as special ferrules.

 

Break even following investment in a crimping machine occurs after just 90,000 crimping operations!

 

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Crimping machine R8 E

Electrically powered wire stripping and crimping machine for taped wire end ferrules on a reel. The R8 E crimping machine is ideal for fast, meticulous processing of insulated wire end ferrules and standard PVC cables in cross-sections ranging from 0.5 – 2.5 mm² (AWG 20 – 14) with a crimping length of 8 mm.

 

For flexible use in the workshop all you need is a power connection.

 

Break even following investment in a crimping machine occurs after just 90,000 crimping operations!

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Crimping machine RC

The RC stripping and crimping machine can be used for processing crimping lengths of 10 mm.

 

The integral 5-way holder allows the RC crimping machine to process five different cross-sections without retooling. This eliminates downtime and the associated set-up costs. The integral daily unit counter provides a continuous overview of your project quantities.

 

Break even following investment in a crimping machine occurs after just 90,000 crimping operations!

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Screwdrivers

Rittal Automation Systems provide the finishing touches to the range, offering screwdrivers with and without insulation, bits and bit holders as precision-manufactured screwdrivers made from high-quality special tool-grade steel, and hex wrench sets with optimum hexagonal profiles and precise ball-head geometry.

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Pliers

Length-cutting, stripping, crimping and gripping tools:

Rittal Automation Systems offer solutions for processing ring terminals, wire end ferrules and crimp tab terminals and for stripping cables and wires, alongside cutting tools with long-term stable cutting performance and a variety of grippers, each with a suitable gripping surface.

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Hole punching tools

Hydraulic punches for punching round, square and rectangular cut-outs:

Rittal Automation Systems offers a comprehensive range. Choose between manual hydraulic punches with 90° angled and 360° rotating cylinder head, electric hydraulic punches with high-performance drive motors and ergonomically styled handles, and hydraulic punches in a practical set with hole punches.

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 Hole punching tool accessories

 

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Tool bags

Available as a practical set of selected Rittal hand tools, designed especially for electricians, or alternatively, you can put together your own selection.

The comfortable, high-quality shoulder bag may be used either as a tool bag or laptop case.

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Wire end ferrules

Our wire end ferrules are available with a plastic collar, certified to CSA-US and UL, available in DIN and Rittal colour codes, heat-resistant to 105 °C, and are suitable for use with all standard cables and special ferrules (AWG).

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RITTAL AUTOMATION SYSTEMS

MACHINING

The products from Rittal Automation Systems will help you to automate your processes and accelerate throughput times. All enclosures, from the smallest to the largest, can be machined.

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Our online Perforex ROI calculator lets you calculate your return on investment with the fully automated Perforex.

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RITTAL HAND TOOLS

All from a single source – Rittal offers a comprehensive range of hand-held tools for professional support with your work operations.

Made from top-quality materials, our tools are exceptionally durable and their ergonomic structure and soft-touch handle sets them apart.

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The tool adapts perfectly to your hand for fatigue-free working.
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Maximise your workflow

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AUTOMATE MACHINING

Fully automated milling or laser machining, plus machining of cable ducts and busbars. 

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MORE FLEXIBLE COMPONENT MOUNTING

Automatic manufacturing and component mounting of terminal strips.

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SYSTEMATIC WIRE PROCESSING

Efficient solutions for wire machining and processing.

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SIMPLIFIED WIRING

To bring about further process advances, Rittal Automation Systems are committed to the ongoing development of systems from pioneering wiring solutions, right through to full automation.

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EASIER HANDLING

Ergonomic, efficient handling systems for transport and lifting operations.

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PERFECTING THE HAND TOOL

High-quality hand tools for professional use in industry and trade.

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Rittal Automation Systems
Downloads

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The benefits of semi-automatic machines Easy cable and wire processing in enclosure manufacturing
Wire Terminal_Video_ EN
Wire Terminal Automated wire processing
secarex
Secarex AC18 - Cutting centre for cable trunking and support rails Precision cutting.
perforex bc
Perforex BC The machining centre for panels and enclosures enables hole-drilling, milling and thread-tapping.
perforex lc
Perforex LC The laser centre for three-dimensional machining of enclosures.
m vs m
Human versus machine The Perforex machine on trial. Who will win? Team people or team machine?
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Length-cutting machine C8+ Achieve more efficient work processes by cutting wires to individually set lengths.

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Got any questions? Please message us. We’ll be happy to answer all your queries about the Rittal Automation Systems.