Automatic Wire Crimping Machine for Automotive Wire Harness(0.3–6mm²)

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Model：Automatic Wire Crimping Machine for Automotive Wire Harness(0.3–6mm²)

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Model:EW-8075
Applicable  wire  range:0.3-6mm2  (AWG9-AWG23)
Cutting  length:60-99999mm
Stripping  length:0.1-18mm
Crimping  force:3.0Ton

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Model	EW-8075
Applicable wire range	0.3-6mm2 (AWG9-AWG23)
Cutting length	60-99999mm
Stripping length	0.1-18mm
Crimping force	3.0Ton
Crimping Stroke	30mm or 40mm stroke both available
Wire collection	2m-4m( Can be customized)
Feeding speed	Max. 8.0m/s
Productivity	4500~ 5000 pcs/hour (depend on wire cutting length)
Air pressure	0.5-0.7Mpa
Stripping/Cutting accuracy	士(0.002mm*Stripping Length/Cutting length)
Detection function	Non-wire, crimp detect, pressure(to be installed with press sensor)
Power supply	220V/110V/50HZ/60HZ
CFM	Optional
Weight	1100Kg 1800W
Dimension	350012001700mm

● 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, 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 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.

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. 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'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.

Q: What wire range and crimping force does the EW-8075 automatic wire crimping machine support?

A: The EW-8075 processes wire from 0.3mm² to 6mm² (AWG9–AWG23) with a crimping force of 3.0T (approximately 30KN). Stripping length is adjustable from 0.1 to 18mm, cutting length from 60mm to 99,999mm, and the machine accepts both 30mm and 40mm stroke OTP applicators — covering the full range of open-barrel terminal applicators used in automotive body, powertrain, and sensor harness production.

Q: What does "crimp height set in program directly" mean, and how does it differ from conventional machines?

A: On conventional terminal crimping machines, the crimp height is adjusted mechanically by turning a screw in the applicator until sample measurements confirm the correct dimension — a process requiring a technician and 15–30 minutes per changeover. On the EW-8075, crimp height is entered as a numerical value in the machine's program; the servo-controlled ram automatically positions to the programmed dimension without mechanical adjustment. This reduces applicator changeover time from 15–30 minutes to under 2 minutes and removes the setup skill dependency that causes first-off crimp height variation on manually adjusted machines.

Q: Is the crimp force monitor (CFM) standard or optional on this machine?

A: The crimp force monitor is integrated in the EW-8075 and monitors every crimp cycle against the stored force envelope during production — it is a core function of the machine rather than a post-purchase add-on. An additional upgraded CFM module (with expanded data logging and reporting capability) is listed as optional for customers requiring enhanced quality documentation output beyond the standard cycle monitoring function. Contact Eastontech to clarify the specific CFM configuration included in your quotation.

Q: What production space and infrastructure does the EW-8075 require?

A: The machine measures 3,500×1,200×1,700mm and weighs 1,100kg — a dedicated production line station requiring planned floor space allocation, typically positioned at a fixed workstation in the harness sub-assembly area. Electrical requirement is AC220V or AC110V at 50/60Hz, 1,800W. Air supply is 0.5–0.7MPa. A wire collection zone of 2–4m (customisable) is integrated at the output end. Installation planning should account for applicator trolley access from the side and operator access at the front panel.

Model：Automatic Wire Crimping Machine for Automotive Wire Harness(0.3–6mm²)