The AST-ZIP600 is a high-performance automated wire harness processing system designed for automotive wire harness and connector manufacturing. It integrates wire cutting, stripping, crimping, seal insertion, and connector housing insertion into a single platform. The machine supports single-end and double-end crimping, single-end and double-end insertion, multi-wire insertion, and can be flexibly configured with up to 12 servo crimping presses and 6 seal insertion stations to meet diverse production requirements.Featuring advanced 3D terminal positioning technology, the AST-ZIP600 ensures precise terminal insertion with real-time insertion force and pull-back force monitoring. Combined with a Crimp Force Monitoring (CFM) system and multiple CCD vision inspection systems, it provides comprehensive quality control for stripping, crimping, terminal insertion, and seal assembly processes, ensuring consistent and reliable production quality.
With a cycle time of up to 3.2 ± 0.4 seconds per wire and a capacity of up to 100 wires (200 terminal insertions), the machine is equipped with MES connectivity, a KEYENCE control system, and high-performance linear motor technology, delivering an efficient, stable, and intelligent solution for automated wire harness production.