Lacon Electronic is your competent and reliable partner in electronics - especially when it comes to ensuring electronic transmission. As an EMS system service provider, we offer you customised solutions in the best quality craftsmanship, from individual wires to complex system cabling.
Thanks to our many years of experience as a cable assembler, we know exactly what is important when assembling a wide variety of cables - and what has delighted our customers for over four decades. See for yourself: We will be happy to advise you on your next project.
Our competences
- Comprehensive advice & planning - we optimise 97% of all projects!
- Component procurement and selection (design-in)
- Production of samples, pre-series - also series in individual quantities
- Cable and wire packages
- Customised logistics concepts
- Complete documentation in 2D and 3D
- Professional cable and device assembly and installation on site
- just-in-time or just-in-sequence delivery
Cutting to length, crimping, twisting, tinning, hotmelt moulding or assembly with different stranded wires - we implement your requirements using modern production techniques. In the field of cable assembly, we offer you proven complete solutions: from small quantities to large industrial series.
High-volume cable assembly
The "Alpha 356" crimping machine from Komax is a universally applicable fully automatic machine - perfect for your customised wire assembly.
The fully automatic machine processes more than 300 different crimp contacts and utilises over 200 available tools.
Technical data
- Length range: 60 mm - 65,000 mm (2.36 in. - 213 ft.), optional 30 - 60 mm (1.18 in. - 2.36 in.)
- Length accuracy (repeating): ± (0.2 % +1.0 mm (0.04 in.)
- Stripping lengths: 0.1 - 35 mm (0.004 in. - 1.38 in.)
- Stripping lengths with partial stripping: 47 mm (1.85 in.) on side 1.35 mm (1.38 in.) on side 2, optionally up to 80 mm (3.15 in.)
- Cable cross-sections: 0.22 - 6.0 mm² (AWG 24 - AWG1 0), optionally from 0.13 mm² (AWG 26)
Services
- Cost- and time-saving high-volume cable assembly thanks to a 10-fold increase in speed with fully automatic machines (compared to the performance of a semi-automatic machine)
- 100% process reliability thanks to continuous crimp force monitoring
- Clear specification of the stranded wire intended for production
- Simple and user-friendly user interface
- Universal applicability thanks to wide performance range and many different assemblies
In robotics, energy supply systems are the pulsating lifelines. For this reason, we assemble customised, high-quality electronic components that literally breathe life into your robots - and ensure that your production processes run smoothly.
Experience the difference with Lacon energy supply systems on and in the robot - and benefit from our proven after-sales services.
Our industrial quality management system has been successfully in use for decades - our testing standards go far beyond the minimum. We have developed our own testing equipment to regularly monitor these high quality requirements. This means you can always plan a project with us with confidence.
As you can see: Your trust is important to us. And that's not just an empty phrase, but a lived reality: from over 40 years of experience, we know that the scope and quality of test standards for customisation is a decisive factor. This is why we attach particular importance to finding the best possible solutions for your individual requirements and orders.
- Crimp control via pull-off tests: In order to check batch production, we carry out random pull-off tests.
- Crimp geometry measurement: Cross-section imaging in our own cross-section imaging laboratory: We test crimp connections on a random basis using cross-section imaging. This involves checking parameters such as the number of strands, crimp height and width as well as the degree of compression and gas density.
- Continuity: All cable harnesses are tested for continuity before delivery.
- High-voltage and insulation test: We can carry out a 100 per cent test on request.
- Measuring points: Programmable cable systems with up to 4000 measuring points.
- Certifications and standards: DIN ISO EN 9001 & 14001 and TS 16949, DIN EN 60352-2, DIN EN 2242, IPC-A 620.
- Customer certifications: Texas Instruments, KnorrBremse, Deutsche Bahn, Siemens TS and many others have been confirming the proven Lacon quality for years.
- Traceability at your request: We track every batch down to the individual item with an individual test certificate.
At Lacon Electronic, we offer you a wide range of services: We label your electrical equipment with legible and permanently adhesive markings - guaranteeing you efficient and safe work processes.
We also mark your components, wires and cables with software-controlled, resistant materials - in all requirement profiles.
Functionality
A generator produces high-frequency alternating current and transmits it to an ultrasonic transducer, which generates a mechanical ultrasonic frequency from the alternating current. This frequency causes a sonotrode to resonate - like a kind of tuning fork. And this oscillation ultimately ensures that the necessary joining temperature level is reached, which is created between the components by molecular and interface friction. As a result, the strands are compacted in the welding chamber - by means of a sideshifter, spotting plate and anvil under a defined contact pressure. This protects the surrounding material, as only a small amount of heat is generated in the welding area.
For ultrasonic compaction to function smoothly, the starting material (strands) must fulfil specific requirements - these are carefully checked as part of a clearly defined qualification process.
Quality characteristics for insulation distance and strand knots are described in IPC-620.
- The conductor material must be bare, silver-plated or gold-plated. Alternatively, copper is also permitted, but not tinned conductors.
- Copper strands must be as free as possible from drawing oils and greases. Furthermore, they must not have any oxide or dirt layers (a pre-cleaning process may be necessary).
- A non-stick coated tool is required for aluminium conductors.
- The components to be processed must be matched to each other if they are not made of the same material (e.g. Cu / Al).
- The system parameters are defined as follows: Frequency, contact pressure, sonode amplitude.
Your advantages at a glance
- Durability: no wire end ferrules or crimp contacts
- No special pressing and crimping tools (one-off costs)
- No need to create micrographs and pull-off tests
- Miniaturisation of connection terminals - smaller diameter for the same cable cross-section
- New connection technologies in combination with hot-melt overmoulding (Y-pieces, taps)
- Cost reduction due to small number of purchased items
- Large cross-section range with one sonotrode
- Connection of different materials possible: e.g. copper and aluminium
There are no limits to your creativity.
Choose your favourite from over 5,000 variants.
That's why you can receive your order within 48 hours on request.
Conclusion
High-volume cable assembly
Lacon offers comprehensive services from consulting to documentation. With the fully automatic "Alpha 356" machine, Lacon enables high-volume cable assembly with high speed and process reliability. Lacon also offers energy supply systems, fibre optic technology, marking services and ultrasonic compaction for reliable connections. Quality assurance, customised markings and flexible solutions characterise Lacon Electronic.
- Stripping: Removal of the insulating sheath from electrical conductors (e.g. stranded wires) to enable connections to be made.
- Cutting to length: Shortening cables to the required length.
- High-voltage cabling: Tear-resistant, flexible and temperature-resistant cabling that enables hybrid and electric cars to be powered - can also be used in aviation and shipping.
- Overmoulding of connectors: Special process to optimise sealing and make the connection of cables and connectors more resistant.
- Hotmelt moulding: Plastic injection moulding process with low temperatures and the use of special granulates to overmould electronic assemblies.
- Low-pressure moulding: Process used to overmould and encapsulate electronic components - serves to protect against harmful environmental influences.
- Cable harnesses: manually produced individual cables bundled using cable ties, hoses or clamps.
- Processing of individual strands: fully or semi-automatic processing according to customer specifications in the required quantity.
- Processing of flat, round, fibre optic and coaxial cables: manual, fully or semi-automatic production of small quantities up to large series according to customer specifications - always using the latest production technologies.
- Cabling: laying and connecting cables, devices and systems.
- Fully and semi-automatic machines: Devices for processing customised stranded wires in large or small batches.
- Customised solutions: high-quality cable assemblies for reliable energy distribution - specially manufactured according to customer requirements.
- Crimping: Connection of a conductor to a special element by plastic deformation - to create an electrical connection.
- Ultrasonic welding: Strands stripped to a few millimetres are connected by heat generated by high-frequency vibrations.
- Spring-loaded connections: Clamping device for a detachable connection of cables based on a spring mechanism to permanently fix cables by self-locking and ensure electrical conductivity.
- Soldering: Joining process for connecting metals (e.g. stranded wires) by melting the metal alloy together - and thus creating an electrical connection.
- Insulation displacement connection and screw terminal technology: Process for the solderless connection of conductors that are connected by an insulation displacement or screw terminal.
- Plug connections: Device with various connection techniques for the simple connection and disconnection of electrical cables.
We offer the following options for labeling your cables according to individual specifications:
- Labels
- Label
- laser
- QR code
- Inkjet
- Cable printing
- Cable markers
- cable tester
- customized marking
Encoder cables are special cables that are used to transmit signals and data in plant and mechanical engineering.
Motor cables supply large industrial motors - so they have to withstand high voltages and stresses caused by heat, movement and acceleration.
Cable drag chains or energy guiding chains are chain links that encase cables. Thanks to their high flexibility, they supply permanently running machines with energy, among other things.
- Genuine metallic connection
- Low contact pressure required
- Particularly gentle - no melting of the materials
- Special process for cold pressure welding in accordance with DIN 8593-6, DIN 1910-11 and DIN 1910-100
- Frequency level of the oscillator system and the transmitted energy
- Contact pressure between sonotrode and anvil
- Amplitude of the horn
We are proud of the high quality standard we offer. To ensure that our customers benefit from our individual cable assemblies for a long time, we not only meet all current test specifications and standards, but also go far beyond them.
For you, this means that no component leaves production until it is guaranteed to function perfectly. We use tried and tested testing systems for this purpose. Our quality assurance includes
- Measurement: Pull-off force measurement
- Monitoring: pull-off monitoring, force-monitored machines and mechanical crimp monitoring
- Testing: electrical continuity, short-circuit and high-voltage testing, insulation and short-circuit testing as well as visual and mechanical testing
