Vertical Crimper (Dover/PCA)
Precision 6-Jaw Radial Swaging Machine for High-Voltage Composite Insulators
Executive Machine Overview
The Vertical Crimper (Dover/PCA) engineered by Probiters Exim LLP represents the pinnacle of special purpose machine manufacturing for industrial production lines. Built on a rigid vibration-damped frame and integrated with industry-standard controls (Siemens S7-1200 (CPU 1214C)), this machine delivers uncompromising accuracy, long-term mechanical reliability, and ultra-low maintenance overhead.
Core Machine Sub-Systems & Mechanical Modules
⚙️ 6-Jaw Synchronized Swaging Head
Tool-steel radial dies guided by ground master slides ensure uniform circumferential pressure without damaging composite rod fibers.
⚙️ Closed-Loop Hydraulic Power Pack
Variable displacement pump with proportional pressure valve and oil-chilled heat exchanger for zero force drift.
⚙️ Siemens S7-1200 Control Center
Integrated high-speed analog module recording load cell force vs LVDT displacement at 1,000 samples per second.
⚙️ Ergonomic Safety Guarding
Category-4 safety light curtain with dual palm anti-tie-down buttons and emergency stop latching circuits.
Comprehensive Parameter Matrix Table
| Engineering Parameter | Verified Specification / Design Basis |
|---|---|
| Crimp Force Range | 20 kN to 200 kN (Closed-loop load cell controlled) |
| Radial Swaging Jaws | 6-Jaw synchronized tool-steel dies with quick changeover |
| Crimp Depth Precision | ±0.02 mm linear displacement tracking |
| Insulator Fitting Size | Ø20 mm to Ø120 mm composite rod & end fittings |
| Hydraulic Unit | Zero-leakage manifold with 7.5 kW motor & oil cooler |
| Cycle Time | 18 seconds per crimped joint |
| Data Logging | Real-time force vs displacement curve logged per cycle |
| Safety Interlocks | Light curtains & dual palm anti-tie-down buttons |
| Control Platform | Siemens S7-1200 (CPU 1214C) |
| HMI Interface | Proface 7" Touch HMI |
| Pre-Dispatch FAT | 100% Pre-Dispatch Acceptance Testing & Calibration Sign-Off |
General Arrangement (GA) CAD Vector Blueprint
Visual 4-Step Process Sequence
Tooling Fixtures & Automation Integration Options
Standard Features Included
- Siemens/Mitsubishi Industrial PLC & Color Touch HMI
- Category-4 Safety Light Curtains & E-Stop Latches
- Automatic Centralized Lubrication Unit
- 100% Calibrated Pre-Dispatch FAT Verification
Optional Tooling & Automation Upgrades
- Automated Vibratory Bowl Feeder & Escaper Mechanism
- 3-Axis Cartesian Gantry Robot Loader Integration
- Laser/Camera Optical Part Inspection Verification
- OPC-UA MES Network Database Telemetry License
Customer Success & Verified Financial ROI
Low-cost competitor crimpers suffered hydraulic pressure drift, leading to 14.2% crimp joint slippage failures under 160 kN tensile loads.
Probiters 6-Jaw Synchronized Radial Swaging Cell featuring a rigid Meehanite frame, Siemens S7-1200 closed-loop feedback, and real-time graphing.
14.2% Reduced to 0.02%
The Probiters Quality & Support Promise
Need a formal technical proposal or 3D layout simulation? Our engineering design team in Ahmedabad prepares custom machine proposals within 3–5 working days.
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