Intelligent optical strip, seal and crimp monitoring for digital inspection of the crimp quality

Operator-independent predefined quality

  • Minimal operator influences due to fixed parameters
  • All-embracing quality monitoring

Robust image capture in any environment

  • High-quality digital camera with dome illumination
  • Detailed photos with perfect illumination.
  • Intelligent control and evaluation

Fully integrated quality system

  • Integrated in Komax HMI control software
  • Complete traceability
  • Minimal changeover times thanks to predefined parameters

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With the Q1250 module, Komax has achieved a new dimension in optical quality monitoring. The intelligent and fully automatic system enables comprehensive monitoring of the crimping process. In a first step, the Q1250 checks every wire end for correct stripping and seal insertion before crimping. The Q1250 then carries out additional quality checks after the crimping process. Visual checking by the operator is largely eliminated. This means that the required quality features are checked automatically and comprehensively.

Innovative technology

An innovative image evaluation algorithm analyzes the high-resolution color image and reliably detects any crimped-on or protruding strands. Using intelligent color recognition, the system also checks whether any insulation is in the crimp and whether sufficient conductor brush length is available.

Full quality control

Initially, the strip quality and the seal insertion (where applicable) are checked as the swivel arm travels towards the crimping module. On the way back, the Q1250 checks the crimp quality within just fractions of a second. During this process, inspections are made for copper overhangs, crimped-on and protruding strands at each end of the wire. The Q1250 therefore provides full control of the production batch. The visual check of the parameterized quality features by the operator is eliminated. All quality features can be tracked and recorded.

Process overview


Cut Strip

Pulled strands

Strip recognition

Strip length

Wire splay

Missing strand (partial)

Partially stripped

Insulation burrs

Seal insertion

Seal position

Seal presence

Insulation in front of seal

Seal orientation

Pierced seal


Missing terminals

Crimped-on strands

Protruding strands

Distance from insulation to conductor crimp

Conductor brush length