CROWN

User Manual
Automati c Terminal Cross Secti on
Testi n g Mach in e Mo d el: WL- S E 4
1 Use of this manual

Scope of application:
This manual applies to SE4 fully automatic terminal cross section
analyzer User:
The technician or the delegated service personnel can use the
instructions to Carry out the following work:
Cutting and grinding machine operation
Analyzer and software operation
Daily maintenance and maintenance of the instrument
The meaning of the symbols used in this manual:
Hazard signs indicate that in a dangerous situation, if not avoided, it will
result in fatal or very serious injury.
Warning signs indicate that in the event of a possible hazard, if not
avoided, it may result in fatal or very serious injury.
Attention signs indicate that if not avoided, there may be some loss or damage.

This manual is an important part of the analytical instrument. Users are advised to
read this manual carefully to use and fully utilize the functions of this
instrument. Keep the instructions in a safe place after reading it each time.
2 Overview
2.1 Main feature
SE4 fully automatic terminal cross-section analyzer (Hereinafter referred to as
instrument ) , is a new auto terminal section analyzer, terminal crimp analysis
instrument. Compared with traditional analytical instruments, the
instrument has the following features:
1.Long-life service with imported German core inspection components. O
2. Newly terminal crimping condition rapid analysis technology.
3.Cutting and grinding are integrated in one space technology, making the
terminal cutting and the direction of the grinding surface consistent.
4.Effectively save operating time.
5.Japan Misumi high-precision ball screw drive technology effectively
guarantees the accuracy of the cutting surface.
6.Japan Misumi high-precision Z fine-tuning grinding technology enables
grinding accuracy of 0.01 mm.
7.Germany imported ultra-thin cutting blade technology, which overcomes
the defects of traditional tool cutting and deformation of terminals.
8.High measurement accuracy, good stability and strong anti-interference
ability.
9.Easy to use and maintain.
10.Speed data acquisition system, so that the instrument can achieve the
corresponding rotating speed of the different diameter terminals.
2.2 Specifications
1Compact and easy to carry, easy to operate
2 Fully automatic cutting and grinding module
3Special fixture module with automatic trimming terminal (fine-tuning)
4 1maging system: Japan HD digital USB 5 million industrial CCD
5Cutting sheet specifications: 0105X0.5mm.
6Wire range: 0.01mm2-50mm2 (Large cutting range can be customized).
7Motor: brushless motor, low energy consumption and high conversion
rate.
8Control mode and motor speed: independent control with dual motors.
9Transmission mode: using MISUMI ultra-high precision ball screw

2.3 Instrument function

Terminal section analyzer is a detection type instrument. This wire
harness terminal section analyzer is a precision inspection and analysis
equipment specially developed for wire harness terminal products. The whole set
of analyzer consists of terminal cutting, grinding integrated system, corrosion
cleaning, section image acquisition system, wire harness terminal picture
measurement and analysis system and other units. The instrument has professional
terminal fixtures, which can meet different types of terminals. The inspection
personnel can complete the processing analysis of a wire harness terminal section
within 3 to 5 minutes, which greatly improves the speed of wire harness
terminal section detection. Easy operation, high quality image acquisition
system, accurate measurement analysis to protect your production.
2.4 Use introduction
Wire harness cross-section analyzer integrated terminal cutting and grinding
table: After the terminal is clamped by a special wire harness clamp, the cutting
disk and the grinding disk are independently controlled, and the speed can be
conveniently controlled. (Because the terminal cutting of different AWGs requires
different speeds to achieve a more perfect cutting, the grinding process also
requires a corresponding speed depending on the size of the terminals. Our
integrated machine is independently controlled by dual-control inverter technology,
using German dual motor) The cutting speed is required to control the rotation
speed according to the material and size of the terminal when grinding and
polishing the terminal section. In the grinding and polishing, the rail structure can
be finely adjusted up and down, which can accurately control the height of the
terminal for customers. The time required for terminal cutting and polishing is 2 to 3
minutes. Extremely thin wires beyond the AWG36 can also be clearly
displayed. With the newly developed software for cross-section evaluation, CH
and CW can be measured, and the cross-sectional area can be calculated
instantaneously. The measurement accuracy at the maximum
magnification is 1 ̴ 2 µm.
 2.5 Working Principle (Wire Harness Terminal Cut and Grind)
The wire harness terminal is cut at a high speed by the cutting piece, so that the
center position of the wire harness and the terminal crimping portion is cut, and
the flat terminal section is obtained.
The wire harness terminal is ground to make the surface of the terminal
after cutting smoother and flatter.

3 Technical data

3.1 Cutting range

Range 0.01mm2-50mm2 ( Large cutting range can be customized)

3.2 Technical indicators

n Cutting. Grinding part:
1)Cutting section: 0.01mm2-50mm2 3) Cutting speed: 2800 rpm
2)Grinding speed: 0-2800 rpm 4) Metallographic sandpaper: 1000#
n Cleaning section:
1)Special wire harness terminal section cleaning fluid
2)Corrosion time: 5-10 second
n Terminal section analysis measurement software:
1)Terminal punching width: C/W 3) Terminal stamping height: C/H
2)Terminal burr angle, opening angle 4) Any planar geometry
(Point, line, circle, area, perimeter, angle, distance, arc, string,
etc.)
n Optical analysis section
1)Microscope: 0.7X-4.5X (Continuous fixed zoom lens)
2)Total video magnification: 16-500X
3)Zoom rati o: 6.5:1
4)Working distance: 100mm
5)Moving working distance: 250mm
6)Imaging system: 5 million Japanese HD CCD imaging system
7)Measurement accuracy: 0.001 mm
8)Illumination source: LED white cold light

3.3 Instrument use conditions

(1) Climatic conditions
Ambient temperature: 5°C—H-40°C
Relative humidity: —< 85% (non-condensing)
Atmospheric pressure: 80KPa-106KPa.
(2) Power Supply Condition
Voltage: 220V±22V.
 Power Frequency: 50Hz±1 Hz.

Note: The above parameters are subject to change without notice.

3.4 Power, dimension, and weight

(1) Power consumption: 600W

(4)Dimension: 457x329x385

(5)Weight: The net weight of the instrument is approximately 40Kg.

4 Overall structure of the instrument

4.1 Automatic interface

1. X-axis work advance O mm, - in the automatic operation, the movement

value change will be displayed
2.Y-axis work advance 0 mm In the automatic operation, the movement value
change will be displayed
3.Diameter selection - Select the appropriate range according to the width of the
terminal (this parameter is to select the cutting speed, and the speed is set in the
parameter setting interface)
4.Cutting switch Forward/Backward - In normal working conditions, the small
terminal don't need to turn on this switch, only turn on it for large terminals. It
need to forward the cutter a certain distance and then backward a certain
distance to prevent motor from overloading. (Forward and backward distance
can be set in parameter setting interface)
 5.Safety switch - When the acrylic protective cover is closed down, the
safety switch indicator will light up, and then you can press the start
switch to automatically run the machine
6.X-Origin - X-axis origin indicator
7.Reset - When the acrylic protective cover is closed, press the reset switch to
return the XY axis to the original position
8.Suspend - Press the pause button during automatic operation, the machine
stops all actions
9.Water pump/Remove dust - When cutting and grinding, press it, the water from
the faucet will cool down, and the vacuum cleaner will remove dust
10.Start - Press it, machine will automatically be cutting and grinding
11.Stop - Same function with Suspend
12.Single Grinding - Press it, machine will automatic grinding only
13.Single Cut - Press it, machine will automatic cutting only
14.Directi on arrows Press them, fixtures start to
move.

4.2 Manual Interface

Press
Manual
interface
can enter below manual operation interface
1)Grinding motor - When press Grinding motor, machine will grind terminal

manually (step by step mode)

2)Cutting motor - When press it, cutting motor will run.
PIs do not manual cutting!
3) The X and Y axes can move freely.
4.3Parameters setting

1. Cutting fast forward position ( ) Speed ( ) - During automatic

operation, the fixture (installed with terminal)follows the moving position
and speed of the cutting blade. Generally, when the cutting fast forward
position is set at the position 3mm from the left side of the cutting blade, fill
in X-axis coordinate data.
2. Slow cutting position ( ) - Fill in the X-axis coordinate data, that is, the
position where the terminal can be cut off.
3. Grinding fast forward position ( ) Speed ( ) - During automatic
operation, fixture (installed with terminal)is moved to a position 10mm
above the grinding disc near the right edge (and speed value at this time), fill
in X-axis coordinate data. After finishing terminal cutting, it need to
grind.Since there is height difference between cutter and grind disc, it will
take a while for terminal to contact grinding sandpaper. The tester has
already set well this space time out of factory, don't need to modify it when
setting parameter.
4. Slow grinding position ( ?Speed ( ) - During automatic grinding, fixture
(installed with terminal) is moved to center of grinding disc. When it reach
the final position and show it's speed, fill in X-axis coordinate data.
5. Grinding fast down distance ( ) Speed ( ) - When it reach the grinding
fast forward position, fixture (installed with terminal)is moved down quickly,
it will show in-time distance and speed data.
 6. Grinding slow down distance ) Speed (. ) - When it reach the grinding
fast down distance, fixture (installed with terminal)is moved down slowly, it
will show in-time distance and speed data.
7.Terminal diameter selection 0-2.5 O - Fill in terminal cutting speed (high speed)
according to terminal width
8.Terminal diameter selection 2.6-5 ) - Fill in terminal cutting speed (middle
speed) according to terminal width
9.Terminal diameter selection 5.1-10 ) - Fill in terminal cutting speed (low speed)
according to terminal width
10.1 0) Terminal diameter selection above 10 t Fill in terminal cutting speed (very
low speed) according to terminal width
11.Y-axis jog speed (manual) - Running speed set at Y-axis manual speed
12.X-axis jog speed (manual), Running speed set at X-axis manual speed
13.Left position of origin, X-axis move to this position first when reset
14.Speed back to origin, Speed when parts return to original position
15.Cutting slow (forward) distance, Distance for single time cutter feed forward
during cutting, after reaching, it will go backward. (Valid when turn on cutting
switch forward/backward in first page)
16.Cutting slow backward distance, Distance for single time cutter feed forward
during cutting, after reaching, it will go forward (Valid when turn on cutting
switch forward/backward in first page)

4.4IO Monitoring
I/O Input and output monitor screen
 4.5 Language
Chinese/English and Korean available to choose

The above is the function description of each button. When the

device is out of factory, a set of parameters has been set well. This
parameter is taken as a reference point in the actual operation, to modify
parameters based on it. The classification number can be saved as a table
form to facilitate the actual operation. When setting the parameters;
please carefully check the written values to avoid unnecessary troubles.
After a period of operation, you will feel the machine is more convenient
to use.
Tips for processing procedure
1)Take a test terminal and place it into the special clamper.
2)Use a ruler to measure the distance from terminal to cutter edge of
collecting testing sample.
3)Insert the fixture into the fixed mounting bracket. Press "UP" function
to move the fixture to the scale according to the pointer on the right
side of the bracket.
4)Close the protective cover.
5)Press the "Start" button to enter the automatic cutting and grinding
progress. After the program is finished, the fixed bracket is fully retracted
to the origin.
6)In the normal state, the small terminal adopts the move straight
cutting mode (turn off cutting switch forward/backward). If it is a large
terminal, it needs to adopt the advance and retreat feed mode (turn on
cutting switch forward/backward).
4.6 Power Supply
The instrument's power cable has a CE standard power plug on one end
and a 3A/250V power plug on the other end with a secure contact. The
power socket of the instrument is the power filter.
Caution! The phase, medium and ground of the power supply
should be connected to the power supply as specified. Power supply
voltage: 220V ± 22V, power supply frequency: 50Hz ± 1 Hz.

4.7 Circuit

Electrical box of these series analyzers equips with switchboard control

circuits, transformer circuits, etc. The internal circuit connections are
shown below:
The instrument case cover is affixed with fragile stickers, the user must not
open it without authorization, and the warranty is invalid if it is torn.

5 Installation and wiring connecting

5. 1 Installation location selection and instrument installation

5.1.1 Installation location selection

Reasonable and correct choice of installation location is very

important for the use of the instrument, so the installation location
must meet the following principles:
A The installation location of the instrument must be surrounded by
an office or test room without vibration and keep sure environmental
stability.
B Avoid direct exposure of the instrument to sunlight, boiler fires, or
other strong radiation.
C The positi on of the power socket must be considered next
to the installation location of the instrument, which is conducive to the
connection of the power line and the space for the operator to operate
the instrument.

5.1.2 Instrument installation

The embedded installation form is generally used when the instrument is

installed in the control cabinet. The thickness of the iron plate on the side of
the control cabinet installation instrument is not less than 4mm
 1)Place the device on a work surface with a bearing capacity greater than
100KG.
2)Connect the plug end of the power cable to the 220V AC power socket
or if the wall socket is too far away, you can connect another multi-port socket
to the work surface (the total power of the machine is 400W total).
3)After connecting, check to make sure that no plug is loose and you can
use it after booting.

5.2 Power cable connection

Power cable connection

There is a power outlet on the back of the instrument that removes the
power cable from the accessory bag and plugs directly into the power outlet.
The power supply should use three-phase system of phase, medium and
ground. The grounding wire should not be missed and must be grounded
reliably.
The grounding wire must not be missed, and it must be grounded reliably to
the earth. Grounding resistance<4 Ω.

5.3 Complete measuring device

This manual mainly introduces the structure principle and installation and
use of the instrument. Does not include optical analysis and measurement
system systems other than instruments.

6 Instrument start-up

6.1 Preparation before start-up

Before the instrument is officially powered on and connected to the power
supply, the following steps must be taken to check the instrument once and
ensure that it is correct before it can be put into operation.
(1) Check the power connection
Check if the power connection is correct and the contacts are loose.

6.2 Instrument start-up

Turn on the power to start the instrument and put it into operation. The speed
display shows the speed rotation value.
Wire harness terminal section analysis instrument operation procedure
Select the cutting part: crimping area 1/3

Fixed to a professional" terminal fixture damper

Adjust the height for horizontal cutting

Horizontal grinding and polishing

Mapped to the computer via software and clearly etched

Conducting measurement and analysis of terminals with clear

corrosion

7. Maintenance

During the normal operation of the instrument, ensuring the normal working
conditions of the instrument is the key to using the instrument. For the instrument
itself, you should also pay attention to the following routine maintenance work:
(1)The instrument is cleaned and maintained in the working chamber every
time interval. After the operation, the ball screw can be used for fuel injection
and lubrication every month or longer.
Grinding sandpaper replacement method: gently lift the edge of the
adhesive sandpaper with a blade and gently pull it up. After cleaning the
surface with alcohol, replace it with new sandpaper.
Thin cutting blade replacement method: Unscrew the pressing shaft screw
counterclockwise, remove the upper mold, replace the mold with a new
cutting piece after the mold is cleaned, and gently buckle the upper mold, and
tighten the screw of the pressing shaft.
(2)If the motor spindle is connected to the mold, it should be checked
regularly for looseness. If it is loose, use an inner hexagonal wrench to tighten the
top screws.
8 Troubleshooting
8.1 Description

The instrument has undergone rigorous testing and inspection before

leaving the factory. In order to ensure the safety of the operation, the user
must operate the instrument under the premise of carefully reading the
instructions and instructions. In order to prevent accidents, please note the
following points:
(1)Ensure that the operating voltage specified by the instrument is
consistent with the external power supply voltage.
(2)When repairing or replacing parts, you must first power off the total
power of the instrument.
(3)When a live calibration or repair is required, it should be carried out by a
professional who is familiar with the dangers that may arise.
(4)After the power of the instrument is cut off, there may be electricity in the
capacitor in the instrument.
(5)Stop the instrument when it is considered that a danger may occur.
8.2 Failure analysis

The following operations that require the opening of the chassis are only
applicable to the maintenance personnel appointed by the manufacturer, or the
manufacturer's professional if the manufacturer agrees to use it.
The circuit board of the instrument is equipped with 220V voltage, to prevent
electric shock!
Do not carry out maintenance work with electricity!

Table 2 Fault judgment and processing method

No. Problem Judgment step Solution

Check if the main power is
Turn on the main power
on
Check if the fuse is blown Replace the spare fuse
The power-on
speed display Replace the connectionand
(1 )
does not light Is the monitor and make sure the connectionis
up motherboard connected secure
Display is broken Replace the display
Detector is broken Return to factory maintenance
9 Saving and guarantee period,
9.1 Save
The instrument must be placed in the following conditions:
(1) Ambient temperature: 0°C —45°C ;
(2) Relative humidity: .85` ) /0;
(3) No corrosive gas.

9.2 Warranty period

If the instrument fails to work properly due to the quality of the
instrument within 12 months from the date of manufacture, the manufacturer
is responsible for free repair or replacement of parts (except for
consumables like cutters/sandpaper/liquid/cotton swab etc.).