Stripping in focus

From hand tools to automatic tools

Before making an electrical connection, conductors need to be stripped a process that varies depending on the type and characteristics of the conductor. Stripping conductors is challenging due to the variety of types and their unique characteristics, with high demands on reliability and efficiency. Stripping involves removing the insulation to a certain length, as determined by the geometry of the terminal or connector. In addition, it can include removing the outer sheath of multi-core cables. Ensuring a safe electrical connection means avoiding damage to the litz wires, single-core wires, or braided shields. The process must conform to DIN IEC 60352-2 standards, which specify the requirements for a perfect stripping result. Depending on which tool is used, clamping the conductor can lead to pressure points and thus to discoloration of the insulation.

To avoid damage to litz wires, the stripping process involves two steps: “cutting into” and “pulling off” the insulation. First, the insulation is cut to a clearance of about 0.1 mm to 0.3 mm from the wires. Then, the uncut area of the insulation is pulled off to complete the removal.

Non-adjustable hand tools

Stripping can be performed using hand or automatic tools. Hand tools are categorized into non-adjustable, adjustable, and automatically adjustable types. Non-adjustable tools, like the Wirefox-MP VDE multifunctional tool, are the simplest and can handle a wide range of conductor sizes (0.2 to 10 mm²), allowing quick processing of different conductors. However, these tools require practice for perfect results and are not suitable when high level of process reliability is needed due to their lack of adjustability.

Adjustable hand tools

Adjustable tools enhance process reliability and require minimal practice. Tools with a rotating blade, like the Wirefox-D 40, are suitable for sheath removal and stripping in cross-sections over 10 mm², ensuring a uniform incision depth. For smaller cross-sections, non-rotating cutting edges are used, increasing the pull-off proportion.

While tools like the Wirefox-D 40 have broad applications, specific tools like the Wirefox D-CX series are designed for multi-stage stripping of coaxial cables. These tools are selected based on the connector type to achieve the required stripping lengths. However, they are not ideal for frequent material changes due to the time needed to set them up.

Automatically adjustable hand tools

Automatically adjustable hand tools offer the combined benefits of non-adjustable and adjustable tools, providing fast material changes and high process reliability. They use different blade geometries for various applications: flat blades for PVC cables up to 10 mm², half-round blades for cross-sections up to 16 mm² to minimize force required, and V-blades for hard insulation materials like PTFE and soft rubber. Stripping lengths can be set with an adjustable stop, and blades can be easily replaced without tools, ensuring long service life.

Automatically adjustable hand tools are also available for special applications, such as stripping SAC cables, AS-Interface flat cables, and flat-ribbon cables. These tools are recommended wherever applicable due to their versatility and efficiency.

Manually adjustable automatic tools

In series production, where quantities and quality demands are high, hand tools are reaching their limits. No matter how ergonomic the hand tools are, fatigue is inevitable. This is where automatic tools, like the entry-level electric WF 1000 stripping device, become essential. Once parameters such as cross-section, stripping length, and pull-off length are set, this device can quickly process many conductors without causing fatigue. However, each material change still requires some time to adjust the stripping parameters. This machine is especially suitable for processing identical materials efficiently.

Automatically adjustable automatic tools

The new E.Fox S 10 automatic stripping device is optimal for production processes that require frequent material or parameter changes. Its electrical adjustment of stripping parameters allows for swift material changes. The device is user-friendly, featuring an intuitive touch display interface. Users can save and recall favorite stripping parameters using a barcode scanner, significantly boosting efficiency.

The E.Fox S 10 automatic stripping device reduces the potential for human error compared to manual settings. It can function as a stand-alone device or be integrated with the Clipx Wire assist worker assistance software via an Ethernet interface. This allows for consistent use of production data and reliable processing of large, multi-version orders. When combined with other automatic tools and printing systems controlled by the same software, an efficient and customized worker assistance system for wire preparation can be created.