The Schleuniger ACO 08 is a compact electronic crimp-force monitoring module designed for quality assurance in automated wire harness production. Integrating into Schleuniger benchtop crimping presses and compatible third-party machines, it captures and analyses the force-displacement signature of each crimp cycle to detect deviations caused by wrong terminals, missing wire strands, or tool wear — before defective assemblies reach downstream processes.

How does dual-channel synchronous monitoring improve quality assurance?

With two independent measurement channels, the ACO 08 can simultaneously monitor both crimps on a double-crimp terminal — a common requirement in automotive wire harness production where insulation and conductor crimps are applied in a single press stroke. Each channel supports 1–20 crimp references with up to 4 different references selectable in multireference mode, enabling a single unit to cover multiple terminal types and wire cross-sections on a production line. Triggering can be internal (force threshold) or external (digital signal), adapting to different press control architectures.

Which sensor technology should I use — piezo or strain gauge?

The ACO 08 accepts both piezo sensors (active or passive, installed in the crimp press base plate) and strain gauge sensors (DMS, frame-mounted). Piezo sensors offer higher sensitivity and faster response for small-cross-section crimping below 2.5 mm², where force signatures are subtle. Strain gauge sensors provide better long-term stability for larger terminals above 6 mm² and are less sensitive to thermal drift in high-volume continuous production. The user selects the sensor type during setup and the ACO 08 adapts its signal conditioning accordingly.

How does WinCrimp software extend the monitoring capabilities?

When networked via Ethernet with WinCrimp 8.0, the ACO 08 contributes crimp-force data alongside pull-tester and crimp-height measurement devices for unified process documentation. The TrendView function graphs the last 40 crimp results in real time, making gradual drift — such as tool wear or material batch variation — visible before it triggers a hard reject. Extended headroom studies and automated parameter setting reduce the engineering time required to establish process windows for new terminal-and-wire combinations.