XB-100 grooving and crimping machine for thermocouple, RTD and PT100 probe assembly with hermetic sealing. Built for precision and durability.
The XB-100 is a high-precision electro-pneumatic crimping and grooving machine designed to handle tubes, capillaries, and metal sheaths with outer diameters ranging from 2 mm to 10 mm. Its operational principle is based on the controlled and symmetrical application of circumferential pressure (grooving effect) using high-alloy interchangeable molds. This controlled plastic deformation securely fastens internal platinum resistance elements (in the case of PT100 sensors) or insulating gaskets, creating a flawless internal mechanical lock that prevents axial displacement and provides a solid foundation for subsequent airtight sealing.
The XB-100 Industrial Grooving and Crimping Machine represents a cutting-edge technological engineering solution specifically developed to optimize assembly, forming, and sealing processes in the manufacturing of temperature probes and sensors, such as thermocouples, RTD elements, and PT100 probes. Within the highly competitive market of industrial instrumentation and thermal process control, mechanical integrity and hermetic sealing are decisive factors that dictate the lifespan, metrological accuracy, and operational resistance of the sensor against severe environmental conditions, vibrations, and extreme pressures.
On a broader level, the XB-100 positions itself as the core pre-treatment and mechanical assembly unit within production lines for industrial heating elements. Temperature sensor manufacturers constantly face the challenge of achieving stable mechanical joints without compromising electrical continuity or fracturing internal mineral insulation. The XB-100 solves this dilemma through its balanced combination of electrical power (130W) and pneumatic assistance, offering a repeatable, high-speed working environment. Its compact and ergonomic design allows for seamless integration into specialized workstations, making it an indispensable tool for prototyping workshops as well as mass-production plants for instrumentation and raw materials for heating elements.
The quality of an RTD or PT100 temperature sensor depends not only on the purity of its platinum resistance, but fundamentally on how it is housed and protected in its working environment. Poor mechanical retention in the cable transition zone causes premature fatigue from vibration and moisture ingress, ruining instrument calibration. The XB-100 ensures that each sheath possesses the exact geometry to withstand the rigors of severe industrial processes.
The operational workflow of the XB-100 has been conceptualized under strict criteria of industrial ergonomics and safety to minimize operator fatigue and maximize line OEE (Overall Equipment Effectiveness). The procedure is divided into six clearly structured phases:
1.Tooling Selection and Installation: The technician selects the set of cylindrical molds corresponding to the exact tube diameter (within the 2 mm to 10 mm range) and secures them onto the crimping head using the supplied tool kit.
2.Auxiliary Services Supply: The single-phase 220V AC electrical grid connection is verified, and the compressed air line is attached via the standard 8 mm flexible tube, adjusting the pneumatic pressure regulator according to the hardness of the material being processed.
3.Part Positioning: The operator manually inserts the metal sheath (already containing the sensor element or filling material) into the working cavity, relying on adjustable depth stops to ensure millimetric location of the groove.
4.Automated Crimping Cycle: By applying slight pressure to the foot switch, the pneumatic system actuates the compression jaws. The complete grooving and forming cycle is executed within an interval of 2 to 4 seconds.
5.Release and Dimensional Control: Upon releasing the pedal, the jaws automatically return to their open position, allowing the processed part to be extracted smoothly and without residual friction.
6.Inspection and Link to Subsequent Processing: The grooved part is mechanically prepared to receive sealing welds, epoxy resins, or to be directly assembled inside our thermowells and protection tubes, ensuring a robust, gap-free coupling.
•Extreme Speed and Productivity: With a cycle time of 2 to 4 seconds per piece, the XB-100 triples the speed of traditional manual pressing methods, dramatically increasing daily production volume.
•Multi-Material Metallurgical Versatility: Its floating jaw design and uniform force distribution allow for processing a wide variety of tubes, including stainless steel (grades 304/316), copper, brass, aluminum, and rigid technical plastic tubes.
•Guaranteed Tightness and Hermeticity: The generated groove profile prevents leaks of pressurized gases or liquids once final sealing is complete, complying with standards required in the chemical and pharmaceutical industries.
•Comprehensive Ergonomic Safety: The use of the foot switch leaves the operator's hands completely free to hold and guide the tube, eliminating entrapment risks and improving working posture.
•Low Operating Cost and Predictive Maintenance: By dispensing with complex hydraulic systems and high-pressure pumps, the machine drastically reduces corrective maintenance needs, utilizing high-durability standard pneumatic components.
To facilitate engineering evaluation and floor space planning, the normalized technical parameters of the XB-100 are detailed below:
|
Technical Parameter |
Commercial / Industrial Specification |
|
Equipment Model |
XB-100 (High-Precision Industrial Series) |
|
Supply Voltage |
220V AC (Single-phase, 50/60 Hz) |
|
Rated Motor Power |
130W |
|
Pneumatic System Requirement |
Requires external regulated compressed air source |
|
Pneumatic Connection Diameter |
8 mm polyurethane flexible tube |
|
Physical Dimensions (L x W x H) |
470 mm x 450 mm x 450 mm (47 x 45 x 45 cm) |
|
Equipment Net Weight |
32 kg (Cast iron and reinforced steel structure) |
|
Tube Diameter Range |
2 mm to 10 mm (Adjustable via molds) |
|
Working Speed / Cycle |
2 to 4 seconds per processed piece |
|
Material Compatibility |
Stainless steel, copper, aluminum, iron, and rigid plastics |
|
Included Factory Accessories |
Control foot switch, power cord, tool set, and diameter dies/molds |
The open architecture of the XB-100 allows the equipment to be tailored to highly specific industrial requirements through various customization options:
•Custom Mold Design: Dies with special grooving profiles (custom depths, double grooves, or helical striations) can be manufactured according to customer blueprint specifications.
•Production Line Synchronization: The machine can be integrated into modular workstations alongside the XB-90 MI Cable Precision Drilling Machine, achieving a continuous flow from mineral cable preparation to terminal crimping.
•Advanced Pneumatic Control Systems: Optional incorporation of digital pressure regulators with feedback sensors to ensure identical clamping force on sensitive materials.
It is recommended to perform weekly cleaning of the crimping molds to remove metal residues or chips, as well as to periodically check the condition of the air filter and the lubrication of moving linear guides.
