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The CS-1100 is an automatic MI cable straightening and cutting machine developed for companies that process mineral insulated (MI) cable for the production of temperature sensors, heating elements and other industrial sensor assemblies.
By combining MI cable straightening and cutting in one machine, the CS-1100 automates production steps that are traditionally skilled, labour-intensive and time-consuming.
Below you will find answers to frequently asked questions about the CS-1100, including supported MI cable diameters, heavy-wall cable, cutting accuracy, burr formation, cutting wheels, production automation, calibration, maintenance and technical support.
The CS-1100 is designed to process mineral insulated (MI) cable with outer diameters ranging from approximately 1 – 8 mm.
Within this range, the machine can straighten and cut a wide variety of MI cable constructions used for manufacturing thermocouples, RTDs, heating elements and other industrial sensor assemblies.
The achievable performance depends not only on the cable diameter, but also on factors such as:
If you are processing a special MI cable construction, TMF can advise on the most suitable machine configuration.
The CS-1100 is designed for companies that process mineral insulated cable for the production of temperature sensors and other industrial assemblies.
Typical applications include MI cable used for:
The CS-1100 combines straightening and cutting in one automated machine, reducing the amount of skilled manual work required during MI cable preparation.
The achievable performance depends on the specific cable construction, including its diameter, sheath material, wall thickness, stiffness, internal conductor configuration and MgO compaction.
The CS-1100 can process mineral insulated cable with different metallic sheath materials.
The sheath material is an important factor when determining the optimum straightening and cutting configuration. The achievable performance therefore depends not only on the cable diameter, but also on the complete MI cable construction.
Relevant factors include:
The selection of the correct cutting wheel can also depend on the sheath material and application.
For special sheath materials or less common MI cable constructions, TMF can advise on the most suitable machine configuration and cutting wheel.
Yes.
The CS-1100 can also process heavy-wall mineral insulated cable. Because these cables are considerably stiffer than standard MI cable, they require a different straightening configuration.
TMF has developed an adapted bushing configuration that provides additional support during the straightening process, allowing heavy-wall constructions to be processed with excellent repeatability.
A good example is MI cable with an HR-160 inner liner. This cladded-wall MI cable design significantly increases the rigidity of the cable, making manual straightening difficult and reducing the effectiveness of conventional straightening machines.
With the adapted straightening configuration, the CS-1100 is capable of processing these demanding cable constructions while maintaining a high-quality cut.
Mineral insulated cable is fundamentally different from ordinary solid wire.
An MI cable consists of:
This construction makes the cable extremely strong and temperature resistant, but also considerably more difficult to process.
Conventional wire cutters are generally designed for solid metallic wire and cannot adequately account for the combination of sheath hardness and compacted MgO.
A dedicated MI cable cutting machine, such as the CS-1100, has been specifically engineered to:
The result is a more consistent production process with improved product quality and reduced manual labour.
Producing a clean, nearly burr-free cut on mineral insulated cable requires much more than simply selecting the right cutting wheel.
Several factors influence the final cutting quality, including:
One of the most important features of the CS-1100 is its unique pneumatic clamping system, which securely holds the cable immediately before cutting.
This minimises cable movement during the cutting process and helps produce a clean, consistent and straight cut.
Selecting the correct cutting wheel is equally important. Depending on the sheath material and application, TMF recommends different wheel types, such as Green Carborundum or White Alundum, to achieve the optimum balance between cut quality and tool life.
Together, the machine design, pneumatic clamping system and correct cutting wheel selection allow manufacturers to significantly reduce burr formation and minimise the need for secondary finishing operations.
The optimum MI cable cutting wheel depends on the production priorities, MI cable construction and desired balance between cut quality and tool life.
TMF offers two cutting wheels that have been specifically selected and tested for use with the CS-1100.
The Green Carborundum cutting wheel is recommended when achieving the highest possible cutting quality is the primary objective.
Its fine abrasive structure produces exceptionally clean cuts with minimal burr formation, reducing or even eliminating the need for secondary finishing operations.
This makes it particularly suitable for manufacturers where cut quality has a direct impact on downstream production processes.
Typical advantages:
Because of its focus on cutting quality, the Green Carborundum wheel has a typical service life of approximately 140–180 cuts on 3 mm MI cable, depending on the cable construction and operating conditions.
The White Alundum cutting wheel is recommended when longer cutting wheel life is more important than achieving the absolute best surface finish.
Although it produces slightly larger burrs than the Green Carborundum wheel, these burrs can generally be removed easily and do not affect subsequent manufacturing processes.
In return, the cutting wheel offers significantly higher durability.
Typical advantages:
Under comparable conditions with 3 mm MI cable, the White Alundum wheel typically achieves 400–500 cuts.
| Priority | Recommended cutting wheel |
|---|---|
| Highest cut quality and minimal burrs | Green Carborundum (GC-320R-15005) |
| Longest wheel life and lower consumable cost | White Alundum (WA-100R-15005) |
If you are unsure which cutting wheel is best for your application, TMF can recommend the most suitable option based on your MI cable construction, sheath material, production volume and quality requirements.
The CS-1100 has been developed for highly repeatable MI cable preparation.
Depending on the cable type, cut length and machine configuration, the machine can achieve cutting accuracy of up to ±0.2%.
Accurate length control is achieved through the combination of:
This repeatability helps manufacturers reduce variation between production batches and improves the consistency of downstream assembly operations.
The CS-1100 software provides the operator with the option to add multiple production jobs to a queue.
This allows the machine to automatically move from one job to the next once the current job has been completed, reducing the need for manual intervention and increasing production efficiency.
For example, it is possible to move automatically from:
The production queue is managed through the CS-1100’s easy-to-use touchscreen interface.
Yes.
The CS-1100 allows operators to perform length calibration themselves.
This enables manufacturers to verify and fine-tune the cutting length without requiring a TMF service engineer on site.
Yes.
The CS-1100 can operate independently as an automatic MI cable straightening and cutting machine, but it can also be integrated into larger production concepts involving additional automation equipment.
This provides manufacturers with the possibility to further automate the handling of MI cable after the straightening and cutting process.
Yes.
The CS-1100 includes an Ethernet communication port that enables communication with future TMF automation equipment.
A practical example is the TMF Sorting Carousel.
After the CS-1100 has cut a cable, it can send a signal to the Sorting Carousel. The carousel then automatically indexes to the next position before the following cable is produced.
This synchronisation allows continuous automated production without manual handling between the machines.
As TMF expands its automation portfolio, additional equipment can be integrated using the same communication platform.
TMF offers additional equipment that can make working with the CS-1100 easier and further improve the production process.
The spool holder holds the MI cable spool in position, allowing the CS-1100 to smoothly pull the cable through during the cutting and straightening process.
The TMF spool holder is designed to work together with the machine and helps minimise problems such as tangling or snarling of the cable.
The product collector is used to neatly collect and organise the straightened and cut MI cable, making the finished pieces easier to handle and transport.
The TMF Sorting Carousel can communicate with the CS-1100. After a cable has been cut, the CS-1100 can send a signal to the carousel so that it automatically indexes to the next position before the following cable is produced.
| Specification | CS-1100 |
|---|---|
| Machine dimensions | 1100 (L) × 600 (W) × 1433 (H) mm |
| Supported cable diameter | 1–8 mm |
| Weight | 300 kg |
| Straightener | Rotary straightener |
| Cable feeder | 2 × rubber timing belts |
| Cutting | Special ceramic cutting disc |
| Extraction unit | External |
| Machine control | Touchscreen LCD |
| Power voltage | 230 V, 50 Hz |
| Communication port | Ethernet |
| Safety certification | CE |
The CS-1100 is suitable for most manufacturing facilities.
The machine requires:
The CS-1100 is not suitable for outdoor use and should be kept away from rain and moisture.
The CS-1100 is based on a standardised machine platform and TMF does not support general customisation requests. The focus is on continuously improving and expanding the complete CS machine range.
For specific MI cable constructions, however, the appropriate machine configuration can be selected where available.
For example, TMF has developed an adapted bushing configuration for heavy-wall MI cable, providing additional support during the straightening process.
Customers processing special MI cable constructions can contact TMF to discuss the available machine configuration.
Yes.
The CS-1100 supports remote diagnostics and technical support, allowing TMF engineers to assist customers without the need for an immediate on-site visit.
Depending on the situation, remote support may include:
Remote service helps minimise production downtime and allows many technical questions to be resolved quickly.
Customers who purchase the CS-1100 can sign up for a service contract, which is available in the Netherlands, Belgium and Germany.
Customers without a service contract or outside the service region can contact TMF for advice regarding their support requirements.
The service contract can include:
Specific coverage is subject to the applicable service contract terms and conditions.
The CS-1100 service contract provides additional technical support and maintenance benefits.
Priority technical support
Customers with a service contract have priority access to technical support, including a response within one working day and guaranteed resolution of problems following problem definition.
Emergency repair services
The service contract includes emergency repair services with a guaranteed response time.
Extended warranty
The service contract includes extended warranty coverage of one year beyond the standard manufacturer’s warranty.
Remote equipment monitoring and diagnostics
TMF technicians can remotely monitor the machine, identify potential issues and diagnose problems.
Discount on replacement parts
Replacement parts such as bushings and cutting discs are available at a 30% discount. Cutting discs can also be returned to TMF for a deposit.
Software updates
Customers with a service contract receive free recurring software updates.
The exact coverage and applicable limitations are specified in TMF’s terms and conditions.
Regular maintenance guidelines can be found in the CS-1100 user manual.
The machine should only be serviced and repaired by qualified and skilled personnel using original parts.
The CS-1100 software is programmed to provide a timely warning when components such as the cutting disc or bushings of the rotary straightener need to be replaced.
This helps ensure that maintenance is performed at the appropriate time, minimising the risk of poor performance, machine downtime or damage.
Yes.
The CS-1100 software is designed to detect machine malfunctions and alert the operator using flashing lights and on-screen warnings.
The software also allows the operator to save operating information in log files, providing a useful reference for troubleshooting and maintenance.
Some components of the CS-1100 are wear parts and need to be replaced periodically.
These include:
A spare-parts price list is available on request.
The CS-1100 is constructed according to a modular design, making maintenance and replacement of worn parts easier. Parts can be changed by the customer’s own staff in accordance with the instructions provided in the user manual.
First consult the Error List in the CS-1100 user manual.
If the issue persists, contact the TMF technical support team for further assistance.
Remote diagnostics may also be used to help identify and resolve technical problems.
The CS-1100 is primarily intended for sale.
TMF can, however, offer lease agreements for companies that prefer to lease equipment for their production facilities.
The CS-1100 comes with a one-year warranty.
Extended warranty coverage is available when a customer chooses a service contract. The service contract includes one additional year of warranty coverage beyond the standard manufacturer’s warranty.
Please refer to TMF’s applicable terms and conditions for further details.
Several resources are available for companies evaluating or operating the CS-1100. View them on our downloads page. The user manual is supplied upon request.
For additional questions about MI cable cutting, MI cable straightening, cutting wheel selection or the suitability of a specific MI cable construction, contact TMF for technical advice.
