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QualityCrimpingHandbook

OrderNo63800-0029 ReleaseDate:09-04-03 UNCONTROLLED COPY Page1of24

Revision:B RevisionDate:10-07-05

QUALITY CRIMPING

HANDBOOK

§Description

§Operation

§Maintenance

QualityCrimpHandbook

OrderNo63800-0029 ReleaseDate:09-04-03 UNCONTROLLED COPY Page2of24

Revision:B RevisionDate:10-07-05

Table of Contents

SECTION

1Introduction

2Purpose

3Scope

4Definitions

5AssociatedMaterials

6Procedure

7Measurement

8ProcessControl

9TroubleShooting

10 WireGaugeChart

11 Notes

QualityCrimpHandbook

OrderNo63800-0029 ReleaseDate:09-04-03 UNCONTROLLED COPY Page3of24

Revision:B RevisionDate:10-07-05

SECTION 1

INTRODUCTION TO CRIMP TECHNOLOGY

Developedtoreplacetheneedtosolderterminations,crimpingtechnologyprovidesahighqualityconnectionbetweenaterminal

andawireatarelativelylowappliedcost. Themethodsforapplying crimpterminations dependonthe applicationand volume,

andrangefrom hand-helddevicestofullyautomatedsystems.

Theapplicationmethodsincludeabasichandtool, apressanddieset,astripper crimper,orafullyautomaticwireprocessing

system. However,nomatter whatmethod isused,thesetupofeachtool iscritical forachieving aqualitycrimp.

Today,manyOEMcompaniesareusingStatisticalProcessControl(SPC)tocontinuouslyimprovetheircrimpterminations. Crimp

terminationisacomplexprocessandtoensureconsistentqualityitisnecessarytounderstandthevariabilityandinter-relational

interactionsthatthetechnologyinvolves.

Withoutathoroughunderstandingofthecrimpingprocess,andallthefactorsthatcanaffectit,theresultmaynot meet

expectations. Thethreekeyelementsinthecrimpingprocessaretheterminal,thewire,andthetooling.

Terminal

Formost applications,it is noteconomically practicalforconnector manufacturerstodesign aterminaltoaccept onewiresize,one

wirestranding, andone insulationdiameter (UL type). Mostterminals accommodatemany wire sizes,stranding, anda range of

insulationdiameters,andtheterminalsaredesignedtomeetacceptablelevelsoverthisentirerange.

Wire

Thewirestrandingandinsulationtypecanvarywidelywithinonewiresize. Forexample,thereismorethan18%morematerialin

an18AWGby19-strandwirethanan18AWGby16-strandwire. Theinsulation diameterof an18 AWGwire canrangefrom

1.78mm(070")toover 4.57mm(180"). Wire strandscan becopper, tinned,overcoated,ortop coated. Wireinsulation materials,

thickness,anddurometers varyfromapplicationtoapplication.

Tooling

Whattypeof toolingdoestheapplicationrequire? Doesthe application require handstripping of the wire ordoes the volume

dictateanautomaticwire-strippingmachine? Does theapplicationand volume requirehand tools, pressanddie, or fullyautomatic

wireprocessmachines? Crimping withamanualhandtool,semi-automatic pressanddie, orfully automaticwireprocessor, all

involvedifferentlevelsofvariability. Theterminal,wire,andtypeofapplicationtoolingallaffectthequalityofthecompleted

terminations.

QualityCrimpHandbook

OrderNo63800-0029 ReleaseDate:09-04-03 UNCONTROLLED COPY Page4of24

Revision:B RevisionDate:10-07-05

SECTION 2

PURPOSE

Thishandbookprovidesgeneralguidelinesand proceduresforunderstandingandachievingacceptablecrimpterminations. A

glossaryinSection4listscommontermsanddefinitions. Section4liststhetoolsthatarenecessarytotakeaccurate

measurementsand evaluatethe crimp'sacceptability.

Thetoolingsetupiscriticalindeterminingthe qualityof thefinished crimp. Theattributes thatneed tobe consideredinclude crimp

height,conductorbrush,bellmouth,andcut-offtaband striplength andinsulationposition. Variability inoneor moreof these

attributescanreducethemeasuredpullforce. Itcanbedifficulttoestablishacceptablevariabilitylimitsbecausetheattributesall

interactwithoneanother.

Forexample,atrackadjustmentforbellmouth alsowillchangethecut-offtablengthandtheinsulationwirepositionwhilestrip

lengthand wirelocationsaffect the conductorbrushand insulationposition. Adjustingthe insulation crimpheightmay resultina

slightchange to theconductor crimpheightmeasurement. Itmaybenecessaryforthe setuppersonto makemultipleadjustments

beforeestablishinganoptimalsetup.

Theorderthesetupisdonemayhelp reducethenumberofrepetitionsrequiredfor anoptimumsetup. Section6has a flowchart

foraprocesssetupwhileSection8isatrouble-shootingguideforcommonproblems. Using StatisticalProcessControl(SPC) during

thecrimping processcan help minimizethe Parts perMillion (PPM) rejectlevels. Section 7 providesa generalexplanation of the

benefitsofusingSPC.

Thishandbookisstructuredsothatparts,orall,ofitscontentscanbeusedasaproceduralguideforISOrequirements.

QualityCrimpHandbook

OrderNo63800-0029 ReleaseDate:09-04-03 UNCONTROLLED COPY Page5of24

Revision:B RevisionDate:10-07-05

SECTION 3

SCOPE

This handbook is intended for Molex customers who are crimping Molex open barrel crimp terminals and are

using Molex tooling, primarilyin semiautomaticorautomatic wireprocessingtermination methods.

Thehandbook's contentsmay slightly differfrom otherconnectormanufacturers' guidelinesorindividual companyprocedures.

Thishandbookprovidesabasicoverviewofwhattolookforinanacceptablecrimp.Itisnotintendedtoreplaceindividualproduct

and/ortoolingspecifications.

Individualterminals orapplications mayhave special requirements. Toolinglimitations alsomaynot permitanattribute tobe

adjustedtomeetoptimumrequirements.

QualityCrimpHandbook

OrderNo63800-0029 ReleaseDate:09-04-03 UNCONTROLLED COPY Page6of24

Revision:B RevisionDate:10-07-05

INSULATION

CRIMP

BRUSH

STRIP

LENGTH

BELL

MOUTH

CRIMP

HEIGHT

CONDUCTOR

CRIMP

CUT-OFF

TAB

SEAM

EXTRUSIONS

EXTRUSION EXTRUSION

TERMINAL CROSS-

SECTION VIEW

Figure 4-1

BEND

DOWN

BEND UP

ROLLING

TWISTING

SECTION 4

DEFINITIONS

Anatomy of a Crimp Termination (Figure 4-1)

§Bell Mouth (Flare)

Theflarethatis formedontheedgeoftheconductor

crimpactsasafunnelforthewirestrands. Thisfunnel

reducesthepossibilitythat asharpedge onthe

conductorcrimpwillcutornickthewirestrands.Asa

generalguideline, theconductor bell mouthneeds to be

approximately1to2timesthethicknessoftheterminal

material.*

§Bend Test

Onewaytotesttheinsulationcrimpis bybendingthe

wireseveraltimesandthenevaluatingthemovementof

theinsulationandwirestrands. Asarule,the insulation

crimpshouldwithstandthewirebeingbent 60 to 90

degrees in any direction, several times. Use care when

workingwithsmallwiresizessothewireatthebackof

theinsulation crimpdoes notshear.

§Conductor Brush

Theconductorbrushis madeup ofthe wirestrands that

extendpasttheconductorcrimpon thecontact sideof

theterminal. Thishelpsensurethatmechanical

compressionoccursoverthefulllengthoftheconductor

crimp. Theconductor brushshould notextend into the

contactarea.

§Conductor Crimp

Thisisthemetallurgical compression of a terminal around the

wire'sconductor. Thisconnectioncreates acommonelectrical

pathwithlowresistanceandhigh currentcarrying

capabilities.

§Conductor Crimp Height

Theconductorcrimpheightismeasured fromthetop surface

ofthe formed crimpto the bottom radialsurface. Do not

includethe extrusionpointsin thismeasurement,(See Figure

4-1). Measuringcrimpheightisaquick,non-destructiveway

tohelpensurethe correctmetallurgicalcompression ofa

terminalaround thewire'sconductor andisan excellent

attributeforprocesscontrol. The crimpheightspecificationis

typicallysetasabalancebetweenelectricalandmechanical

performanceoverthecomplete rangeofwire strandingand

coatings,andterminalmaterials and plating. Althoughitis

possibleto optimizea crimp heightto individual wire

strandingandterminalplating,onecrimp heightspecification

isnormallycreated.

*Consultindividualterminalspecificationrequirements

QualityCrimpHandbook

OrderNo63800-0029 ReleaseDate:09-04-03 UNCONTROLLED COPY Page7of24

Revision:B RevisionDate:10-07-05

Figure 4-2

§Cut-off Tab Length

Thismaterialprotrudesoutsidetheinsulationcrimpafter

theterminal is separated fromthecarrier strip. As a rule,

thecut-offtabisapproximately1.0to1.5timesterminal

materialthickness. * Acut-off tabthatistoolong may

exposeaterminaloutsidethehousingorit mayfail

electricalspacingrequirements.In mostsituations,a toolis

setuptoprovideacut-offtabthatisflushto onematerial

thickness.

§Extrusions (Flash)

Thesearethesmallflaresthatformonthebottomofthe

conductorcrimpresultingfromtheclearance betweenthe

punchandanviltooling.Iftheanviliswornortheterminal

isover-crimped,excessiveextrusionresults. Anuneven

extrusionmay alsoresult ifthe punch andanvil alignment

isnotcorrect,ifthefeedadjustmentisofforifthereis

insufficient/excessiveterminaldrag.

§Insulation Crimp (Strain Relief)

Thisisthepartoftheterminalthat providesbothwire

supportforinsertioninto thehousingand allowsthe

terminaltowithstandshockandvibration. Theterminal

needstoholdthewireasfirmlyaspossiblewithoutcutting

throughtotheconductorstrands. Theacceptabilityofan

insulationcrimpissubjectiveanddepends onthe

application. Abend testisrecommended todetermine

whetherornotthestrainreliefisacceptableforeach

particularapplication.

§Insulation Crimp Height

Molexdoes notspecify insulation crimpheights because of

thewidevarietyofinsulationthickness, material,and

hardness. Mostterminalsaredesignedtoaccommodate

multiplewire ranges. Withintheterminal’s range,the

strainreliefmaynot completelysurroundthewireorfully

surroundthediameterofthewire. Thisconditionwill still

provideanacceptable insulationcrimpformost

applications.

§Alargestrainrelief shouldfirmlygrip atleast88% of

thewire.

§Asmallerstrainreliefshouldfirmlygripat least50%of

thewireandfirmlyholdthetopofthewire.

Toevaluatetheinsulationcrimpsection,cutthewireflushwith

thebackoftheterminal. Oncethe optimum settingforthe

applicationisdetermined,itisimportanttodocumentthe

insulationcrimpheight. Then,as partof thesetup procedure,

theoperatorcancheckthecrimpheight.

§Insulation Position

Thisisthelocationoftheinsulationin relationto the

transitionareabetweentheconductorandinsulationcrimps.

Equalamountsoftheconductorstrandsandinsulationneeds

tobevisibleinthetransitionarea. Theinsulation position

ensuresthatthe insulationiscrimpedalongthefulllengthof

theinsulation crimp,and thatno insulation iscrimped under

theconductorcrimp. Theinsulationpositionissetbythewire

stopandstriplength forbenchapplications. Forautomatic

wireprocessingapplications,theinsulationpositionis set by

thein/outpressadjustment.

§Strip Length

Thestriplengthisdeterminedbymeasuringtheexposed

conductorstrandsafterthe insulationisremoved. Thestrip

lengthdeterminestheconductorbrushlength whenthe

insulationpositionis centered.

*Consultindividualterminalspecificationrequirements

QualityCrimpHandbook

OrderNo63800-0029 ReleaseDate:09-04-03 UNCONTROLLED COPY Page8of24

Revision:B RevisionDate:10-07-05

Figure 4-4

28.5

29.5

30.5

31.5

Thousandths

Measurements

Crimp Height

1 2 3 4 5 6 7 8 9 10111213 14 1516 17 18 1920 21 2223 24 25

Sample

Contol Limit

Control Limit

UpperSpecification

LowerSpecification

ExampleControlChart

Figure 4-3

Figure 4-5

RAM

PRESS BASE

PLATE

SHUT HEIGHT

GAUGE

Figure 4-6

PUNCHES

WIRE

ANVILS TERMINALS

§Process

Thecombinationofpeople,equipment,tooling,

materials,methods, and proceduresneeded to produce a

crimptermination. ProcessControlisusedtotrack

attributesovertimetoaidinthedetectionofchangeto

theprocess. Detecting aprocess changewhen it happens

helpspreventmanythousandsofbadcrimps.

§Pull Force Testing

Pullforcetestingisaquick,destructiveway toevaluatethe

mechanicalpropertiesofacrimptermination. When

makingacrimp,enough pressuremustbeappliedtobreak

downtheoxidesthatmaybuildupon thestrippedconductor

andthetin-platingontheinsideoftheterminalgrip. This is

necessarytoprovideagood metal-to-metalcontact.Ifthis

doesnotoccur, resistancecanincrease. Over-crimping a

crimpterminationwillreduce thecirculararea ofthe

conductorandincrease resistance.

Pullforcetestingisalsoagoodindicatorofproblemsinthe

process. Cutornickedstrandsinthe strippingoperation,

lackof bellmouth orconductor brush, orincorrect crimp

heightortoolingwillreducepullforce. Wireproperties and

stranding, and terminal design (material thickness and

serrationdesign),alsocanincrease ordecrease pullforce

levels.

§Shut Height

Thedistance(atbottom deadcenter ona press),from the

toolingmountingbaseplate tothetoolingconnectionpointon

theramofthepress.

§Terminal Position

Theterminalpositionissetbythealignmentoftheterminalto

theforming punchandanvils, andthecarrier stripcut-off

tooling. Thetoolset-updetermines conductorbell mouth,cut-off

tablength,andterminalextrusions.

QualityCrimpHandbook

OrderNo63800-0029 ReleaseDate:09-04-03 UNCONTROLLED COPY Page9of24

Revision:B RevisionDate:10-07-05

SECTION 5

ASSOCIATED MATERIALS

§Caliper

Agauge,consistingoftwoopposingblades,formeasuring

lineardimensionalattributes.

§Eye Loop

Amagnification tool,normally 10

timespowerorgreater,whichis

usedtoaid visualevaluationofa

crimptermination.

§Crimp Micrometer

Thisisamicrometerspecificallydesignedtomeasurecrimp

height. Themeasurementis takenin thecenter ofthecrimpso

theconductorbell mouthdoes notinfluence it. Ithasathin

bladethatsupportsthetopofthecrimpwhileapointedsection

determinesthebottomradialsurface.

§Ruler (Pocket Scale)

Thisisusedtoestimatethefive-piecemeasurement ofbell mouth,

cut-offtab, conductor brush, wireposition,and strip length. The

recommendedmaximumresolutionis0.50mm(.020”).

§Pull Tester (ReferenceFigure5)

Adevice used to determinethemechanical strength of a crimp

termination. Mostpulltestingisdonewithadevicethatclamps

thewire,pulls atasetspeed,and measuresforce bymeansofa

loadcell. A pulltesteralsocanbeassimpleashangingfixed

weightsonthewire foraminimum ofoneminute.

§Toolmaker’s Microscope

Thisisusedfor closevisualevaluationandstatisticalmeasurement

ofbellmouth, cut-off tab,conductorbrush,wirepositionand strip

length.

Inhaltsverzeichnis

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