11-01-0185

11-01-0185 Datasheet

Part	Datasheet
11-01-0185	11-01-0185 (pdf)

Related Parts	Information
63811-0200	63811-0200
11-01-0198	11-01-0198
11-01-0008	11-01-0008
11-01-0197	11-01-0197
11-01-0084	11-01-0084
11-01-0006	11-01-0006

PDF Datasheet Preview
Quality Crimp Handbook QUALITY CRIMPING HANDBOOK Order No. 63800-0029 Order No TM-638000029 Release Date 09-04-03 UNCONTROLLED COPY Page 1 of 24 Quality Crimp Handbook Table of Contents SECTION 1 Introduction 2 Purpose 3 Scope 4 Definitions 5 Associated Materials 6 Procedure 7 Measurement 8 Process Control 9 Trouble Shooting 10 Wire Gauge Chart Order No TM-638000029 Release Date 09-04-03 UNCONTROLLED COPY Page 2 of 24 Quality Crimp Handbook SECTION 1 INTRODUCTION TO CRIMP TECHNOLOGY Developed to replace the need to solder terminations, crimping technology provides a high quality connection between a terminal and a wire at a relatively low applied cost. The methods for applying crimp terminations depend on the application and volume, and range from hand-held devices to fully automated systems. The application methods include a basic hand tool, a press and die set, a stripper crimper, or a fully automatic wire processing system. However, no matter what method is used, the setup of each tool is critical for achieving a quality crimp. Today, many OEM companies are using Statistical Process Control SPC to continuously improve their crimp terminations. Crimp termination is a complex process and to ensure consistent quality it is necessary to understand the variability and inter-relational interactions that the technology involves. Without a thorough understanding of the crimping process, and all the factors that can affect it, the result may not meet expectations. The three key elements in the crimping process are the terminal, the wire, and the tooling. Terminal For most applications, it is not economically practical for connector manufacturers to design a terminal to accept one wire size, one wire stranding, and one insulation diameter UL type . Most terminals accommodate many wire sizes, stranding, and a range of insulation diameters, and the terminals are designed to meet acceptable levels over this entire range. Wire The wire stranding and insulation type can vary widely within one wire size. For example, there is more than 18% more material in an 18 AWG by 19-strand wire than an 18 AWG by 16-strand wire. The insulation diameter of an 18 AWG wire can range from 1.78mm 070" to over 4.57mm Wire strands can be copper, tinned, over coated, or top coated. Wire insulation materials, thickness, and durometers vary from application to application. Tooling What type of tooling does the application require? Does the application require hand stripping of the wire or does the volume dictate an automatic wire-stripping machine? Does the application and volume require hand tools, press and die, or fully automatic wire process machines? Crimping with a manual hand tool, semiautomatic press and die, or fully automatic wire processor, all involve different levels of variability. The terminal, wire, and type of application tooling all affect the quality of the completed terminations. Order No TM-638000029 Release Date 09-04-03 UNCONTROLLED COPY Page 3 of 24 Quality Crimp Handbook SECTION 2 PURPOSE This handbook provides general guidelines and procedures for understanding and achieving acceptable crimp terminations. A glossary in Section 4 lists common terms and definitions. Section 4 lists the tools that are necessary to take accurate measurements and evaluate the crimp's acceptability. The tooling setup is critical in determining the quality of the finished crimp. The attributes that need to be considered include crimp height, conductor brush, bell mouth, and cut-off tab and strip length and insulation position. Variability in one or more of these attributes can reduce the measured pull force. It can be difficult to establish acceptable variability limits because the attributes all interact with one another. For example, a track adjustment for bell mouth also will change the cut-off tab length and the insulation wire position while strip length and wire locations affect the conductor brush and insulation position. Adjusting the insulation crimp height may result in a slight change to the conductor crimp height measurement. It may be necessary for the setup person to make multiple adjustments before establishing an optimal setup. The order the setup is done may help reduce the number of repetitions required for an optimum setup. Section 6 has a flowchart for a process setup while Section 8 is a trouble-shooting guide for common problems. Using Statistical Process Control SPC during the crimping process can help minimize the Parts per Million PPM reject levels. Section 7 provides a general explanation of the benefits of using SPC. This handbook is structured so that parts, or all, of its contents can be used as a procedural guide for ISO requirements. Order No TM-638000029 Release Date 09-04-03 UNCONTROLLED COPY Page 4 of 24 Quality Crimp Handbook

PDF Datasheet Preview

Quality Crimp Handbook

QUALITY CRIMPING HANDBOOK

Order No. 63800-0029

Order No TM-638000029 Release Date 09-04-03

UNCONTROLLED COPY

Page 1 of 24

Quality Crimp Handbook

Table of Contents

SECTION
1 Introduction 2 Purpose 3 Scope 4 Definitions 5 Associated Materials 6 Procedure 7 Measurement 8 Process Control 9 Trouble Shooting 10 Wire Gauge Chart

Order No TM-638000029 Release Date 09-04-03

UNCONTROLLED COPY

Page 2 of 24

Quality Crimp Handbook

SECTION 1

INTRODUCTION TO CRIMP TECHNOLOGY

Developed to replace the need to solder terminations, crimping technology provides a high quality connection between a terminal and a wire at a relatively low applied cost. The methods for applying crimp terminations depend on the application and volume, and range from hand-held devices to fully automated systems.

The application methods include a basic hand tool, a press and die set, a stripper crimper, or a fully automatic wire processing system. However, no matter what method is used, the setup of each tool is critical for achieving a quality crimp.

Today, many OEM companies are using Statistical Process Control SPC to continuously improve their crimp terminations. Crimp termination is a complex process and to ensure consistent quality it is necessary to understand the variability and inter-relational interactions that the technology involves.

Without a thorough understanding of the crimping process, and all the factors that can affect it, the result may not meet expectations. The three key elements in the crimping process are the terminal, the wire, and the tooling.

Terminal

For most applications, it is not economically practical for connector manufacturers to design a terminal to accept one wire size, one wire stranding, and one insulation diameter UL type . Most terminals accommodate many wire sizes, stranding, and a range of insulation diameters, and the terminals are designed to meet acceptable levels over this entire range.

Wire

The wire stranding and insulation type can vary widely within one wire size. For example, there is more than 18% more material in an 18 AWG by 19-strand wire than an 18 AWG by 16-strand wire. The insulation diameter of an 18 AWG wire can range from 1.78mm 070" to over 4.57mm Wire strands can be copper, tinned, over coated, or top coated. Wire insulation materials, thickness, and durometers vary from application to application.

Tooling

What type of tooling does the application require? Does the application require hand stripping of the wire or does the volume dictate an automatic wire-stripping machine? Does the application and volume require hand tools, press and die, or fully automatic wire process machines? Crimping with a manual hand tool, semiautomatic press and die, or fully automatic wire processor, all involve different levels of variability. The terminal, wire, and type of application tooling all affect the quality of the completed terminations.

Order No TM-638000029 Release Date 09-04-03

UNCONTROLLED COPY

Page 3 of 24

Quality Crimp Handbook

SECTION 2

PURPOSE

This handbook provides general guidelines and procedures for understanding and achieving acceptable crimp terminations. A glossary in Section 4 lists common terms and definitions. Section 4 lists the tools that are necessary to take accurate measurements and evaluate the crimp's acceptability.

The tooling setup is critical in determining the quality of the finished crimp. The attributes that need to be considered include crimp height, conductor brush, bell mouth, and cut-off tab and strip length and insulation position. Variability in one or more of these attributes can reduce the measured pull force. It can be difficult to establish acceptable variability limits because the attributes all interact with one another.

For example, a track adjustment for bell mouth also will change the cut-off tab length and the insulation wire position while strip length and wire locations affect the conductor brush and insulation position. Adjusting the insulation crimp height may result in a slight change to the conductor crimp height measurement. It may be necessary for the setup person to make multiple adjustments before establishing an optimal setup.

The order the setup is done may help reduce the number of repetitions required for an optimum setup. Section 6 has a flowchart for a process setup while Section 8 is a trouble-shooting guide for common problems. Using Statistical Process Control SPC during the crimping process can help minimize the Parts per Million PPM reject levels. Section 7 provides a general explanation of the benefits of using SPC.

This handbook is structured so that parts, or all, of its contents can be used as a procedural guide for ISO requirements.

Order No TM-638000029 Release Date 09-04-03

UNCONTROLLED COPY

Page 4 of 24

Quality Crimp Handbook

Notice: we do not provide any warranties that information, datasheets, application notes, circuit diagrams, or software stored on this website are up-to-date or error free. The archived 11-01-0185 Datasheet file may be downloaded here without warranties.

Datasheet ID: 11-01-0185 649983