Qual Crimp - Molex

1 QUALITYCRIMPINGHANDBOOKPRODUCEDBYTHEMOLE XAPPLICATIONTOOLINGGROUPQUALITYCRIMPINGH ANDBOOKB ringing People & Technology Together, WorldwideSMCorporate Headquarters :2222 Wellington Court, Lisle, IL, 60532, , Tel : 630-969-4550 Application Tooling Division :1150 E. Diehl Rd., Naperville, IL 60563, Tel : 630-969-4550 European Headquarters :Munich, Germany, Tel : 49-89-413092-0 Far East North Headquarters :Kanagawa, Japan, Tel : 81-462-2336 Far East South Headquarters :Jurong Town, Singapore, Tel : 65-268-6868 Printed in JI 6/96 1996, Molex IncorporatedOrder Number - 63800-0029 Illustrations by Julie of ContentsIntroduction To Crimp Technology .. Materials .. Height .. Process and Cut-Off Tab Length Brush and Insulation Position Height.

2 Gauge Wire Gauge ChartAW #sq. mmsq. inch36 INTRODUCTION TO Crimp TECHNOLOGYD eveloped to replace the need to solder terminations, crimping technologyprovides a high quality connection between a terminal and a wire at a relative-ly low applied cost. The methods for applying Crimp terminations depend onthe application and volume, and range from hand-held devices to fully-auto-mated systems. The application methods include a basic hand tool, a press anddie set, a stripper crimper or a fully automatic wire processing system. But nomatter what method is used, the setup of each tool is critical for achieving aquality Crimp . Today, many OEM companies are using Statistical Process Control (SPC) to continuously improve their Crimp terminations.

3 Crimp termination is a com-plex process and to ensure consistent quality it is necessary to understand thevariability and inter-relational interactions that the technology a thorough understanding of the crimping process and all the factorsthat can affect it, the end result may not meet expectations. The three key ele-ments in the crimping process are the terminal, the wire and the tooling. TerminalFor most applications, it is not economically practical for connector manufac-turers to design a terminal to accept one wire size, one wire stranding, and oneinsulation diameter (UL type). Most terminals accommodate many wire sizes,stranding, and a range of insulation diameters so the terminals are designed tomeet acceptable levels over this entire range.

4 WireThe wire stranding and insulation type can vary widely within one wire example, there is more than 18% more material in an 18 AWG x 19 strandwire than an 18 AWG x 16 strand. The insulation diameter of an 18 AWG wirecan range from .070" (1,78 mm) to over .180" (4,57 mm). Wire strands canbe copper, tinned, overcoated, or topcoated. Wire insulation materials, thick-ness, and durometers vary from application to type of tooling does the application require? Does the applicationrequire hand stripping of the wire or does the volume dictate an automaticwire stripping machine? Does the application and volume require hand tools,press and die, or fully automatic wire process machines? Crimping with amanual hand tool, semi-automatic press and die, or fully automatic wireprocessor, all involve different levels of variability.

5 The terminal, wire, andtype of application tooling all affect the quality of the completed terminations. TROUBLE Crimp PULL FORCEA djust tooling back to targetDamaged or worn toolingChanged tooling set-upChanged terminal reel(lot code)Changed press type(manufacturer)Changed Crimp press(shut height)Changed Crimp toolingChanged insulation color ordurometerChanged wire type, vendor, orstrandingCrimp height off target(Fig. 42)Stripping process adjustmentCrimp height adjustmentGage capability analysisTooling replacement ortighteningInspect incoming or missing wire strandsTerminal spring back too great,over crimpingMeasurement errorDamaged, loose, or worntoolingTerminal variabilityWire variabilityCrimp height variability to high(Fig. 43)Raise insulation Crimp heightAdjust tooling trackAdjust Crimp heightCheck the stripping processInsulation Crimp throughinsulation wallSmall or no bellmouthCrimp height too lowCut or nicked strandsWire breaks before conductorcrimp - low pull force (Fig.)

6 45)Contact your local salesengineerEvaluate the terminalapplicationAdjust tooling trackIncrease strip lengthAdjust Crimp heightLight serrations on terminalTerminal material thickness toosmallGold terminal applicationConductor bellmouth too bigSmall or no conductor brushCrimp height too highWire pulls out of conductor grip- low pull force (Fig. 45) PURPOSEThis handbook provides general guidelines and procedures for understandingand achieving acceptable Crimp terminations. A Glossary in Chapter 3 listscommon terms and definitions. Chapter 4 lists the tools that are necessary totake accurate measurements and evaluate the Crimp 's tooling setup is critical in determining the quality of the finished attributes that need to be considered include Crimp height, conductorbrush, bellmouth, cut-off tab, strip length and insulation position.

7 Variabilityin one or more of these attributes can reduce the measured pull force. It canbe difficult to establish acceptable variability limits because the attributes allinteract with one another. For example, a track adjustment for bellmouth alsowill change the cut-off tab length and the insulation wire position while striplength and wire locations affect the conductor brush and insulation the insulation Crimp height may result in a slight change to theconductor Crimp height measurement. It may be necessary for the setup per-son to make multiple adjustments before establishing an optimal setup. Theorder the setup is done may help reduce the number of repetitions requiredfor an optimum setup. Chapter 5 has a flowchart for a process setup whileChapter 7 is a trouble shooting guide for common problems.

8 Using StatisticalProcess Control (SPC) during the crimping process can help minimize theParts per Million (PPM) reject levels. Chapter 6 provides a general explana-tion of the benefits of using SPC. This handbook is structured so that parts, or all, of its contents can be used asa procedural guide for ISO requirements. 6 Figure 41 - Optimal Crimp Height ChartFigure 43 - Crimp Height Variability Too HighFigure 42 - Crimp Height Off TargetFigure 44 - Optimal Pull Force ChartFigure 45 - Low Pull Force SCOPEThis handbook is intended for Molex customers who are crimping Molexopen barrel Crimp terminals and are using Molex tooling, primarily in semi-automatic or automatic wire processing termination methods. The handbook'scontents may slightly differ from other connector manufacturers' guidelinesor individual company handbook provides a basic overview of what to look for in an acceptablecrimp.

9 It is not intended to replace individual product and/or tooling specifi-cations. Individual terminals or applications may have special limitations also may not permit an attribute to be adjusted to meetoptimum requirements. INSULATION CRIMP8 Figure 1 - Terminal Anatomy33 Terminal surrounds less than88% of a large diameter wire(Fig. 37) Crimp too loose, not enoughterminal insulation barrelEvaluate terminalTighten insulation Crimp heightTerminal contacts less than50% of a small diameter wire(Fig. 38)Too much terminal insulationbarrelEvaluate terminalInsulation Crimp barrels cutthrough insulation intoconductor strands (Fig. 39) Crimp too tightAdjust insulation crimpheight*Insulation not firmly grippinginsulation, fails bend test(Fig.)

10 40) Crimp too looseAdjust insulation Crimp heighttighterSolutionCauseProblem*Inexpe nsive hand tools provide no adjustment for the insulation Crimp . Ahand tool is intended for low volume applications. Although you are not ableto adjust the insulation Crimp on a hand tool, an insulation Crimp whichpierces the insulation may still be considered acceptable for many applica-tions. This criteria only applies to hand tools due to their low speed crimpcycle. If the insulation Crimp pierces the insulation, the wire strands tend tomove aside without DEFINITIONS(Anatomy of a Crimp Termination)BELLMOUTH(FLARE)The flare that is formed on the edge of the conductor Crimp acts as a funnelfor the wire strands. This funnel reduces the possibility that a sharp edge onthe conductor Crimp will cut or nick the wire strands.