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Steps of crimping terminals and details of crimping measurement

  • Categories:Company News
  • Author:线束智
  • Origin:本文转载线束智造公众号
  • Time of issue:2020-07-20 09:52
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(Summary description)Crimpingsteps Toolsettings(refertoflowchart) 1.Checkwhetherthecrimpingdieiscleanandworn.Cleanandreplacewornmoldsifnecessary.2.Disconnectthepowersupplyofthecrimpingmachineandremovetheprotectivedevice.3.Loadthecorrespondingmold.4.Loadtheterminalsintothemoldsothatthefirstterminalisabovetheanvil.5.Manualcyclecrimpingmachine,completeacompletecrimpingcycletoensuresmoothcrimpingprocess.Ifitisnotsmooth,removethemoldandchecktheclosingheight.Gotostep3.6.Checkifthemoldisaligned.Checktheindentationfromtheanvilonthebottomoftheterminal.Checkwhetherthecompressionpointissymmetricalandthecrimpingpointiscentered.Iftheasymmetricalisnotcentered,alignthetools,andthengotostep5.7.Checkwhethertheterminalfeedingdevicefeedsthenextterminaldirectlyabovetheanvil.Ifnot,pleaseadjusttheterminalfeedingdeviceandthefeedinghead,andgotostep5.8.Reinstallallthepreviouslyremovedguards.(Complywithallsafetyregulationslistedinthecrimpingmachineand/orcrimpingtoolmanual)9.Electriccrimpingterminalsamples.10.Evaluatethelengthofthecuttailandtheflaredofthecorewirecompressionframe.Ifadjustmentisrequired,disconnectthepowersupplyofthecrimpingmachineandremovetheprotectivedevice.Adjustthetrackposition.Manuallycyclethecrimpingmachineandcheckthefeedingpositionofthefeedingfinger,gotostep7.11.Evaluatetheconductorbrush.Ifadjustmentisrequired,disconnectthepowersupplyofthecrimpingmachineandremovetheprotectivedevice.Adjustthewirestoponthecrimpingworkbenchorthecrimpingpositionoftheautomaticwireprocessingequipment.Gotostep8.12.Checktheinsulationsheathposition.Ifnecessary,adjustthestrippinglength,crimpthenewsample,andthengotostep11.13.Adjustthecrimpheightoftheinsulationsheathsothatthecrimpoftheinsulationsheathdoesnottouchthewirecore.14.Crimpterminalsamples.15.Measurethecorewirecrimpheight(ifapplicable)andcompareitwiththespecification.Ifnecessary,cutoffthepowersupplyandremovetheprotectivedevice.Adjustthecrimpingheightofthecorewire,replacetheprotectivedevice,connectthepowersupply,andthengotostep14.16.Performatensiletest.Ifthetestfails,pleaserefertothetroubleshootinginstructions.17.Adjustthecrimpingoftheinsulationsheath.18.Crimpterminalsamples.19.Evaluatetheinsulationcrimp.Ifnecessary,cutoffthepowersupplyandremovetheprotectivedevice.Adjustthecrimpheightoftheinsulationsheath,installtheprotectivedevice,connectthepowersupply,andthengotostep18.20.Measurethecrimpheightandcomparewiththespecification.Ifnecessary,cutoffthepowersupplyandremovetheprotectivedevice.Adjustthecrimpingheightofthecorewire,replacetheprotectivedevice,connectthepowersupply,andthengotostep18. 21.Recordthemeasurementresults.   Duringoperation,alwaysensuresafety! flowchart       measuring Tensiletest 1.Cutthewiretoalengthofabout150mm.2.Peelofftheinsulationskinatoneendtoadegreeof13mmorlongenoughthatthereisnoinsulationskinundertheinsulationchuck,orloosentheinsulationskincrimpingsothatithasnogripontheinsulationskin.3.Crimpthecorrespondingterminaltothewireaccordingtotheratedcrimpheight.4.Visuallyinspectthebellmouth,conductorbrushandcutcorewire.5.Setthetensiletesterto25.4mmperminute.Formostapplications,thefasterspeedwillnothaveasignificantimpactonthedata.Theslowerspeedcanpreventthecorewirefrombeingbrokenbysuddenforceortwitching.6.Ifnecessary,tieaknotontheendofthewirethatisnotconnectedtotheterminal(iftheinsulationisslidingonthecorewire).7.Thewiresandterminalsmustbeclampedwhentestingwithatensiletester.(Note:Clamptheterminalinterfaceduringthetest,notclampthecorewirecrimpingplace)8.Carryoutatensiletest.9.Theintelligenttensiletestercanautomaticallyrecordtensilereadings.Atleastfivepulltestsmustbeperformedforeachcrimpingoperationsetting,andatleasttwenty-fivereadingsmustbecollectedtodeterminethecapabilityoftheprocess.10.Comparetheminimumreadingwiththespecifiedminimumtensilestrength.Note:Whentwowiresarecrimpedtogether,thereareoftenlargerdeviationsandlowerprocesscapabilityindexvalues.Theincreaseindeviationisduetotheincreaseinthedeviationoftheconductorbrush,theincreaseinthedeviationoftheconductorbellmouth,andthedecreaseinthenumberofcorewiresthatcancontacttheserrationsoftheterminalconnectionframeonasetofcorewireharness.Theindustrybelievesthatdoublewirecrimpingisnotbetterthancrimpingthethinnestwire.Iftwowiresaregraspedtightlyandpulledatthesametime,thepullreadingishigher.Ifonlyoneofthewiresispulled,thepullreadingwillbemuchlower.Ifthethicknessofthetwowiresisthesame,thetensionvalueoftheupperwireislowerthanthetensionvalueofthelowerwirebecauseofthebiteoftheterminalserrations.Wirelegend:Thepull-outforceonlyspecifiestheminimumvalue.WhencalculatingCpk,assumingthattheaveragereadingistheratedreadingandtheupperlimitisset,thenCpandCpkareequal.Thehightensionreadingincreasesthestandarddeviation,whichreducestheCpkvalue,andtheaverageandminimumreadingsincreaseintime.     Crimpheightmeasurement 1.Followthestepstocompletethetoolsettings.2.Crimpatleast5samples.3.Clamptheflatbladeofthecrimpingmicrometertothedoubleradiuscenterofthecorewirecrimpingframe.Donotmeasurenearthehornofthecorewirecrimpingframe.4.Rotatethedialofthemicrometeruntilthemeasuringhea

Steps of crimping terminals and details of crimping measurement

(Summary description)Crimpingsteps Toolsettings(refertoflowchart) 1.Checkwhetherthecrimpingdieiscleanandworn.Cleanandreplacewornmoldsifnecessary.2.Disconnectthepowersupplyofthecrimpingmachineandremovetheprotectivedevice.3.Loadthecorrespondingmold.4.Loadtheterminalsintothemoldsothatthefirstterminalisabovetheanvil.5.Manualcyclecrimpingmachine,completeacompletecrimpingcycletoensuresmoothcrimpingprocess.Ifitisnotsmooth,removethemoldandchecktheclosingheight.Gotostep3.6.Checkifthemoldisaligned.Checktheindentationfromtheanvilonthebottomoftheterminal.Checkwhetherthecompressionpointissymmetricalandthecrimpingpointiscentered.Iftheasymmetricalisnotcentered,alignthetools,andthengotostep5.7.Checkwhethertheterminalfeedingdevicefeedsthenextterminaldirectlyabovetheanvil.Ifnot,pleaseadjusttheterminalfeedingdeviceandthefeedinghead,andgotostep5.8.Reinstallallthepreviouslyremovedguards.(Complywithallsafetyregulationslistedinthecrimpingmachineand/orcrimpingtoolmanual)9.Electriccrimpingterminalsamples.10.Evaluatethelengthofthecuttailandtheflaredofthecorewirecompressionframe.Ifadjustmentisrequired,disconnectthepowersupplyofthecrimpingmachineandremovetheprotectivedevice.Adjustthetrackposition.Manuallycyclethecrimpingmachineandcheckthefeedingpositionofthefeedingfinger,gotostep7.11.Evaluatetheconductorbrush.Ifadjustmentisrequired,disconnectthepowersupplyofthecrimpingmachineandremovetheprotectivedevice.Adjustthewirestoponthecrimpingworkbenchorthecrimpingpositionoftheautomaticwireprocessingequipment.Gotostep8.12.Checktheinsulationsheathposition.Ifnecessary,adjustthestrippinglength,crimpthenewsample,andthengotostep11.13.Adjustthecrimpheightoftheinsulationsheathsothatthecrimpoftheinsulationsheathdoesnottouchthewirecore.14.Crimpterminalsamples.15.Measurethecorewirecrimpheight(ifapplicable)andcompareitwiththespecification.Ifnecessary,cutoffthepowersupplyandremovetheprotectivedevice.Adjustthecrimpingheightofthecorewire,replacetheprotectivedevice,connectthepowersupply,andthengotostep14.16.Performatensiletest.Ifthetestfails,pleaserefertothetroubleshootinginstructions.17.Adjustthecrimpingoftheinsulationsheath.18.Crimpterminalsamples.19.Evaluatetheinsulationcrimp.Ifnecessary,cutoffthepowersupplyandremovetheprotectivedevice.Adjustthecrimpheightoftheinsulationsheath,installtheprotectivedevice,connectthepowersupply,andthengotostep18.20.Measurethecrimpheightandcomparewiththespecification.Ifnecessary,cutoffthepowersupplyandremovetheprotectivedevice.Adjustthecrimpingheightofthecorewire,replacetheprotectivedevice,connectthepowersupply,andthengotostep18. 21.Recordthemeasurementresults.   Duringoperation,alwaysensuresafety! flowchart       measuring Tensiletest 1.Cutthewiretoalengthofabout150mm.2.Peelofftheinsulationskinatoneendtoadegreeof13mmorlongenoughthatthereisnoinsulationskinundertheinsulationchuck,orloosentheinsulationskincrimpingsothatithasnogripontheinsulationskin.3.Crimpthecorrespondingterminaltothewireaccordingtotheratedcrimpheight.4.Visuallyinspectthebellmouth,conductorbrushandcutcorewire.5.Setthetensiletesterto25.4mmperminute.Formostapplications,thefasterspeedwillnothaveasignificantimpactonthedata.Theslowerspeedcanpreventthecorewirefrombeingbrokenbysuddenforceortwitching.6.Ifnecessary,tieaknotontheendofthewirethatisnotconnectedtotheterminal(iftheinsulationisslidingonthecorewire).7.Thewiresandterminalsmustbeclampedwhentestingwithatensiletester.(Note:Clamptheterminalinterfaceduringthetest,notclampthecorewirecrimpingplace)8.Carryoutatensiletest.9.Theintelligenttensiletestercanautomaticallyrecordtensilereadings.Atleastfivepulltestsmustbeperformedforeachcrimpingoperationsetting,andatleasttwenty-fivereadingsmustbecollectedtodeterminethecapabilityoftheprocess.10.Comparetheminimumreadingwiththespecifiedminimumtensilestrength.Note:Whentwowiresarecrimpedtogether,thereareoftenlargerdeviationsandlowerprocesscapabilityindexvalues.Theincreaseindeviationisduetotheincreaseinthedeviationoftheconductorbrush,theincreaseinthedeviationoftheconductorbellmouth,andthedecreaseinthenumberofcorewiresthatcancontacttheserrationsoftheterminalconnectionframeonasetofcorewireharness.Theindustrybelievesthatdoublewirecrimpingisnotbetterthancrimpingthethinnestwire.Iftwowiresaregraspedtightlyandpulledatthesametime,thepullreadingishigher.Ifonlyoneofthewiresispulled,thepullreadingwillbemuchlower.Ifthethicknessofthetwowiresisthesame,thetensionvalueoftheupperwireislowerthanthetensionvalueofthelowerwirebecauseofthebiteoftheterminalserrations.Wirelegend:Thepull-outforceonlyspecifiestheminimumvalue.WhencalculatingCpk,assumingthattheaveragereadingistheratedreadingandtheupperlimitisset,thenCpandCpkareequal.Thehightensionreadingincreasesthestandarddeviation,whichreducestheCpkvalue,andtheaverageandminimumreadingsincreaseintime.     Crimpheightmeasurement 1.Followthestepstocompletethetoolsettings.2.Crimpatleast5samples.3.Clamptheflatbladeofthecrimpingmicrometertothedoubleradiuscenterofthecorewirecrimpingframe.Donotmeasurenearthehornofthecorewirecrimpingframe.4.Rotatethedialofthemicrometeruntilthemeasuringhea

  • Categories:Company News
  • Author:线束智
  • Origin:本文转载线束智造公众号
  • Time of issue:2020-07-20 09:52
  • Views:
Information
Crimping steps
 
Tool settings (refer to flowchart)
 
1. Check whether the crimping die is clean and worn. Clean and replace worn molds if necessary. 2. Disconnect the power supply of the crimping machine and remove the protective device. 3. Load the corresponding mold. 4. Load the terminals into the mold so that the first terminal is above the anvil. 5. Manual cycle crimping machine, complete a complete crimping cycle to ensure smooth crimping process. If it is not smooth, remove the mold and check the closing height. Go to step 3.6. Check if the mold is aligned. Check the indentation from the anvil on the bottom of the terminal. Check whether the compression point is symmetrical and the crimping point is centered. If the asymmetrical is not centered, align the tools, and then go to step 5.7. Check whether the terminal feeding device feeds the next terminal directly above the anvil. If not, please adjust the terminal feeding device and the feeding head, and go to step 5.8. Reinstall all the previously removed guards. (Comply with all safety regulations listed in the crimping machine and/or crimping tool manual) 9. Electric crimping terminal samples. 10. Evaluate the length of the cut tail and the flared of the core wire compression frame. If adjustment is required, disconnect the power supply of the crimping machine and remove the protective device. Adjust the track position. Manually cycle the crimping machine and check the feeding position of the feeding finger, go to step 7.11. Evaluate the conductor brush. If adjustment is required, disconnect the power supply of the crimping machine and remove the protective device. Adjust the wire stop on the crimping workbench or the crimping position of the automatic wire processing equipment. Go to step 8.12. Check the insulation sheath position. If necessary, adjust the stripping length, crimp the new sample, and then go to step 11.13. Adjust the crimp height of the insulation sheath so that the crimp of the insulation sheath does not touch the wire core. 14. Crimp terminal samples. 15. Measure the core wire crimp height (if applicable) and compare it with the specification. If necessary, cut off the power supply and remove the protective device. Adjust the crimping height of the core wire, replace the protective device, connect the power supply, and then go to step 14.16. Perform a tensile test. If the test fails, please refer to the troubleshooting instructions. 17. Adjust the crimping of the insulation sheath. 18. Crimp terminal samples. 19. Evaluate the insulation crimp. If necessary, cut off the power supply and remove the protective device. Adjust the crimp height of the insulation sheath, install the protective device, connect the power supply, and then go to step 18. 20. Measure the crimp height and compare with the specification. If necessary, cut off the power supply and remove the protective device. Adjust the crimping height of the core wire, replace the protective device, connect the power supply, and then go to step 18.
 
21. Record the measurement results.
 
 
 
During operation, always ensure safety!
 
flow chart
 
 
 
 
 
 
 
measuring
 
Tensile test
 
1. Cut the wire to a length of about 150 mm. 2. Peel off the insulation skin at one end to a degree of 13 mm or long enough that there is no insulation skin under the insulation chuck, or loosen the insulation skin crimping so that it has no grip on the insulation skin. 3. Crimp the corresponding terminal to the wire according to the rated crimp height. 4. Visually inspect the bell mouth, conductor brush and cut core wire. 5. Set the tensile tester to 25.4 mm per minute. For most applications, the faster speed will not have a significant impact on the data. The slower speed can prevent the core wire from being broken by sudden force or twitching. 6. If necessary, tie a knot on the end of the wire that is not connected to the terminal (if the insulation is sliding on the core wire). 7. The wires and terminals must be clamped when testing with a tensile tester. (Note: Clamp the terminal interface during the test, not clamp the core wire crimping place) 8. Carry out a tensile test. 9. The intelligent tensile tester can automatically record tensile readings. At least five pull tests must be performed for each crimping operation setting, and at least twenty-five readings must be collected to determine the capability of the process. 10. Compare the minimum reading with the specified minimum tensile strength. Note: When two wires are crimped together, there are often larger deviations and lower process capability index values. The increase in deviation is due to the increase in the deviation of the conductor brush, the increase in the deviation of the conductor bell mouth, and the decrease in the number of core wires that can contact the serrations of the terminal connection frame on a set of core wire harness. The industry believes that double wire crimping is not better than crimping the thinnest wire. If two wires are grasped tightly and pulled at the same time, the pull reading is higher. If only one of the wires is pulled, the pull reading will be much lower. If the thickness of the two wires is the same, the tension value of the upper wire is lower than the tension value of the lower wire because of the bite of the terminal serrations. Wire legend: The pull-out force only specifies the minimum value. When calculating Cpk, assuming that the average reading is the rated reading and the upper limit is set, then Cp and Cpk are equal. The high tension reading increases the standard deviation, which reduces the Cpk value, and the average and minimum readings increase in time.
 
 
 
 
 
Crimp height measurement
 
1. Follow the steps to complete the tool settings. 2. Crimp at least 5 samples. 3. Clamp the flat blade of the crimping micrometer to the double radius center of the core wire crimping frame. Do not measure near the horn of the core wire crimping frame. 4. Rotate the dial of the micrometer until the measuring head touches the bottom radial (curved) surface. If using a caliper, be sure not to measure the crimp extrusion. 5. Record the crimp height reading. At least five crimp height readings must be taken to confirm each setting. At least twenty-five readings are required to determine the process capability. 6. During the crimping operation, check the crimp height after every 250 to 500 terminals.
 
 
 
 
 
 
 
 
 
 
 
 
 
Note: The crimp height is usually drawn as a control icon, because the crimp height measurement is a fast and non-destructive measurement, and it is very important to the electrical and mechanical reliability of the terminal. There are three main purposes for drawing control charts. First of all, the number of samples collected for setting is usually small, so its statistical value is limited. Secondly, there must be a means to record deviations in a timely manner when special circumstances that can cause consequences in the process occur irregularly and unpredictably. This prevents thousands of termination joints from being scrapped after the operation. The third and most important point is that data is necessary to evaluate and improve the crimping process.
 
This article is reproduced in the public number of Wiring Harness Intelligent Manufacturing

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