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Analysis of crimping terminal and crimping process control
- Categories:Company News
- Author:线束智造
- Origin:本文转载线束智造公众号
- Time of issue:2020-07-20 10:15
- Views:
(Summary description)BellmouthAftercrimping,abellmouthisformedontheedgeofthecorewirecrimpingframetobecomeacorewirefunnel.Thisfunnelreducesthepossibilitythatthesharpedgeofthecorewirecrimpingframewillcutorcutthecorewire.Thethicknessofthebellmouthofthecorewirecrimpingframeshouldgenerallybeabout1to2timesthethicknessoftheterminalmaterial. BendingtestThebendingtestisamethodtotestthecrimpqualityoftheinsulationsheath.Webendthewirebackandforthseveraltimes,andthenevaluatethemovementoftheinsulationsheathandcorewirebundle.Asarule,thecrimpingoftheinsulatingsheathmustwithstandthewirebendsat60to90degreesinanydirectionseveraltimes.Whencrimpingthinwires,becarefulnottocuttheinsulatinglayerbehindthecrimpingpartoftheinsulatingsheath. ConductorbrushTheconductorbrushisacorewirebundlepassingthroughthecorewirecrimpingframeandfacingtheterminalcontactarea.Duetothecorewirebundleprotrudingfromthecrimpingframe,themechanicalcrimpingforcecanallactonthecorewire.Theconductorbrushshouldnotextendtotheterminalinsertionarea. CorecrimpingThecorewirecrimpingisthecompressionoftheterminalcrimpingframeonthecorewire.Thisoperationestablishesanelectricalpathwithlowresistanceandhighcurrentcarryingcapacity. CorewirecrimpheightThecorewirecrimpheightisthedistancefromthetopsurfaceofthecrimpformedtothebottomradialsurface.Thisheightdoesnotincludetheheightoftheextrusion(seeabovepicture).Thecrimpheightmeasurementadoptsafastandnon-destructivemeasurementmethodtomeasurewhetherthecrimpingframeoftheterminalsurroundingthecorewireiscorrectlycrimpedtothecorewire.Themeasurementresultisanimportantindicatorinprocesscontrol.Whenformulatingcrimpheightspecifications,itisusuallynecessarytotakeintoaccounttheelectricalandmechanicalpropertiesofcrimpingfordifferentstrands,coatings,terminalmaterialsandelectroplatedwires.Althoughdifferentoptimalcrimpheightscanbeformulatedfordifferentstrandsandterminalplating,generallyonlyonecrimpheightisspecified. TaillengthAftertheterminalisseparatedfromthecarriertape,theterminalheadisnotflatbutaprotrudingpart,whichiscalledtailcutting.Asarule,thetaillengthshouldbe1.0 to1.5 timesthethicknessoftheterminalmaterial(pleaserefertothespecificterminalspecifications).Ifthetailistoolong,theterminals(duetoimproperinsertion)willbeexposedoutsidetheconnectorplasticshell,ortheelectricalspacingrequirementswillnotbemet.Usually,atoolcanbesettomakethecuttingtaillevelwiththethicknessofamaterial. Extrusion(outreach)Crimpingcausesabductionatthebottomofthewirecrimpingframe.Thereasonfortheabductionisthegapbetweenthepunchandtheanvil.Iftheanviliswornortheterminalisover-punched,itwillcauseexcessiveabductionofthebottomoftheterminal.Ifthepunchandanvilaremisaligned,ifthefeedingadjustmentfunctionisturnedoff,andifthedistanceoftheterminalbeingdraggedisnotenoughortoolarge,anunevenextrusioneffectwilloccur. Insulationcovercrimping(stressrelief)Insulatingsheathcrimpingcanprovidesupportforthewiresothatthewirecanbeinsertedintotheplasticcase.Italsohelpstheterminaltoresistvibration.Theterminalmustgraspthewireasfirmlyaspossible,butmustnotpressthroughtheinsulatingsheathandtouchthecorewire.Thecriterionforjudgingwhethertheinsulatingsheathispress-fittedornotissubjective,dependingontheconnectionanduseoccasion.Forspecificapplications,werecommendthatyouperformcorrespondingbendingteststodeterminewhetherthestressreliefabilityprovidedbytheinsulationcrimpingisqualified. InsulationcovercrimpheightThecrimpingheightoftheinsulationsheathisusuallynotspecifiedbecauseoftheexistenceofvariousinsulationsheaththicknesses,materialsandhardness.Mostterminalsaredesignedtoaccommodatemultiplespecificationsofwires.Iftheterminaliswithinitsapplicablerange,itmaynotbeabletocompletelyembracetheinsulatingsheath,oritmaynotbeabletoholdthewiretightly.Butinthiscase,thecrimpingoftheinsulationcoverisusuallyqualified. 1.Ifthewireistoothick,theinsulationsheathcrimpingframeshouldholdatleast88%ofthewire.2.Ifthewireistoothin,theinsulatingsheathcrimpingframeshouldholdatleast50%ofthewireandholdtheheadofthewirefirmly. Tocheckthecrimpingsectionoftheinsulationsheath,cutthewirefromthebackoftheterminalsothatthecutsurfaceisflushwiththebackoftheterminal.Afterdeterminingthebestcrimpsetting,recordthecrimpheightoftheinsulationsheath.Theoperatorcancheckthecrimpheightoftheinsulationsheathaspartofthesetupprocedure. EndpositionofinsulationsheathThispositionisthepositionoftheendoftheinsulationsheathinthetransitionzonefromtheinsulationsheathcrimpingpointtothecorewirecrimpingpoint.Inthistransitionzone,thelengthofthecorewireshouldbethesameasthelengthoftheinsulationsheath.Thepositioningoftheendoftheinsulatingsheathshouldensurethatthereisaninsulatingsheathundertheentirelengthoftheinsulatingsheathcrimpingframe.Ontheotherhand,theinsulatingsheathmustnotextendunderthecorecrimpingframe.Ifcrimpingwithadesktopcrimpingmachine,theendpositionoftheinsulationsheathisdeterminedbythewirestopandstrippinglength.Ifanautomaticwireprocessorisusedforcrimping,theendpositionoftheinsulationsheathisdeterminedbythein/outadjustmentofthecrimpingmachine. StrippinglengthThestrippinglengthist
Analysis of crimping terminal and crimping process control
(Summary description)BellmouthAftercrimping,abellmouthisformedontheedgeofthecorewirecrimpingframetobecomeacorewirefunnel.Thisfunnelreducesthepossibilitythatthesharpedgeofthecorewirecrimpingframewillcutorcutthecorewire.Thethicknessofthebellmouthofthecorewirecrimpingframeshouldgenerallybeabout1to2timesthethicknessoftheterminalmaterial. BendingtestThebendingtestisamethodtotestthecrimpqualityoftheinsulationsheath.Webendthewirebackandforthseveraltimes,andthenevaluatethemovementoftheinsulationsheathandcorewirebundle.Asarule,thecrimpingoftheinsulatingsheathmustwithstandthewirebendsat60to90degreesinanydirectionseveraltimes.Whencrimpingthinwires,becarefulnottocuttheinsulatinglayerbehindthecrimpingpartoftheinsulatingsheath. ConductorbrushTheconductorbrushisacorewirebundlepassingthroughthecorewirecrimpingframeandfacingtheterminalcontactarea.Duetothecorewirebundleprotrudingfromthecrimpingframe,themechanicalcrimpingforcecanallactonthecorewire.Theconductorbrushshouldnotextendtotheterminalinsertionarea. CorecrimpingThecorewirecrimpingisthecompressionoftheterminalcrimpingframeonthecorewire.Thisoperationestablishesanelectricalpathwithlowresistanceandhighcurrentcarryingcapacity. CorewirecrimpheightThecorewirecrimpheightisthedistancefromthetopsurfaceofthecrimpformedtothebottomradialsurface.Thisheightdoesnotincludetheheightoftheextrusion(seeabovepicture).Thecrimpheightmeasurementadoptsafastandnon-destructivemeasurementmethodtomeasurewhetherthecrimpingframeoftheterminalsurroundingthecorewireiscorrectlycrimpedtothecorewire.Themeasurementresultisanimportantindicatorinprocesscontrol.Whenformulatingcrimpheightspecifications,itisusuallynecessarytotakeintoaccounttheelectricalandmechanicalpropertiesofcrimpingfordifferentstrands,coatings,terminalmaterialsandelectroplatedwires.Althoughdifferentoptimalcrimpheightscanbeformulatedfordifferentstrandsandterminalplating,generallyonlyonecrimpheightisspecified. TaillengthAftertheterminalisseparatedfromthecarriertape,theterminalheadisnotflatbutaprotrudingpart,whichiscalledtailcutting.Asarule,thetaillengthshouldbe1.0 to1.5 timesthethicknessoftheterminalmaterial(pleaserefertothespecificterminalspecifications).Ifthetailistoolong,theterminals(duetoimproperinsertion)willbeexposedoutsidetheconnectorplasticshell,ortheelectricalspacingrequirementswillnotbemet.Usually,atoolcanbesettomakethecuttingtaillevelwiththethicknessofamaterial. Extrusion(outreach)Crimpingcausesabductionatthebottomofthewirecrimpingframe.Thereasonfortheabductionisthegapbetweenthepunchandtheanvil.Iftheanviliswornortheterminalisover-punched,itwillcauseexcessiveabductionofthebottomoftheterminal.Ifthepunchandanvilaremisaligned,ifthefeedingadjustmentfunctionisturnedoff,andifthedistanceoftheterminalbeingdraggedisnotenoughortoolarge,anunevenextrusioneffectwilloccur. Insulationcovercrimping(stressrelief)Insulatingsheathcrimpingcanprovidesupportforthewiresothatthewirecanbeinsertedintotheplasticcase.Italsohelpstheterminaltoresistvibration.Theterminalmustgraspthewireasfirmlyaspossible,butmustnotpressthroughtheinsulatingsheathandtouchthecorewire.Thecriterionforjudgingwhethertheinsulatingsheathispress-fittedornotissubjective,dependingontheconnectionanduseoccasion.Forspecificapplications,werecommendthatyouperformcorrespondingbendingteststodeterminewhetherthestressreliefabilityprovidedbytheinsulationcrimpingisqualified. InsulationcovercrimpheightThecrimpingheightoftheinsulationsheathisusuallynotspecifiedbecauseoftheexistenceofvariousinsulationsheaththicknesses,materialsandhardness.Mostterminalsaredesignedtoaccommodatemultiplespecificationsofwires.Iftheterminaliswithinitsapplicablerange,itmaynotbeabletocompletelyembracetheinsulatingsheath,oritmaynotbeabletoholdthewiretightly.Butinthiscase,thecrimpingoftheinsulationcoverisusuallyqualified. 1.Ifthewireistoothick,theinsulationsheathcrimpingframeshouldholdatleast88%ofthewire.2.Ifthewireistoothin,theinsulatingsheathcrimpingframeshouldholdatleast50%ofthewireandholdtheheadofthewirefirmly. Tocheckthecrimpingsectionoftheinsulationsheath,cutthewirefromthebackoftheterminalsothatthecutsurfaceisflushwiththebackoftheterminal.Afterdeterminingthebestcrimpsetting,recordthecrimpheightoftheinsulationsheath.Theoperatorcancheckthecrimpheightoftheinsulationsheathaspartofthesetupprocedure. EndpositionofinsulationsheathThispositionisthepositionoftheendoftheinsulationsheathinthetransitionzonefromtheinsulationsheathcrimpingpointtothecorewirecrimpingpoint.Inthistransitionzone,thelengthofthecorewireshouldbethesameasthelengthoftheinsulationsheath.Thepositioningoftheendoftheinsulatingsheathshouldensurethatthereisaninsulatingsheathundertheentirelengthoftheinsulatingsheathcrimpingframe.Ontheotherhand,theinsulatingsheathmustnotextendunderthecorecrimpingframe.Ifcrimpingwithadesktopcrimpingmachine,theendpositionoftheinsulationsheathisdeterminedbythewirestopandstrippinglength.Ifanautomaticwireprocessorisusedforcrimping,theendpositionoftheinsulationsheathisdeterminedbythein/outadjustmentofthecrimpingmachine. StrippinglengthThestrippinglengthist
- Categories:Company News
- Author:线束智造
- Origin:本文转载线束智造公众号
- Time of issue:2020-07-20 10:15
- Views:
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