Index - Technical book (2017-1)
1. Preface
1.1 Important notes about this documentation
1.2 Partners & Sources
2.Crimp contacts - Cable lugs - Compression connectors
2.1 General
2.2 Open crimp barrel
2.3 Closed crimp barrel
2.4 Overview crimp- und press forms
2.4.1 The open crimp barrel
2.4.2 The closed crimp barrel
3. The conductor
3.1 The structure of the conductor
3.2 Instructions for processing circuit materials
3.3 Cross section – Nominal cross section
3.4 The insulation of the conductor
3.5 Conductor with reduced insulation
3.6 The AWG number – What does mean AWG?
3.7 Providing / supply of cables and wires
3.7.1 Storage
3.7.2 Damage to the insulation
3.7.3 Draught-free supply
3.7.4 The cable storage
3.7.5 Sag control
3.7.6 The cable alignment device
3.7.7 Management of cables and wires
3.7.8 Feeding cables and conductor
3.7.8.1 Roller feed
3.7.8.2 Belt feed
3.8 Access of cables and wires
3.8.1 General
3.8.2 Execution of the gripping surface
3.8.3 Gripper types
3.8.4 Flat gripper
3.8.5 Prism-form gripper
3.8.6 Form gripper
3.9 Cutting of cables and conductors
3.9.1 General
3.9.2 Blade with straight cutting edge
3.9.3 V – Cutting blade
3.9.4 The cable shears
3.10 Stripping of conductors - cables
3.10.1 Basic rules for stripping
3.10.2 Stripping tasks
3.10.3 Partial strip of insulation rest
3.10.4 Stripping blades - Variants
3.10.5 Straight stripping blade
3.10.6 V – Stripping and cutting blade
3.10.7 Matrix form cutting and stripping blade
3.10.8 Matrix form stripping blade
3.10.9 Special blades – Blade combinations in fully automatic machines
3.10.10 Rotary stripping
3.10.11 Rotary stripping - Multi-step stripping of shielded cables
3.10.12 Insulation – Strip characteristics
3.10.12.1 Arrangement of blade-blade edge to pull-off direction
3.10.12.2 Pressure of the gripper
3.10.12.3 Pressure of the feed rollers
3.10.12.4 Cutting edge quality (sharpness) of the strip blades
3.10.13 Cutting and stripping - Systems
3.10.13.1 Free programming stripping on machines
3.10.13.2 Stripping and twisting
3.10.13.3 Blade block system
3.10.13.4 Blade block (Komax)
3.10.14 Error description while stripping
3.10.14.1 Overview
3.10.14.2 Single wires damage and/or cut off
3.10.14.3 Insulation unclean cut
3.10.14.4 Insulation rest on the stranded wires
3.10.14.5 No twisted stranded wires
3.10.14.6 Fanned out stranded wire
3.10.14.1 Heavily oxidized single wires
3.10.14.2 Insulation damaged
3.10.14.3 Stranded wire overtwisted
3.10.14.4 Pulled single wires
3.10.14.5 Fluctuations in the stripping length
3.11 Stripping mulitcore jacked cables
3.11.1 General
3.11.2 Structure of multicore jacked cables
3.11.3 Cutting of multicore jacked cables
3.11.4 Types of blade for multicore jacked cables
3.11.4.1 V-Stripping and cutting blade
3.11.4.2 Matrix form blade
3.11.4.3 Special blade
3.11.5 Inner conductor processing
3.11.6 Dimensioning von stripping blades
3.11.7 Stripping – Schematic process
3.11.8 Rotary stripping
3.11.9 Error description
3.11.9.1 Outer jacked unclean cut
3.11.9.2 Deformed end of the cable– Deformed inner conductor
3.11.9.3 Damaged inner conductor
3.11.9.4 Damage of the outer jacked
3.11.10 Stripping devices and machines
3.12 Thermal stripping
4. Crimping – Open crimp barrel
4.1 General
4.2 Definition of terms
4.3 The function areas of the crimp connection
4.3.1 The function area
4.3.2 The chamber match
4.3.3 Locking function – Locking lugs
4.3.4 The plug thickness
4.3.5 Plug-in forces – Traction
4.4 Processing form of open crimp barrel
4.4.1 Patterns in the wire crimp
4.4.2 The taped crimp contact
4.4.3 Single contact
4.4.4 Crimp forms
4.5 Principles in the processing of open crimp barrel
4.5.1 Assignment contact - cross section – crimp tool
4.5.2 The crimp process - Wire crimp (schematic flow)
4.5.3 Roll crimp
4.6 The wire crimp height
4.6.1 Crimp height and the mechanical characteristics of the crimp connection
4.6.2 Crimp height and the electrical characteristics of the crimp connection
4.6.3 Crimp height - a compromise
4.6.4 Crimp heights in the micrograph
4.7 Filler cross-section – Effect of missing single wires
4.8 Soldering of crimp connections
4.9 What means „Gas tight“?
4.10 Quality requirments for crimp connection
4.10.1 The rear bellmouth
4.10.1.1 Bellmouth – Function and built up
4.10.1.2 Size of the rear bellmouth
4.10.1.3 Bellmouth setup - MQC Sidefeed
4.10.1.4 Bellmouth setup - MQC Endfeed
4.10.1.5 Fluctuations in size and direction of the bellmouth
4.10.1.6 Effects in the absence of a rear bellmouth
4.10.1.7 Reason for missing of the bellmouth
4.10.1.8 Effects of too largerear bellmouth
4.10.2 The front bellmouth
4.10.3 Stripping lenght
4.10.4 Conductor end / Head of state
4.10.5 Position conductor and seal in the crimp contact
4.10.6 Position of the single wire seal
4.10.7 Position deviation (Flip down) of the insulation crimp flanks
4.10.8 Position deviation (Bent) wire crimp (WC) / insulation crimp (IC)
4.10.1 Position deviation function area to the crimp area
4.10.2 Twist of WC/IC area to function area
4.10.3 Transition WC – Function area
4.10.4 Function area
4.10.5 Cut-of tap
4.10.5.1 Cut-of tap - Length
4.10.5.2 Cut-of tap - Length in the endfeed crimp tool
4.10.5.3 Cut-of tap - Length in the sidefeed crimping tool
4.10.5.4 Cut-of tap - Length: Error descriptions
4.10.5.5 Sidefeed – Rear cut-of tap too long
4.10.5.6 Endfeed – Rear cut-of tap too long
4.10.5.7 Sidefeed – Rear cut-of tap too short
4.10.5.8 Endfeed – Rear cut-of tap too short
4.10.5.9 Cut-of tap – Length: Fluctuations
4.10.5.10 Cut-of tap – Burr
4.10.5.11 Cut-of tap – Burr: Error description
4.10.6 Crimp height - Wire crimp
4.10.7 Crimp width - Wire crimp
4.10.8 Burr height and burr width of the crimp bottom
4.10.9 The pressure level
4.10.10 Number of covered singel wires and from stripping results
4.10.11 Execution of crimp flanks
4.10.11.1 Symmetry of the crimp flanks
4.10.11.2 Position and location of the crimp flanks
4.10.11.3 Bottom thickness of the crimp contact
4.10.11.4 Support height
4.10.11.5 Support angle
4.10.12 Error description – Roll-in of the crimp flanks
4.10.12.1 Crimp contact is already damaged
4.10.12.2 Insertion error: Hand crimp plier
4.10.12.3 Sidefeed – The wrong feed
4.10.12.4 Sidefeed –Contact brake set up incorrectly
4.10.12.5 Endfeed – Contact guide set up incorrectly
4.10.12.6 Error examples in the micrograph
4.10.13 Insulation crimp forms and requirements
4.10.13.1 Insulation crimp forms in the overview
4.10.13.2 Defining of the insulation crimp measurement
4.10.13.3 Bending test
4.10.13.4 Wrap test
4.10.13.5 The insulation crimp form B/F
4.10.13.6 Error: Insulation crimp B/F
4.10.13.7 Insulation crimp B/F Special form
4.10.13.8 Overlap crimp
4.10.13.9 Buit-up of an Overlap crimp
4.10.13.10 Error: Overlap crimp
4.10.13.11 Asymmetric Wrap crimp
4.10.13.12 Error: Asymmetrc wrap crimp
4.10.13.13 Asymmetric wrap crimp (with seal)
4.10.13.1 Error: Asymmetric wrap crimp (with seal)
4.10.13.2 Symmetric wrap crimp (with seal)
4.10.13.3 Error: Symmetric wrap crimp (with seal)
4.10.13.4 Insulation crimp: Position deviation and Contact geomerty
4.11 Seal assembly – Single wire seal
4.11.1 The single wire seal
4.11.2 Association seal to crimp contact
4.11.3 Separation - Feeding of the Seals
4.11.4 Discontinuation of seals on the conector
4.11.5 Automatic control of the sealposition
4.11.6 Insulation crimp forms for the processing of seals
4.11.7 Assembly of crimp contacts with seals
4.12 The „Shark claw“
4.13 The multi-unit clip
4.13.1 The multi-unit clip – Wear part
4.14 The clip with and without insulation crimp
5. Test methodes and application
5.1 Crimp force monitoring
5.1.1 Philosophy
5.1.2 Schematic buit-up
5.1.3 The "Piezo-effect"
5.1.4 The „Froce curve“
5.1.5 Strength in dependence of the conductor cross section
5.1.6 Disturbance forces
5.1.6.1 Crimp machine
5.1.6.2 Tool holder plate – Tool base plate
5.1.6.3 Crimp tool
5.1.6.4 Crimp contact
5.1.6.5 Stripped conductor
5.1.7 “Teach in” – Calibration process
5.1.8 Headroom
5.1.9 Drift of the strength curve
5.1.10 Drift compensation
5.2 Measurement of crimping capacities
5.2.1 Wire crimp height
5.2.2 Measuring tools
5.2.3 Mensuring procedure
5.2.4 Wire crimp width
5.3 Pull-out test
5.3.1 General
5.3.2 Requirements for the pull-out tester
5.3.3 Test procedure
5.3.4 Visual inspection on the pull-out test
5.3.5 Pull force in dependance of the wire crimp height
5.3.6 Pull-out values
5.3.7 Pull-out values for closed crimp barrels with big cross sections
5.4 Production of a micrograph
5.4.1 Preface
5.4.2 Position of the cut plane
5.4.3 Cutting, grinding and polisching
5.4.4 Celaning the cut plane
5.4.5 Mensuring the crimp geometry
5.4.6 Error micrograph production
5.4.7 Example of a micrograph documentation
5.5 Slow-Motion-Test
5.5.1 Basics
5.5.2 Test
5.5.3 Required changes
5.5.4 Alternative processing
6. Machine technology
6.1 Fundamentals
6.2 Machinetypes
6.3 Crimp machine
6.3.1 Structure
6.3.2 Tool holder
6.3.3 Machine stroke
6.3.4 Lower dead center
6.3.5 Setting of the lower dead center
6.3.6 Alternative setting of the crimp height
6.3.7 Use of crimp tools
6.3.8 Machine capability
7. Tool technology - Mini quick change (MQC)
7.1 Overview
7.1.1 Assignment of the wear parts
7.1.2 Anvil
7.1.3 Wire crimp AND insulation crimp
7.1.4 References – MQC Sidefeed
7.1.5 Reference - MQC Endfeed
7.2 Adjustment - Crimp height
7.2.1 Slide conductor
7.2.2 Rotary disc with several adjusted crimp hights
7.2.3 Rotary disc with stepless adjustment
7.2.4 Ram an ist most important components
7.2.5 Adjustment of the crimp hight– Principle
7.3 Mechanical feed: Principle and built up
7.4 Pneumatic feed
7.5 Contact position
7.6 Feed stroke
7.7 Contact break
7.8 Contact guide
7.8.1 Contact guide - MQC Endffed
7.8.2 Contact guide - MQC Sidefeed
7.9 Feed finger
7.9.1 MQC Endfeed
7.9.2 MQC Sidefeed
7.10 Depth stop and stripper as a locator
7.11 Sensor triggered as a positioning aid
7.12 Stripper
7.13 Push down device systems
7.13.1 Function and applications
7.13.2 Push down device systems for sidefeed and endfeed crimp tools
7.13.3 Push down device for MQC Sidefeed
7.14 Wear part set
7.14.1 Wear part set - Exploded assembly drawing
7.14.2 Wear part change
7.14.2.1 Basics
7.14.2.2 Wire crimp / Insulation crimp
7.14.2.3 Blade unit – MQC Sidefeed
7.14.2.4 Blade unit – MQC Endfeed
7.15 Maintenance and repair
7.15.1 Maintenance of crimping tools
7.15.2 Maintenance plan:
7.15.3 Visual inspection of wear parts
7.15.3.1 Wire – and insulation crimp
7.15.3.2 Anvil
7.15.3.3 Blade unit
7.15.4 Visual inspection – MQC crimp tool
7.15.5 Storage of crimp tools
8. Hand crimp pliers: Processing of open crimp barrels
8.1 Preface and Basics
8.2 How to start? – Really know what you are doing!
8.3 Crimp contact
8.4 Hand crimp plier
8.5 Crimp height setting
8.6 Dies
8.7 Locator
8.8 Requirements of the locator
8.9 Crimp contact – Positioning in the die
8.10 Stripped conductors - Positioning in the crimp contact
8.11 Crimp Result
8.12 Error descriptions
8.13 Bad crimp result – Which doing?
8.14 Cut off and a new one!
9. Splice technology
9.1 Splice machine
9.2 Schematic work flow
9.3 Splice tape
9.4 Examples of use
9.5 Alternative applications
10. Assembly – Disassembly of crimp contacts
10.1 Connector Housing
10.2 Locking function – Locking lugs
10.3 Chamber match
10.4 The Crimp contact in the connector housing
10.5 Crimp contact mounting
10.6 Disassembly of crimp contacts
11. Closed crimp barrel
11.1 Contakt variants and press form
12. The Hexagonal crimp
12.1 Contact types
12.2 Hexagonal crimp - Al/Cu-cable lugs and connectors
12.3 Crimping direction
12.4 Visual Inspection: Faulity hexagonal crimps
12.5 Production of a hexagonal crimp
12.6 Measurement of a hexagonal crimp
13. Mandrel crimp
13.1 The solderless terminal
13.2 Production of a mandrel crimp
14. Deep indent crimp - AL / ALCU compression cable lugs
14.1 General
14.2 Tool texture
14.3 Single and double crimp
15. Other press forms
15.1 Dual crimp system
15.2 Side indent crimp
16. Pre-insulated crimp barrels
16.1 General
16.2 Allocation of cross-sections with colour and identification code
16.3 Construction of pre-insulated crimp barrels
16.4 Die form for pre-insulated crimp barrels
16.5 Quality characteristic pre-insulated crimp barrels
16.6 Compression on the insulation sleeve
16.7 Positioning of the stripped conductor
16.8 Micrograph
16.9 Visual inspection
17. Wire pin – Ferulles – Cable end sleeve
17.1 Processing of wire pins
17.2 Wire pins - Variants
17.3 Crimp forms
17.4 Wire pin - Quality characteristics
17.5 Colour code for wire pins (Ferulles)
18. Turned contacts – Four mandrel crimp
18.1 General
18.2 Contact form
18.3 Structure and geometry
18.4 Requirements for the contact material
18.5 Four mandrel crimp - Hand crimp plier
18.6 Mandrels
18.7 Positioning and crimping
18.8 Crimp process in the micrograph
18.9 Error description
18.9.1 Deformed crimp contact
18.9.2 Deformed crimp contact AFTER crimping!
18.9.3 Hidden errors
18.9.4 Broken single wires
18.9.5 Micrographs
19. The crimp quality is "Handle" to get – Only how to start?
19.1 Preface
19.2 Basic
19.3 Crimp specification:
19.4 Data sheet
19.5 Data collection
19.5.1 Crimp contact
19.5.2 Conductor
19.6 Crimp tool
19.7 The crimp tool: A first check
19.8 The pattern crimp and the visual inspection
19.9 Pattern crimp measurement results to determine
19.10 Intermediate result and correction
19.11 Micrograph
19.12 Evaluation and archiving
19.13 Crimp connection ist not correct! And now?
20. Mensurement protocol
20.1 Contact and cross section
20.2 Stripping result
20.3 Dimensions for the wire crimp (WC)
20.4 Micrograph + Mensurement protocol
20.5 Dimensions in micrograph: The position of the crimp flanks
20.6 Dimensions in micrograph: Symmetry of the crimp flanks
20.7 Dimensions in micrograph: Burr at the crimp bottom
20.8 Bellmouth
20.9 Pull-out test
20.10 Insulation crimp: B/F
20.11 Insulation crimp: Overlap (OV)
20.12 Insulation crimp: Asymmetric wrap crimp without Seal
20.13 Insulation crimp: Asymmetrc wrap crimp with Seal
20.14 Insulation crimp: Symmetric wrap crimp
20.15 Stripping length
20.16 Conductor end
20.17 Conductor position in the crimp conatct
20.18 Cut-of tap & Cut-of tap burr
20.19 Position deviation (Flip down) of the insulations crimp flanks
20.20 Position deviation (bent) – Wire crimp – Insulation crimp
20.21 Distortion in the crimp contact
21. Electrical fundamentals of the crimping technology
21.1 Electrical resistance
21.2 Resistivity and conductivity
21.3 Conductor resistance
21.4 Temperature dependence of resistance
21.5 Temperature coefficients of materials at 20 °C
21.6 Contact resistance - Transitional resistance
22. Alternative processing techniques
22.1 Tinning – Tip of tining
22.1.1 Basic
22.1.2 Stripping and twisting
22.1.3 Flux-station – Flux
22.1.4 Tinning station
22.1.5 Full tinning – Tip tinning
22.1.6 Error when tinning