Donnerstag, 28 März 2024

 

=>>NEU: Die Crimpwochen 2024 in der Crimp Akademie<<=


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joomplu:3172 Willkommen im KabelForum

Seit vielen Jahren beschäftigt sich KabelForum mit Dokumentationen und Seminaren rund um die Kabelbearbeitung.

Begonnen hat alles damit, dass es keine tiefergreifenden Informationen rund um die Crimptechnik gab und die offiziellen Normen in Ihrer Aussagefähigkeit zur Crimpqualität sehr begrenzt waren und immer noch sind. So entstanden vor rund 20 Jahren die ersten Dokumentationen und Präsentationen zur Schulung von Mitarbeitern in der Kabelkonfektion.

Auch heute gibt es noch keine etablierte Berufsausbildung in der die Bearbeitung von Kabel und Leitungen sowie die Herstellung von Crimp- und Pressverbindungen erlernbar sind. Die Folge davon ist, dass in diesem Industriebereich Firmen ihre eigenen Ausbildungsprogramme installieren müssen.

Dabei stellen die ständig wachsenden Anforderungen an die Qualität von Crimpverbindungen immer neue Herausforderungen an Fertigung und somit auch an die themenorientierte Ausbildung von Mitarbeitern in der Kabelkonfektion.

In der Zwischenzeit sind unterschiedliche Dokumentationen, Präsentationen und Schulungstools entwickelt worden, die ständig aktualisiert und erweitert werden. Auch finden Sie hier Informationen über Seminare rund um die Crimptechnik und Kabelbearbeitung.

Fragen? Senden Sie uns bitte eine E-Mail an email@kabelforum.de

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

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