BROCHURE Applicators (English)
Contents
1. Crimp height can be tested with a micrometer that has been fitted with appropriately shaped jaws More effective is the TE Crimp Quality Monitor CQM which can be installed on the terminator to provide real time 100 measurement Increasing Mechanical Strength amp Electrical Performance Decreasing Crimp Height gt Actual real time measurement of force vs ram position shows a good quality crimp NIV T For information about tooling call 888 777 5917 or 717 810 2080 E email toolingsales te com Catalog 296393 2 Revised 10 2011 For drawings or technical data contact your TE Connectivity sales engineer or call the Technical Support Center 1 800 522 6752 Dimensions are in millimeters unless specified otherwise Values in brackets are English equivalents unless specified otherwise Specifications subject to change Consult TE Connectivity for latest specifications TE Bs Applicators connectivity In the side feed applicator the applicator feed strip moves perpendicular to the axis of the individual terminals from side to side with respect to the operator End feed terminals move from the back of the applicator toward the operator barrel first for manual wire insertion Quality Applicators Making the Right Choice End Feed or Side Feed A Terminal Driven Decision Feed Determined by the Terminal Supply The two main classes of terminal feed are side2. e Pre feed and post feed cams k e Cut and no cut carrier options e Adjustable terminal stripper e Adjustable spring loaded terminal hold down e Mechanical counter e Fine adjust crimp height mechanisms Ocean Applicator Part Number System Because so many features have been added to the new applicator the part numbering system used to identify the applicators can be simplified significantly Now when ordering a new applicator the customer will only need to identify what style and feed type they require Part Number System Feed Type Description Part Number Atlantic Style Spare Parts Kit 7 2151054 7 Feed Type Description Part Number Fine Crimp Height Adjust 2 2151054 1 ee Fine Crimp Height Adjust 2 2151054 2 Fine Crimp Height Adjust 2 2151054 5 Fine Crimp Height Adjust 2 2151054 7 Spare Parts Kit 7 2151054 8 Non Crimp Height Adjust Applicator is designed to run in a terminator with System III Crimp Height Adjust Technology NIV T For information about tooling call 888 777 5917 or 717 810 2080 Mi email toolingsales te com Catalog 296393 2 For drawings or technical data contact your TE Connectivity sales engineer or call the Technical Support Revised 10 2011 Center 1 800 522 6752 Dimensions are in millimeters unless specified otherwise Values in brackets are English equivalents unless specified otherwise Specifications subject to change Consult TE Connectivity for latest specifications TE connec
3. after the operator activates the switch In pre feed applicators the terminal is positioned prior to crimping This is particularly useful for closed barrel terminals so that the operator can more easily insert the wire end NIV eee For information about tooling call 888 777 5917 or 717 810 2080 E email toolingsales te com Catalog 296393 2 For drawings or technical data contact your TE Connectivity sales engineer or call the Technical Support Revised 10 2011 Center 1 800 522 6752 Dimensions are in millimeters unless specified otherwise Values in brackets are English equivalents unless specified otherwise Specifications subject to change Consult TE Connectivity for latest specifications TE Applicators connectivity Choosing an Applicator Ocean Applicator Series With the knowledge and experience of over a half century designing and manufacturing world leading applicators and tooling TE Connectivity is taking terminal crimping to a new level Using the time proven HDM and HDI applicator platforms as a base and the innovation and improvements from the System MI Applicator TE is taking a large step forward TE has listened to customer input and market demands to innovate and improve the combined strength of these industry leading designs to create the new Ocean Applicator The lead and harness industry of today is more price and quality competitive than ever before Crimping standards continue to be raised to higher l
4. Fast Facts TE Connectivity applicators with reliable long life quality and construction for a vast variety of terminals from TE and other manufacturers Versatile applicators for side or end feed terminals In stock selection for over 5 000 terminal types Special designs to meet unusual and international requirements Highest quality replaceable crimp tooling Flexible plans for ownership or rental Options for fast cost effective troubleshooting and service Selection Use Maintenance and Troubleshooting for Maximum Productivity Applicators and tooling from TE Connectivity can be your key to productive profitable wire harness manufacturing These applicators come from a long tradition of quality reliability and precision Manufactured from high grade tool steels and processed through state of the art CNC equipment for tightest tolerances TE applicators are made for high repeatability and fast throughput Every piece goes through an exhaustive test and calibration process with each one shipped with test samples verifying operation and full documentation for operation adjustment and maintenance Applicators gt TE TE Connectivity offers an unmatched selection of applicator styles and terminal types with configurations for both TE and other manufacturers terminals Styles are available for non TE terminating machines from both domestic and foreign sources At TE we do more than
5. Ss Applicators connectivity Continuing Effective Crimp Performance Maintenance Keeps You in Correct Shut Height Production Having all your terminators set to the It s easy to overlook but routine correct shut height facilitates quick greasing can be a factor in reducing change from one terminator to production downtime Checking another This straightforward tooling inspecting crimpers and adjustment procedure calls for use of anvils before they break also will a calibrated shut height gauge If you support production continuity cannot perform this adjustment ask your TE field service person to do so Lubrication A Simple Step to Reliable Crimping Just as with any machinery lubrication of the applicator reduces wear and even protects against corrosion Specific use of contact lubricant on terminals prevents the friction that can lead to sticking in the crimper bent terminals and premature crimper wear Transporting Applicators Safely Although they are manufactured to withstand the impact of crimping crimpers and anvils do not fare well when they contact each other Such Proper adjustment of shut height contact can scrape the plating or the facilitates quick change of applicators crimping surface causing a friction into different terminators point Such a friction point can form metal buildup ultimately causing reject crimps and even tool breakage This problem is easily avoided Always leave a term
6. al NIV T For information about tooling call 888 777 5917 or 717 810 2080 E email toolingsales te com Catalog 296393 2 For drawings or technical data contact your TE Connectivity sales engineer or call the Technical Support Revised 10 2011 Center 1 800 522 6752 Dimensions are in millimeters unless specified otherwise Values in brackets are English equivalents unless specified otherwise Specifications subject to change Consult TE Connectivity for latest specifications TE Bs Applicators connectivity Standard Features on all Ocean Applicators One of the major design goals of the Ocean Applicator Series was increased flexibility By giving the applicator the ability to flex between different terminator configurations it allows customers to quickly adapt their applicators to whatever configuration is needed All parts to reconfigure the applicator are included and attachable to the unit for safe storage and quick access As standard equipment the new applicator will have all the accessories needed to switch between 30 and 40mm stroke terminators pre feed and post feed cam configurations and cut and no cut carrier options The wire stop wire stripper can also be easily adjusted for the desired applications and a mechanical counter is included for tracking cycle counts The applicator comes with all parts needed to configure it to any terminating method that is acceptable to the application Ba Standard Features
7. d from the terminal that can cause incorrect crimps on subsequent operations Determining Crimp Quality The connection designer having once specified the wire and terminal type also defines the crimp parameters The critical characteristic is the area reduction of the wire during the crimp A quality crimp must achieve the required area reduction without inducing conditions such as flash over or under crimp or bending which can compromise the reliability of the connection Beyond visual inspection the traditional test is pull out force This is a gross measure of crimp quality and may be difficult to perform on a 100 basis in a production environment Crimp force has also been used as a measure but by itself does not provide the data required Driven by the requirements of 6 Sigma and other international quality standards TE has developed crimp height measurement testing technology which provides dependable non destructive evaluation of 100 of crimped terminals without impact on production throughput Crimp height measurement is a well established methodology and in combination with crimp force measurement is superior to destructive methods sampling methods or techniques that depend on crimp force alone Material buildup in the crimper results in gross deformation of the crimped terminal Material buildup on the crimper results in visible deformation of the outer crimp surface in this example
8. ding can result in oremature wear of the crimper because the terminal contacts the crimper surface in unprotected areas The applicator must be capable of repeatable feed distances or both tool life and crimp quality will be compromised Be certain that the feed is properly set Your user s manual gives the full procedure for feed adjustment Tooling Alignment is Crucial Incorrect tooling alignment can mean rejects due to excessive flash or terminals sticking in the crimper and being damaged or bent It also can reduce tooling life leading to out of specification crimping and oremature tool failure A simple setup procedure using heavy paper such as that taken from the terminal supply reel can ensure proper alignment of the crimper to the anvil This should be performed on a periodic basis or whenever there are signs of incorrect alignment When the crimper and anvil are not aligned it is impossible to achieve a good crimp NEV T For information about tooling call 888 777 5917 or 717 810 2080 E email toolingsales te com Catalog 296393 2 Revised 10 2011 For drawings or technical data contact your TE Connectivity sales engineer or call the Technical Support Center 1 800 522 6752 Dimensions are in millimeters unless specified otherwise Values in brackets are English equivalents unless specified otherwise Specifications subject to change Consult TE Connectivity for latest specifications TE
9. eep your production running Catalog 296393 2 10 11 Application Tooling 2011 Tyco Electronics Corp AMP AMP O LECTRIC AMP O MATIC TE Connectivity logo and TE Connectivity are trademarks All other trademarks used are the properties of their respective owners Tyco Electronics Corporation Harrisburg PA 17105 Phone 717 564 0100 Fax 717 986 3316 Disclaimer While TE Connectivity has made every reasonable effort to ensure the accuracy of the information in this catalog TE Connectivity does not guarantee that it is error free nor does TE Connectivity make any other representation warranty or guarantee that the information is accurate correct reliable or current TE Connectivity reserves the right to make any adjustments to the information contained herein at any time without notice TE Connectivity expressly disclaims all implied warranties regarding the information contained herein including but not limited to any implied warranties of merchantability or fitness for a particular purpose The dimensions in this catalog are for reference purposes only and are subject to change without notice Specifications are subject to change without notice Consult TE Connectivity for the latest dimensions and design specifications a APPLICATION 8 TOOLING connectivity
10. evels of quality and repeatability The industry continues to expect more from application tooling The new Ocean Applicator Series was designed specifically to exceed the requirements of today and meet the demands of tomorrow By consolidating our applicator offering to this new Ocean Applicator TE can provide design consistency and tooling standardization to the market One of the major benefits to the customer is offering the ultimate flexibility with a choice of feeding options New and improved Mechanical and Pneumatic feeds combined with the innovative and precise Servo Feed option The Ocean Series design makes it possible for customers to perform field upgrades to System III technology It will provide an upgrade path for terminal intelligence that allows the machine to obtain set up features as the applicator is upgraded Request Catalog 4 1773460 5 for more information about the Ocean Applicator Series or view it online at tooling te com applicator asp One Applicator Platform Modular Family Design e 2 ram interface styles C Atlantic or Pacific style ram collar e Same wire crimper insulation crimper and anvil used on both applicator styles e 3 feed options Mechanical Pneumatic Servo e Same feed units can be used on Side Feed and End Feed style applicators All units can be easily removed and interchanged for upgrades if desired Pacific Style SF Servo Pacific Style SF Pneumatic Pacific Style SF Mechanic
11. feed and end feed This determination depends on the terminal geometry stamping process and other factors in the terminal manufacture In both cases the terminals are supplied in a continuous strip coiled on a reel For side feed where the terminals move typically into the applicator from the operator s left to right the terminals are formed attached to a carrier strip that includes feed holes spaced with the same pitch as the terminals on the strip The axis of the terminals i e the direction that the wires are inserted for crimping is perpendicular to the feed direction so the terminals are parallel on the strip As part of the crimp process the terminal is cut free from the strip which is Side feed terminals a are made on a single or double carrier strip End feed discarded terminals b are For end feed the terminals enter the seri pil applicator from the rear and move Yen Se pale toward the operator barrel end first In Ss mich etal oF this case the terminals are aligned with have too great a the direction of motion and have blank b pitch if made as metal between the front edge of one the side feed crimp end and the rear edge the trailing terminal end of the next There is no separate carrier As part of the crimping process this small blank piece of metal or slug is cut out and discarded Pre Feed or Post Feed In post feed applicators the terminal is positioned for crimping
12. feed post feed Loose Piece Large Wire Applicators Note All loose piece applicators have a micro switch installed at the end of the moveable table stroke This allows it to be Dedicated for Crimpmatic 970 97 Wire Range up to 40 0mm Fine Adjustment Press Stroke 44 0mm Shut Height 158 0mm Moveable table with dedicated terminal seat according to terminal geometry to load and unload terminals Stroke 40 to 50mm Custom designs available for nearly any terminal connected in the terminator electrical system for preventive safety Pneumatic Large Wire Applicator Pneumatic Mid Size Wire Applicator Loose Piece Large Wire Applicators For information about tooling call 888 777 5917 or 717 810 2080 Need More Information A email toolingsales te com Catalog 296393 2 Revised 10 2011 For drawings or technical data contact your TE Connectivity sales engineer or call the Technical Support Center 1 800 522 6752 Dimensions are in millimeters unless specified otherwise Values in brackets are English equivalents unless specified otherwise Specifications subject to change Consult TE Connectivity for latest specifications 10 Bp TE ed Applicators connectivity Selecting the Applicator for Your Requirements A convenient lookup function on the TE web site will guide you through lt TE applicator selection and provide access to all necessary documents and drawings 1 Use yo
13. g te com europe applicator asp JE Mini liester a iam par Teena ee HEE Replied Pa Hamim mMasgtp trisi 1 ets i isr P Z EET Ta i g gmt hee ree rng ca Tooling Categories for 61116 3 DE tira a soci of ec de eed ees ope beeing or This powerful search application If you don t find what you need allows you to search by terminal or that does not mean that there is not applicator part number anything available for your application Call 888 777 5917 or 717 810 2080 for personal assistance or email toolingsales te com Simply enter the part number select a manufacturer from the drop down box and our application will display a comparative array The data in this application is Additional information is available updated on an ongoing basis via hypertext including the specific PN s required for the different application options NEI eee For information about tooling call 888 777 5917 or 717 810 2080 E email toolingsales te com Catalog 296393 2 For drawings or technical data contact your TE Connectivity sales engineer or call the Technical Support Revised 10 2011 Center 1 800 522 6752 Dimensions are in millimeters unless specified otherwise Values in brackets are English equivalents unless specified otherwise Specifications subject to change Consult TE Connectivity for latest specifications Request for New Applicator Quotation Company Name C
14. ical data contact your TE Connectivity sales engineer or call the Technical Support Center 1 800 522 6752 Dimensions are in millimeters unless specified otherwise Values in brackets are English equivalents unless specified otherwise Specifications subject to change Consult TE Connectivity for latest specifications TE connectivity No buildup of material is visible on a chromium plated crimper surface after 100 000 terminations Note significant buildup of material on an unplated crimper surface after only 60 000 terminations Crimp height can be measured using a micrometer with appropriately shaped jaws The TE Crimp Quality Monitor uses sensors mounted on the terminator ram to combine crimp force and ram position in a calculation of crimp height on a real time basis Applicators 4 Surface Treatment A commonly accepted approach to improved crimp tooling performance and life has been to apply a surface treatment to the crimp area Applying an appropriate surface treatment to the wire crimper will have the most benefit to crimp performance and tooling life An example of an effective treatment is chrome plating Chrome plating has a very low coefficient of friction so there is less tendency for terminal distortion It also has greater surface hardness reducing adhesive wear Finally the plating enhances resistance to adhesion and cold welding so there is no buildup of material transferre
15. imp Work Basic Status Helght Index Foree P2P FFT Last Crimp gt ERT neem i PENT EEE ET eT regu ur Pass FFT 12 EY Applicators Crimp Quality Monitor II Simply put crimp height measurement is the best non destructive way to ensure meeting the stringent mechanical and electrical properties of the crimp New easy to use intuitive menus along with enhanced monitoring and graphing lead the improved feature set of the CQM II Another major enhancement is the ability to use CQM II on non TE terminators Versatile On screen programmability allows quick flexible job set up Enhanced ability to support the use of USB peripherals such as flash drives for database backup saving reports and updating firmware It also includes a full library of USB printers for easy printing of the many graph and report options Precise Crimp height measurements are repeatable to within 0 12mm 0 0005 for every crimp analyzed CQM II is the only crimp monitoring system that offers continuous Crimp Height analysis for every crimp produced Five different analysis methods monitor the process to the fullest extent This ensures quality crimps are produced and faulty crimps are detected Convenient Setup is simple and fast Only a few parameters need to be set to get the system up and running All functions are controlled through the touch screen with an intuitive easy to use graphical interface The system walks you through al
16. inal in the crimp tooling when moving the applicator from one location to another This allows the terminal to receive any possible contact and protects the tooling NIV T For information about tooling call 888 777 5917 or 717 810 2080 E email toolingsales te com Catalog 296393 2 For drawings or technical data contact your TE Connectivity sales engineer or call the Technical Support Revised 10 2011 Center 1 800 522 6752 Dimensions are in millimeters unless specified otherwise Values in brackets are English equivalents unless specified otherwise Specifications subject to change Consult TE Connectivity for latest specifications TE Applicators connectivity A simple cross reference lookup will help you find the replaceable tooling for your application 15 TE Connectivity Replaceable Tooling Only by the use of genuine TE Connectivity tooling can you be assured of the longest tool life and most reliable production The design materials and manufacturing quality of TE tooling translate directly into fewer rejects and fewest breakdowns and interruptions To determine the part number for tooling for a specific applicator simply set your web browser to www tooling te com searchparts asp enter the applicator part number and click on Search Parts The part numbers of replaceable tooling will be presented The same lookup allows you to enter the part number of a crimper and find out what applicators it
17. is suitable for The wire crimper is configured for precision positioning and adjustment Insulation crimpers follow the positioning of the wire crimper with a separate height adjustment disc TE quality crimpers are available for thousands of wire and terminal requirements A AT For information about tooling call 888 777 5917 or 717 810 2080 E email toolingsales te com Catalog 296393 2 For drawings or technical data contact your TE Connectivity sales engineer or call the Technical Support Revised 10 2011 Center 1 800 522 6752 Dimensions are in millimeters unless specified otherwise Values in brackets are English equivalents unless specified otherwise Specifications subject to change Consult TE Connectivity for latest specifications The Right Choice for Crimped Connections With a long standing tradition of quality TE Put TE quality crimp tooling to work in your Connectivity brings you a complete solution for production Contact the Technical Support Center at 1 crimped terminal manufacturing 800 522 6752 call your TE authorized representative e Precision applicators for nearly any terminal choice or visit www tooling te com for more information e Crimp Quality Monitor H to maintain the highest quality performance and production dependability e Highest quality replaceable crimp tooling e Convenient web based tools for finding the parts for your exact requirement e Service and support to k
18. l is plastically deformed and extruded to complete the termination The anvil experiences some of the same conditions but to a much lower level of severity Specific material characteristics bearing on the crimp process include the toughness to withstand the shocks generated during crimping and sufficient wear resistance to maintain dimensional tolerances 3 Surface condition Surface condition can affect the performance of the crimp tooling as well as the longevity of service A hard smooth surface improves adhesive wear properties and thus increases service life The other attribute that needs to be considered is friction Friction is a contributing factor in determining the final crimp form and process characteristics Low tooling friction results in lower crimping force and thus can influence crimp form as well as tooling life Consistent frictional characteristics between tooling sets reduces process variation Crimp Force Versus Distance Cleaned High Friction a Lubricated with crimping lubricant Grime Force Ibs Lubricated with grease O06 O Dig 0 02 0 00 0 02 O 04 0 06 0 08 Distance inches Figure 16 Crimping forces versus distance A polished lubricated crimper surface reduces friction and the associated material buildup NIV eee For information about tooling call 888 777 5917 or 717 810 2080 E email toolingsales te com Catalog 296393 2 Revised 10 2011 For drawings or techn
19. l the required steps to start production CQM II has more choices to observe and monitor the crimping process than ever before Analysis Methods The five analysis method s can be used individually or in combination to provide the most flexible and complete coverage of the crimping process Crimp Height The crimp height is the measured height of the terminals crimp barrel formed around the wire Crimps are analyzed to be within the set tolerance zone Work Index The work index is a value that is used to compare the relative position of a specified section of the crimp curve that occurs while the wire and terminal are compressed Crimps are compared to historical data to determine pass fail The work index is a dimensionless value Peak Force The peak force is the maximum force reading that occurs during the crimp minus the idle force reading Crimps are compared to historical data to determine pass fail The peak force is a relative value Point to Point P2P A series of points are established along the crimp curve in the P2P analysis During production each point is compared to its upper and lower control limits and if no points are out of their limits the analysis method considers the crimp to be a PASS crimp Fast Fourier Transform FFT The FFT analysis method converts the force profile into its component frequencies It computes mean and standard deviation for each of the lowest 32 frequencies from the learn crimps updates the
20. lingsales te com Catalog 296393 2 Revised 10 2011 For drawings or technical data contact your TE Connectivity sales engineer or call the Technical Support Center 1 800 522 6752 Dimensions are in millimeters unless specified otherwise Values in brackets are English equivalents unless specified otherwise Specifications subject to change Consult TE Connectivity for latest specifications TE connectivity W crimp ELO Overlap Crimp O crimp img Applicators Common Crimp Forms A brief review of common wire and insulation crimps indicates the variety of crimping requirements that can be implemented in TE Connectivity applicators F CRIMP The most common crimp form Features a U shaped open barrel which is closed during the crimp cycle pressing tightly together with the conductor This form is also common as an insulation crimp TAB LOK An asymmetrical terminal useful when there is only a narrow space available for the terminal Incorporates a locking tab to support the asymmetric forces when it is in use W CRIMP Common with metallic closed crimp barrels for both stranded and solid conductors C CRIMP A metallic closure with plastic barrel on top of it provides good support for insulation OVERLAP CRIMP Insulation crimp suitable for leads with thin walled insulation WRAP OVER CRIMP An insulation crimp in which the crimp ends interlace completely enclo
21. mean and standard deviation with each good crimp If 4 or more frequencies are outside the tolerance limits the crimp status is FAIL Otherwise the crimp status is PASS NIV T For information about tooling call 888 777 5917 or 717 810 2080 E email toolingsales te com Catalog 296393 2 For drawings or technical data contact your TE Connectivity sales engineer or call the Technical Support Revised 10 2011 Center 1 800 522 6752 Dimensions are in millimeters unless specified otherwise Values in brackets are English equivalents unless specified otherwise Specifications subject to change Consult TE Connectivity for latest specifications TE connectivity The Technical Support Center can provide access to telephone troubleshooting on site service or factory level repair of applicators and electronic equipment An over fed terminal can scrape the entire crimper surface 13 Applicators Continuing Effective Crimp Performance Service While on site service may appear to be the most convenient a less expensive solution may be to ship your applicator to our Applicator Terminator Service Center Services include e Warranty Services with no charge for labor or parts e Calibration Services e Equipment Repair to application specifications e Quick Turnaround e 90 day Warranty on Repairs Technical Tips Feed is Critical Misfeeds are the most common cause of production downtime Over or under fee
22. ns TE Connectivity quality tooling is proven through years of experience to achieve superior performance Four aspects of the crimp tooling have the maximum impact 1 Geometry and Associated Tolerances Terminals are designed to perform to specification only when the final crimp form is within a narrow range of dimensions Controlling critical crimp dimensions is influenced by many factors including e Wire size and material variation e Terminal size and material variation e Equipment condition The final quality and consistency of a crimp can never be any better than the quality and consistency of the tooling that is used If other variations could be eliminated tooling can and should be able to produce crimp forms that are well within specified tolerances Also variation from one tooling set to another should be held to a minimum Crimp tooling features that are well controlled and exhibit excellent consistency from tooling set to tooling set can result in shorter setup time as well as more consistent production results 2 Material The wire crimper and the anvil have different functional demands Both have the need to withstand high loads and moderate shock However the wire crimper is in fact an aggressive forming tool It must withstand high shear loading that is a result of frictional loads generated as the terminal barrel slides along the crimper surfaces in the forming process and then as the barrel termina
23. nt any special crimp cut off bend housing requirements or special qualification requirements Please complete this form in its entirety All the information is required in order to provide a quotation Be sure to include contact name for further communication Submit a copy of this information product prints or 5 sample terminals on carrier strip and an application specification or 5 properly terminated samples to your TE Connectivity Sales Representative Note When an applicator is ordered if applicable 50 seals and one terminal housing and for the final assembly and applicator qualification TE connectivity a jaan otto 10 aS 100 SAMMI a md e ate 10 50 Basic Status Crimp Work Crimp Height 0 0743 in Pass Work Index 274 aa Fail Peak Force 3 009 Pass Point To Point 14 Status Calibrated Yaluee 2 0 Reset Gain Crimp Height Calibration Measured 075 Crimp Height Entry Height Index Force Peak P P WL DDGS in eto M0770 f LEOL Dorain Ti OOF 30 in LOL 311 LO F91 WoL Lard Lok ad Force vi Position Y Total 10 eg 63537 2 140 o SAMPLE aod 10 5 Crimp Work Basic Status Height Index Crimp MPi daan aana A History TAN umber w Peak Force Crimp Height Distribution P2P FFT d prepr if oo eH niai Std De Production Crimp Height ed AVS 07 3 MiA otal 10 E O O 100 ed E O O 50 Cr
24. settings for wire and insulation crimp height feed parameters and adjustments Summarizing the conductor crimp ensures a good connection between the wire and the terminal The insulation crimp supports the wire to reduce the effects of vibration and movement on the conductor crimp Accomplishing the Desired Crimp Terminal type and wire parameters depend on the production requirement Both open barrel and closed barrel terminals are supplied on continuous strips Crimping is performed by an applicator a mechanism that performs the functions of feeding the terminal cutting the terminal from the strip and crimping wire and insulation Crimping force is provided by a terminator in which the applicator is mounted Terminators and other lead processing systems can incorporate varying degrees of automation from one at a time machines with wires hand fed activated by an operator driven foot switch to fully automated lead makers that cut and strip the wires and feed wires and terminals Applicators are configured by TE according to the wire and terminal type and in some cases by the terminator specifications Terminals to be crimped in automatic equipment are generally supplied in continuous strips shown here or in some cases as loose pieces A terminator provides the crimping force for the applicator installed within NEV T For information about tooling call 888 777 5917 or 717 810 2080 E email too
25. sing the insulation O CRIMP Useful for processing individual seals Tab Lok Wrap over Crimp NIV T For information about tooling call 888 777 5917 or 717 810 2080 E email toolingsales te com Catalog 296393 2 For drawings or technical data contact your TE Connectivity sales engineer or call the Technical Support Revised 10 2011 Center 1 800 522 6752 Dimensions are in millimeters unless specified otherwise Values in brackets are English equivalents unless specified otherwise Specifications subject to change Consult TE Connectivity for latest specifications TE connectivity okie U gt gt PoE s WIRE CRIMPED WIRE BARREL AREA OT RIMP AREA WIRE RR Area Index Total Crimped Area Total Un Crimped Area The connection designer selects a terminal and crimp parameters that achieve the desired reduction in Area Index Proper crimper and anvil design provide necessary clearances without excessive tolerances that can lead to flash and other crimping errors Significant flash can be generated with excessive anvil to crimper clearance as illustrated by nominal design condition a and 0 003 in over nominal condition b Applicators Crimp Tooling A Critical Element for a High Quality Crimp The crimp tooling the actual crimper and anvil that are in contact with the wire and insulation is one of the most important factors in meeting crimp quality specificatio
26. supply the world s leading applicators We provide service technical support and maintenance and repair both on site and at our service centers We know how critical reliable production is and our products and services are committed to keeping your production running We also recognize that your needs may change quickly so our extensive selection of applicators is available in flexible purchase and rental plans With these choices you can manage your costs while maintaining the capacity and capability you need APPLICATION TOOLING connectivity TE connectivity Successful crimping results from the correct relationship between wire terminal and crimping tool Applicators are built for specific terminal and wire sizes and feed arrangements Applicators Keys to Quality Crimping Crimping Conditions Crimp connections are the standard in industrial manufacturing maintaining good connection under extreme mechanical thermal and environmental conditions Successful crimping results from the correct relationship between wire terminal and crimping tool Once the terminal selection is made and crimping criteria defined by the connection designer the tooling characteristics are fully determined These conditions are realized in e Wire conductor section and insulation diameters and material e Terminal conductor and insulation barrel crimp styles and dimensions e Crimping equipment
27. tivity Crimpmatic 970 and 971 Machines The CRIMPMATIC 970 can process loose or reeled terminals for wires up to 16mm 5 2 AWG Working with even larger size wires The CRIMPMATIC 971 can handle all the way up to 50mm 0 AWG But automating the crimping process isn t the only benefit Crimping is faster and more reliable So your crimping process will be safer and more productive with higher quality finished products Both CRIMPMATIC models come in a space saving design have an inching mode for setup include a reel holder for spooled terminals and allow two handed operation for the application of loose piece terminals You can even order the following options e Crimp force monitoring e Fine adjustment of lower dead center e Paper spooler Crimpmatic 971 Crimpmatic 970 Applicators Pneumatic Large Wire Applicators for Strip Form Terminals Dedicated to Crimpmatic 970 971 Wire Range up to 40 0mm Fine Adjustment Press Stroke 44 0mm Shut Height 158 0mm Applicator Feed up to 50 0mm pre feed post feed Pneumatic Mid Size Wire Applicators for Strip Form Terminals For terminators with standard AMP style base plate 4 to 8 tons and Crimpmatic 970 with base plate for conventional applicators Wire Range up to 25 0 mm maximum Fine Adjustment Press Stroke 40 0mm Shut Height 135 8mm Applicator Base Plate Conventional Base Plate TE style Applicator Feed up to 50 0mm pre
28. ur web browser to go to http tooling te com applicator asp ara sparr irn T Mea TE Serica of Applicators Newt Applicator Sarias 2 Under More Information click on the link called Tooling Cross Reference 3 Enter the part number of the terminal in the indicated box and click on Search 4 On the resulting Part Detail page click on the Tooling link in the Related Part Information section This page also gives complete information on the selected terminal with links to drawings specifications and other documents 5 Click on your geographic region You will be taken to a page that gives references to appropriate applicators including references for selecting an applicator for use in a particular terminator with documentation and drawings 6 If you do not find an applicator to meet your requirements contact your TE sales engineer or the Technical Support Center at 1 800 522 6752 Applicators for Non TE Terminals Find Toalimg for Products 1 Use your web browser to go to http tooling te com applicator asp T Tyco Electronics Baist bea A ya 2 Click on the link called Applicators for non TE Terminals rials 3 Use your browser s Search function to find the terminal you need to crimp 4 If you do not find an applicator to meet your requirements contact your TE sales engineer or the Technical Support Center at 1 800 522 6752 Finding Applicators by Part Number Search Go to www toolin
29. ustomer Contact Title Address City State ZIP Code Country Phone Number Fax Number TE Connectivity Customer Acct Number Ram Type Type of Terminal 1 TE Terminal 1 non TE Terminal For non TE Terminal Use Terminal Manufacturer Manufacturer s Part Number include additional info Terminal to be inserted into housing J Yes Part Seal or grommet to be applied J Yes Part Carrier Strip Type I End to End I Loose Piece Large Wire I Other Specify amp attach terminal drawing Wire Gauge s Wire Crimp Height s Insulation Crimp Height s Insulation Outside Diameter s Pull Test Minimum Wire Quantity Crimped Simultaneously LJ Single J Multiple Cross Section Analysis LINo LlYes if yes order 1424359 1 Splice Application LJ No LiYes IfYes LJ Pigtail or LI Thru Splice E Mail Address Choose one of each category Feed Type J Mechanical _ Pneumatic _ Servo Terminator Stroke _1 30mm _1 40mm Crimping Machine _1 Leadmaker _1 Bench Large Wire Terminator _1 5 Ton _1 16 Ton Crimp Specification Information Indicate crimp specification dimensions and tolerances Open Barrel Wire Crimp W _ O Type W J Ey Type SR J o Type RS J oy Type Insulation Crimp Reel Feed Direction with operator facing front of machine _J Rear End to End J Left to Right Applicator Note Please list and docume
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