terminations stripping for quality crimping and … crimping on the insulation conductor stripping...

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Welcome To

Quality Crimping and

Stripping For

Terminations

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Components of a Quality

Termination

•Wire

•Terminals

•Tooling

•Documentation

•Quality Trained Personnel

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Components of a Quality

TerminationWIRE

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COPPER CONDUCTORS

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INSULATION TYPES

18AWG

18AWG

18AWG

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INSULATION VARIATION

18AWG

18AWG

18AWG

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Components of a Quality

Termination

WIRING

DEFINITIONS

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Components of a Quality

Termination

COAXIAL CABLE

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ELEMENTS OF A WIRE

Wire Strands Gage of Wire

Low Twist

High Twist

Solid

Insulation

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WIRE SIZES

12AWG

18AWG

24AWG

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WHAT IS CMA ?

d

D

CMA = D2

CMA = d x N

N = Number of Strands

2

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CMA CHART

STRANDS

CMA Number MM

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STRIPPING WIRE; GOOD STRIPS

Square, even cut

No nicks or cut strands

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STRIPPING WIRE; BAD STRIPS

Nicked Strand

Cut Strands

Cut at Angle

Tapered or Torn Insulation

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Results of Bad Strips = Loss of Electrical Characteristics

Nicked and cut strands =

Decreased electrical and

mechanical strength

Uneven or tapered strip =

Insulation in wire crimp

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COMPONENTS OF A QUALITY

TERMINATION

• Wire

• Terminals

• Tooling

• Documentation

• Quality Trained Personnel

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TYPES OF TERMINALSClosed Barrel

FAST-ON

Receptacle

Open Barrel, End Feed

Ring Tongue

Open Barrel, Side Feed

FAST-ON Tab

Closed Barrel

Slotted Ring

Tongue

Open Barrel

Pin

Open Barrel

FAST-ON

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PARTS OF A TERMINAL -OPEN BARREL

Wire Barrel

Wire Barrel and

Contact End

Wire Barrel and Contact End

with Insulation Support

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PARTS OF A TERMINAL -CLOSED BARREL

Wire Barrel

Contact End

Insulation Support

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ADVANTAGES OF INSULATION SUPPORT

Stress Point

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ENVIORMENTAL SPLICES

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TYPICAL CONTACT

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CONTACT COLOR CODE –

BIN CODE

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TYPICAL CONNECTOR

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COMPONENTS OF A

QUALITY TERMINATION

• Wire

• Terminals

• Tooling

• Documentation

• Quality Trained Personnel

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UGH! ME CRIMP GOOD !

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THESE ARE NOT CRIMPERS

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WIRE CUTTERS

Dike Cutting

(Incorrect)T Cutter Cutting

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TOOLS FOR CUTTING WIRE

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STRIPPERS

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WIRE STRIPPING

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STRIPPERS

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BASIC STRIPPER - GRIPPER

PADS AND BLADES

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CORRECT STIRIP LENGTH

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CORRECT STIRIPPING

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CORRECT STIRIP LENGTH

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CORRECT STIRIP LENGTHCorrect

Incorrect

-Correct stripping

-Insulation correctly

positioned into the insulator

support

Insulation stripping to long

Insulation stripping to short

and crimping on the

insulation

Conductor stripping too short

Strands crimped with the

insulator support

One or more strands of the

conductor not crimped

Correct

Incorrect

-Strands apparent in the

inspection hole

-The insulation penetrates

correctly into the cup

Insulation stripping too

short, conductor not visible

through the inspection hole

Insulation stripping too

long, the insulation does

not penetrate into the cup

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PROPER STRIP LENGTH AND PLACEMENT

OF WIRE

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FINISHED CRIMP

Bellmouth Must be Visible

Wire Strands Must be VisibleAnywhere in This Area

Cutoff Tabs Must be Visible

Wire Strands and InsulationMust Both be Visible Anywherein This Area

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IMPROPER PLACEMENT

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STRIPPING COAX

ShieldOuter InsulationDielectric

Center Conductor

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DANIELS CRIMPER WITH TURRET HEAD

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DANIELS CRIMPER TURRET HEAD

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SMALL DANIELS CRIMPER

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ENVIRONMENTAL SPLICE

CRIMPER

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ENVIRONMENTAL SPLICE

CRIMPING

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MOLEX CRIMPER

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MOLEX CRIMPING

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RED & BLUE LUGGER

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MECHANICAL AND

ELECTRICAL

CHARACTERISTICS

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Insulation Support Crimp

Wire Barrel Crimp

WIRE

Insulation Support Barrel

Wire Barrel

Strip Length

FUNCTIONS OF WIRE BARREL ANDINSULATION SUPPORT BARREL

(OPEN BARREL)

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FUNCTIONS OF WIRE BARREL ANDINSULATION SUPPORT BARREL (CLOSED

BARREL)

Wire Barrel

WIRE

Strip

Length

Insulation Support Crimp

Wire Barrel Crimp

Insulation Support

Barrel

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AREA REDUCTION

+WIRE =

4100 CMA WIRE BARREL =

6900 CMA

TOTAL =

11,000 CMA

CRIMPED

TERMINATION

8800 CMA

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MECHANICAL STRENGTH

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MECHANICAL STRENGTH

IncreasingMechanical

Strength

Increasing Crimping ForceDecreasing Crimp Height

Crimp

Design

Range

MechanicalStrength

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ELECTRICAL PERFORMANCE

Poor Termination

Good

Termination

Poor Termination

Good

Termination

Poor Termination

Poor Termination

Good

Termination

Good

Termination

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ELECTRICAL PERFORMANCE

Increasing Crimping ForceDecreasing Crimp Height

ElectricalPerformance

(DecreasingMill volt Drop

& Resistance)

Crimp

Design

Range

Electrical Performance

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CRIMP DESIGN PARAMETERS

IncreasingMechanicalStrength &Electrical

Performance

Decreasing Crimp Height

MechanicalStrength

Crimp

Design

Range

ElectricalPerformance

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COMPONENTS OF A

QUALITY TERMINATION

• Wire

• Terminals

• Tooling

• Documentation

• Quality Trained Personnel

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COMPONENTS OF A QUALITY

TERMINATION

• Wire

• Terminals

• Tooling

• Documentation

• Quality Trained Personnel

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QUALITY MEASUREMENTS

AND PROPERLY

CRIMPED TERMINALS

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CRIMP HEIGHT

Wire Barrel

Anvil

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PULL TESTING

Tensile Strength Tester

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A Winning Hand !