terminations stripping for quality crimping and … crimping on the insulation conductor stripping...
TRANSCRIPT
P1767 1
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 !