FineAdjust Applicator
Doc. No: TM-638004900
Release Date: 09-04-03
UNCONTROLLED COPY
Page 41 of 50
Revision: G
Revision Date: 01-15-13
A.3 Conductor Height Measurement
NOTE:
Conductor height should be measured with a blade type micrometer or a caliper.
CAUTION:
Care must be taken not to measure the extrusions
A.3.1 Crimp height off target
Cause:
1) Changed wire type, stranding or vendor.
2) Changed insulation diameter.
3) Changed crimp tooling.
4) Changed crimping press.(Shut-height)
5) Changed press type. (Manufacturer)
6) Changed terminal reel. (Lot code)
7) Changed tooling set-up.
8) Damaged or worn tooling.
Solution:
Adjust tooling back to target
(Refer to Section 2)
A.3.2 Crimp height variability too high
Cause:
1) Wire variability.
2) Terminal variability.
3) Damaged, loose, or worn tooling.
4) Measurement error *.
5) Cut or missing wire strands.
Solution:
1 or 2) Inspect incoming product for variability.
3) Tooling replacement or tightening.
4) Gauge capability analysis.
5) Tooling crimp height adjustment.
6) Stripping process adjustment.
* Most common cause of crimp height variability
A.4 Insulation Crimp
A.4.1
Preferred Insulation Crimp
It is preferred that the insulation crimp completely
surrounds the outside diameter of the insulation. The
terminal should hold on to the wire as firmly as possible
without cutting through to the conductor strands. It
should be noted that a preferred crimp only occurs in a
small portion of the full insulation range a terminal can
accommodate. A preferred insulation crimp is
recommended for high vibration or movement
applications.
An overlap insulation crimp is normally only developed
for high vibration or movement applications where the
wire diameter is near the lower terminal specification
limit.
A.4.2
Acceptable Insulation Crimp
CALIPER
Figure A-3.1
CRIMP HEIGHT MEASUREMENT
EXTRUSION
POINTS
MICROMETER
Figure A-4.1 Preferred Insulation Crimp
Figure A-4.2 Acceptable Insulation Crimp
