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The Crimp Quality Monitor II monitors the forces that occur during the crimping process. The forces are the
result of forming the crimp profile of the terminal and the compression of the wire strands within the terminal.
Headroom is the difference between the peak force of a complete crimp and an empty crimp.
A complete crimp is defined as a crimp at nominal crimp height, with both the insulation and the wire
barrel properly filled with the wire.
An empty crimp consists of only the insulated wire crimped in the insulation barrel of the terminal.
Headroom is specified as a percentage. Studies have shown that Crimp Quality Monitors have a better
detection capability when the headroom is greater than 35%.
Crimped terminals that use a small wire (in some cases, the smallest allowed by the manufacturer)
rarely meet this 35% minimum requirement. In this case, a Crimp Quality Monitor II might not be very
effective at detecting minor crimping defects.
A crimped terminal with a larger specified wire is more likely to exceed this 35% minimum requirement,
allowing the Crimp Quality Monitor to perform better and detect more crimping defects.
The quick headroom check described in section 0 provides a better understanding of how successful Crimp
Quality Monitoring will be with the wire and terminal combination you are using.
2.8.2 Crimp Height
The crimp height is the measured height of the terminal on the wire. The CQM II uses a patented method to
analyze data from the precision sensors and calculate the crimp height of the terminal.
The maximum value for a good crimp is the nominal plus the tolerance.
The minimum value for a good crimp is the nominal minus the tolerance.
