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molex TM2000 Handbook

Industrial crimp quality
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Industrial Crimp Quality Handbook
Doc No: TM-640160065
Revision: C
INDUSTRIAL CRIMP QUALITY
HANDBOOK
Order No. 64016-0065
Release Date: 00-00-02
Revision Date: 12-23-09
UNCONTROLLED COPY
Page 1 of 27

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  • Page 1 Industrial Crimp Quality Handbook INDUSTRIAL CRIMP QUALITY HANDBOOK Order No. 64016-0065 UNCONTROLLED COPY Doc No: TM-640160065 Release Date: 00-00-02 Page 1 of 27 Revision: C Revision Date: 12-23-09...

  • Page 2: Table Of Contents

    Industrial Crimp Quality Handbook Table of Contents SECTION Introduction to Crimp Technology Purpose and Scope Definitions and Terms Associated Materials Terminal Description 5.1. Features of Solderless Terminals 5.2. Barrel Serration/Dimples 5.3. Barrel Styles 5.4. Splices Procedures 6.1. Preparing the Wire 6.2.

  • Page 3: Introduction To Crimp Technology

    Industrial Crimp Quality Handbook SECTION 1 INTRODUCTION TO CRIMP TECHNOLOGY Developed to replace the need to solder terminations, crimping technology provides a high quality connection between a terminal and a wire at a relatively low applied cost. The methods for applying crimp terminations depend on the application, volume, and range from hand-held devices to fully automated systems.

  • Page 4: Purpose And Scope

    This handbook is structured so that parts, or all, of its contents can be used as a procedural guide for ISO requirements. Scope This handbook is intended for Molex customers who are crimping Molex open and closed barrel crimp terminals and are using Molex tooling. The handbook's contents may slightly differ from other connector manufacturers' or individual company guidelines and procedures.

  • Page 5: Definitions And Terms

    Industrial Crimp Quality Handbook SECTION 3  Circular Mil (CM) A unit of area used to indicate wire size. It is the DEFINITIONS AND TERMS computed total cross sectional area of conductors. One circular mil equals cross-sectional area of a ...
  • Page 6  Insulation Crimp Height Molex does not specify insulation crimp heights  Extrusions (Flash) because of the wide variety of insulation thickness, These small flares form on the bottom wire barrel material, and hardness.
  • Page 7 Industrial Crimp Quality Handbook Within the terminal’s range, an insulation grip may the terminal, causing them to break off. The not completely surround the wire or fully surround connection is weakened if the wires are cut or the diameter of the wire. This condition will still nicked.
  • Page 8 Industrial Crimp Quality Handbook If this does not occur, resistance can increase. connection. It is a synonym for contact. There are Over-crimping a crimp termination will reduce the two main types, which include the open barrel and circular area of the conductor and increase the closed barrel.
  • Page 9 Industrial Crimp Quality Handbook associated insulation. There are two kinds: a solid  Wire Stop wire, which is one single strand of material, or It is a stop at the end of a terminal wire barrel. It stranded group of wire, which is a bundle of wires prevents wire from passing completely through the twisted together to act as one.

  • Page 10: Associated Materials

    Industrial Crimp Quality Handbook SECTION 4 ASSOCIATED MATERIALS  Caliper It is a gauge, consisting of two opposing blades, for measuring linear dimensional attributes.  Pull Tester A device used to determine the mechanical strength of a crimp termination. Most pull testing is done with a device that clamps the wire, pulls at a set speed,...

  • Page 11: Terminal Description

    The properties of the base material must be evaluated. The material (metal) is either copper or brass depending on the product.  Molex base metals are purchased, inspected, and received to product specifications.  Most of these terminals are applied the guidelines of UL; Underwriters Laboratories is a US organization that sets certain standards for connector testing.

  • Page 12: Barrel Styles

    It is available in 10 to 26 AWG (0.10 to 6.60mm The barrel is the part of the terminal that is crimped TIN-PLATE around the wire. Molex offers different styles listed BRASS SLEEVE below. TONGUE (STYLE VARIES) 1.
  • Page 13 Industrial Crimp Quality Handbook 7. The Perma-Seal STAR RINGS MULTI STUDS NYLON SHRINK ™is specifically TUBING designed for water resistant applications. The color-coded barrel PERMA-SEAL™ has a permanent FEMALE QUICK rigid color-coded nylon insulated sleeve. It has a MALE QUICK DISCONNECTS DISCONNECTS funnel entrance that eliminates wire strand fold back.

  • Page 14: Splices

    Perma-Seal Splices™ 5.4 Splices The tough sleeve of Perma-Seal splices resist abrasion and cutting. This protective helps to Molex offers standard and special splices for nearly maintain the insulation and sealing properties even every type of wiring need. in hostile environments, not ...
  • Page 15 Industrial Crimp Quality Handbook  Parallel Splice This connector has stripped wires that lie side-by- side in the splice. They are secured by a single crimp in the middle.  Window Butt Splice This connector has military approval (Mil-T-7928/5) to withstand the harshest environments. The window guarantees proper wire insertion and crimp tool alignment.

  • Page 16: Procedures

    Industrial Crimp Quality Handbook SECTION 6 REJECT ACCEPT PROCEDURES Improper Stripping “Nicked” Strands 6.1 Preparing the Wire Check the stranded wire to see if any strands have loosened and expanded to be larger than the wire and the insulation together. If this has occurred, twist the Proper Stripping Undamaged wires to the size they were before they were stripped.

  • Page 17: Setup And Operation Of A Hand Crimp Tool

    Industrial Crimp Quality Handbook track position. Manually cycle the press and check 3. Place the terminal in the tool. Select the proper the feed finger for feed location, go to procedure 7. color-coded crimp nest. 11. Evaluate conductor brush. If adjustment is 4.

  • Page 18: Crimping Dies

    6.5 Crimping Dies The Molex product line includes seven types of dies for different terminals: Two piece INDENTOR CRIMP, VersaKrimp™ Two piece CONFINED CRIMP, Krimptite™ and VersaKrimp™...
  • Page 19 Industrial Crimp Quality Handbook Molex provides a complete line of fully automatic wire such as ARTOS, KOMAX, and others. This Manual processing machines, semi-automatic and manual wire shows the basics of Manual and Semi-Automatic crimping tools. Each system is tailored to our customer’s equipment.

  • Page 20: Quality Crimps

    Industrial Crimp Quality Handbook SECTION 7 REJECT ACCEPT QUALITY CRIMPS Insulation Insulation Quality is something that must be measured by some Slightly Pierced or set of criteria. Four major agencies give test criteria for Damaged Crushed quality of solderless terminals. They are: ...
  • Page 21 Industrial Crimp Quality Handbook  Good Bell Mouth Present ACCEPT REJECT REJECT ACCEPT Wire Slight Wire Bell Mouth Crimped Protrudes No Bell Mouth Wire Crimp  Wire Extension 1. Be sure that a good bell mouth is present in the 1.
  • Page 22 Industrial Crimp Quality Handbook 1. Be sure that the wire is visible in the inspection 1. Be sure that the wires are either flush with the window so that there is evidence of a good end of the conductor barrel or extend past the crimp.
  • Page 23 Industrial Crimp Quality Handbook  Insulation Support Crimp REJECT ACCEPT Metal Sleeve Snug Metal Sleeve Not Snug 1. On closed barrel terminals that have a secondary metal sleeve (AviKrimp™), the metal sleeve should be formed snugly around the wire. UNCONTROLLED COPY Doc No: TM-640160065 Release Date: 00-00-02 Page 23 of 27...

  • Page 24: Importance Of Proper Crimping

    Industrial Crimp Quality Handbook SECTION 8 8.2 Testing Mechanical IMPORTANCE OF PROPER CRIMPING The tensile test or pull test is a means of evaluating the Once the correct terminal is selected, proper mechanical properties of the crimped connection. The attachment to the wire is critical. One indication of the chart on this page shows the UL and Military importance of proper crimping is evidenced in a study Specifications (MIL-T-7928) for various wire sizes.

  • Page 25: Final Tensile Value

    Another way to cause tensile failure is not compressing the barrel enough to hold the conductor Dielectric tests are made on insulated terminals after securely. Molex crimp tools are designed to eliminate crimping to determine that the crimp process is not these problems.

  • Page 26: Crimp Joints

    Industrial Crimp Quality Handbook corners of the crimp shape and more evenly distribute the forces of the crimp. Brazed barrel terminals usually give higher tensile test than the non-brazed (for specific values, tensile tests Where: must be performed on each terminal). R is the resistance (in milliohms) E is the voltage drop (in millivolts) Annealing...

  • Page 27: Miscellaneous

    2222 Wellington Ct. 1-800-78MOLEX 81-462-65-2324 65-6-268-6868 49-89-413092-0 Lisle, IL 60532 U.S.A. amerinfo@molex.com feninfo@molex.com fesinfo@molex.com eurinfo@molex.com 630-969-4550 Fax: 630-969-1352 Visit our Web site at http://www.molex.com UNCONTROLLED COPY Doc No: TM-640160065 Release Date: 00-00-02 Page 27 of 27 Revision: C Revision Date: 12-23-09...

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