Crimp Quality

Manual

Insulation Cross Section Crimped Contact Photo Conductor Cross Section

Insulation Cross Section Crimped Contact Photo Conductor Cross Section

JST
The Quality connection
 Table of Contents

1. Crimping Checklist…………………………………………….. 3

2. Good Crimp Example………………………………………….. 4

3. Wire Position in Contact……………………………………….. 5

4. Strip Length……………………………………………………. 6

5. Contact Centered on Anvil…………………………………….. 7

6. Proper Bell Mouth……………………………………………... 8

7. Crimp Height…………………………………………………... 9

8. Wire Selection………………………………………………... 10

9. Uncollected Strands……………………………………………. 11

10.Tab dimensions………………………………………………… 11

11.Locking Lance…………………………………………………. 11

12.Bent or Deflected Terminal……………………………………. 12

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 Crimping Checklist
1. Check that the conductor chosen is within the specified range for the
contact.
2. Check that the insulation O.D. of the wire is within specification for
the contact.
3. Check that the appropriate crimp tooling is being used for the contact.
4. Check that the crimp tooling has been properly maintained.
5. Check that the wire is stripped to the appropriate strip length for the
contact.
6. Check that the conductor is not damaged in stripping process.
7. Check that the strands of the wire are not frayed.
8. Check that the applicator has been properly installed in the press and
any guarding has been properly installed.
9. Check that the conductor crimp height has been adjusted to the
specified range.
10.Check that the insulation barrel has been adjusted to provide proper
strain relief without puncturing the insulation to the point that the
conductor is damaged.
11.Check that the crimped contact has a proper bell mouth.
12.Check that the cut off tabs on either end of the contact are proper
dimensionally after crimped.
13.Check that there are no excessive burrs on the conductor crimp barrel
after crimped.
14.Check that locking lance on the contact has not been damaged after
crimped.
15.Check that the mating portion of the contact has not been deformed
after crimped.
16.Check that there is no excessive bend in the terminal after crimped.
17.Check that there is no excessive deflection after crimped.
18.Check that the wire is being crimped in the correct position.

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 SPS-61T-250

Insulation Cross Section Crimped Contact Photo Conductor Cross Section

SVF-42T-P2.0

Insulation Cross Section Crimped Contact Photo Conductor Cross Section

The above pictures are examples of good crimps and the cross sections of
these good crimps. When inspecting the cross section of a crimp the
following points should be checked:

Insulation

• Insulation barrel crimp is symmetric

• Insulation barrel sufficiently grasps the insulation for strain relief
• Insulation barrel does not penetrate the insulation and damage the
conductor
• Insulation does not extrude out between open insulation barrel

Conductor

• Conductor barrel crimp is symmetric

• Conductor barrel is closed and conductor does not extrude out of the
barrel
• There are no cracks in the contacts material
• There are no excessive burrs on the contact
• Conductor barrel wings do not touch the bottom of the contact

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 Wire Position In Contact

When the wire is properly positioned, the

conductor of the wire will protrude past the
conductor barrel 0.5~1.0mm. The insulation
will be halfway between the insulation
barrel and the conductor barrel. It is critical
that strip length is correct in order to
achieve proper wire position in the contact.

When a properly stripped wire is not

inserted into the contact far enough the
conductor does not protrude beyond the
conductor barrel and the insulation is not
halfway between the insulation barrel and
the conductor barrel. This condition will not
provide proper strain relief to the insulation.
This could also potentially reduce the
tensile strength of the crimp.

When a properly stripped wire is inserted

too far into the contact the conductor
protrudes too far past the conductor barrel.
In an extreme case the conductor will
interfere with the working area of the
contact and possibly prevent the contact
from properly seating. When the wire is
inserted too far into the contact the
insulation is beyond halfway between the
insulation barrel and the conductor barrel. In an extreme case the insulation
will be crimped in the conductor barrel.

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 Strip Length

When the wire is stripped to the specified

strip length the conductor will protrude
past the conductor barrel 0.5~1.0mm and
the insulation will be halfway between the
conductor barrel and the insulation barrel.

When the strip length is too long it is not

possible to properly position the wire in
the contact. Either the conductor will
protrude too far past the conductor barrel
and possibly interfere with the working
area of the contact or the insulation will
not be halfway between the insulation
barrel and the conductor barrel and the
insulation barrel will not provide proper
strain relief.

When the strip length is too short either the

conductor will not protrude past the
conductor barrel possibly lowering the
tensile strength or the insulation will be
crimped in the conductor barrel.

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 Contact Centered on Anvil
Left Of Center Properly Centered Right Of Center

It is very important that the feed of the crimping applicator is adjusted

properly. If the feed is off and the contact is not properly centered over the
anvil the cross section may not be symmetrical. As you can see from the
photos prior to cross sectioning above this problem is difficult to visually
detect. This problem is especially difficult to detect with a post feed cam
must be checked for during set up of the tooling. The symmetry of the
insulation cross section would be off as well.

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Proper Bell Mouth

The bell mouth is determined by the

placement of the contact over the anvil. If
the contact is properly adjusted there will
be a small bell mouth on the end of the
conductor barrel closest to the insulation
barrel. Adjusting the contact to the left will
make the bell mouth smaller. Adjusting to
the right will make the bell mouth larger.

A proper bell mouth will allow a transition

area to funnel the conductor into the
conductor crimp barrel so that the
conductor is not damaged.

If the contact is adjusted too far to the right

over the anvils the bell mouth will be too
large. On an end feed contact this
maladjustment can cause damage to the
insulation barrel and a large tab on the
working end on the contact.

If the contact is adjusted too far to the left

over the anvils there will be no bell mouth.
This will cause damage to the conductor
leading into the conductor barrel. Often
times some of the strands will be severed.
On an end feed contact a large tab will be
left on the insulation end of the contact and
part of the working area can be cut off.

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 Proper Crimp Height

The above contact has been crimped to the specified crimp height. The
conductor and insulation barrels are symmetric. Both barrels are closed with
no material is protruding out. The insulation barrel is properly grasping the
insulation and the conductor barrel has no excessive burrs, spaces, or any
cracks in the material.
Excessive Crimp Height

The above contact has been crimped tighter then specified. The insulation
barrel has cut through the insulation and into the conductor. The conductor
has been crimped so tight that the individual strands are no longer
discernable.
Insufficient Crimp Height

The above contact has been crimped looser then specified. The insulation
barrel is open and not grasping the insulation to provide strain relief. The
conductor barrel has large open spaces and the strands are not compacted.

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 Proper Wire Selection

The above contact has been crimped to the specified wire size. The
conductor and insulation barrels are symmetric. Both barrels are closed with
no material is protruding out. The insulation barrel is properly grasping the
insulation and the conductor barrel has no excessive burrs, spaces, or any
cracks in the material.
Oversized Wire

The above contact has been crimped on a wire that is above the specified
wire range. The conductor and insulation barrels will not close.

Undersized Wire

The above contact has been crimped on a wire that is below the specified
wire range. The insulation barrel is not lending proper strain relief. There are
large open areas in the conductor barrel. The wings of he conductor barrel
have touched the bottom of the contact.

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 Uncollected Strands
All conductor strands must be collected into the
conductor barrel when crimped. Uncollected strands
are not acceptable.

Proper Tab Dimension

Tab Too Large Good Tab Tab Too Small

Tab Too Large Good Tab Tab Too Small

Unless otherwise specified, the tab dimension should be 0.2~0.5mm. There

is usually a direct correlation between the size of the tab and the size of the
bell mouth.
Damaged Locking Lance

Damaged Lance Proper Lance Damaged Lance

Check that the locking lance is not deformed, bent, or damaged. The locking
lance will not retain the contact in the housing if it is damaged.

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 Bent or Deflected Terminals

Bent Down Good Sample Bent Up

Good Sample Deflected Up

Check that there is no excessive bent or deflection after crimping.

Written By: Approved By:

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