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Document and Revision
Specification Number
Procedure Owner
GME- COSEE Crimping CFM YEL-CE-S-214
Controlling Department
YEL-GME - COSEE
Crimping Force Monitor New
10.3. MAINTENANCE SETTINGS............................................................................................................................12
10.4. TEACH MODE ...................................................................................................................................................12
10.5. TEACH WHAT IS GOOD .................................................................................................................................13
11. TOLERANCE PARAMETERS ................................................................................................................ 13
12. TYPICAL ERRORS ................................................................................................................................. 14
12.1. MISSING STRANDS.........................................................................................................................................14
12.2. INSULATION IN THE CRIMP..........................................................................................................................15
12.3. DEFECTS ANALYSIS ......................................................................................................................................15
13. RELATED DOCUMENTS........................................................................................................................ 16
14. REVISION................................................................................................................................................ 16
GME Template Form No. YEL-CE-P-01_F1 Revision N 07.05.2012 Page 2 of 16

** REFERENCE ONLY **
** This Procedure is valid for the day printed - SEE NETWORK FILE FOR CURRENT ISSUE
Procedure Owner
YEL-GME - COSEE
1. OBJECT
The objective of this specification is to standardise and define clear criteria with respect to CFM
parameterization.
2. SCOPE
This specification is applicable to all activities related to CFM in all YEL W/H Plants. If the customer
specifications do not contain any or have insufficient directions with regard to CFM, the standards laid
down in this specification are to be applied.
However the customer requirements always take precedence.
3. RESPONSABILITIES
Global Manufacturing Engineering – COSEE Crimping (GME-CC):
The GME-CC department is responsible for creating, approval and controlling this specification. In
addition GME-CC will support the Plant/CSC to resolve any problem/difficulty on the appliance of this
specification.
European Quality Office (EQO):

The EQO has to approve the release of this specification and any further revision.
Yazaki Global Procurement/YEL Supply Management (Capital Equipment):

By means of the “Preferred Suppliers" list, the Yazaki Global Procurement/ YEL Supply Management
(Capital Equipment) department, specifies which equipments suppliers have been officially approved by
COSEE and are allowed to be used. All prices must be according to the supplier Global Purchasing
Agreement.
Process owner, Engineering and Purchasing Departments of the individual plants:

These are responsible to identify and control the availability of the required parts (e.g. wearable parts), the
documentation (material and processing specifications from CFM equipment supplier, documentation
according to order request from Plants / equipment supplier) as well as a sufficient amount of terminals
and wires to be produced and carrying out the proof of capability by the CFM equipment supplier. They are
also responsible to predefine tolerance for the several equipments available, per each crimping
combination.
It is Plant responsibility to translate this document into local language. Translation of each paragraph
can be inserted under the corresponding English texts on the actual document.
The English text will remain the official version and takes precedence in case of doubts.
Quality assurance departments of the plants:

The Quality Assurance Department carries out the internal approval specification using the cross-sectional
pictures, the capability study and the comparison with the original documents. This is done in the plant in
co-operation with the Process owner and the Tool Maintenance Dept. They also give its official approval in
case of any CFM intervention is done.
4. TERMS
CFM – Crimping Force Monitor (for Komax it is also called as CFA – Crimping Force Analyser)
CPU – Central Processing Unit
PK – Peak Force
PE – Production Engineering
** This Procedure is valid for the day printed - SEE NETWORK FILE FOR CURRENT ISSUE **
Procedure Owner
YEL-GME - COSEE
GME – Global Manufacturing Engineering

COSEE – Committee of Standardization and Evaluation of Equipment
EQO – European Quality Office
BCC – Bad Crimp Cutter
PN – Press Noise
5. DEFINITION
5.1. BASIC DEFINITION & CONCEPTS

Crimping equipment, which include both automatic machines and bench top press (P104 & P107), must
be equipped with a device for continuous automatic monitoring of crimp quality.
In case of P200 (Battery Cable Crimp Press) CFM can be installed depending of customer requirement
however by default it’s not mandatory to use it.
A Crimp Force Monitor (CFM) is an electronic device that compares the forces involved throughout a
crimping operation with those of a known good crimp (reference). In doing so, and by setting tolerance
levels, we can instantly tell if a crimping process is stable and that the terminals being produced satisfy
the necessary quality criteria.
All CFM measuring concept are basically the same. There is a load cell that measures force, some
different type of trigger device to tell the CFM when to start reading and a control unit that performs the
analysis. The CFM consists on three main parts (force sensor; encoder/trigger; CPU):
The FORCE SENSOR – register the forces that occur during the crimp. This sensor (piezo) is placed in
the press:
In the press ram;

Or in the base plate;
Or in the frame of the press (only in case of battery cable crimp press);
The optical ENCODER/TRIGGER – fitted to the crimping press, is required to tell when the CFM start
and stop analyzing the force signal.
The CPU (Central Processing Unit) – the signals from the sensor and triggers are transferred into the
electronics boards and combined in the control unit (CPU) to create a force-angle or a force-time curve.
COMPUTER
CURVE
X
Procedure Owner
YEL-GME - COSEE
5.2. INTRODUCTION TO THE CURVE FORCE
What is the reference curve?
The reference curve is the force curve from a good crimp (visually, crimp standard measurement…). If
the learn process is successful, the CFM generates the reference crimp curve to which the CFM will
compare all subsequent crimps. Each subsequent crimp is analyzed in shape and amplitude to
determine if it passes or fails according to the tolerance parameters.
It’s strictly recommended to use test Reference

samples (of same wire kind) for CFM curve
teach. In case of Manual Crimping the
stripping must be made in semi-automatic
stripping machines in order to assure the
correct strip length!!
5.3. MEANNING OF THE T1, T2, T3 or Z1, Z2, Z3 or AB, BC, CD?
When crimping dies touch the material is called T1 or Z1 area, the processing area is T2 or Z2, and
when the crimping completing the cycle, this area is T3 or Z3 depending on device used. Every area
change is controlled by tolerance. If any of them exceed individual tolerances, the crimp is defective.
Teach-in curve Good sample

Data curve
The yellow curve area below

the zero line, shows how big
the errors are at T1, T2 and
T3 ( or Z1, Z2, Z3) areas
respectively.

Procedure Owner
YEL-GME - COSEE
1. Insulation crimp phase(T1, Z1 or AB)

Force increases as crimping dies contacts the insulation wings and then reduces as they are folded
and tight (the small peak(s) that occur in the beginning of the curve). This occurs when the crimping
dies tooling making the initial contact with the terminal and begins to bend the crimp wings.
2. Main crimp phase(T2, Z2 or BC)

Force increases as crimping dies compress the copper strands
3. Peak force(T3, Z3 or CD)

The highest force during machine cycle. Final compaction of the wire strands.
• During referencing, the required crimps are counted backwards until the desired number has been
completed.
• The first test crimp is requires for the modulation of signal amplifier.
• The remaining crimps are used to calculate the reference curve.
• A check is also run to ensure that the values of the test crimps are correct before they are accepted as
references.

Procedure Owner
YEL-GME - COSEE
6. EQUIPMENT & TOOLS PRE-REQUIREMENTS

The way to implement a CFM is basically the same, no matter what type of system is being used,
whether they are on a bench top press or on an automatic machine.
To reduce the impact of variability we have to ensure the following:
Equipment calibration and preventive maintenance are within the valid period.
The equipment must be rigid and consistent in terms of speed and shut height. All the press must be
measured using PAL 3001 software. Follow YEL Specification “YEL-CE-S-211 YEL Headroom
Specification”.
Press applicator fixation mechanism must be in perfect condition. When applicator is fixed at press,
there is not allowed to have any lateral and diagonal movements.
When applicator is fixed at Press, head of the

applicator must be in the centre of press ram.
For automatic cutting and crimping machines, they must be set-up correctly according specification
from equipment supplier.
Special focus must be given to strip/cut blades condition, Swivel 1 & Swivel 2 position/or arm position
toward Press stations (applicator), and wire position during crimping cycle.
Applicator condition has a critical role in CFM effectiveness, because an applicator in bad condition will
inevitably be a source of variation. The crimp may look fine from the outside, but it will not pass with the
CFM.
Another factor is applicator age and lack of maintenance. Variation on the crimp curve can also result
from worn crimping dies, inconsistencies in feeding or bell-mouth position, or a ram that is not sliding
smoothly enough. Over the time, applicator will wear out. In order to keep the good condition of the
applicator, it’s mandatory to follow the YEL Guideline for applicator maintenance.
Noise on the crimp curve can be introduced by any of the following: a ram that does not slide smoothly,
worn Crimping dies, inconsistent feeding or inconsistent bell-mouth position. These issues might not be
perceptible by a quick glance at the resulting crimp, but the CFM will see variation.
7. OTHER VARIABLES IN THE CFM PARAMETERS

Before any CFM system can be used, the process has to be stable; this means all the factors that influence
the using of CFM: not just the equipment, applicator, but the headroom of the combination, the wire, the
terminal and crimp, the operators in case of bench top machines and the tolerance parameters for the CFM.
Each of these variables can affect the resulting crimp curve that the CFM will register via its sensors and
software. Unfortunately, a CFM cannot eliminate a specific variable, but monitors the process as a whole.
Therefore, the entire system must produce consistent forces for the CFM to work correctly.
Terminal material can also play a role in how variation the CFM sees.
Thickness - variations in material thickness can cause force-curve variations.
Pre-insulated terminals - the plastic insulation are too soft and exhibit too much variation.
Oil pots – using oil on contacts can add another variable. Although oil doesn’t necessary cause
problems when a machine is running at a normal setup, operators might see some errors
Procedure Owner
YEL-GME - COSEE
immediately after returning from a break, because the oil on the terminals between the anvil and the
oil pot has dried slightly.
Terminal racks – the storage of the terminals in the racks can be a source of problems, because
the way the terminals are stored on the racks will affect the way they enter in the applicator.
Terminal feeding – the terminal reel must always be aligned with applicator in order to avoid
feeding problems which consequently cause CFM error. Check pictures below, showing a bad
feeding of the terminal.
Non-concentric wire – including wire strands, will lead to stripping problems. Also, some insulation
materials will adhere to the strands and cause stripping problems. If the insulation concentricity or
adhesion is not consistent, a problem may be even harder to eliminate. The CFM, however, can detect
variations in the force curve when strands have been scratched or cut easier than we can see the
problem by visual checking. These errors frequently can’t be seen after the crimp has occurred.
Wire striping quality and positioning at crimp has also influence to crimp force curve variation. Relating
wire striping focus on:
• Correct striping length;
• No missing or damage wire strands;
• Well straightening wire;
• No frayed wire
Wire, Terminal Combination – Sometimes a terminal that is either too small or too large for a given
wire can cause problems in terms of quality and productivity.
Oversized terminals can also cause problems as a result of variations in wire placement.
Specifically, the strands from the wire can end up in different areas of the crimped terminal,
depending on their orientation prior to crimping. The result can be different crimping force, even in a
pair of terminals that look identical (principal manual crimping process).
Head room refers to the difference between the crimping forces when the wire is present and when it is
not. This difference can be used to estimate whether a CFM will be able to identify those crimps in which
a strand has been left out. Follow the YEL Guideline for Headroom.

Procedure Owner
YEL-GME - COSEE
Relative spread refers to the deviation in the peak force values of an “x” number of good crimps. It is
calculated as a relative measure of variability in percentage, normally in X,XX%.
"S": Corresponds Standard deviation from X number

of Full Crimps.
Relative spread is the variation of the peak force around

the standard curve that will tell us the general status of
entire system (press, crimping tool, terminal, etc…).
The higher the relative spread, the worst will be the
ability of the CFM to monitor the crimping.
8. CFM PARAMETRIZATION
Depending on the CFM device used on each press, to set up the parameters we need to follow the
related instructions:
8.1. YEL-CE-S-214-A1 Komax CFA system parameterization

8.2. YEL-CE-S -214-A2 MX CFM system parameterization
8.3. YEL-CE-S-214-A3 LT3x CFM system parameterization
9. CFM EXPECTATIONS
The crimping force monitoring has to detect the following crimping defects:
9.1. MISSING STRANDS

The strands should not be scratched or otherwise damaged when insulation is stripped.
No more than x% of available strands must be cut off, depending on cable type.
X = 10% for all cables

Ex 1: Number of strands = 7 (conductor type A; 0,35mm²) 10% of 7 strands = 0, 7 strands, which
yields 1. No more than 1 strand must be cut off when “missing strands” simulation process is
performed.
Note: in case of terminal combination with head room < 35% or RS >1% the following X % must be
revised according tests simulation and customer and CSC must be informed accordingly.
Below a list of the most common wires taking into account the number of missing strands per wire
and the number of allowable cut strands. For more details consult PTC applicators.

Procedure Owner
YEL-GME - COSEE
Missing strands
Wire Size Wire type Number of Strands
10%
0.3F AVSS 19 2
0.3 CAVS
A3F
A3Z
FLRYA 7 1
0.35 NEWA3Z
T2IRSAPL
T3ZH
FLRYB 12 1
0.5F AVSS
A3F 19 2
FLRYA
A3Z
NEWA3Z
0.5 T2IRSAPL
7 1
T3ZH
AVS
CAVS
FLRYB 16 2
0.75F AVSS
A3F
A3Z
FLRYA 19 2
0.75 NEWA3Z
T2IRSAPL
T3ZH
FLRYB 24 2
AVS 16 2
0.85
CAVS 11 1
A3F
A3Z
FLRYA
19 2
1 NEWA3Z
T2IRSAPL
T3ZH
FLRYB 32 3
AVS
1.25 16 2
CAVS
1.25F AVSS 37 4
A3F
A3Z
FLRYA
NEWA3Z
19 2
1.5
T2IRSAPL
T3ZH
FLRYB 30 3
2 AVS 26 3
2F AVSS
A3F
A3Z 37 4
NEWA3Z
2.5 T2IRSAPL
T3ZH
FLRYA 19 2
FLRYB 50 5
Procedure Owner
YEL-GME - COSEE
9.2. INSULATION CRIMPED

Insulation cannot be crimped under wire gripers. CFM shall detect in case of 20% of insulation
crimped under wire griper.
10. CFM – PROCESS/EQUIPMENT CONTROL
10.1. MANUAL PRESS

Machines stops when a defect is detected:
The connection between CFM unit and Manual Press must be set-up in a way that there is not
possible to perform follow-up crimp cycle until the error indication is not reset/confirmed at CFM unit
by Quality or supervisor. This means access to CFM parameters modification, need to be blocked
for machine operators in order to ensure that operators use correct parameters for each crimping
combination.
Dongle Settings:
To protect modes from unwanted button touching is mandatory to set the dongle key protection in
parameter (C-TEC device).
Segregation of defect:
In case of bad crimp is detected at manual press, it’s mandatory for each press the installation of
BCC (Bad Crimp Cutter). If the press is not equipped by automatic Bad Crimp Cutter (BCC), crimp
detected as bad must be excluded from the good products.
Even if at those crimps detected as bad is not visible or measurable crimp defect, crimp must be
excluded from the good products.
Only Quality Department responsible is allowed to decide how to proceed further with crimps
detected as bad without visible or measurable crimp defects.
Validation of active Trigger sensor

Concern MX and LT3x, it’s mandatory to use:
Trigger sensor. This means that it’s mandatory to activate at CFM system menu the
trigger sensor, changing the switch to “ON”. If this option is activated, MX show error
message in case when crimping cycle is performed and “Trigger sensor” is
malfunctioned.
Note:
• If the “Trigger Error” option is deactivated, in case when “Trigger sensor” will be malfunctioned, it will
be possible to perform crimping cycle but crimp quality won’t be monitored.
Procedure Owner
YEL-GME - COSEE
Sensor cable connection:

In case of change the type of CFM device, please be aware that the trigger sensor have different
connection for LT31 and for C-TEC as described below:
The main difference is the black wire connection.

For C-TEC this wire is soldering to the 5 pin of the connector
For LT31 the black wire is soldering to the 1 pin of the connector
.
10.2. AUTOMATIC CUTTING/CRIMPING MACHINES

Machines stops when a defect is detected:
In case of automatic cutting/crimp machines, connection/communication between CFM unit and
machine must be set-up in way that machine stop after bad crimp is detected.
Segregation of defect:
Bad cutter option must be active in all automatic cutting/crimp, in order to segregate the good from
the bad crimps.
10.3. MAINTENANCE SETTINGS

It’s mandatory for maintenance to:
Verify mentioned settings by responsible persons during preventive maintenance;

Have CFM Parameters back up file (MX & LT3x devices);
Always work with latest version of software
10.4. TEACH MODE

As a first step, the crimp needs to be verified for all specifications (crimp geometry and appearance),
including:
• stripping
• crimp height;
• bell mouth;
• a visual inspection;
…before proceeding with the “Teach-mode” or “Learning” of the CFM, to ensure a good baseline.
Note:
• It’s not allow to perform any changes to the crimp process after the Teach mode is complete and then
try to run production, as this action will result in production scrap because the CFM sees a different
crimp curve and assumes it is bad. If a change in crimp process is carried the tech mode must be set
again.

Procedure Owner
YEL-GME - COSEE
Before the CFM start to evaluate anything, it needs to know what it is looking for. Therefore, is
mandatory the user to “Teach” the CFM in order to recognize a good crimp. The number of teach cycles
required is 5, regardless of whose CFM is used. The reference curve is than calculated automatically on
the basis of these test crimps.
Once the teach-in process has been completed and tolerance parameters are chosen, then production
can be run. All subsequent crimps will be compared to the reference curve with the tolerance
parameters chosen.
10.5. TEACH WHAT IS GOOD

During the programming process, is very important for the operator to check that all the parts are in fact
good crimped. If the operator performs the process of teaching with an incorrect crimp height and then
notes these values are correct, the CFM will not know. He will seek and accepts parts with crimping
height incorrect and may reject parts with suitable crimp heights.
Note:
• Bad teach equals bad crimps.
Normally, Teach mode has to be performed just only at the beginning of new batch/lot is going to be
produced. It is strongly not recommended to re-Teach CFM during batch production.
Sometimes there can be terminal material variation in case when new terminal reel is used during batch
production. When this is the case, theoretically re-teach during batch production could eliminate terminal
material variation influence to CFM results. However, when this case is occurring, it must be assured (by
measurements) those products which are used for re-tech must fulfil all the quality requirements.
11. TOLERANCE PARAMETERS

Tolerances need to be tight enough to ensure that no bad crimps will pass as good, however over tight
tolerances will result on phantom error which means that good parts may be identified as bad crimps.
For many combinations, a default set of parameters might be used but the user needs to understand
that not all combinations are created equal. Tolerance settings may need to be adjusted depending on
the terminals used. Below there are examples of two crimp curves for a wire cross section 0, 5 mm² and
a wire cross section 1, 5 mm². The basic shapes are similar but there are many differences in both
timing and amplitude.
Wire cross section 0.5 mm²
Wire cross section 1.5 mm²

Procedure Owner
YEL-GME - COSEE
Remark:
• Another example is the difference between running a small, gold-plated contact versus a larger, bronze
contact. With all other things equal, harder material will give more consistent forces. Gold is very soft
and will show much more variation. Therefore, tolerance parameters may need to be slightly larger to
allow for more variation.
The force curves can be analyzed in several ways. The most common approach is to look at both the
area under the curve and the shape. It’s recommended that the two be monitored simultaneously,
because it is possible for one parameter to be within tolerance at the same time the other is out.
If the deviation in curves is substantial, the currently measured crimp does not comply with the reference
crimp and is treated by the system as a bad crimp.
For good/bad separation, the

current crimping curve is
compared with the drift
Insulation crimped
Missing strands
12. TYPICAL ERRORS
12.1. MISSING STRANDS
This error creates a negative error area and a negative result in Zone 3.
In Zone 2 the error can cause a negative and/or a positive error area, although the negative components
will probably predominate.
Zone 1 is not relevant to this type of error.
Zone 3 and zone 2 are relevant to these errors

Procedure Owner
YEL-GME - COSEE
12.2. INSULATION IN THE CRIMP
This error creates a positive error area and thus error a positive result in zone 1.
Zone 2 may have a positive and a negative error area.
Zone 3 is not predictable; its response depends largely on the insulation material. Hard insulation can
cause a sharp increase in peak force. Thin PVC insulation due to a lubricating effect can cause a drop in
peak force and thus a negative error in zone 3.
Zone 1 is relevant to this error
Note that only a part of the curve is usually analyzed. The “noise” at the beginning of most curves, in
particular, has little bearing on the quality of the crimp. This noise - in the form of a small bump in the
force reading - occurs as the tooling makes contact with the terminal and begins bending the crimp
wings.
Because the actual crimping process has not yet occurred – the wings have not yet contacted the wire –
these readings does not influence in the final quality.
Similarly, it is sometimes necessary to analyze a particular zone of the curve, to catch especially fine
defects. To use a zone approach, the rest of the process has to be very stable. Each zone will then have
its own tolerance parameters.
12.3. DEFECTS ANALYSIS

See below samples of the force curves deviations from the red line (reference curve).
Wire strands out 2/7 Insulation in the crimp ±20% Low insulation in the crimp
pcs

Procedure Owner
YEL-GME - COSEE
.
13. RELATED DOCUMENTS
YEL-CE-S-214-A1 Komax CFA System parameterization

YEL-CE-S-214-A2 MX CFM System parameterization
YEL-CE-S-214-A3 LT3x CFM System parameterization
YEL-CE-P-201 Press analyser PAL 3001
YEL-CE-S-211 Headroom Specification
YEL-CE-P-202 Applicator specification
Also based on site Reality of CFM
14. REVISION
Index Last modification/comments Name Date

Revision N New CFM crimping force Monitor Fernando Santos 28-05-2012


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10.3. MAINTENANCE SETTINGS............................................................................................................................12

10.4. TEACH MODE ...................................................................................................................................................12

10.5. TEACH WHAT IS GOOD .................................................................................................................................13

11. TOLERANCE PARAMETERS ................................................................................................................ 13

12. TYPICAL ERRORS ................................................................................................................................. 14

12.1. MISSING STRANDS.........................................................................................................................................14

12.2. INSULATION IN THE CRIMP..........................................................................................................................15

12.3. DEFECTS ANALYSIS ......................................................................................................................................15

13. RELATED DOCUMENTS........................................................................................................................ 16

GME Template Form No. YEL-CE-P-01_F1 Revision N 07.05.2012 Page 2 of 16

European Quality Office (EQO):

Yazaki Global Procurement/YEL Supply Management (Capital Equipment):

Process owner, Engineering and Purchasing Departments of the individual plants:

Quality assurance departments of the plants:

CPU – Central Processing Unit

GME Template Form No. YEL-CE-P-01_F1 Revision N 07.05.2012 Page 3 of 16

GME – Global Manufacturing Engineering

EQO – European Quality Office

BCC – Bad Crimp Cutter

5.1. BASIC DEFINITION & CONCEPTS

In the press ram;

5.2. INTRODUCTION TO THE CURVE FORCE

What is the reference curve?

It’s strictly recommended to use test Reference

Teach-in curve Good sample

The yellow curve area below

GME Template Form No. YEL-CE-P-01_F1 Revision N 07.05.2012 Page 5 of 16

1. Insulation crimp phase(T1, Z1 or AB)

2. Main crimp phase(T2, Z2 or BC)

3. Peak force(T3, Z3 or CD)

GME Template Form No. YEL-CE-P-01_F1 Revision N 07.05.2012 Page 6 of 16

6. EQUIPMENT & TOOLS PRE-REQUIREMENTS

To reduce the impact of variability we have to ensure the following:

When applicator is fixed at Press, head of the

7. OTHER VARIABLES IN THE CFM PARAMETERS

GME Template Form No. YEL-CE-P-01_F1 Revision N 07.05.2012 Page 8 of 16

"S": Corresponds Standard deviation from X number

Relative spread is the variation of the peak force around

8.1. YEL-CE-S-214-A1 Komax CFA system parameterization

9.1. MISSING STRANDS

X = 10% for all cables

GME Template Form No. YEL-CE-P-01_F1 Revision N 07.05.2012 Page 9 of 16

9.2. INSULATION CRIMPED

10. CFM – PROCESS/EQUIPMENT CONTROL

10.1. MANUAL PRESS

Validation of active Trigger sensor

Sensor cable connection:

The main difference is the black wire connection.

10.2. AUTOMATIC CUTTING/CRIMPING MACHINES

10.3. MAINTENANCE SETTINGS

Verify mentioned settings by responsible persons during preventive maintenance;

10.4. TEACH MODE

GME Template Form No. YEL-CE-P-01_F1 Revision N 07.05.2012 Page 12 of 16

10.5. TEACH WHAT IS GOOD

11. TOLERANCE PARAMETERS

Wire cross section 1.5 mm²