auto industry draft rev9-final.qxd:layout 1...2012/06/15 · for drawings or technical data,...

Application Toolingfor Automotive, Industrial CommercialTransportation and Hybrid & Electric Mobility Solutions

Application Tooling Key Contacts

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For drawings or technical data, contact your TE Connectivity sales engineer or call the Technical SupportCenter: 1-800-522-6752. Dimensions are in millimeters unless specified otherwise. Values in brackets areEnglish equivalents unless specified otherwise. Specifications subject to change. Consult TE for latest specifications.

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www.tooling.te.comwww.tooling.te.com/chinawww.tooling.te.com/europe

TE Application Tooling Product Overview

Catalog 8-1773462-5Revised 05-2012

USA – Harrisburg, PATooling Assistance CenterPhone: +1-800-722-1111

Tool Repair627 N Grant StWaynesboro, PA 17268Phone: [email protected]

PricingPhone: 800-526-5142or 717-986-5536

Field Engineering ServicesPhone: 800-722-1111 or 717-986-3434

CanadaPhone: [email protected]

BrazilMauricio OliveiraPhone: [email protected]

Mexico – Mexico City Tooling Assistance CenterPhone: +1-717-986-3434

Product Information CenterPhone: +86-400-820-6015 [email protected]

ShanghaiPhone: +86-21-24071588 Fax: 86-21-24071599

BeijingPhone: +86-10-65693488Fax: 86-10-65693208

Hong KongPhone: +852-27351628Fax: +852-27350243

AustraliaPhone: +61-2-95542612Fax: +61-295543859

JapanPhone: +44-900-5027Fax: +44-900-5037

KoreaPhone: +82-2-3415-4636Fax: +82-2-3486-6873

SingaporePhone: +65-64164567Fax: +65-64821012

EMEA

AMERICAS

ASIA / PACIFIC

AustriaPhone: [email protected]

Belarus - Russia - UkrainePhone: +7-910-452-3571 [email protected]

Belgium - Netherlands - LuxemburgPhone: [email protected]

Bulgaria - Hungary - LatviaLithuania - Poland - RomaniaPhone: [email protected]

Czech - SlovakiaPhone: [email protected]

Denmark - Norway - SwedenPhone: [email protected]

Egypt - Ireland - United KingdomPhone: [email protected]

Finland and EstoniaPhone [email protected]

France - Morocco - TunisiaPhone: [email protected]

Germany - Slovenia - TurkeyPhone: [email protected]

India - Middle EastPhone: [email protected]

Italy - GreecePhone: [email protected]

SwitzerlandPhone: +41-71-447-02 [email protected]

Spain - PortugalPhone: +34-93-291-03-96 [email protected]

Product Information Center FrancePhone: +33 134208943Fax: +33 [email protected]

Product Information Center GermanyPhone: +49 (0) 6251 1331999Fax. +49 (0) 6251 [email protected]

Product Information CenterNetherlandsPhone: +31 736246999Fax: +31 [email protected]

Product Information Center PolandPhone: +48 224576704Fax: +48 [email protected]

Product Information Center Spain Phone: +34 932910330Fax: +34 [email protected]

Tool RepairAmperestr 7-1163225 Langen GermanyPhone: +49 (0) 6103 709 1534Fax: +49 (0) 6103 709 [email protected]


TE Application Tooling (AT) Key Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

TE Application Tooling Worldwide Leadership in Wire and PCB Manufacturing Products . . . . . . . . .5

TE Application Tooling Global ServicesField Engineering Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Factory-Level Service, Certification and Tool Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7ProductionCHEK Process Optimization Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10Production Consultation Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-12Field Service Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-15

New Developments — Collaborative Efforts Involving Automotive & Application ToolingAutomotive and Application Tooling Business Units Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-17OCEAN Applicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18Hybrid & Electric Mobility Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19Compliant Pins / Press-Fit Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20Standard and Custom Hand Tool Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Low Volume Prototype, Maintenance and Repair Wire ProcessingPRO-CRIMPER III Hand Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22CERTI-CRIMP Hand Tools and Flip Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22JacKnack Cable Prep Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22LightKnack Magnetic L.E.D. Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22SDE (Standard Die Envelope) Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23BT3500 Battery-Hydraulic Hand Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23SDE Electric Terminator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23SDE SA and SDE DA Hand Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236-26 and Micro-Pneumatic Tool System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24AT-SC Pneumatic Safety Crimp Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24AT-55 Pneumatic Crimp Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24AT-66 Hydraulic Crimp Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25Hydraulic Crimp Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25Pistol Grip Tooling for IDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25Hand Tool Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26Insertion / Extraction Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Intermediate Volume Wire Processing ProductsOcean Applicator, SMART Applicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28-29Replacement Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29AMP 3K/40 and AMP 5K/40 Terminator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30AMP-O-LECTRIC Model G Terminator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30Stripping Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30Crimp Quality Monitor II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30Crimpmatic 970 and 971 Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31Applicators — Pneumatic Large Wire, Mid-Size Wire and Loose Piece Large Wire . . . . . . . . . . . . . . . . . . . . . .31

High Volume Wire Processing ProductsGamma 263 and Gamma 333 Fully Automatic Crimping Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32Precision Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32Alpha 355, Alpha 477 and Alpha 488 Fully Automatic Crimping Machines . . . . . . . . . . . . . . . . . . . . . . . . . .32-33Zeta 633/633 L Fully-Automatic Crimping Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33Zeta 655/656 Lead Maker Double End Block Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

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Table of Contents

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Wire Preparation EquipmentCosmic Series of Wire Strippers, K206, K206S Cutting Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34Kappa Series of Wire Strippers and AT-ST Wire Stripping and Twisting Machine . . . . . . . . . . . . . . . . . . . . . . .35

Tooling for AMP+ High Current Connectors and HeadersHVA280 AMP+ High Current Connectors and Headers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36HVA630 AMP+ High Current Connectors and Headers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37HVP800 AMP+ High Current Connectors and Headers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38APT & IPT High Voltage Shielded Ring Tongue Terminal Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Magnet Wire Application EquipmentAMPLIVAR Product Terminators (APT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40AMPLIVAR Terminator for Parallel and End Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40AMP-O-LECTRIC Model G Terminator with Thru-Splice Applicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41Power Splice Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41Crimpband Application Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41MAG-MATE and SIAMEZE Inserter Mark II with PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42MAG-MATE and SIAMEZE Inserter Mark II with PLC and Insertion Force Control . . . . . . . . . . . . . . . . . . . . . . .42Pneumatic Insertion Tool for MAG-MATE Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42MPT-5 S/L Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43MPT-5 MAG-MATE Product Terminator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43MAG-MATE Terminal Cavity and Fixture Design and Product Line Integration . . . . . . . . . . . . . . . . . . . . . . . . .43

FFC - FPC EquipmentFFC Hand Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44FFC Termination Machine for Flexible Sensor Foil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44FFC Applicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44Assembly Machine to connect FFC and PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45FFC/FPC Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Assembly Automation ProductsP50 Manual Bench Insertion Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46P100, P200, P300 and P350 Insertion Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46M Series of Insertion Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47CBP 5T Benchtop Electric Servo Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48CMP 6T/12T Manual Electric Servo Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48CAP 6T Automatic Electric Press and CAPI-6T In-Line Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48CSM 5T Connector Seating Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48CSP 3T Shuttle Electric Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48Tooling for Press-Fit Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Automatic Cable & Components TestingMOST Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-51

Wire & Terminal General InformationCrimp Quality Guidelines — Good Crimp; Bad Crimp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52Crimp Tooling — Where Form Meets Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53-58Computing CMA of Wire, Terminal Wire Range & Color Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59-60Charts — PIDG Terminals, SOLISTRAND/STRATO-THERM Terminals, Raychem Product . . . . . . . . . . . . . .61-63

Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64-66

Application Tooling Product Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Table of Contents, continued

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Worldwide Leadership in Wire and PCB Manufacturing ProductsLeadership demands commitment and TE Connectivity is committed to meeting manufacturing needs worldwide with technology, products and systems, and service.

TE Application ToolingTE has long been recognized as a leader in providing the tools for wire harnessand printed circuit manufacturing. There’s a good reason. Our products aredesigned to meet our customers’ ever-changing requirements and built to highquality standards, for long, productive performance lifetimes.

Whatever your production volume and job mix, we can offer the tools to get itdone. With a full range of tooling from hand tools to high volume, fully automat-ed systems, TE Connectivity is able to meet manufacturing demands worldwide.It’s an ability that comes from our experience with manufacturers large andsmall, giving us a unique view of the trends and challenges in wire harness andPCB manufacturing. It all derives from our commitment to your manufacturingchallenges, giving you the advantage in your marketplace.

This catalog is just a sampling of the types of solutions that can help make yourjob easier, faster, more productive and more profitable. Tooling, assembly equip-ment, and service is TE Application Tooling’s core competence. Create a strate-gic advantage by making TE work for you.

TE Connectivity Service and SupportFew suppliers can match TE Connectivity’s customer service and support. Fromhelping you select the tooling for your requirements for maintenance and repairto analyzing your operation for maximum productivity, our worldwide capabili-ties and experience will help make a real difference in your production and bot-tom line.

ProductionCHEK Service — In a consultative role, our field engineer will meetwith you to determine your objectives and known production issues, thenobserve and record in detail each step in your operation. Based on this informa-tion, the engineer will make recommendations for production improvement, typi-cally in people, process or equipment.

Production Consultation Service — A service designed to systematically evalu-ate equipment and personnel in the manufacturing environment and to providerecommendations along with an action plan to improve manufacturing efficiency.

Tool Repair and Certification — Our field engineers will set up, certify, and repairapplication tooling on site or recommend our factory-level service. Flexible plans,including options for premium access to parts and service, keep your equipmentrunning at peak performance.

For additional maintenance services, the TE Connectivity technical support cen-ter is dedicated to providing the answers you need, toll-free at 1-800-722-1111.Support contracts are available for preventive maintenance, training, emergencysituations and other specific requirements.

For more information regarding theproducts and services shown in thisbrochure, visit our website atwww.tooling.te.com


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In addition to installation, warranty, and repair service, TE field specialists can help you withequipment choices, training of maintenance and operation personnel, troubleshooting and spareparts. Service contracts to cover all your application equipment needs are also available.

We have implemented a service management tool that provides standardization of reporting thatgives us the ability to continuously improve our global service organization. Throughout the yearwe educate our field service engineers on the latest industry technologies and equipment.

Service Offerings:Standard ServiceIncludes troubleshooting issues, making repairs, and/or installing parts.

Equipment InstallationsProviding installation, set-up, and training of application equipment at the time of delivery.

TrainingProviding customers with practical training programs addressing machine operation, set-up,maintenance, inspection, and connector application. Training programs can be scheduled at thecustomer’s site or at a TE Connectivity training center. A training certificate will be issued uponthe completion of each formal training course.

We are proud to be able to offer a comprehensive range of customer training programs. The following are some of the standard training programs we offer:

Service ContractsPreventive Maintenance and/or Inspection Certification

Provides service for periodic visits to perform preventive maintenance and/or inspectioncertification service on hand tools, applicators, bench and automatic equipment.

Comprehensive ServiceProvides for a specified number of field specialist visits. A visit can be used for services such asstandard service, installation, set-up and training for all application equipment, preventivemaintenance and/or inspection certification, spare parts management, equipment processevaluation, and technical assistance on application tooling and/or product related issues orconcerns.

Application Tooling Global ServicesField Engineering OrganizationTE Connectivity provides Global Field Service support on our application tooling. Field Specialistsare located across every continent to provide timely response to customer needs.

• The Fundamentals of Crimp Technology• The Proper Handling of Crimping

Applicators• The Proper Handling of Crimping Hand Tools• FFC Crimp Technology

• Crimp Terminating Machines• Leadmaking Machines• Magnet Wire Connection Technology• MAG-MATE Module• Insulation Displacement Technology


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Application Tooling Global ServicesFactory-Level Service, Certification and Tool Repair

The Key to Crimp PerformanceYou’ve already made the right choice in crimp tooling—TE Connectivity qualitytooling. TE Connectivity quality certification and maintenance are also the rightchoices to keep your crimp tooling operating at peak performance. In this catalogyou’ll find details on the most popular services available at TE Connectivity serv-ice centers, complementing our on-site services. To request more information orto schedule a service, refer to the contact information on page 2.

Applicator and Terminator ServiceServices include:

• Warranty services— with no charge for labor or parts

• Certification services

• Equipment repair— to application specifications

• Quick turnaround

• 90-day warranty on repairs

Hand Tool Repair and CertificationCERTI-CRIMP hand tools and die sets; pneumatic crimping heads and die sets;and hydraulic hand tools, crimping heads, and die sets all benefit from factory oron-site service.

Services include:

• Recertification—promotes quality improvement per ISO 9000. Recommendedevery 6 months or 5,000 cycles to verify that tools meet TE Connectivity’s application specification.

• Visual inspection—checks tool operation and looks for missing or damagedparts.

• Handle pressure check—measures pressure with calibrated machine or gauge;adjusts to match design specification.

• Quality inspection plan (QIP)

• 90-day warranty on repairs

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Application Tooling Global ServicesProductionCHEK Process Optimization ServiceUse of the ProductionCHEK process, evidence-based recommendations generated through an interactive, consultative process of observation and analysis of your operations, can lead to higher productivity and more efficient use of equipment and staff.

Applied Cost—the True Measure for ManufacturingThe applied cost—the actual cost of every wire assembled—is a sensitive function of a number of variables, including:

• Equipment procurement cost

• Operator and maintenance training and support cost

• Support and spares/consumables inventory

• Equipment—uptime, efficiency, throughput

• Floor space

The observation, analysis, and recommendations in the ProductionCHEK process identifies factorsthat can be improved or fine-tuned, helping you plan your capital and operating budgets, staffing,and equipment utilization for higher productivity and profitability.

Business Challenges in Electronics ManufacturingMaintaining profitability in manufacturing and responding to global competitive pressures callfor attention to every detail of your production process. Quality problems and inefficiencies cancreep into harness production in ways that can be difficult to recognize from within the opera-tion. TE can help meet these challenges with our ProductionCHEK process to help improve yourbottom line.

Applying the Knowledge and Experience of TE ConnectivityAt TE, we bring a broad, objective view to reviewing your pro-duction process, and to helping you find a path toward improve-ment. That view is informed by our own development processand by our experience in dealing with our customers’ electronicproduction worldwide.

Using a methodology inspired by the principles of Six Sigma, wecreated the ProductionCHEK process. Using this tool, we lookfor opportunities to eliminate waste, standardize and streamlinesetup procedures, and optimize value-adding activities, alltoward increasing quality and profitability.

Our recommendations are based on our observation of youroperations, with analysis incorporating our knowledge and expe-rience. This service comes about from our commitment to pro-viding you with the tools and knowledge to give you an advan-tage in your business and marketplace.


9





Application Tooling Global ServicesProductionCHEK Process Optimization ServiceThe ProductionCHEK process provides a basis for both short-term improvement and ongoing manufacturing process optimization.


Our process for improving your process...We start by identifying areas where major improvement is desired or appropriate, according toyour production flow and needs. This is the first of the many consultative steps we take, coor-dinating between a specially trained field service specialist and your production staff.

When the target areas have been identified, we observe and record operations, using data col-lection tools we’ve developed specifically for that purpose. We are able to break down theoperation into individual components or steps — for example, a crimping operation might bebroken down into terminal loading, applicator change, feed adjustment, jam or problem resolu-tion, etc. Observations continue for a full 8-hour day. Our data collection tools include a set ofcodes to identify each portion of the operation; we use them in the analysis.

The entire observation and analysis process is carried out by our field service specialist, with noinvestment of your time or interference with normal operations.

Making Recommendations — a Consultative ProcessOnce we have your actual data, we have a clearer picture of where issues need to be resolved,whether quality breakdowns, productivity bottlenecks, machine downtime, or any of the otherproduction roadblocks where inefficiencies and ineffective process can creep into your opera-tion unnoticed.

Six Sigma programs have driven improvements in quality throughout the manufacturingprocesses. The same kind of systematic approach helps identify areas for concern and forfocus in production efficiency.

Building on ExperienceThrough years of experience in serving the wire harness manufacturing industry with systemsand technical support, TE Connectivity has developed a comprehensive, extensive knowledgebase in understanding production processes.

Typically, we find the major areas where TE can apply best demonstrated practices including:

• People—training, scheduling, and orientation in the culture of quality

• Process—work scheduling and equipment readiness

• Equipment—optimizing existing equipment, and adding technology enablers, like the newSmart Applicator with iButton.

To request a quote for the ProductionCHEK process, reference part number 396450-1. It justtakes a phone call to get started. To request more information or to scheduleProductionCHEK, refer to the contact information on page 2.

10





Application Tooling Global ServicesProductionCHEK Process Optimization Service

Basing it on the EvidenceThe ProductionCHEK process provides a systematic approach to improvement based on actualdata from your operation. The process results in both a measurable starting point and the tools tore-check at subsequent milestones. It is the basis for making productivity review a part of theongoing operation, leading to better quality product and better utilization of resources.

Results of the initial evaluation often reveal a surprisingly low proportion of productive machinetime. However, by following the study’s recommendations, it’s often possible to make adjustmentsin the process that have almost immediate results. Then implement the broader recommendationsfor continuing improvement in your capacity and productivity.

A Case for ImprovementA manufacturer was producing 4,100 leads per shift, with over 35 changeovers. They brought inthe TE field service specialist for a ProductionCHEK analysis. In the initial meeting, the manufac-turer expressed a goal of a 20% increase in production, without having to add machine capacity.

The ProductionCHEK data showed that actual productive time was only about 20% of the total.Analyzing the data and looking at the potential areas for improvement, the TE field service spe-cialist determined that, if all the recommendations were followed, not only could the customer’s20% improvement goal be met, but additional improvement was possible. This would involve real-istic decreases in each overhead time segment, other than fixed operator time. The expectedincrease could be up to 7,000 leads per shift, or an increase in productive time of 62%!

An example from one of our customers illustrates the productive machine time before the ProductionCHEK process and the expected improvementupon implementing the recommendations. Actual results would depend on the specific customer situation and the degree of commitment to the rec-ommendations of the program.

After ProductionCHEK ProcessBefore ProductionCHEK Process


11





Application Tooling Global ServicesProduction Consultation Service (PCS)A proactive consultation relationship that assists customers in identifying improvement opportunities in theirmanufacturing processes, quality processes, employee knowledge and current equipment status.


Application Tooling Field Service is now offering a proactiveconsultation service designed to assist customers in identi-fying improvement opportunities in the production process.

Focusing on the wire harness industry, the TE ConnectivityProduction Consultation Service (PCS) is designed to sys-tematically evaluate equipment and personnel in the manu-facturing environment and to provide recommendationsalong with an action plan to improve manufacturing effi-ciency. This is accomplished through a customer site visitto review the operation and identify areas where produc-tivity improvement and/or cost savings could be realized.Interviews are performed with a small sampling of person-nel in key areas such as production, maintenance, quality,engineering and management.

Our skilled field engineers will combine the interviewresults with their own observations to identify opportuni-ties for improvement. A specialized tool allows the fieldengineer to quickly assemble the data into a feedbackreport which is provided to the customer at the end of theassessment. Working with the customer, TE can facilitatethe process of implementing changes designed to addressthe opportunities identified in the assessment process.

The TE Connectivity Production Consultation Service is avaluable tool that will help customers to reveal those areaswhere improvements in production efficiency may be pos-sible. Contact TE today for more information.

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Application Tooling Global ServicesProduction Consultation Service (PCS)

Goal and Benefits of the Production Consultation Service (PCS)

TE will work with customers to provide solutions for a more efficient manufacturing environment,including:

• Observe processes and make recommendations for improving production efficiency and quality,such as:

• Equipment operation• Work cell layout• Material flow• Equipment upgrades

• Assess personnel knowledge of the equipmentbeing used and, when appropriate, make recom-mendations for additional training to improvecompetency and efficiency.

• Identify issues with tooling and equipment

• Make recommendations for best demonstratedpractices to help reduce down time.

• Promote reduction of waste through:

• Product staging• Material planning• Job scheduling to reduce setup and

changeover

Process Overview

A PCS assessment takes approximately 5 hoursand includes:

• Interview and observation of multiple depart-ments including operators, maintenance, quality, engineering, and management

• Almost 100 detailed and department specificquestions

• Written summary report outlining fact-basedfeedback, action items and recommendations forincreasing manufacturing efficiency

It just takes a phone call to get started. For more information, or to schedule a PCS assessment,call the Tooling Assistance Center at 800-722-1111 and reference part number 396459-1.

13






TE Application Tooling Americas Field Service Locations

Americas Field Service Locations

CanadaToronto

Brazil

MexicoChihuahuaGuadalajaraHermosilloJuarezReynosa

United StatesCaliforniaFloridaMinnesotaMissouriNew JerseyOhioPennsylvaniaTexas

AMERICAS FIELD SERVICE [email protected]

TE Application Tooling Europe Field Service Locations

Europe, Middle East and Africa Field Service LocationsAustria

Czech Republic

Denmark

Finland

France

Germany

Great Britain

India

Italy

Morocco

Netherlands

Norway

Poland

Russia

South Africa

Spain

Sweden

Switzerland

Tunisia

EUROPE FIELD SERVICE +49 (0) 6251 133 1376

[email protected]

14






15






TE Application Tooling Asia/Pacific Field Service Locations

Asia Pacific Field Service LocationsAustraliaChinaJapanKoreaMalaysia

SingaporeTaiwanThailandVietnam

ASIA PACIFIC FIELD SERVICEPlease contact your local Sales or Service Engineer.See contact on page 2.

16





TE Automotive and TE Application Tooling Business Units — Overview


Connector Systems ● ● ● ● ● ● ● ●

High-Current ● ● ●Connector Systems

Hybrid Housings ● ● ● ● ● ● ● ●

Relays / Power Relays ● ● ● ● ● ● ●

Distribution Boxes / ● ● ●Fuse & Relay Boxes

Mechatronics ● ● ● ● ● ● ● ●

Inductive Systems ● ● ● ● ● ●

Inductive Sensors ● ● ● ● ● ●

Radar Sensors ● ● ●

Telematics / GPS Antennas ● ● ●

Wire & Cable including ● ● ● ● ● ● ● ●Special Solutions

Heat Shrink Tubing ● ● ● ● ● ● ● ●

Flexible Film Solutions ● ● ● ● ● ● ● ●

Optical Systems ● ● ●

Circuit Protection ● ● ● ● ●

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17





TE Automotive and TE Application Tooling Business Units — Overview


Connector Systems ● ● ● ● ●

High-Current ● ● ● ● ●Connector Systems

Hybrid Housings ● ● ● ● ●

Relays / Power Relays ● ●

Distribution Boxes / ● ● ● ●Fuse & Relay Boxes

Mechatronics ● ● ● ●

Inductive Systems ● ● ● ●

Inductive Sensors ●

Radar Sensors ● ● ●

Telematics / GPS Antennas ● ●

Wire & Cable including ● ● ●Special Solutions

Heat Shrink Tubing ● ●

Flexible Film Solutions ● ● ●

Optical Systems ● ● ● ●

Circuit Protection ● ● ● ●

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Application Tooling

18



New Developments — OCEAN ApplicatorThe latest TE Connectivity Series of Applicators is well suited for smaller, lighter connector systems.

Collaborative Efforts Involving TE Automotive and TE Application

Tooling Product Teams

TE Connectivity is addressing the Automotive Industry’s need for weight and spacereduction through the development of products like the .5mm terminal system.

TE Application Tooling’s new OCEAN applicator was developed to provideimproved precision and reduce setup times. These applicators are more capablethan previous generations of applicators to apply terminals like Nano MQS and.5mm terminal systems. They enable vehicles to be more fuel efficient (by beingsmaller and lighter). This new applicator has the potential to increase tooling accu-racy and tool life.

For more information please go to http://tooling.te.com/applicator.asp or requestcatalog 9-1773460-5.

Features of OCEAN ApplicatorNew Feed Mechanisms

• Modular feed units (mechanical, pneumatic, servo) are easily interchangeable &upgradable

• Mechanical feed offers cam & follower to maintain constant contact

• Micro adjustment feed

Adjustable spring loaded terminal hold-down• Provides terminal straightness

Detachable Lubricator Assembly• Broad wick and variable adjustments for complete terminal coverage

• Clear polycarbonate shell for easy viewing of lubricant level

Data Chip (SMART Applicator)• Integrated data chip stores and relays set-up and

maintenance information

• Data chip stores:

• Terminal data— crimp height, feed distance/speed, wiresize, strip length

• Applicator data— serial #/part #, complete listing of wear-able tools, cycle counts for each item, service history

• Data chip available on all styles

Wire & Insulation Crimp Adjustment• Wire crimp height adjustment range (0-1.5mm)

• 0.01mm adjustment increments

• Positive detent positioning

• Fine increment, tool-less insulation height adjustments

• 18 steps with various sizes that can be adapted to a variety of applications

NEWNEW

Data chip

Detachable LubricatorAssembly

Spring-Loaded Terminal

Hold-Down

Cam Follower

Adjustable Wire Stripper

Micro-Adjust FeedPosition (Pneumatic)



19






Tooling Product TeamsNEWNEW

New Developments — Hybrid & Electric Mobility SolutionsTE Connectivity Hybrid & Electric Mobility Solutions address the emerging market of creatingsolutions for the hybrid, electric, and fuel cell transportation technology.

Hybrid & Electric Mobility Solutions: Components for hybrid, electric and fuel cell technology.TE Connectivity is a leader in next-generation transportation technologies and products forhybrid and electric vehicles. TE Connectivity is your source for high voltage power distribu-tion, high current contacts, high voltage connectors and cables, high voltage relays, sensorsand temperature protection devices for hybrid and other alternative power vehicles.

Request catalog 1654294-3 for more information or go to http://te.com/automotive

TE Connectivity has created a world-class engineering team to create solutions for hybrid,electric, and fuel cell technology. These solutions address the system requirements withvoltage levels between 300-800 volts and current from 200-1000 amps. TE Connectivityoffers a wide range of components and subsystems for HEV’s including:• High power electrical connectors and cables• High power contactors for battery switching and control• Circuit protection devices like Raychem Poly Switch and PPTC’s• Power distribution units• Service disconnect units

Application Tooling for Hand Processing/Low Volume

• Die set (bottoming dies to insure proper crimp geometry)• Die set with locator (assembly aid used during assembly)• Hand hydraulic tool (provides accurate, consistent crimps)• Bench mounted hand hydraulic tool (increases comfort/ promotes higher output)

Application Tooling for Semi-automatic Processing/Medium to High Volume

• Die set (bottoming dies to insure proper crimp geometry)• Die set with locator (assembly aid used during assembly)• Locator fixtures (secures location in terminating unit)• Bench top termination unit (provides consistent

crimping force)

*For details regarding application tooling, refer to theappropriate application specification.

20





New Developments — Compliant Pins, Fuse Insertion and Press-FitConnectors

TE Connectivity is addressing the requirements of the automotive industryfor compliant pins used in control modules and instrumentation panels. TEApplication Tooling offers a full line of pin insertion and press-fit machinesto properly assemble the PCB.

The M Series of insertion machines provides flexibility and cost savings tomeet a wide range of customer requirements of thru hole technology. Ourfull range of systems can help with insertion of reeled components, loosecomponents and odd shaped components.

The M2000M machine utilizes vibratory bowls to feed bulk loaded fuses,pneumatic insertion heads, and an X-Y table to automatically populate thejunction box.

For more information on our full line of equipment for compliant pin andpress-fit, please go to http://tooling.te.com/pressfit.asp,http://tooling.te.com/pin_insertion.asp or request catalog 7-1773439-0.



CSP 3T Shuttle Electric Press

P350 Pin Insertion Machine

P50 Bench Insertion Machine M2000M Insertion Machine

21





New Developments — Standard and Custom Hand Tool Kits

TE Application Tooling has the capability to provide hand tool kits to be utilized by dealer-ship or field service. Kits can be configured for a specific repair/upgrade or can possibly beconfigured to crimp terminals located throughout the entire vehicle. Custom designed diesets can be created to crimp TE as well as non-TE terminals.

Contact your local application tooling representative to learn more. Generally, these handtool kits require collaboration between the OEM, the account manager, and TE ApplicationTooling.

TE Application Tooling provides complete hand tool kits, which may includethe following:

• Storage box or kit

• Hand tool frame

• Multiple die sets as required by the application

• Extra terminals and seals

• Wire stripping/cutting tools

• Instruction sheet



22




Low Volume, Prototype, Maintenance and Repair Wire Processing ProductsSuitable for R & D, prototyping, field work or low volume production, these hand tools combine ease of usewith reliability and precision.

PRO-CRIMPER III Hand ToolsPRO-CRIMPER III hand tools combine the versatility of generalpurpose, commercial tools with the reliability and features incor-porated in our premium grade tools. They’re suitable for prototyp-ing, networking applications, and commercial, industrial, and institution-al maintenance work. Request catalog 1773379-1 for more information.

CERTI-CRIMP Hand ToolsCERTI-CRIMP hand tools are premium, hand-operated tools for crimping a broadrange of terminals, contacts and special wiring devices. All CERTI-CRIMP handtools feature a reliable ratchet control that, when used properly, provides a com-plete crimp. These tools are well-suited for low production runs, prototype workand repairs. Request catalog 65780 for more information.

Flip LocatorNew wire size trends have translated into application challenges.Small terminal handling is a particular challenge as terminals continueto miniaturize. As a result, TE Connectivity is releasing its new “fliplocator” on selected Premium CERTI-CRIMP II straight action handtools. The flip locator allows an operator to “flip” the locator approx 150degrees providing exact placement of small terminals. Request catalog65780-7 for more information.

JacKnack Telecommunications Cable Preparation ToolThe JacKnack tool provides a simple method to perform basic cable preparationfunctions. When the tool is used in conjunction with the TE SL mod jack hand tool,the results are a quick termination that is reliable and repeatable between operators.

To untwist wire pairs, simply press the finger loop to extend the wire clamp, placethe wires in the clamp, release the finger loop, and twirl the tool around your fin-ger. This method is quicker than untwisting by hand and is easier on the installer’sfingers. Request catalog 8-1773456-7 for more information.

LightKnack Portable Magnetic L.E.D. LightThe LightKnack is designed to provide light anywhere you need it.Attach it to hand tools, use it in engine compartments, or behind acomputer...the possibilities are endless! It's small enough to fit in the tightestspaces. The high-intensity LED provides hours of bright light onto the work sur-face. The (included ) CR1216 batteries are replaceable.


PRO-CRIMPER Hand Tool

CERTI-CRIMP Hand Tool

Flip Locator on CERTI-CRIMP

Application Tooling Product Overview

JacKnack Tool

LightKnack L.E.D Light

NEWNEW

23


Need More Information?www.tooling.te.comwww.tooling.te.com/chinawww.tooling.te.com/europe


Low Volume, Prototype, Maintenance and Repair Wire Processing ProductsSuitable for R & D, prototyping, field work or low volume production, these hand tools combine ease of usewith reliability and precision.

Standard Die Envelope (SDE) Crimp ToolingThe SDE tooling system allows use of the same dies across a range of application plat-forms. These crimping tools serve the purpose at the bench, in the lab, in production orin the field, without fitting dies for each tool required. Request catalog 1773379-1 formore information. Choose from these SDE-Compatible tools:

BT3500 Battery-Hydraulic Hand ToolThe BT3500 hand tool is designed to provide the ultimate in flexibility, modularity, andpowered efficiency in a lightweight, ergonomic, powerful crimp unit. It is compatiblewith all SDE dies and CERTI-CRIMP II heads utilizing the appropriate adapters. Requestcatalog 1773381-5 for more information.• Spring loaded terminal grip allows you to properly locate the terminal

• Ram retract feature provides the capability to stop the crimp process and retract the ram

• Use as a portable bench top device positioned in the tool case, use with two shoulder strapoptions, a belt option or use the shoulder strap on the BT case.

SDE Electric TerminatorOffering an excellent price-to-performance ratio, the SDE electric benchtop terminator incorporates features normally found on more expensive models. It is suitable for low- to medium-volume production and harness assembly. Requestcatalog 1654714 for more information.

SDE SA (Straight Action) Hand ToolWith a unique geometry and comfortable, easy-to-use handle design, this tool isoptimized for easy accessibility in space constrained applications. The large crimpjaw arc minimizes “roll”, particularly important when crimping open barrel terminals.Request catalog 1773379-1 for more information.

SDE DA (Double Action) Hand ToolSpecifically designed for closed barrel terminals with SDE compatibility, this toolincorporates the convenient operational features of other TE Connectivity hand tools.The long handles give it excellent mechanical advantage, enhancing user comfort.Request catalog 1773379-1 for more information.

• PRO-CRIMPER III Tool

• BT3500 Battery-Hydraulic Tool

• 6-26 Pneumatic Tool System

• SDE Benchtop Terminator

SDE SA Hand Tool

SDE Dies

BT 3500 Hand Tool

SDE Electric Terminator

Application Tooling Product Overview

24




Low Volume, Prototype, Maintenance and Repair Wire Processing ProductsMaximize your productivity while minimizing your effort for crimping a broad range of terminals, by replacing your hand tools with pneumatic power tools.

6-26 Pneumatic Tool SystemReplace manual hand tools with the 626 pneumatic tool system to maximize productivity and minimize effort. This system makes it easier to terminate wiresfrom 26-6 AWG [0.12-13 mm2], while continuing to use most existing TE-compati-ble crimp heads and die sets. Request catalog 124208 for more information.

• Flexible for hand- or foot-switch operations

• Rotating head assembly reaches difficult termination locations

Micro-PneumaticSystemThe micro-pneu-matic systemprovides minimalweight and toolsize with maxi-mum productionquality.Compatible with the small tool and adapter holders used in the 6-26 system, thisunit and compatible heads terminate 26-14 AWG [012 - 2mm2] products. Requestcatalog 124208 for more information.

• Small size — 5.75” [146.1mm]

• Lightweight — 1.5 lb [0.7kg]

AT-SC Pneumatic Safety Crimp MachineThis pneumatic crimp machine was created with a newly developed safety mecha-nism. It is designed to crimp connections up to 50 mm2 depending on the terminaldesign. Request catalog 6-1773444-9 for more information.

AT-55 Pneumatic Crimp MachineThis pneumatic crimp machine was designed to crimp insulated and non-insulated terminals from 0.14 mm2 to 120 mm2 depending on the terminal. With theoptional cutting unit, this machine is able to cut ribbon cable up to a width of30mm as well as copper conductors up to max ∅ 28mm. Request catalog 6-1773444-9 for more information.


6-26 Pneumatic Tool

Micro-Pneumatic Tool

AT-SC Machine

AT-55 Machine

POWER SOURCE

Die/Head Hand Battery- Micro 626 SDETool Powered Pneumatic Pneumatic Electric

CERTI-CRIMP II ● ● ● ● ●

Double Action Head ● ● ● ●

Heavy Head ● ● ●

T-Head ● ● ● ●

C-Head, Large Die ● ● ●

Large Die ● ● ● ●

SDE Dies ● ● ● ●


25





Low Volume, Prototype, Maintenance and Repair Wire Processing ProductsAchieve maximum crimping power for the largest wires with hydraulic tooling, featuring interchangeable U-dies or shank dies for force greater than 12 tons.

AT-66 Hydraulic Crimp MachineThis hydraulic crimp machine is characterized by its extremely compact design and itslow space requirement. The hydraulic power is provided by a separate hydraulic unitwith main switch, power distribution and pump. This machine can be used for wire sizesfrom 0.14 mm2 up to 300 mm2. Request catalog 6-1773444-9 for more information.

Hydraulic Crimp ToolingThe hydraulic crimp tooling product line offers industry-standard 10,000 psi hydrauliccompression crimp heads, pumps, and interchangeable U-dies for precision crimping atfixed or remote locations. Request catalog 1654519 for more information.

• U-dies for crimp force up to 14 tons [128 kN] and U-die stroke options of 25mm[1”] and 38mm [1.5”].

• Heads compatible with shank dies available for larger wires requiring crimp forcegreater than 14 tons [128 kN].

• Battery-powered, rechargeable pump and tool options providing portability forremote crimping applications.

Pistol Grip Hand Tooling System for Insulation Displacement Connectors (IDC)The pistol grip hand tooling system uses interchangeable terminating heads to applya broad range of TE Connectivity IDC products. The basic tool requires a pistol griphandle assembly and a terminating head; terminating force is provided by a manual,pneumatic, or electric-powered assembly. Request catalog 296176 for more information.

• Power-assist and bench mount versions available

• Most terminating heads able to automatically index connectors to the next contact position or advance connectors by hand to the next position.

AT-66 Machine

Hydraulic Tooling

Pistol Grip Tooling


26






Low Volume, Prototype, Maintenance and Repair Wire Processing Products

Hand Tool KitsTE Connectivity provides standard kits thatcontain the necessary equipment to carry outspecific tasks to high professional standards.We can also provide custom kits for volumerequirements containing only tools, or acombination of tools and terminals tailored toyour specific requirements. Please visit ourtooling website to view our online hand toolcatalog for standard kits, or find your local TEcontact to discuss custom kits.

27






Low Volume, Prototype, Maintenance and Repair Wire Processing Products

Insertion and Extraction ToolsInsertion/extraction tools are used for inserting discrete terminals intoconnector housings or removing them, without causing damage to either theterminals or housings.

Our new standard design features a comfortable handle and snap-in/outprotective cover that allows users to stow the business end of the tool tohelp protect from inadvertent personal injury when the tools are not in use.

Many different design types currently exist for our vast terminal productrange, which we continue to convert. If you would like the tool you useconverted to the new design, want a custom kit or tools in this design forother manufacturers’ products – contact us, and where volumes permit, wewill be pleased to provide you with a quotation for your requirement.

“Protective Cover” out“Protective Cover” in

Intermediate Volume Wire Processing ProductsApplicators and tooling from TE Connectivity can be your key to productive wire harness manufacturing.These applicators come from a long tradition of quality, reliability and precision.

OCEAN ApplicatorThe lead and harness industry of today is more price andquality competitive than ever before. TE Connectivity OCEANapplicators are designed to meet these demands. We striveto keep our applicators competitively priced while providingthe consistent, high-quality terminations you’ve come toexpect from TE Connectivity.

Why a new TE Connectivity Applicator Design?We standardized our applicator offerings to provide global design consistency andto offer the ultimate flexibility with choices in feeding options.

The OCEAN applicator is designed so that all feed options are interchangeable withthe common base applicator. Our pneumatic and mechanical feed options have beencompletely redesigned. They offer finer, more precise terminal positioning along withquicker adjustability while being much more user friendly. The interchangeability alsomakes it possible to upgrade to smart applicator technology.

Advantages of the OCEAN Applicator:• One applicator platform — modular family design

• Two styles with 3 feed options: mechanical, pneumatic and servo

• Same wire crimper, insulation crimper and anvil used on both applicator styles

• Open architecture allows for design flexibility

• 60% tighter fit between the ram and housing for improved alignment and crimpconsistency

• Finer incremental crimp height adjustment

• Improved and simpler adjustments on all feed units

Request catalog 9-1773458-6 for more information.

28





ATLANTIC-Style Side-Feed Pneumatic Applicator

ATLANTIC-Style End-Feed Mechanical Applicator

PACIFIC-Style Side-Feed Mechanical Applicator

PACIFIC-Style Side-Feed Servo Applicator

NEWNEW


29




Intermediate Volume Wire Processing ProductsManufactured from high grade steel, and processed through state-of-the-art CNC equipment for tightesttolerances, our applicators are made for high repeatability and fast throughput.


Replacement Tooling


Design Re-use• Same wire crimper, insulation crimper, and anvil

used on both applicator styles

• 3 feed options: mechanical, pneumatic, servo

• Design automation program (Pro-E, SmartAssembly & Microsoft Excel) has beendeveloped to enable design consistency anddesign re-use

• Reduces manufacturing timethrough design consistency and standardization

TE Connectivity pres-ents “SMART Applicator”— Electronic Data Integrationhas been extended to the new OCEAN applicator seriesIt is now possible to have “smart applicators” on any of the feed styles of the newapplicator series. Electronic data integration is now extended to an entire “SMARTApplicator” strategy. It allows the operator to conveniently view all the data aboutthe applicator. The data contains serial numbers, part numbers, wearable toolingpart numbers (and tooling cycle counters), strip length, instruction sheet numbersand more.

This data includes the terminals, with acceptable crimp heights, that can be terminated with the applicator. With this information conveniently available to theoperator, programming and verifying the crimp application has never been easier.Setup will be less time consuming and more accurate.

This system also extends the availability of the high precision servo feeder technology recently developed by TE Connectivity. Request catalog 3-1773464-0for more information.

Replacement Crimp ToolingTE Connectivity replacement tooling is made for longer replacement tool life, trouble-free operations, and high-yield crimping performance.

• Bell-mouth design on both ends of the crimp produces better crimp compliance andlonger-lasting terminations

• Special alloy steel for maximum strength withstands shocks during crimping

• Precision finished surfaces, reduces friction and terminal sticking

SMART Applicator

Pacific Style

Mechanical Pneumatic Servo

Atlantic StyleATLANTIC-Style

Mechanical Pneumatic Servo

PACIFIC-Style

30





Intermediate Volume Wire Processing ProductsWe provide a range of equipment to meet most levels of production and efficiency. Our terminators have along track record of dependable production and accept a variety of heavy-duty mini Applicators.

AMP 3K/40 and AMP 5K/40 TerminatorsThe AMP 3K/40 and 5K/40 terminators are powerful, economically-pricedmachines for terminating wire using reeled terminals and contacts. These ter-minators deliver the increased output and quality of a semiautomaticmachine, while meeting production specifications. Request catalog1654856 for more information.

• 3,000 pound [13 kN] crimp force capacity in AMP-3K/40, capableof crimping 32-14 AWG [0.03-2 mm2] wire sizes.

• 5,000 pound [22 kN] crimp force capacity in AMP-5K/40,capable of crimping 32-10 AWG [0.03-6 mm2] wire sizes.

AMP-O-LECTRIC Model G TerminatorNot CE Approved.

The Model G is the most advanced bench-top design in the AMP-O-LECTRIC series. It features a reliable direct motor drivesystem and has modular construction to allow configuration foruse either on the bench or in fully-automatic leadmaking equipment. Request cata-log 65828 for more information.

• Precision adjustment for crimp height used with the optional crimp quality moni-tor will maintain the tight tolerances required for high yields and productivity

Stripping Module for AMP 3K/40, AMP 5K/40 and Model G TerminatorsThe stripping module combined with the AMP 3K/40, AMP 3K/40 orAMP-O-LECTRIC Model G terminators provides an economic and pro-ficient method of stripping wire and crimping terminals on the samemachine. The wires are stripped moments before crimping, meaningthat there is virtually no chance of wire conductor damage during han-dling or storage. Request catalog 1309085 for more information.

Crimp Quality Monitor II (CQM II)The CQM II is an easy-to-use tool for measuring crimp height as part of a compre-hensive quality management program. The CQM II utilizes a patented technologywhich is constantly measuring both ram position and force throughout the crimpcycle. Intuitive menus on a convenient touch screen give you complete control ofyour quality process. Request catalog 82275 for more information.

AMP 5K/40 Terminator

Model G Terminator

Stripping Module

CQM


31




Intermediate Volume Wire Processing Products

CRIMPMATIC 970 and 971 MachinesThe CRIMPMATIC 970 machine can process loose or reeled terminals for wires upto 16mm2 [51/2 AWG]. Working with even larger size wires? The CRIMPMATIC 971machine can handle all the way up to 50mm2 [0 AWG]. But automating the crimp-ing process isn't the only benefit. Crimping is faster and more reliable. Your crimpingprocess will be safer and more productive, with higher-quality finished products.

Both CRIMPMATIC models come in a space-saving design, have an inching mode forsetup, include a reel holder for spooled terminals, and allow two-handed operation forthe application of loose piece terminals. You can also order the following options:

• Crimp force monitoring

• Fine adjustment of lower dead center

• Paper spooler

Request catalogs 65828-1 (970) and 65828-2 (971) for more information.

Pneumatic Large Wire Applicators (for strip form terminals)• Dedicated to CRIMPMATIC 970 / 971 machines

Pneumatic Mid-Size Wire Applicators (for strip form terminals)• For terminators with standard TE Connectivity-style base plate (4 to 8 tons) and

CRIMPMATIC 970 machine with base plate for conventional applicators.

Loose Piece Large Wire Applicators• Dedicated for CRIMPMATIC 970 / 971 machines

• Custom designs available for nearly any terminal

Request catalog 296393-2 for more applicator information.


CRIMPMATIC970 Machine

CRIMPMATIC971 Machine

Pneumatic Large Wire Applicator Pneumatic Mid-SizeWire Applicator

Loose Piece LargeWire Applicator


32





High Volume Wire Processing ProductsThe automatic lead maker machine is one step above semi-automatic bench terminating equipment.However, this level of tooling presents the opportunity for significant cost savings in wire processing.

Alpha 355 Leadmaker

Gamma 333 Leadmaker

Precision Controller


Gamma 263

Gamma 263 Crimping MachineThe Gamma 263 machine provides high output with reliable, well known processes.

Although compact in size, this fully automatic crimping machine combinessimplicity and functionality with economy and process reliability to delivera high piece output. It is an excellent value. Whether you opt for the roller

or belt drive, you can adjust the use of this device to your individual needs.Request catalog 6-1773462-5 for more information.

Gamma 333 Fully Automatic Crimping MachineThe fully-automatic PC-controlled Gamma 333PC lead maker can be equippedwith up to three processing stations enabling the crimping of both ends of thewire, double-crimp connections with three different contacts, single-ended sealapplications, tinning or ink-jet marking. Features include ultra-short conversiontimes, easy-to-use graphic-based TopWin interface with multiple-language capa-bility, crimp force analyzer with statistical analysis, seal monitoring, and integrat-ed good/bad sorting. Request catalog 7-1773440-9 for more information.

SMART Applicator System integrated with leading wire-processingtechnology / Precision ControllerNot ready to invest in a new leadmaker now but still want theadvantages of our System III and SMART Applicator technology?TE’s Precision Controller can be installed on many of your lead-makers or terminators in order to take advantage of the produc-tion improvements. Request catalog 1-1654956-0 for more information.

Alpha 355 Fully Automatic Crimping MachineThe Alpha 355 crimping machine is designed for one and two-sided crimpingand seal loading. It even handles double-crimp connections involving varyinglengths with the same wire. The dual channel cuthead allows for a largerange of wire sizes without blade changes. Request catalog 7-1773440-8 for more information.

33





High Volume Wire Processing ProductsThe automatic lead maker machine is one step above semi-automatic bench terminating equipment. This levelof tooling presents the opportunity for significant cost savings in wire processing. In addition, lead makers aremodular in design; thus, providing a common base for use in a variety of wire applications, such as doublingwires, applying seals and tinning wire strains.

Alpha 477 Fully Automatic Crimping MachineThe Alpha 477 fully automatic double crimping machine allows you toprocess two different wires simultaneously to produce your choice of doublecrimp or single wires. Four processing stations at the lead termination andtwo at the trailing end provide a large number of possible processes.Request catalog 3-1773439-9 for more information.

Alpha 488 Fully Automatic Crimping MachineDrawing on continuous stock, the Alpha 488 fully automatic twister producestwisted pairs completely cut to length and terminated with all quality con-trols included. The modular design of the system provides maximum flexi-bility. Four processing stations at the lead termination and two at the trail-ing end provide an array of processing possibilities. Request catalog 3-1773439-9 for more information.

Zeta 633/633 L Fully Automatic Crimping MachineThe Zeta 633 and 633 L are highly flexible fully-automatic crimpingmachines for just-in time production. The flexible machine concept createsan almost unlimited number of possibilities for handling small jobs or wiresequences. The operator is able to reduce the required material changeoversand interruptions in produc tion to a minimum. The Zeta 633 crimping machineis ready to accom mo date five crimping presses and the 633L-Version canhandle up to eight, for even more flexibility.

Zeta 655/656 Lead Maker Double End Block LoaderThe Zeta 655/656 lead maker is the flexible solution for single and double-sided housing insertion. This machine is characterized by a high degree ofautomation and a reliable insertion process. The precise force sensor monitorsthe entire insertion process to provide seamless, integrated process monitoringin regards to collisions, loading force and contact locking. The innovative quickchange pallet system can replace the harness specific insertionapplication and convert to another harness.

Alpha 477 Leadmaker

Alpha 488 Leadmaker

TopWin is a trademarkof Komax AG.


Zeta 633 Machine

Zeta 655 Machine

34





Wire Preparation EquipmentThe new Cosmic series of strippers offer options including a model for jacket stripping and a precision micro-cable stripping machine. * Cosmic Stripper sold and distributed only in North America

Cosmic 32M Electric Wire StripperThe Cosmic 32M stripper is the latest high-speed electric wire stripper. Achievinghigher precision, more power, and a wider AWG range, all in quicker cycle time thanits predecessor. It is equipped with a digital stripping diameter display and a sensi-tive wire-tip touch sensor for easy operation.

Cosmic 42R Micro-Coaxial Cable StripperThe Cosmic 42R stripper is our newest-developed cable stripper for ultra-microcoaxial cables. This ultra precision machine is made through state-of-the-art engineering.

Cosmic 48R Coaxial Cable StripperThe Cosmic 48R stripper is designed for quick cycle timeswhether stripping coaxial, multiconductor or standard wires.With these extremely versatile features, this could be theright machine for your operation.

Cosmic 60R Rotary-Jacket StripperThe Cosmic 60R stripper is designed for jacket stripping ofmulti-conductor or single cable. Its rotary blade centralizersystem can strip various insulation material cables withoutchanging the blades.

Cosmic 927R and 927RX Micro-Cable Strippers

The Cosmic 927R stripper was designed to strip various insulation materials and micro-cable. The stripping diameter display can be set to within 0.1mm incrementsoptimizing quality and limiting potential conductor damage.

The Cosmic 927RX stripper shares the features of the Cosmic 927R stripper but isrecommended for hard to strip insulations.Request catalog 1654956 for more cosmic stripper information. The cosmic strippers are not CE Approved.

K206 and K206S Cutting MachinesThe K206 cutter is the all-round model of the pair, while the K206S Mmchine is thespecialist. The two cutting machines cut round and flat conductors, hose, PVC strips,various types of foil, paper, textiles, etc. Rated for high power, these cutting unitsperform cuts of stranded wires up to 35mm2 in diameter. Both machines delivermaximum flexibility in processing, process control and precision. Request catalog 8-1773457-1 for more information.

Cosmic 32M Electric Wire Stripper

Cosmic 927RMicro-Cable Stripper

K206 Cutting Machine

Cosmic 42R Electric Wire Stripper


35




Wire Preparation EquipmentPower, performance and a new type of sensors are the key features of the fully automatic Kappa cutting andstripping machines. Simple, intuitive controls allow these machines to be used efficiently in daily operation.

Kappa 310 StripperThe Kappa 310 stripper is an ultra-compact, high-speed machine designed for thereliable controlled processing of the finest wire sizes from 0.02mm2 to 6mm2. Allprocess parameters can be saved along with applied pressure values.

Kappa 320 StripperThis machine processes wire sizes from 0.05 to 10mm2. It features a powerful bladehead and a number of options. From this machine type and higher, all fully automaticcutting and stripping machines can be controlled and networked via TopWin soft-ware to allow inkjet marking.

Kappa 321 StripperThe Kappa 321 stripper features the swivel technique utilized in the wire drive axes.Two different processing positions can be approached with this feature. The machineis designed for a wide variety of special applications or the separation and process-ing of inside wires in multipole cables.

Kappa 330 StripperThis model is designed for processing cables with a cross section of up to 35mm2,multi-core conductors with an outside diameter of up to 16mm or flat cables with awidth of up to 40mm. The machine uses either a belt drive or various types ofdrive rollers depending on your requirements.

Kappa 350 StripperThis powerhouse with its double blade design is built for processing round conduc-tors with a cross section of up to 120m2 and a maximum outside diameter of up to35mm. The powerful belt drive provides gentle processing across the entire crosssection range. The elimination of initial cut losses makes an especially big differencein this model for the top of the cross section range.

Request catalog 1654956 for more Kappa Stripper information.

AT-ST Wire Stripping and Twisting MachineThe AT-ST machine strips and twists wires with sizes from 0.03-6mm2 (AWG 32-10). The adjustable turret head with 8 guide tubes for different wire sizes central-izes positioning of wires. Special ground blades cut and strip special insulations.Request catalog 6-1773444-3 for more information.

Kappa 310 Stripper

Kappa 320 Stripper

Kappa 330 Stripper

Kappa 350 Stripper

AT-ST Stripping and TwistingMachine


Komax and TopWin aretrademarks of Komax AG.


36






Application Tooling for Hybrid & Electric Mobility Solutions

AMP+ HVA280 Low-Medium Current Connectors and HeadersTE Connectivity’s AMP+ touch-proof 2 or 3 position low-medium current connectorsand headers are designed for flexibility with options for various EV device applica-tions.

With a current carrying capability up to 40A* at 85°C and a 2-4mm2 multicore wirerange, the AMP+ connectors and headers can be utilized with mutlicore or individu-ally shielded wire. Multiple latching options and an integrated internal HVIL withmultiple routing options allow package size optimization and flexibility.

For more information please go to http://te.com/ev.

OCEAN Applicator (for 2.8mm terminals on strip)Standardized applicator offering provides global design consistencyand offers the ultimate flexibility with choices in feeding options.


• Die set (bottoming dies to insure proper crimp geometry)• Die set with locator (assembly aid used during assembly)• Hand hydraulic tool (provides accurate, consistent crimps)• Bench mounted hand hydraulic tool (increases comfort/promotes higher

output)

Application Tooling for Semi-automatic Processing/Medium to HighVolume

• Die set (bottoming dies to insure proper crimp geometry)• Die set with locator (assembly aid used during assembly)• Locator fixtures (secures location in terminating unit)• Bench top termination unit

(provides consistent crimpingforce

*For details regarding applicationtooling, refer to the appropriateapplication specification.

AMP+ HVA280

37







AMP+ HVA630 Low-Medium Current Connectors and HeadersTE Connectivity’s AMP+ touch-proof 2 position low-medium current connectorsand headers are designed to meet AK 4.3.3, LV215-1 specifications. With a cur-rent carrying capability up to 40A* at 140°C and a 4-6mm2 multicore wire range,the AMP+ connectors and headers can be used in many EV device applications.The package size is optimized with an integrated internal HVIL.



• Die set (bottoming dies to insure proper crimp geometry)• Die set with locator (assembly aid used during assembly)• Hand hydraulic tool (provides accurate, consistent crimps)• Bench mounted hand hydraulic tool (increases comfort/ promotes higher

output)


• Die set (bottoming dies to insure proper crimp geometry)• Die set with locator (assembly aid used during assembly)• Locator fixtures (secures location in terminating unit)• Bench top termination unit (provides consistent crimping force

*For details regarding application tooling, refer to the appropriate ApplicationSpecification.

AMP+ HVA630

38







AMP+ HVP800 High Current Connectors and HeadersTE Connectivity’s touch-proof 2-3 position high current connectors and headersare designed to meet AK 4.3.3, LV215-1 specifications. With a current carryingcapability up to 250A (continuous) on 50mm2 wire, an ample temperature rangeand a wide wire range, the AMP+ high current connectors and headers can beused in various EV applications. An integrated internal HVIL with multiple routingoptions allow package size optimization and flexibility. Assembly is simplified witha lever assist for low insertion force.



• Die set (bottoming dies to insure proper crimp geometry)• Die set with locator (assembly aid used during assembly)• Hand hydraulic tool (provides accurate, consistent crimps)• Bench mounted hand hydraulic tool (increases comfort/ promotes higher

output)


• Die set (bottoming dies to insure proper crimp geometry)• Die set with locator (assembly aid used during assembly)• Locator fixtures (secures location in terminating unit)• Bench top termination unit (provides consistent crimping force)

*For details regarding application tooling, refer to the appropriate applicationspecification.

AMP+ HVP800

39







AMP+ IPT

AMP+ APT & IPT High Voltage Shielded Ring Tongue Terminal CableAssembliesConnect easily and conveniently to devices with TE Connectivity's 1, 2 or 3 positionAMP+ APT and AMP+ IPT high voltage shielded ring tongue terminal cable assem-blies. The AMP+ APTs and IPTs are used with a range of individually shielded wiresthat accommodate TE's family of AMP+ high voltage connectors. The AMP+ APT,with a wire range of 2-4mm2, is suitable for accessory devices and the AMP+HVA280 or AMP+ HVA630 headers and connectors. The AMP+ IPT, with a wirerange of 16 - 50 mm2, is suitable for high power battery, inverter and e-motorapplications. and the AMP+ HVP800 headers and connectors.



• Die set (bottoming dies to insure proper crimp geometry)• Die set with locator (assembly aid used during assembly)• Hand hydraulic tool (provides accurate, consistent crimps)• Bench mounted hand hydraulic tool (increases comfort/ promotes higher output)


• Die set (bottoming dies to insure proper crimp geometry)• Die set with locator (assembly aid used during assembly)• Locator fixtures (secures location in terminating unit)• Bench top termination unit (provides consistent crimping force

*For details regarding application tooling, refer to the appropriate application specification.

40





Magnet Wire Crimp Application EquipmentMAG-MATE and AMPLIVAR splices and terminals are available in a wide range of configurations to meetmost magnet-wire termination needs. All provide high reliability with minimal wire preparation.

AMPLIVAR Product Terminator 5A and 5E (APT) MachinesThe new APT 5A magnet wire pigtail splice machine offers a fast, efficient system,with no need to strip mag-wire insulation. Simply place the wires in the target areaand depress the foot switch. The machine automatically shears the splice or con-tact from the strip, crimps it, shears off excess wire, and advances the nextsplice or contact into position. APT bench machines are available in two versions: the 5A with automat-ic precision adjustment controlled by the crimp quality monitor (CQM)and the 5E with manual precision adjustment. Using CQM, the APT 5Aprovides 100% inspection and automatic adjustment of crimp height. Ifa questionable crimp is detected, visual and audible alarms alert theoperator.The lower cost, manual adjust APT 5E is a simpler version with theadvantage of faster set-up times but without CQM capability.

AMPLIVAR Terminator for Parallel and End ConnectionsPrimarily sold in Europe.This machine was developed for processing magnet wire connections with separateversions available for end- and side-feed. The design takes into account that themotor windings and coils can be supplied directly to the connectors. The exposedcrimp position permits precise handling. In case of end connections the projectingmagnet wires are cut off.AMPLIVAR splices and terminals are specifically designed to terminate magnet wiresin combination with standard solid or stranded wire. In a one-step operation themagnet wire is stripped of its insulation as it is forced into the serrations during theprecisely controlled crimping operation. As many as three magnet wires can beterminated simultaneously in one splice.

AMPLIVAR ProductTerminator 5A

AMPLIVARTerminator


41





Magnet Wire Crimp Application Equipment

AMP-O-LECTRIC Model G Terminator with Thru-Splice ApplicatorNot CE Approved.

Applying thru-splices is fast and efficient when you have access to both sides ofthe applicator for placing and holding the wires. The AMP-O-LECTRIC Model Gsplice terminator with a standard G splice applicator provides front and rear accessto maximize production efficiency. It provides full guarding for operator safety andis available with or without a crimp quality monitor. Request catalog 889021 formore information.

Power Splice MachineNot CE Approved, contact engineering for quotation.

The power splice terminator and applicator from TEConnectivity provides reliable pigtail splice termination of magnet wire and solid orstranded lead wire. This machine can terminate pigtail splices consisting of up totwo solid or stranded copper lead wires in wire size from 10-14 AWG and having acircular mil area (CMA) of 4,200 - 10,000. The splice will simultaneously acceptcombinations of multiple copper magnet wires 11-20 AWG. Request catalog 82221 formore information.

Crimpband Application ToolingNot CE Approved, contact engineering for quotation.

TE Connectivity offers solderless crimping systems to handle a wide range of wire con-nections including solid and stranded lead wire, insulated magnet wire, and componentleads. Each system is comprised of continuous, serrated crimpband material and acrimping machine. The TE Connectivity solution allows the flexibility to create a shapeand size, which optimizes the crimp’s electrical and mechanical performance.

The TE Connectivity crimping system produces a very economical and reliable inter-connection. Utilizing a continuous crimpband material the machine will feed, cut form,and crimp your application resulting in a very strong and uniform interconnect crimp.

Whether your application requires a wire-to-wire, wire to components leads, wire toterminals, or magnet wire splice termination, these crimping machines will providehigh-speed scrap free interconnects.

The Mod I Crimping System is used when running standard RTM and MTM crimpbandproduct. In addition, left and right horn termination machines are available when yourapplication requires additional working envelope.

Request catalog 82221 for more information.

Power SpliceMachine

Model G Terminator

Mod I Crimper


42





Magnet Wire MAG-MATE Application EquipmentTE Connectivity offers a wide variety of Magnet-Wire Termination Solutions for thru splicing, pigtail splicing andcoil termination.

MAG-MATE and SIAMEZE Inserter Mark II with PLCPrimarily sold in Europe.

TE Connectivity magnet wire terminations are a great connecting alternative tosoldering techniques used in a lead-free environment. Special knowledge isrequired to design a mass manufacturing line for insulation displacement crimpson thin lacquerd insulated wires with high yield. Design aspects of the terminal,the cavity and the machine all need to be harmonized. With the inserter mark IITE Connectivity can offer an economic solution especially for the application of MAG-MATE and SIAMEZE terminals.

MAG-MATE and SIAMEZE Inserter Mark II withPLC and Insertion Force Control Primarily sold in Europe.

This advanced insertion machine provides the features of the MAG-MATEinserter mark II with an additional force distance control system. The machine isdesigned to apply multiple different contacts and will be customized accordingto the customer or product specific requirement. The contacts can be used assingle contacts or in strip form (bridge function adjusted "on-the-fly").

A gauge is available to check the adjusted insertion forceand to recalibrate the insertion force control sensor.Request catalog 7-1773440-4 for more information.

Pneumatic Insertion Tool for MAG-MATE TerminalsPrimarily sold in Europe.

The pneumatic tool for MAG-MATE terminals features a rotary insertion finger tofaciliate different insertion angles.

This tool is designed for use in TE Connectivity P200 and P300 standardinsertion machines but can also be integrated into customized production linesor assembly cells.

Mark IIInserter

Mark II Inserterwith InsertionForce Control

PneumaticInsertion Tool


43




Magnet Wire MAG-MATE Application Equipment

MPT-5 S/L Product Terminator (SIAMEZE and Lead Lok terminals)Not CE Approved, refer to Mark II.

For quick, easy and reliable termination of magnet wire, TE Connectivity offers the MPT-5S/L product terminator — an air-operated insertion machine with microprocessor control.

The MPT-5 S/L machine inserts a SIAMEZE terminal into a customer-designed cavity in thecoil bobbin or similar mag-wire housing, terminating the wire and providing an I/O terminalor other connection. It can insert both the SIAMEZE terminal and the lead lok terminal toconfirm your lead wire connection. The MPT-5 S/L offers dual reel capability. Request cata-log 82221 for more information.

MPT-5 Product Terminator (MAG-MATE)Not CE Approved, refer to Mark II.

The MPT-5 terminator is an air-operated machine with microprocessor controlthat inserts MAG-MATE terminals into customer-designed cavities in the coilbobbin or similar magnet-wire housing, terminating the wire for connec-tivity. Please note: The customer designed cavities must follow TEConnectivity specification guidelines.The dual reel capability of the MPT-5 machine allows insertionof two different MAG-MATE terminals, with the capability toalternate between inserting one and two terminals at a time.The MPT-5 is also capable of trimming excess magnet wire. Request catalog 1308387 for more information.

MAG-MATE Terminal Cavity and Fixture Design MAG-MATE terminals insert into a molded-in cavity in the coil bobbin. The bobbin is generallysecured in a fixture during the insertion/termination process. TE Connectivity engineers workwith our customers to support cavity and fixture design, at any level. We can provide com-plete design of cavities and fixtures for customer’s applications, work with our customer’sengineers, or simply provide CAD models and other engineering data as needed. Consultationearly in the design process allows customers maximum benefit from our decades of magnet-wire experience.

Product Line Integration The MPT-5 and APT IIIA machines have the production capacity and the electronics for easyintegration into automated production lines. TE Connectivity engineers work with your systemintegrators to successfully integrate the TE Connectivity equipment into your line’s designand assembly.


MPT-5Terminator

MPT-5Module

MPT-5 S/LTerminator


44





FFC-FPC EquipmentFlexible Flat Cable (FFC) and Flexible Printed Circuits (FPC) are widely used in automotive and householdappliances, wherever space restrictions enforce a minimum of height. Standard crimp connections cover awide range of applications: foil and cable, foil and connector, foil and foil, and foil and splice.

FFC Hand Tool The very easy-to-handle 10 position hand tool allows variable settings for boththe foil stop and foil guide. A correct and repeatable crimp process is achievedby an integrated ratchet mechanism.

A FFC hand tool case can be built up around your particular applicationrequirements. The tool allows crimp connections to be made between foil and 1 to 10 position MQS terminals. The crimp height is set for 70 mm thick foil.

FFC Termination Machine for Flexible Sensor Foil The termination machine is an electrical driven semi-automatic assembly machinethat uses different applicators to terminate reel-feed FFC contacts to manuallysupplied FFC cables. The machine terminates a predefined number of contacts tothe supplied cable end.

TE Connectivity products FFC MQS, FFC AMPMODU .100, Junior Timer, AMPMODU .50 and soldered contacts are compatible. Request catalog 1309407for more information.

• Interchangeable applicators available for different products

• Quick-change of applicator

• Alignment of the cable is realized in the machine

• Number of pins can be programmed (max. 38mm with pitch2.54mm)

• Pitch 1.27 mm up to 5.08 mm can be programmed

• Individual wire positions can be skipped

• Operator friendly interface via touch screen

• Integrated crimp force monitoring by CQM (optional)

FFC Applicator The FFC applicator is designed for FFC and FPC terminations. It is normallydelivered with a special TE Connectivity crimp machine, but is also compa tiblewith standard presses (press stroke 40 mm), if a wire feed is supplied.

The adjustment of the crimp height is similar to other TE Connectivity crimpapplicators. The wear parts are easy to change. The FFC Applicator is availablefor different TE Connectivity contacts, such as: FFC MQS, FFC Junior Timer, FFCAMPMODU .100, FFC AMPMODU .050, FFC Card Edge, FFC ACTION PIN andFFC soldering pin.

FFC Hand Tool

FFC TerminationMachine

FFC Applicator


45





FFC-FPC EquipmentTE Connectivity’s comprehensive range of tools and machines are suitable for processing these demands.

Assembly Machine to Connect FFC and PCB This machine has been specially designed to connect a flexible printedsensor with a PCB using an ACTION PIN FFC contact. The flexible printedsensor and the PCB are manually loaded into the machine. After the cyclehas been started, the insertion head is positioned above the first insertionposition.

The pre-formed contact is cut off the carrier strip and simultaneouslyinserted into the PCB and crimped to the flexible printed sensor. Severalcontacts form the complete connection between the sensor and the PCB.The force, required to insert the ACTION PIN contact with the PCB, ismonitored by a force sensor.

To accommodate two types of PCBs, the PCB holder is positioned bypneumatic cylinders. The desired position is selected via the operatorinterface.

FFC/FPC Machine The FFC/FPC bench machine creates electrical connections between TEConnectivity FFC terminals and flexible flat cables. Thanks to itsadaptable circuit fixture the machine is simple and easy to load. Prior toinitializing a crimp cycle, the vision system establishes the preciselocation of the first conductor track. A positional correction is effectedas appropriate.

The equipment combines the functions of terminal feed, cutting theproduct off the carrier strip, crimping, and chopping of the carrier strip.An integrated crimp force monitor provides high quality crimpconnections. An optional faulty crimp cut off device prevents the furtheruse of defect circuits.

FFC/PCBAssembly Machine

FFC/FPC Machine


46





Assembly Automation Products — Insertion Machines for Single ContactsTE Connectivity insertion machine platforms combined with performance enhancing accessories provide the flexibility to meet a wide range of customer requirements in the manufacturing of printed circuit boards.



P200 Semi-Automatic Bench Machine


P50 Manual Bench Insertion MachineThe successful product line of single pin insertion machines has beenexpanded with the addition of the P50 manual operated benchmachine for low volume production, repair work and sample production.

The newly designed pneumatic insertion head uses the well known conversion kitsfrom the upper machine range P300 / P350 and can also be used on othermachines in the product line. These kits can easily be changed to run different terminal types and provide all features to feed, cut and insert the terminal.

P100 Pin Insertion Machine (formerly Accuserter 2)CE review in process, call for current status.

The semi-automatic P100 machine is the newest addition to the line of TEConnectivity pin insertion systems. Designed and manufactured with a focus onmid-volume level production, the P100 machine provides a broad range of featuresat a very competitive price.

P200 Semi-Automatic Bench MachineThe stand-alone P200 insertion machine targets low to medium volume produc-tion. Equipped with a rotary insertion finger, the P200 machine can apply productsat up to 7 different angles without having to rotate or remove the board.

P300 Pin Insertion MachineThe fully automatic P300 insertion machine processes reeled press-fit and thru-hole components into PCBs. Available in either a stand alone unit or integratedinto a SMEMA compatible production line, the P300 machine can increasethroughput by lowering cycle times and the scrap associated with human applica-tion errors.

P350 Pin Insertion MachineThe fully automatic P350 pin insertion machine for high volumes is capable ofapplying reeled products from TE Connectivity or other manufacturers. With inlineoperation, an automatic tool changer and insertion rates up to 5 per second, it isfocused at fully automatic high speed operation to maximize throughput while

minimizing costly scrap.

For information on additional TE insertion equipment,request catalog 7-1773439-0, Pin Insertion and Press-FitMachines.

NEWNEW

P50 Bench Insertion Machine

47





Assembly Automation Products — Insertion Machines for Contacts andDevices


M300T Machine

M2000M Machine

M2000T Machine

M200 Machine

M Series of Insertion MachinesCE review in process for all M Series Machines, call for current status.

The M Series of insertion machines from TE Connectivity provides flexibility and cost sav-ings to meet a wide range of customer requirements in the compliant pin / thru holetechnology. Our full range of systems can help with the application of insertion fromreeled components to loose piece components including odd shaped components.Request catalog 7-1773439-0 for more information.

M200 Automatic Multi-Head Insertion MachineThe M200 machine is designed to insert terminals in loose piece form (eyelet pins, grip-per pins, round pins, lugs and odd-shaped components) into PCBs. The operator canselectively choose any combination of three insertion heads according to the productionrequirements.

M300T Automatic Multi-Insertion MachineThe M300T machine is designed to insert lugs, taps, fuse holders, terminals and odd-shaped components into PCBs.

M2000M Mini Fuse Inserter MachineThe M2000M machine automatically inserts mini fuses into a junc-tion box. This machine has a max of six insertion heads allowing asmany as 6 different fuses to be inserted by one machine. (Machinecan insert relays with modifications.)

M2000T Automatic Terminal Insertion MachineThe M2000T insertion machine is designed to insert terminals and odd-shaped compo-nents into PCBs. The operator can selectively choose any combination of three Insertionheads according to the production requirements.

M2000RA Automatic Terminal Insertion MachineThe M2000RA insertion machine is designed to insert odd-shaped components such asrelay, IC, axial parts and more into PCBs. The customer can select 1 to 4 heads dependingon the application.

48






Assembly Automation Products — Press Fit MachinesTE Connectivity insertion machine platforms combined with performance enhancing accessories provide the flexibility to meet a wide range of customer requirements in the manufacturing of printed circuit boards.

CBP 5T Benchtop Servo Electric Press (formerly BMEP 5T)This servo electric press provides the ability to process most compliant pin connec-tor applications in a compact benchtop system. Board size capacity and press forcerange allow the system to handle a wide range of applications for low-to-mediumproduction volume operations. Request catalog 1309329-2 for more information.

CMP 6T/12T Manual Servo Electric Press (formerly MEP 6T/12T)This manual servo electric press, designed with a rigid 'H' frame to minimize deflec-tion, is available in two models (6 ton and 12 ton). The operator can manually adjustthe press head and/or the PCB between connector press cycles. Request catalog1309329 for more information.

CAP 6T Automatic Electric Press (formerly AEP 6T)The CAP 6T press provides proven force control capabilitiesand quality assurance in an automatic press. It provides greatercontrol and simplified processing to help improve quality, lowerrework and prevent rejects. This provides users with lower trueapplied cost and higher end profits. The CAP-6T can also beupgraded with an automatic transport system used to increasethroughput capabilities. The in-line CAP-6T press can also be configured in shuttlemode using an additional bi-directional buffer. Request catalog 1309329-3 for moreinformation.

CSM 5T Connector Seating Machine (formerly CSM 200)This machine provides end users with a faster, more reliable and less operator inten-sive method for processing compliant pin connectors. The heart of the CSM 5Tmachine is a CBP servo electric press to allow for monitoring and control of force,distance and speed. Request catalog 7-1773439-1 for more information.

CSP 3T Shuttle Electric Press (formerly SEP 3T)This press incorporates an automatic shuttle system for fastand simple product presentation. Focused at the applicationof PCBs onto compliant pin housings, this system provides fullcontrol and monitoring of force, distance and speed for quali-ty assurance of every product applied. Request catalog1309328-2 for more information.

CSM 5T Seating Machine

CAP 6T AutomaticElectric Press

CBP 5T Benchtop Electric Servo Press

CMP 6T Electric Servo Press

49






Tooling for Press Fit EquipmentPC-controlled servo-electric presses precisely control the speed, position and pressingforces for installing press-fit connectors into PCBs.

Insertion Tooling for CAP / CAPI 6T: • TE Connectivity press-fit machines use standard connector insertion tools

mounted to a tool bar

• Use existing tools for processing flat rock and header connectors

• Utilizes ID tag to confirm that the proper tool is used

Fixture Tooling for CAP / CAPI 6T: • A lower support tool is used to provide support for the PCB during press operation

• PCB specific fixture provides support during press process

• Slide drawer for easy access to change fixture or load/unload PCB

Assembly Automation Products — Connector Seating ToolingConnector manufacturers design and provide pressing (connector seating) tools specifically for each oftheir connectors. These tools are often referred to as top tools to distinguish them from the tooling thatsupports the PCB from below.

Tooling ConsiderationsMany connectors may be pressed by flat-rock techniques, meaningthe tool can be a simple flat surface. Most right-angle daughtercard connectors, for example, are amenable to flat-rock pressing,making specialized tooling unneccesary. For flat-rock pressing, theconnector’s insulating housing must be sufficiently strong to sup-port the pressing force.

Bottom tools for fixtures support the PCB during pressing. Thesespecialized fixtures can usually be used only for a specific PCBdesign. The connector pins often protrude through the PCB whenpressed, so clearance holes or slots must be provided at all connec-tor sites. Tooling pins in the fixture must pre-align the PCB holeswith the fixture. Most manual and semi-automatic presses use acustom fixture to support the PCB under the connector beingpressed.

ArticleThe Ultimate Lead-Free Solution: Press-Fit Connector Assembly can be found under more information at tooling.te.com/pressfit.asp

50






MOST ToolingMOST — Media Oriented Systems Transport — is the de-facto standard for multimedia and infotainmentnetworking in the automotive industry. The technology was designed from the ground up to provide anefficient and cost-effective fabric to transmit audio, video, data and control information between anydevices attached even to the harsh environment of an automobile.

Lambda 9100 POF Fully-Automatic Processing of MOST LeadFor processing large quantities of plastic optical fibers (POF) with low human resourses,TE Connectivity offers the fully-automatic machine Lambda 9100 POF.

All processing steps – from feeding and preparation to testing and deposition – are fully-automatic. Functions likelength measurement, integratedmarker software and monitored laserwelding are available for consistentlyhigh quality. To provide gentlehandling, the fiber ends are held fixedthroughout the process so that nouncontrollable bending radius occurs.The lead maker is equipped with adual laser module.

MOST SetsThe MOST sets are simple andinexpensive solutions for repair work in the workshop. To meet your requirements weoffer several different versions of sets. The basic version is equipped with two hand tools -one for stripping and cutting of POF, another one for crimping of POF and an additionalspare cutting unit.

A second version contains such items as a 20 meters POF, some male and femalecontacts and one position inline couplings. Other accessories are available in differentequipment versions.

51






MOST ToolingTE Connectivity Application Tooling offers tooling solutions ranging from hand tools (suitable for test laband repair) to fully-automatic machines (suitable for high volume) for creating fiber optic cable assemblies.TE also offers measurement/test devices and laser welding capabilities.

MOST Measuring DevicesThese devices accurately measure the position of the prepared end of the optical fibersrelative to the reference point of the insert. The result is displayed clearly by means of thedigital read out. The digital display can be zeroed via the setting gauge.

A special digital crimp height micrometer verifies the crimp height of metalinserts. Two opposed probe tips measure the crimp height of the insertsacross the diameter.

Tooling and Equipment for Glass Fiber Optics (GOF/PCS) for AutomotiveIn the future glass fiber may be used in the automobile industry. To keep pace with thistrend, TE is developing process equipment for the manufacture of GOF and PCS leads.Developments are based on experience gained in processing plastic and glass fiber forNETCONNECT communication technology products. With both GOF and PCS the primary

goal in the process is to achieve a high quality fiber endsurface. The goal of our development is to process thePCS fiber end with a laser module. Further processinginvolves joining a connector to the fiber end with a laserwelding module. The manufacture of the GOF fiber endfaces involves the additional processing of heat formingand polishing. A laser module is used to accomplishoptical connector assembly.

53






Introduction Quality, cost and throughput are associated with specificmeasurements and linked to process variables. Crimpheight, pull test values, leads per hour, and crimp symme-try are some of the measures used to monitor the produc-tion termination process. Many variables affect the processsuch as wire and terminal quality, machine repeatability,setup parameters, and operator skill.

Crimp tooling is a significant contributor to the overallcrimp termination process. The condition of crimp toolingis constantly monitored in production by various means.Typically, these means are often indirect measures. CrimpQuality Monitors and crimp cross sections are methodolo-gies that infer the condition of the crimp tooling. Visualinspection of the crimp tooling can be used to check forgross failures such as tool breakage or tooling deformationwhich occurred as a result of a machine crash. Continuousmonitoring of production will help determine when theprocess needs to be adjusted. The replacement of crimptooling can be one of the adjustments that is made.

Crimp tooling can have a positive effect on the quality,cost, and throughput of the termination process. High qual-ity crimp tooling can produce high quality crimps with lessin-process variation over a greater number of terminations.

It is difficult to distinguish critical tooling attributes withvisual inspection only. Some attributes cannot be inspectedeven by running crimp samples. This discussion will presentthe reader with information that identifies key crimp tool-ing attributes and the effect of those attributes on thecrimping process.

Key Crimp Tooling Characteristics

There are four major categories of key characteristics forcrimp tooling. These are:

• Geometry and associated tolerances

• Materials

• Surface condition

• Surface treatment

Each of these categories contributes to the overall per-formance of the production termination process.

Geometry and Associated TolerancesTerminals are designed to perform to specification onlywhen the final crimp form is within a narrow range ofdimensions. Controlling critical crimp dimensions is influ-enced by many factors including:

• Wire size and material variation

• Terminal size and material variation

• Equipment condition

The final quality and consistency of a crimp can never beany better than the quality and consistency of the toolingthat is used. If other variations could be eliminated, toolingcan and should be able to produce crimp forms that arewell within specified tolerances. In addition, variation fromone tooling set to another should be held to a minimum.Crimp tooling features that are well controlled and exhibitexcellent consistency from tooling set to tooling set canresult in shorter setup time as well as more consistent pro-duction results.

Some critical crimp characteristics are directly defined bythe tooling form and are obvious. These include:

• Crimp width

• Crimp length

Other critical crimp characteristics can be related to sever-al tooling form features and/or other system factors. Thesemay be less obvious and include:

• Flash

• Roll, twist, and side-to-side bend

• Up/down bend

• Crimp symmetry

• Bellmouth

The following discus-sion focuses on twocharacteristics—crimpwidth and flash—asexamples of how tool-ing can affect crimpform. Similar argu-ments can be appliedto the others. Cross section defining crimp width,

crimp height, and flash

Crimp Tooling Quality Factors — Where Form Meets FunctionQuality, cost and throughput are key attributes for any production process. Many variables contribute to theresults. Crimp tooling, defined here as crimpers and anvils, is one of those variables. The following topics providean overview of the considerations of crimper design and how the basic geometry of the tooling affects tolerancesand artifacts, such as flash.

Crimp WidthCrimp width is a good example of a feature that shouldbe consistent and in control between different crimpersof the same part number. The reason for this is quitestraightforward. For a given terminal and wire combina-tion, it is necessary to achieve an area index (AI) which isdetermined by the terminal designer for optimal mechani-cal and electrical performance. Crimp height (CH) andcrimp width (CW) directly affect achieving proper AI. AI(as a percentage), is defined as:

where At is the total area of the wire and barrel aftercrimping. AW and AB are, respectively, the initial cross-sectional areas of the wire and barrel before crimping.

A typical design point for AI is 80%. In order to maintainthe same AI, the crimp height, CH, needs to changeinversely to the change of crimp width, CW, in approxi-mately the same proportion. Thus, if the CW increases+2%, the CH needs to change approximately -2% in orderto achieve the same AI design point. At first glance thatmay not seem significant, but in reality it can be very sig-nificant. Using another general industry design rule of theratio of CH to CW of approximately 65%, a typical set ofdimensions used as an example may be:

CW = 0.110 in

CH = 0.068 in

Therefore, varying the CW by 2% would result in a CHvariation of 2%, or 0.0014 in. At a CH tolerance of ± 0.002in, 35% of the total CH tolerance would be used by a 2%variation in CW. Thus, the importance of crimp width con-trol is obvious when tooling is changed during a produc-tion run.

FlashMost crimp terminations have a requirement to limit flash.Flash is defined as the material which protrudes to thesides of the terminal down and along the anvil. Flash isnormal in the crimping process; excessive flash is veryundesirable. Controlling flash requires a balance of severalgeometric factors. Other factors influencing flash arerelated to surface finish and friction which will be dis-cussed later.

A dominant factor in controlling flash is controlling theclearance between the crimper and anvil during the crimpprocess. Defining the ideal clearance could in itself be asimple matter were it not for two facts:

• In order to minimize terminals sticking in the crimper,the sides of the terminal are tapered. Thus, the clear-ance between the anvil and crimper varies throughoutthe stroke.

• Crimper and anvil sets are typically designed to termi-nate two to four wire sizes. This creates multiple crimpheights. Since the sides of the crimper are tapered tominimize terminal sticking, the maximum clearance per-mitted without creating flash must be assigned to themaximum crimp height specified for the tooling set. Inaddition, a minimal clearance must be maintained forthe smallest crimp height specified by the tooling setto prohibit contact between the anvil and crimper.

54





(a)

(b)

Cross sections showingminimum (a) and maxi-mum (b) area index perterminal specification—avariation of ± 3.5%

AI = ________ x 100At

AW + AB

Crimp Tooling Quality Factors — Where Form Meets Function


55






Crimper-to-anvil clearance = X + Y at thefinal crimp height

Crimper to anvil clearance is thus acombination of crimp width, crimperleg taper, anvil width, and crimpheight. The critical design point is atthe largest crimp height. This contri-bution to the gap is directly depend-ent on dimensional control. The fol-lowing is offered as an example:

Nominal condition:

CH = 0.073 in

CW = 0.110 in

Crimper leg taper = 3.0 degrees

Anvil width = 0.109 in

Nominal anvil to crimper total clearance = 0.005 in

The clearance can grow rapidly withsmall changes to the nominal dimen-sions:

Crimp height remains unchanged =0.073 in

Increase in crimp width = 0.0008 in

Increase in crimper leg taper = 0.8degree

Decrease in anvil width = 0.0008 in

The total increase in total clearance is this case = 0.0026 in

This is more than a 50% increase inthe nominal design clearance, whichcan result in unacceptable flash (seebelow). Dimensional control is clearlycritical.

Material SystemThis topic addresses considerationsin material selection for the crimptooling, and the effect on crimpingperformance and reliability, as well ason wear resistance.

The material selection for tooling iscritical. The material must be able tomeet the in-service demands placedon the tooling components. The twocritical tooling components to bereviewed are the wire crimper andthe anvil.

The wire crimper and the anvil havedifferent functional demands. Bothhave the need to withstand highloads and moderate shock. However,the wire crimper is in fact an aggres-sive forming tool. It must withstandhigh shear loading that is a result offrictional loads generated as the ter-minal barrel slides along the crimpersurfaces in the forming process, andthen as the barrel terminal is plasti-cally deformed and extruded to com-plete the termination.The anvil expe-riences some of the same conditions,but to a much lower level of severity.

The wire crimper and the anvil can belikened to a punch and die in theworld of metalworking. The materialsused in punch and die applicationshave been well documented, alongwith the material selection process.The added severity of the aggressiveforming and the terminal and wireextrusion during crimping add com-plexity to the material selection. Thematerial selection process involves:

• Strength of materials with empha-sis on toughness needed to with-stand the moderate shocks gener-ated during crimping

• Wear resistance to maintain form

In addition to the above design con-siderations, there exists another phe-nomenon that occurs during crimping

that can significantly shorten the use-able life of a wire crimper. Materialcan be transferred from the terminalbarrel to the wire crimper. This mate-rial buildup can result in unaccept-able terminations. The crimped termi-nal surfaces can actually bedeformed by the indentations of thedeposited material. Crimp deforma-tion may result due to increased fric-tion. Tooling wear can be accelerateddue to higher crimp forces. Surfacetreatments that minimize this materi-al transfer are critical to extendedtooling life.

(a)

(b)

Significant flash can be generated withexcessive anvil to crimper clearance, asshown by nominal design condition (a) and +0.003 in over nominal condition (b).


56







Strength of MaterialsCrimpers and anvils are designed tobe able to withstand stresses that aretypically encountered during crimp-ing. The basic design of tooling, withreference to size and geometry, hasbeen well analyzed. It shows thatgenerally stresses generated duringcrimping are able to be accommodat-ed. However, there are alwaysdemanding applications that will taxthe design to its stress limits. In thosecases, geometry and material maydepart from the standard design.These exceptions are dealt with on aone-by-one basis and will not be dis-cussed here.

It is the unique requirement of stressand shock that needs to be dis-cussed. Peak crimp loads go fromzero to maximum in less than 40 ms.Tooling needs to withstand this loadcycle at a rate of greater than onceper second. Several classes of toolsteels are suitable and are welldescribed in the material handbooks.It is the processing of these materialsthat can make a significant perform-ance difference.

In order to withstand the rapid load-ing to a high stress on a repeatedbasis, the surface of the material mustminimize cracks and imperfectionsthat may be generated during themachining and/or heat treat opera-tions. It is important that grain struc-ture be controlled in size and orienta-tion to achieve maximum and consis-tent service life. Decarburization ofthe surface during heat treating mustbe controlled. Heat treating processcontrols are critical to reproducingthe optimal surface. Machiningprocesses must also be controlled toavoid surface cracking due to exces-sive heat generation during overlyaggressive material removal.Likewise, localized tempering mayoccur, which can soften materialbeyond the effective range.

These variations in final material andsurface conditions are not readilydetectable with a visual inspection.They can manifest themselves duringservice and result in unacceptabletooling performance.

Wear ResistanceWear is generally described as thegradual deterioration of a surfacethrough use. Several types of wearexist and include adhesive, abrasive,and pitting. By design, the tooling is able to withstand nor-mal surface loads. Thus, pitting is typ-ically not an issue. Abrasion canoccur depending on terminal sur-faces. If a terminal is plated with an abrasive substance, the tool-ing could suffer from abrasive wear.This would be an atypical conditionand would be handled by specialdesign.

The primary wear mode experiencedby crimp tooling is adhesive wear.Adhesive wear occurs as two surfacesslide across each other. Under load,adhesion, sometimes referred to ascold welding, can occur. Wear takesplace at the localized points of adhe-sion due to shear and deformation.Adhesion is highest at the peaks ofsurface finish because that is wherethe load is greatest. During crimping,the ideal conditions exist for adhesivewear. That is:

• High loading due to crimp force

• Sliding surfaces due to crimp for-mation, and terminal and wireextrusion

Wear will generally manifest itselfmore significantly at edges of a sur-face. However, adhesive wear is oftenobserved over substantial areas ofthe tooling. It is important to notehere that the wire crimper is the com-ponent most susceptible to adhesivewear. Generally, adhesive wear will bedirectly related to load and to theamount of relative movement

between the two materials. Althoughthe anvil may have equal loading, theamount of relative movementbetween the terminal and tooling ismany times more at the crimper thanat the anvil. The insulation crimpertypically experiences lower adhesivewear because the load is reducedcompared to the wire crimp and therelative movement is less than that ofthe wire crimper, since there is noterminal and wire extrusion at theinsulation crimp.

Adhesive wear can be controlled inthe selection of the material. Differentalloys exhibit better or worse wearproperties. These properties can bemeasured and are well documented.Adhesive wear is inversely propor-tional to the hardness of the material.Thus, the harder the material, the lessadhesive wear. In crimp tooling, thereis often a tradeoff that is made. Inorder to achieve higher wear resist-ance, the material often exhibitslower toughness by composition,hardness, or both. The final materialselection is often based on years ofexperience. One material may havehigh wear characteristics and lowertoughness, and be suitable for a smallterminal since the margin of safety onstress is high. Another terminal maybe large and the toughness could beof more importance due a lowerstress design margin. The ability todesign and manufacture crimpersfrom several materials will enableoptimal material selection for a spe-cific application.

The final property that affects adhe-sive wear is surface finish. As statedearlier, adhesion is highest at thepeaks of the surface. Thus, thesmoother the finish, the less signifi-cant the peaks and the less significantthe adhesion. Adhesive wear can bereduced with a lower surface finish.Surface finish affects other crimpingperformance parameters.

57







Surface ConditionThis topic addresses the conditionand preparation of the crimping sur-face, and the resultant effects on fric-tion with the terminal, wear, andcrimp distortion. It also introducessome quality specifications.

Surface condition can affect the per-formance of the crimp tooling as wellas the longevity of service. As notedin the previous section, a hard,smooth surface has improved adhe-sive wear properties and, thus, longerservice life. The other attribute thatneeds to be considered is friction.

Friction is a contributing factor indetermining the final crimp form andprocess characteristics. Low toolingfriction results in lower crimpingforce and thus can influence crimpform as well as tooling life.Consistent frictional characteristicsbetween tooling sets will result inreduced process variation.

Friction of the crimp tooling surfacesis influenced by similar factors thatinfluence adhesive wear—hardnessand surface finish. Generally, hardermaterials exhibit lower coefficientsfor sliding friction. Friction coeffi-cients have also been shown to berelated to surface finish.Manufacturing processes need toproduce consistent results such thatwhen tooling sets need to be

changed in production, minimum dis-ruption in crimp quality is achieved. Ithas been found that maintaining sur-face hardness above Rc 55, as well askeeping surface finishes to 8 micro-inches or less, is desirable to obtainconsistent crimp results and minimizeadhesive wear.

Surface TreatmentA commonly accepted approach toimproved crimp tooling performanceand life has been to apply a surfacetreatment to the crimp area. The wirecrimper has been defined in previousdiscussions as tooling componentthat is subjected to the severest duty cycle. Thus, apply-ing an appropriate surface treatmentto the wire crimper will have themost benefit to crimp performanceand tooling life. These treatments caninclude hard metal plating or ceramiccoating.

An example of a treatment that hasbeen successful in achieving signifi-cant levels of performance and lifeimprovements is hard chromium plat-ing. There are several valid reasonsfor this success.

First, chromium plating has a verylow coefficient of friction. As noted,friction has a significant effect oncrimp form. The static and slidingcoefficients of friction for steel onsteel are typically 0.30 and 0.20respectively. Chromium plated steelon steel can reduce the static andsliding coefficients to 0.17 and 0.16. Inaddition, chromium plating can behighly polished so that there is noloss of surface finish characteristicsdue to the plating process.

The second area that is greatlyimproved with chromium plating iswear resistance. Adhesive wearresistance is improved as surfacehardness improves. Chromium platingtypically exhibits a hardness of Rc65+. This hardness level greatly

enhances resistance to adhesivewear. Also, this now frees up thedesigner to consider more basemetal options. A base material ofreduced wear resistance but greatertoughness can be selected and itswear resistance improved withchromium plating. Thus, chromiumplating can enable a better toolingsolution for the crimp productionprocess.

Third, and perhaps one of the mostsignificant effects of chromium plat-ing, is its resistance to adhesion andcold welding. A side effect of adhe-sive wear is the transfer of materialfrom the terminal to the wirecrimper. By definition, adhesive wearis caused by material adhering tolocalized points on the surface. Someof the adhesion results in the surfacematerial being worn away and somein the transfer of material from theterminal to the crimper.

Typical effect of friction on crimp force

Chromium plated crimper surface after100,000 terminations. Note there is no visible build up of material.

Unplated crimper surface after 60,000 termi-nations. Note significant buildup of material.

58






Gross deformation of crimped terminalresulting from material buildup in crimper.

Visible deformation of outer crimp surface as a result of indentation from materialbuildup on crimper.

As more cycles occur, more material is transferred. Thus, there is aresultant buildup of terminal material on the crimper. This buildup canresult in two potentially catastrophic failures:

• The built-up material will create deformations in the terminal surface,resulting in unacceptable crimps.

• Crimps will be greatly distorted due to significant changes in the fric-tion factor and result in the terminals not conforming to the desiredform. Unacceptable crimp forms, such as unsymmetrical cross-sec-tion, excessive flash, and open barrels can result.

Chromium plating has the ability to be applied uniformly and consistent-ly and exhibits excellent adhesion to the base metals. The unique bene-fits of chromium plating, such as ease of application, consistency ofplating, adhesion to base metal, extremely low coefficient of friction,very high hardness, and resistance to adhesion, make it truly difficult tomatch in crimp performance and durability. However, many alternativecoatings are being attempted, and some show excellent promise in spe-cific applications.

SummaryThis discussion has explored four categories of characteristics that arekey to high performance tooling. Several examples have been discussedwhich demonstrate how minor variations in those characteristics canhave measurable and sometimes significant effects on the resultantcrimp form and its compliance to specifications. These same character-istics can affect tooling service life. It is also a logical extension of thesediscussions to conclude that variations of these characteristics from onetooling set to another tooling set can affect process control when tool-ing changes are required in production. Maintaining process control mayrequire additional setup time. Quality tooling that addresses the keycharacteristics of geometry, materials, surface condition, and surfacetreatment is an important component of your total quality control pro-gram.


59






Computing Circular Mil Area / (CMA) of Wire

Wire Size CMA Wire Size CMA Wire Size CMA Wire Size CMAWire Size CMA Wire Size CMA Wire Size CMA Wire Size CMA

26 250 18 1,620 10 10,400 2 66,500[0.13 mm2] [0.82 mm2] [5.27 mm2] [35 mm2]24 475 16 2,580 8 16,500 1/0 106,400[0.24 mm2] [1.31 mm2] [8 mm2] [54 mm2]22 750 14 4,110 6 26,300 2/0 133,000[0.38 mm2] [2.08 mm2] [15 mm2] [67 mm2]20 1,200 12 6,530 4 41,700 3/0 167,200[0.6 mm2] [3.31 mm2] [21 mm2] [85 mm2]

4/0 210,900[105 mm2]

CMA Table (Typical Values)

60





Terminal Wire Range and Color Code

Product Terminal Size CMA Range∗ ProductColor Code**

26-22 202-810 Yellow[0.10-0.41mm2]24-20 320-1,290 White or

[0.16-0.65mm2] Translucent22-16 509-3,260 Red[0.26-1.65mm2]

20-16 HD@

992-2,800 Green[0.50-1.42mm2]16-14 2,050-5,180 Blue[1.04-2.62mm2]

16-14 HD@

2,050-5,180 Yellow or[1.04-2.62mm2] Black@@

12-10 5,180-13,100 Yellow[2.62-6.64mm2]

8 [6.64-10.5mm2] 13,100-20,800 Red6 [10.5-16.8mm2] 20,800-33,100 Blue4 [16.8-26.7mm2] 33,100-52,600 Yellow2 [26.7-42.4mm2] 52,600-83,700 Red

1/0 83,700-119,500 Blue[42.4-60.6mm2]2/0 119,500-150,500 Yellow[60.6-76.3mm2]3/0 150,500-190,000 Red[76.3-96.3mm2]4/0 190,000-231,000 Blue[96.3-117mm2]

Product Terminal Size CMA Range

26-16 [0.10-1.65mm2] 509-3,26016-14 [1.04-2.62mm2] 2,050-5,180

16-14 HD@ [1.04-2.62mm2] 2,050-5,18014-12 [1.65-4.17mm2] 3,260-8,230

12-10 [2.62-6.64mm2] 5,180-13,1008 [6.64-10.5mm2] 13,100-20,8006 [10.5-16.8mm2] 20,800-33,1004 [16.8-26.7mm2] 33,100-52,6002 [26.7-42.4mm2] 52,600-83,700

1/0 [42.4-60.6mm2] 83,700-119,5002/0 [60.6-76.3mm2] 119,500-150,5003/0 [76.3-96.3mm2] 150,500-190,0004/0 [96.3-117mm2] 190,000-231,000

250-300 MCM 231,000-300,000[117-152mm2]300-350 MCM 300,000-380,000[152-193mm2]

400 MCM 380,000-478,000[193-242mm2]500-600 MCM 478,000-600,000[242-304mm2]6 [13-15mm2] 20,800-33,100

4 [21mm2] 33,100-52,6002 [34-35mm2] 52,600-83,700

1/0 [50-60mm2] 83,700-119,5002/0 [67-70mm2] 119,500-150,5003/0 [80-95mm2] 150,500-190,000

4/0 [100-125mm2] 190,000-231,000250 MM [127mm2] 231,000-275,000

300 MCM [152mm2] 275,000-325,000350 MCM [177mm2] 325,000-375,000400 MCM [203mm2] 375,000-450,000500 MCM [253mm2] 450,000-550,000600 MCM [304mm2] 550,000-650,000700 MCM [355mm2] 650,000-750,000800 MCM [405mm2] 750,000-850,0001000 MCM [507mm2] 950,000-1,125,000

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64


Glossary of Terms

ACTION PIN Contact (connector):Manufactured exclusively by TE Connectivity,having a split pin to provide gas tight reten-tion in a printed circuit board plated-thruhole without solder.

Anvil (tooling): Most commonly used to iden-tify that part of the crimping die — normallystationary — which positions and supportsthe terminal during crimping. Sometimesreferred to as “nest”.

Arc Voltage: Voltage that continues to passthrough a surge protector during activationof GDT (approx. 20 volts).

ASTM (American Society for Testing andMaterials): A nonprofit industry-wide organi-zation that formulates test methods andmaterial specifications, and publishes stan-dards, testing methods, recommended prac-tices, definitions and other materials.

AWG (American Wire Gauge): The recog-nized method (in the United States) of speci-fying conductor size. The higher the gaugenumber, the smaller the conductor size.

Bare Conductor: A conductor not coveredwith insulating material.

Barrel: 1.) Connector Barrel: The section ofthe terminal, splice, or contact that accom-modates the stripped conductor. 2.)Insulation Barrel: The section of the terminal,splice, or contact that accommodates theconductor insulation. 3.) Open Barrel: Thesection of a cap that accommodates the con-ductor.

Bellmouth: Flared at the mouth. The rear of aproperly crimped wire barrel will have aslight flare (bellmouth) to relieve the strainon the wire strands as they leave the area ofhigh compression and take their natural “lay”.A bellmouth may also be present in front ofthe wire barrel.

Breakdown Voltage: The voltage at which aninsulator or dielectric fails to maintain theapplied voltage.

Breakout: A region in a harness assemblywhere a wire or a group of wires is detachedto form a separate, terminated branch. Alsoknown as a transition.

Bunch Stranding: A method of twisting indi-vidual strands to form a finished strandedconductor. Specifically, a number of strandstwisted together in a common direction andwith a uniform pitch (or twist) per inch.

Butt Splice (electrical): A splice wherein twowires from opposite ends butt against eachother, or against a stop, in the center of thesplice.

Cable: Two or more wires in a twisted or par-allel configuration. Also, a shielded wire.

Cabler: A machine that mechanically assem-bles a group of insulated wires.

Cabling: The act of twisting together two ormore insulated components to form a cable.

Capacitance: The property of an electricalconductor (dielectric in a capacitor) that per-mits the storage of energy as a result of elec-trical displacement. The basic unit of capaci-tance is the farad, however, measurement ismore commonly in microfarads or picofarads.

Carrier: A group of strands or ends used toform a finished braid.

Circular Mil Area (CMA): A unit of area equalto the area of a circle whose diameter is 1 mil(0.001 inch). Used chiefly in specifying cross-sectional areas of conductors.

Closed Entry Contact: Female contactdesigned to prevent entry of a pin or probingdevice having a cross-sectional dimension(diameter) greater than the mating pin.

Component: A wire or cable that is combinedwith other wires or cables to make a multi-component cable.

Concentric Stranding: A method of strandingconductor. Specifically, the final conductor isbuilt up in layers so that the inner diameterof a succeeding layer is always equal to theouter diameter of the underlying layer.

Conductivity: The capability of a material tocarry electrical current, usually expressed asa percentage of copper conductivity (copperbeing 100%). Specifically, the ratio of the cur-rent flow to the potential difference causingthe flow. The reciprocal of resistance.

Conductor: The metallic strand or strandsused to carry an electric current.

Conductor Resistance: The resistance to flowof the electrical current along a conductor.Expressed in ohms/1,000 feet. (Usually refer-enced to 20°C).

Conduit: A tubular raceway for holding wiresor cables.

Connector: A device used to physically andelectrically connect two or more conductors.

Contact: The element in a connector thatmakes the actual electrical connection. Alsothe parts of a connector that actually carrythe electrical current, and are touchedtogether or separated to control the flow.

Contact Crimp: A contact whose rear portionis a hollow cylinder that accepts the conduc-tor. A crimping tool is applied to swage orform the contact metal firmly against theconductor. Sometimes referred to as a sol-derless contact.

Contact Engaging and Separating Force:Force required to either engage or separatecontacts. Values are generally established formaximum and minimum forces.

Contact Resistance: Measurement of electri-cal resistance of mated contacts whenassembled in a connector under typical serv-ice use. Electrical resistance is determined bymeasuring from the rear of the electrical areaof one contact to the rear of the contact areaof the mating contact (excluding bothcrimps) while carrying a specified test cur-rent.

Contact Size: The diameter of the engage-ment end of a pin contact; also related to thecurrent carrying capacity of a contact.

Continuity: A continuous path for the flow ofcurrent in an electrical circuit.

Core: 1.) In cables, a component or assemblyof components over which additional compo-nents, such as a shield or a sheath, areapplied. 2.) Inner wall of dual-wall heat-shrinkable tubing.

Crimp: The final configuration of a terminalbarrel after the necessary compression forceshave been applied to cause a functionalunion between the terminal barrel and thewire.

Crimper (tooling): Often used to identify thatpart of the crimping die — usually the movingpart — which indents or compresses the ter-minal barrel. Also called indenter.

Crimp Height: A top to bottom measurementof the crimped barrel, using a crimp heightcomparator in the prescribed manner.

Crimping Chamber: Area of a crimping toolin which a contact or terminal is crimped; thecrimping enclosure formed by the mating ofthe anvil (nest) and crimper (indenter). Whenthe dies or jaws are fully closed or bottomed,it is the crimping chamber that is checkedwith a go no-go plug gauge to confirm thatthe crimp produced by the tooling satisfiesthe crimp height specification.





65


Glossary of Terms

Crimping Dies: A term used to identify theshaping tools that, when moved toward eachother, produce a certain desirable shape tothe barrel of the terminal or contact that hasbeen placed between them. Crimping diesare often referred to as die sets or as dieinserts.

Crimping Head: Tooling containing jaws andlinkage for use in pneumatic or hydraulicpowered units to crimp loose-piece con-tacts/terminals that may be too large forhand tool applications.

Crimping Tool: A term commonly used toidentify a hand held mechanical device thatisused to crimp a contact, terminal or splice.

Cross Crimp: A crimp that deforms the termi-nal by exerting on the top and bottom of theterminal barrel without confining the sides.Usually identified by a raised crescent(moon) shaped form on the surface of thecrimp.

Current: A movement or flow of electrons.Also, the measure of this flow, expressed inamperes.

Current-carrying Capacity: The maximumcurrent an insulated conductor is capable ofcarrying without exceeding its insulation-and/or jacket temperature limitations underspecified ambient conditions.

Current Rating: The maximum continuouselectrical flow of current recommended for agiven situation. It is expressed in amperes.

Die: See crimping dies.

Die Closure: Term used to designate a crimp-ing area (crimping chamber) when the diesare fully closed or bottomed. Die closure ischecked with go/no go plug gauge to con-firm that the crimp produced by the toolingsatisfies the crimp height specification.

Dielectric: A material that serves as an insu-lator. The amount of resistance to voltage ina given insulation.

Dielectric Isolation (IC): Most silicon inte-grated circuits depend on back biased semi-conductor junctions to provide isolationbetween components on the chip. Dielectricisolation involves a number of additionalprocess steps which result in silicon dioxiderather than a junction surrounding each com-ponent to be isolated. The silicon dioxide, adielectric, provides the necessary isolation.

Dielectric Strength: Maximum voltage adielectric can withstand without rupture.Expressed as volts per mil.

Discontinuity: Rated interconnection: brokenconnection (open circuit) or loss of a speci-fied connection characteristic. Transient phe-nomena: Short term interruption or unaccept-able variation in current or voltage.

Drain Wire: In a cable, an un-insulated con-ductor laid over the component, or compo-nents, in a foil-shield cable. Used as a groundconnection.

Electromagnetic Compatibility (EMC): Theability of an electronic device to operate inits intended environment without its perform-ance being affected by EMI and without gen-erating EMI that will affect other equipment.

Electromagnetic Interference (EMI):Unwanted electrical or electromagnetic ener-gy that causes undesirable responses,degrading performance or complete malfunc-tions in electronic equipment.

Electromotive Force (emf): See voltage.

EMI: Abbreviation for electro magnetic inter-ference.

Extraction Tool: A tool used for removingcontacts from a connector body.

F Crimp: A crimp that b rings the center ofthe barrel along an open seam downwardinto a V.

Ferrule: A short tube used to make solderlessconnections to shielded or coaxial cable. Alsomolded into the plastic inserts of multiplecontact connectors to provide strong, wear-resistant shoulders on which contact retain-ing springs can bear.

FFC: Flexible flat cable; flat flexible cable; orflexible flat conductor. A form of multipleconductor cable consisting of parallel flatmetal strips imbedded in a flat flexible insu-lating material.

Flat Braid: A braided shield composed offlatstrands.

Flat Cable: A cable with each component in asingle, flat plane.

Flat Conductor: A conductor having a rec-tangular cross section, as opposed to a roundor square cross section.

Fretting Corrosion: A form of excelleratedoxidation that appears at the interface ofcontacting materials undergoing slight cyclicrelative motion. All non-nobel metals (tin) aresusceptible to some degree of fretting corro-sion and will suffer contact resistanceincreases.

Gauge: A term used to denote the physicalsize of a wire. See also AWG.

Ground: A connection, intentional or acciden-tal, between an electrical circuit and theearth or some conducting body (e.g. chassis)serving in place of earth.

Grounding Conductor: A conductor that pro-vides a current return path from an electricaldevice to ground.

Hardness: A general term that correlateswithstrength, rigidity, and resistance to abra-sion or penetration. Measured on Shore orRockwellscales.

Harness: A system providing electrical con-nection between two or more points.

Hertz (Hz): International standard term forcycles per second. Named after the Germanphysicist Heinrich R. Hertz (e.g., 60 cyclesper second is equal to 60 hertz or 60 Hz).

Inductance: One cause of reactance. An elec-tromagnetic phenomenon in which theexpanding and collapsing of a magnetic fieldsurrounding a conductor or device tends toimpede changes in current. The effects ofinductance become greater as frequenciesincrease. The basic unit for inductance is thehenry.

Insertion Tool: A tool used to insert remov-able contacts into a connector.

Insulation Barrel: See barrel.

Insulation Crimp: The area of a terminalsplice or contact that has been formedaround the insulation of a wire.

Insulation Displacement: A terminating tech-nique whereby an insulated wire is forcedinto a restrictive slot in a terminal, duringwhich time the wire insulation is displaced,and the bare wire engages the sides of theslot.

Insulation Grip: The ability of certain crimpedterminals to hold firmly in place both theconductor and a small portion of insula-tion.This prevents the conductor from beingexposed due to insulation receding awayfrom the terminal.

Insulation Resistance: The electrical resist-ance between two conductors separated byan insulating material.

Interference: Electrical or electromagneticdisturbance causing undesirable response inelectronic equipment.





66


Glossary of Terms

Jack: A connecting device into which a plugcan be inserted to make circuit connections.The jack may also have contacts which openor close to perform switching functions whenthe plug is inserted or removed. See also:receptacle.

Jacket: 1.) A material covering over a wire orcable assembly. 2.) Outer covering of a dual-wall heat-shrinkable tubing.

Jackscrew: A screw attached to one half of atwo-piece, multiple-contact connector andused to draw both halves together and toseparate them.

kV (kilovolt): A unit equal to 1,000 volts.

Mega (M): A prefix meaning one million(106).

Multiconductor: More than one componentwithin a single-cable complex.

Nominal: A descriptor applied to a dimensionrepresenting the center of the range of toler-ance or a value if no tolerance is applied.

“O” Crimp: An insulation support crimp foropen barrel terminals and contacts. In itscrimped form it resembles an “O” and con-forms to the shape of the round wire insula-tion. “O” crimp is also used to describe thecircumferential crimps used on COAXICONferrules.

Open Barrel: See barrel.

Peripheral Seal: A seal provided around theperiphery of connector inserts to prevent theingress of fluids or contaminants at theperimeter of mated connectors.

Pigtail: A short conductor or wire extendingfrom an electrical or electronic device toserve as a jumper or ground connection.

Pin Contact: An electrical terminal, usually ina connector. Normally a smaller terminationthan a lug.

Pretinned: Description of an electrical com-ponent to which solder has been appliedprior to soldering.

Primary Insulation: The inner member of adual wall wire insulation. The insulationapplied directly on the conductor.

Printed Circuit Board (PCB): An insulatingboard serving as a base for a printed circuit.When the printing process is completed, theboard may include printed components, aswell as printed wiring.

Rated Voltage: The maximum voltage atwhich an electric component can operate forextended periods without undue degrada-tion.

Receptacle: Usually the fixed or stationaryhalf of a two-piece multiple contact connec-tor. Also the connector half usually mountedon a panel and containing socket contacts.

Removable Contact: A contact that can bemechanically joined to or removed from aninsert. Usually special tools are required tolock the contact in place or remove it forrepair or replacement.

Resistance: A measure of the difficulty inmoving electrical current through a conduc-tor or insulation when a voltage is applied. Itis measured in ohms.

Resonance: A frequency at which captivereactance and inductive reactance

Ribbon Cable: Flat cable with conductorsthat have been individually insulated togeth-er. Its structure is usually characterized byindividual colors of insulation for each con-ductor, although a single color may be usedfor all conductors.

Serrations: The small grooves or indentationswithin a terminal wire barrel. The serrationsincrease the tensile strength and improve theelectrical conductivity of the crimped termi-nation.

Sleeve: The insulated or metallic coveringover the barrel of a terminal.

Solid Conductor: A conductor composed ofone single strand.

Splice: A joint connecting conductors withgood mechanical strength and conductivity;a terminal that permanently joins two ormore wires.

Strand: A single unit of a conductor.

Strip: To remove insulation from a wire orcable.

Surface Resistance: The ratio of the directcurrent applied to an insulation system to thecurrent that passes across the surface of thesystem.

Surface Resistance: The ratio of the directcurrent applied to an insulation system to thecurrent that passes across the surface of thesystem.

Tab: Used to scribe the flat blade portion ofcertain terminals (e.g. FASTON tab, tapertab, solder tab).

Tab-lok Crimp: A type of crimp used on FAS-TON flag terminals whereby a tab on the wirebarrel is inserted through a slot in the termi-nal. The crimping action flattens the tabbetween two lances, which in turn are lockedover the tab.

Terminal: An electrically conductive itemdesigned to be attached to a circuit ordevice for convenience in making electricalconnections..

Terminal Area: The portion of a printed cir-cuit — usually along the edge — used formaking the input-output connections.Sometimes this term is used synonymouslywith pad.

Terminal Barrel: See barrel.

Trimming: The adjustment of resistor orcapacitor values in thick or thin film circuitsby pattern changes, irreversible thermallyinduced changes, or removal of portions ofmaterial by laser or abrasive techniques.Dynamic trim is unique to these technologies,and of great value to circuit design and man-ufacture.

Volt (V): The unit of measurement for elec-tromotive force (emf). It is equivalent to theforce required to produce 1 ampere througha resistance of 1 ohm.

Voltage (E): The term most often used todesignate electrical pressure that existsbetween two points and is capable of pro-ducing a flow of current when a closed cir-cuit is connected between the two points.Voltage is measured in volts, millivolts,microvolts and kilovolts. The term selectro-motive force (emf), potential, potential differ-ence and voltage drop are often referred toas voltage.

Voltage Drop: The voltage developed acrossa component or conductor by the flow ofcurrent through the resistance or impedanceof that component or conductor.

Voltage Rating: The voltage that may becontinuously applied to wire.

W Crimp: A confined type of crimp thatmakes two longitudinal indentations whichform a “W” cross section. Used on SOLIS-TRAND terminals.

Wall Thickness: The thickness of the appliedinsulation or jacket.

Wire: A single conductor covered with insu-lation.

Wire Barrel: See barrel.

Wire Crimp: See crimp.





67






The literature on this page can be found on our websites in pdfformat or can be ordered through TE Connectivity customerservice or your local TE representative.

65780 ......................................................................................................................CERTI-CRIMP Hand Tools

65780-7 ..................................................................................................................Flip Locator Hand Tool Accessory

65828 .......................................................................................................................AMP-O-LECTRIC Model G Terminator

65828-1 ...................................................................................................................Crimpmatic 970 Machine

65828-2...................................................................................................................Crimpmatic 971 Machine

82221 ........................................................................................................................Magnet Wire Terminals

82275 .......................................................................................................................Crimp Quality Monitor II (CQM II)

124208.....................................................................................................................6-26 Pneumatic Tool System

1307619 ...................................................................................................................Application Tooling Field Service

1-1307619-0 ...........................................................................................................Factory Level Service & Certification

2-1307619-0 ..........................................................................................................ProductionCHEK Process Optimization Service

1308387 ..................................................................................................................MPT-5 MAG-MATE Product Terminator

1309085..................................................................................................................Stripping Module for TE Terminators

1309328-2 ..............................................................................................................CSP 3T Shuttle Electric Press

1309329 ..................................................................................................................Pressfit Overview Catalog

1309329-2 ..............................................................................................................CBP 5T Benchtop Electric Servo Press

1309329-3 ..............................................................................................................CAP 6T Automatic Electric Press

1309407..................................................................................................................FFC Termination Machine

1654519 ...................................................................................................................Hydraulic Crimp Tooling

1654714 ...................................................................................................................SDE Electric Terminator

1654856 ..................................................................................................................AMP 3K/40, AMP 5K/40 Terminators

1654956 ..................................................................................................................Wire Preparation Overview

1-1654956-0 ..........................................................................................................Precision Controller

1773379-1 ...............................................................................................................Standard Die Envelope (SDE) Crimp Tooling

1773381-5 ...............................................................................................................BT 3500 Battery-Hydraulic Hand Tool

3-1773439-9 ..........................................................................................................Lead Makers and Harness Makers

4-1773439-6..........................................................................................................High Voltage Test Equipment

7-1773439-0..........................................................................................................Insertion Machine Overview

7-1773439-1 ...........................................................................................................CSM-5T Connector Seating Machine

5-1773440-8 .........................................................................................................SIM 50E/51E/52E/25E/27E Modular IDC Workstations

7-1773440-4 .........................................................................................................MAG-MATE and SIAMEZE Inserter Mark II

7-1773440-8 .........................................................................................................Alpha 355 Crimping Machine

7-1773440-9 .........................................................................................................Gamma 333 Crimping Machine

8-1773440-9 .........................................................................................................Gamma 255 Crimping Machine

1-1773444-7 ..........................................................................................................FHM IDC Flexible Harness Maker

6-1773444-3..........................................................................................................Wire Preparation Equipment for the European Market

6-1773444-9 .........................................................................................................Special Crimp Machines for Loose Piece Terminals

8-1773456-7 ..........................................................................................................JacKnack Telecommunications Cable Preparation Tool

8-1773457-1 ...........................................................................................................K206 and K206S Cutting Machines

4-1773460-5 .........................................................................................................Ocean Applicator

9-1773460-4 .........................................................................................................Production Consultation Service

6-1773462-5 ..........................................................................................................Gamma 263 Fully Automatic Crimping Machine

3-1773464-0 .........................................................................................................SMART Applicator

296176 .....................................................................................................................Pistol Grip Hand Tool System for IDC

296393-2 ................................................................................................................Applicator Overview

889021.....................................................................................................................AMP-O-LECTRIC Model G Thru-Splice Terminator

Application Tooling Product Literature

68

8-1773462-5 / 05-12 / Application Tooling © 2012 Tyco Electronics Corp, a TE Connectivity Ltd company. All Rights Reserved. ACTION PIN, AMP, AMP+, AMPLI-BOND, AMP DUOPLUG, AMP DUOPLUG 2.5, AMP-EDGE, AMPLIMITE, AMPLIVAR, AMPMODU, AMP MONOSHAPE, AMP-O-LECTRIC, AMPOMATOR, AMPOWER, CERTI-CRIMP, CERTI-SEAL, CHAMPOMATOR, COPALUM, DIAMOND GRIP, FASTON, JacKnack, MAG-MATE, MiniSeal, MQS, Nano MQS, NETCONNECT, PIDG, PLASTI-BOND, PLASTI-GRIP, POLY-SWITCH, PRO-CRIMPER, Raychem, SIAMEZE,SOLARLOK, SOLISTRAND, STRATO-THERM, T-HEAD, TERMI-FOIL, TERMINYL, TETRA-CRIMP, TE Connectivity (Logo) and TE Connectivity aretrademarks.

Alpha, Cosmic, Gamma, Kappa, Komax, Zeta and TopWin are trademarks of Komax AG. iButton is a trademark of Maxim Integrated Products, Inc.MOST is a trademark.Other logos, product and company names mentioned herein may betrademarks of their respective owners.

Tyco Electronics Corporation, Harrisburg, PA 17105, Phone: 717-564-0100; Fax 717-986-3316

Disclaimer

While TE Connectivity has made every reasonable effort to ensure the accuracy of the information in this catalog, TE does not guarantee that it iserror-free, nor does TE make any other representation, warranty or guarantee that the information is accurate, correct, reliable or current.

TE reserves the right to make any adjustments to the information contained herein at any time without notice. TE expressly disclaims all impliedwarranties regarding the information contained herein, including, but not limited to, any implied warranties of merchantability or fitness for aparticular purpose.

The dimensions in this catalog are for reference purposes only and are subject to change without notice. Specifications are subject to changewithout notice. Consult TE for the latest dimensions and design specifications.

Tooling Solutions from TE Connectivity

Keeping up with changes and trends in manufacturing is critical for your survival.With our exposure in the global industry, weare in a position to develop systems andtooling that respond to these trends.

Stay in touch with TE Connectivity for thelatest innovations in the industry.

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