vipin kumar

8/6/2019 Vipin Kumar

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CERTIFICATE

This is to certify that VIPIN KUMAR student of B.TECH IV-YEAR

MECHANICAL ENGINEERING Branch of GURU TEGH

BAHADUR KHALSA INSTITUTE OF ENGINEERING AND

TECHNOLOGY; MALOUT has successfully made the project report on

(MAINTENANCE DEPARTMENT SECTION) under my guidance

during the training period.

Mr. HARENDRA SINGH TOMAR

ASSTT. Manager, MAINT.DEPTT

M.S.S.L, NOIDA


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ACKNOWLEDGEMENT

I take this opportunity to express my deep gratitude to Mr. HARENDRA

SINGH TOMAR (ASSIST.MANAGER, MAINT. DEPTT.) for giving me an

opportunity to conduct training in their company. I also thanks to production

department of M.S.S.L (NOIDA) . I particularly thanks to all members of

production department for their kind cooperation and expert guidance. I

wish to mention the special attention given by them and for their valuable

advice.

Finally, I express my sincere thanks to the staff of M.S.S.L for their

continuous help during the whole period and providing me with their valuable

guidance and sharing their knowledge from time-to-time.

VIPIN KUMAR

B.TECH (IV- YEAR)

MECHANICAL ENGINEERING


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PREFACE

In continuation of my earlier efforts of understanding the

difference between the theoretical and practical aspects of the

knowledge, I underwent six months practical training at

MOTHERSON SUMI SYSTEMS LIMITED, NOIDA.

The practical trainings helped me to understand the basic

difference between what we generally are taught in lectures

and what happens in practical. The knowledge that I gained

here of course will help me immensely in the future. These

trainings also made the fundaments concepts related to

management in a company.

The objective of this training is to make one clear about the

working of production systems along with the environment

inside the industry and the management related concepts, and

with the assistance received from the staff members of the

company. I can state that this objective of mine is certainlyfulfilled.


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INDEX

Company Profile

1. Wire harness

2. Department in M.S.S.L.3. Material Movement

4. Applicators

5. Crimping

6. CFM Wire Processing

7. Komax Gamma

8. Ultra Sonic Wielding.


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SUMI MOTHERSON

COMPANY PROFILE

Admn. /Comm. Personal: 22.5%

Engineers - Doctorate/ PostGraduate/GraduateEngineers DiplomaTechnicians - I.T.I

Overview


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The Sumi Motherson Group is a focused, dynamic and progressive group providing

customers with value added products, services and innovative solutions.

The Group has a diversified product range to serve multiple industries, with automotive

industry being the main industry served .

The Group business portfolio comprises electrical distribution systems (wiring

harnesses), polymer processing, injection moulding tools, elastomer processing, modules

and systems, machined metal products, cutting tools, IT services, design engineering,

CAE services, sunroofs, vehicle air conditioning systems, lighting systems, cabins for

offhighway vehicles, cutting tools and thin film coating metals.

The Group has invested in technologies that provide manufacturing support, includingcompressors, paint coating equipment, auxiliary equipment for injection moulding

machines, sales, installation and servicing of industrial robots and automotive

manufacturing engineering services.Key Facts

Largest in India:

Largest automotive wiring harnesses manufacturer.

Largest automotive wire manufacturer.

Largest manufacturer of rear view mirrors for passenger cars in India. One of the largest supplier of molded plastic components, assemblies & modules

for automotive industry.

One of the largest manufacturer of automotive rear view mirrors in the world.

Presence in 20 countries across the globe.

Group sales over $USD 806 Million (FY 2007-08).

Joint ventures in key technology areas.

Over 22,000 qualified professionals.


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HISTORY

1975 Motherson was founded

1977 First Cable factory started

1983 Technical agreement with Tokai Electric Co. (Now Sumitomo Wiring Systems -Japan) for Wiring Harness

1986 JV with Sumitomo Wiring Systems Japan

1989 Injection Molding

1992 Cutting Tool Manufacturing

1994 Tool Room for small and Medium sized Molds (upto 650 Tons)

1995 Cockpit Assemblies

Automotive Mirrors

1997 Blow Molding

1998 Rubber Injection Molding

1999 First Overseas office established (Austria)

2000 IT and Design Company

Representative Office at Singapore

2001 Liquid Silicon Rubber Injection molding

Machined Metal Components

2002 Wiring Harness manufacturing at SharjahDesign Centre at Ireland

2003 Offices in USA & UK established

Tool Room at Sharjah

Automotive Sunroofs

2004 European Headquaters at Germany

Sheet Metal Die Design

2005 Injection Molding & metal Machining in Germany

JVs for

Environment Management Systems

Industrial Robots

Automotive Manufacturing Engineering

Plastic Molding & Metal Machining at Germany


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PVC Tube Manufacturing

2006 Wiring Harness Manufacturing in UK

Bus Airconditioning Systems

2007 Rubber parts Manufacturing in Australia

JVs for

HVAC Systems, Meterclusters, Body Control Modules & Compressors

Bimetal BandSaws

Transport & Stationary Refrigeration Systems

Thin Film coating metals

2008 JV for Lighting Systems, Pedal Box Assembly & Air Intake manifolds

JV for Precision machined metal components

2009 Visiocorp becomes a part of Sumi Motherson Group.


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WIRE HARNESS

The largest manufacturer of integrated wiring harnesses in India, the Sumi Motherson

group holds over 65% share of the Indian passenger car wiring harness market.

The group manufactures wiring harnesses for the entire cross-section of the automotive

industry - from passenger cars to commercial vehicles, two wheelers and three wheelers,

multi utility vehicles, farm, material handling equipment and off-the-road vehicles. The

group also manufactures specialised wiring harnesses for white goods, office automation,

medical diagnostic equipment, electrical and electronic equipment.

Designing and developing wiring harnesses from first principle concepts on latest design

software, the group provides total solutions in wiring harness manufacturing.

The group has complete backward integration for manufacturing critical wiring harness

components.

In-house capability for design and manufacturing of applicators, jigs, assembly boards

and circuit checking boards enable process design control and flexibility.The EngineeringCapabilities for Wiring Harness

Process Design & Development

In-house capability of process design and validation

Designing & manufacturing of Jigs & Fixtures

Applicator design & manufacturing

Design & manufacturing of circuit checking & assembly boards

Tooling design for wiring harness process equipment, testing & assembly equipment


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Elelctrical Distribution System - Products

Cable & Harness

Wiring Harness

Lead Wire

Battery Cable

Flat Cable Harness

High Tension Cords (Engine Cables)

Wiring Harness Components

Wires

Terminals

Connectors

Caps & Sleeves

Clamps & Binders

Fuse Boxes

Modules with integrated wiring harnesses


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D E P A R T M E N T S I N M . S . S . L

Research & Development (R&D) Department.

Purchase Department.

Production Department.

Marketing Department.

Personal and Administration Department (P&A).

Customer Support Department.

Quality Control Department (Q.C.).

Store Department.


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MATERIAL MOVEMENT

In an organization, there is a flow material with different departments

right from the raw material to the final assembled product.

The material movement steps may be summarized as follows:

According to order placed, the material is delivered to the

company from the supplier.

The received material is kept in the store and its quantity is

verified.

From here it goes to RQL (Receipt Quality Control) where it is

checked for its quality and the defective and non-defective materials

are segregated.

The non-defective material is stocked in the store.

The production department places its order according to the

requirement and receives the components Accordingly from store.

After the complete assembly of the product, it is sent to PQC

(Product Quality Control) that looks after the product quality.

If the product meets the required standards it is sent to PDI (Pre

Dispatch Inspection) that is done with the help of customer support.

If the product does not meets required standards, it is sent back

to production department for rectification and reworking.Once the product is inspected it is ready for dispatch to the

customer


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APPLICATORS

CIC has developed expertise in manufacturing of Applicators of various designs over the

past 10 years. These applicators have proved their credibility as we have all the major

Multinationals as our customers. Our standard design applicator fixes on most of the

popular quick change applicator fixing arrangemnts avilable in presses. The applicators

have a shut height of 135.8 mm and works well on both 30mm & 40 mm stroke press.

These applicators have either mechanical or pneumatic feed of the terminal reel and

micro-setting of crimp height is continous (stepless).

All the parts are fully hardened & tempered and made from special steel so that we get

maximum life of the part. The components in the applicator assembly are made in

Jigs/Fixtures & CNC Machining Center to ensure interchangibility of parts.

We have all the perishable tooling permanantly marked for easy identification and spare

ordering. Normally any spare will be shippied the very next day of receving the order.


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SIDE FEED APPLICATOR

Side Feed Mini Applicator are designed crimp Side Feed Terminals being fed into the

applicator from left to right. The present Dial Type adator can be changed to Screw Type

if the terminal is thicker. These applicator are modified to suit thick base plate of Asian

Style .

This design applicator is also suitable to run fine terminals, center carrier terminals,

middle carrier terminals, rear carrier terminals, double carrier terminals etc.

Applicators can also be supplied with proper documentation , trial samples and in ready

to use condition.


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END FEED APPLICATOR

End Feed Mini Applicators are designed to suit various types of End Feed Terminals (end

to end) in chain form.

An option is available where we change the Dial Type arrangement to a screw type whereterminal is heavy (above 0.6 mm). We can also modify the Base Plate to suit to the Asian

Type model.Applicators are supplied with proper documentation and ready to use

condition.


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CRIMPING

Crimping is joining two pieces of metal or other malleable material by deforming one or

both of them to hold the other. The bend or deformity is called the crimp.

Crimping is most extensively used in metalworking. Crimping is commonly used to join

bullets to their cartridge cases, and for rapid but lasting electrical connectors. Because it

can be a cold-working technique, crimping can also be used to form a strong bond

between the workpiece and a non-metallic component. Sometimes, a similar deformity

created for reasons other than forming a join may also be called a crimp.

Outside of metalworking, crimping is notably used for joining the edges of food products

such as jiaozi, patties, and sealed crustless sandwiches.


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What exactly is a crimp ?

Crimping is a complex procedure requiring an optimal interaction of different processes

and processing media. Depending on the final product and the required quality, the ability

to automate the process must be taken into consideration early in the terminal designstage. Although the choice of appropriate materials (conductor type, wire cross-section,

crimp terminal design, etc) is strongly related to the end product, the ability to automate

the process should also be considered in the early stages of development.

fully automatic processing:

CrimpCenter 64

At first sight, it is not possible to tell whether a crimped wire was processed using semi-

or fully-automatic equipment. Therefore, important issues to consider are the quality to

be achieved and the necessary expense and effort during the process. Since the basic

processing steps are identical for both processing types, the same quality requirements

apply. The main difference is in how the wire is moved between the individual

processing steps. It can be moved automatically (=high process security, short cycle

times) or manually (=high flexibility).

Some types of terminals can not be crimped automatically, or can only be automated with

considerable expense and effort. An example is crimping of loose-piece closed barrel

terminals onto battery cables.

Example of processed tube type terminal

Here, the terminal must first be manually placed onto the stripped cable end, whereby all

individual strands must be covered by the barrel/sheath. This process requires fingertip

touch and is therefore usually carried out manually. This type of terminal is

often crimped using hexagonal form (cable cross-sections >25 mm). Battery cables are


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large and heavy, making them difficult to handle. They are often fitted with loose-piece

closed barrel terminals or battery connectors and run in small production quantities. In

most cases, special heavy duty crimp applicators are used for the different designs.

For large tube type terminals:

UniCrimp 2500 T

HeavyCrimper XL

Quality Assurance

Fault recognition and fault prevention processes are also critical steps of the crimping

process. Crimp force monitoring (CFM) is the "in-process" quality control method used

to monitor the quality of the crimping process during production. The CFM measures the

crimping force during the crimping process. It compares the force/time curve of each

terminal being crimped against the stored reference curve. If the measured values are

outside of the specified tolerance limits, the crimp is identified as bad. Today, two out of

three crimping presses have a CFM system installed on them.

In modern production environments, early recognition of production faults is generally

standardized and supported by numerous measuring methods. Follow-up costs can be


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reduced, but only after a few faulty wires have already been produced. It is better to avoid

faults in the first place. Alongside internal organizational measures, faults can also be

avoided through the use of modern technology. Most measures can be used in both semi-

automatic and fully-automatic processing.

Human Factor

With semi-automatic processing, the individual processes are carried out using different

machines (in different places). This requires additional processing steps and thereby

creates additional potential for error. Through the combination of processing steps (e.g.

Stripper-Crimper) and a targeted quality assurance, the highest quality requirements can

also be realized here.

The human factor is not just important during semi-automatic processing. Specialist

competency in setting up, operation, and maintenance is just as important as material

quality and precision of the processing medium. In the end, the interplay of people and

technology determines the crimp quality.

Crimping, also known as terminating, can be understood as the gastight connection of a

wire and a terminal. There are an almost infinite number of different crimp terminalsavailable on the market, but they all have one thing in common: they are joined to a wire

through a mechanical deformation process (crimping).

Banded or Loose?

Terminals are either sold as banded (connected together on a carrier strip) or as

loose piece terminals. Banded terminals are simpler to handle as they can be easily fed

from a terminal reel and processed on semi- or fully automatic machines.

single-banded, carrier strips front


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single-banded, carrier strips in the middle

double-banded, carrier strips front and back

With loose terminals, there are no carrier strips. Loose-piece terminals must be brought

into the correct position either manually or by a vibratory feeder. Due to their more

demanding handling, loose-piece terminals are not used as often as banded terminals.

Open or Closed?

Both banded as well as loose-piece terminals can be open- or closed-barrel type

terminals. This term "open" or "closed" relates to the design of the terminal. With closed

barrel terminals, such as insulated wire end ferrules or insulated quick-disconnects, the

terminal is shaped like a fully closed cylinder. The stripped wire must be inserted into

the circular crimp barrel from the open end of the terminal. Open barrel terminals are

shaped like the letter "U," allowing the wire to be moved downwards from the top into

the crimp barrel. As open-barrel terminals are easier to automate, they are used most

often in mass production.

Side- or Rear-Feed?

With open-barrel, banded terminals, a deciding factor in the selection of an appropriate

processing medium is whether the terminals are connected on the carrier strip end-to-end

or side-by-side. The arrangement on the carrier strip determines the type of feed into the

crimping press as well as the transport direction of the crimping tool (from left, right or


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rear). Manufacturers of crimping machines and tools, such as Schleuniger, offer different

variants of their equipment to be able to process virtually all terminal types.

Single or Double?

Other than open or closed, and side or rear feed, banded crimp terminals can also be

single-banded or double-banded, depending on the number of carrier strips between the

terminals. The position of the carrier strip between the terminals, as well as the number of

carrier strips, determines the design of the crimping tools. The majority of crimp

applicator manufacturers have focused on the most common terminal types. However, the

Schleuniger crimping specialists follow a different strategy: from standard terminals to

complex terminal types, Schleuniger offers machines and tooling to process every

terminal. For instance, the Uni-A crimp applicator, for cable cross-sections up to 6 mm,

is available as a side- and rear-feed applicator, with mechanical or pneumatic feed, for

single- and double-banded terminals of different types.

In addition, the Uni-A and Schleuniger crimping presses, such as the UniCrimp 200 (with

standard Split Cycle Function), can also process closed barrel terminals (e.g. insulated

wire end ferrules) or Mylar banded terminals. In addition to the Uni-A and FlexoCrimper

(up to 6 mm) universal crimp applicators, the Schleuniger range of applicators also

includes the HeavyCrimper applicator up to 35 mm as well as special crimping tools for

loose terminals up to 50 mm.

Wire and Insulation Crimp?

As a rule, with banded terminals, two connection procedures take place simultaneously

the wire crimp and the insulation crimp.


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Insulation and wire crimp

The continual development of connection technology has led to many new crimp

connections types, such as the 3-zone crimp for coaxial cable. The wire crimp forms the

mechanical-electrical connection between the stripped inner wire (e.g. stranded

conductor) and the terminal. It must be gas-tight. The insulation crimp should absorb

influencing forces such as vibration or tension so that they do not affect the wire crimp.

The insulation crimp forms a purely mechanical connection between the terminal and theinsulation of the cable. Therefore, it is important that the insulation is not damaged during

the insulation crimp process.

B-Crimp, O-Crimp or U-Crimp?

The final shape of the terminal after the crimping process has led to the relativelycommon terms B-crimp, O-crimp and U-crimp.

Different types of insulation connections


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Other types of crimps, which are used less frequently, include the 4-point crimp, the hex-

crimp and the trapez-crimp. After the stripped wire is inserted into the terminal, the

terminal and wire are compressed through terminal-specific parts (known as tooling) of

the crimp applicator during the crimping procedure. The characteristic shape, which has

led to the name, can be seen in the cross-section of the crimped terminal and wire, in both

the insulation crimp and the wire crimp.

Wire Crimp

The most common wire crimp used for stranded wires is the B-crimp. When the ears of

the terminal are formed during the crimping process, the individual wire strands move

symmetrically within the terminal inner space due to the symmetry of the crimped

terminal shape. A gas-tight connection is easier to achieve for stranded conductors with a

B-crimp than with an O-crimp. In contrast, crimping of solid wires cannot be gas-tight

with a B-crimp since there are no individual strands that can move during the crimping

process. Therefore, the wire crimp for solid wires is generally carried out as an O-crimp.

Different types of wire crimp connections

Insulation Crimp

As the insulation crimp serves exclusively to absorb influencing forces on the wire crimp,

the challenge is to form a connection to the insulation without damaging it. In this case, a


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B-crimp allows very high connection stability but damages the insulation to a certain

degree. The danger of damage is greater than with an O-crimp or U crimp, where the

crimping ears only surround, rather than penetrate, the insulation.

Why Dont Crimp Tools Cost More?

The crimp applicator is the heart of the crimping process regardless whether it is

carried out semi-automatically or fully automatically. With the deformation of the

crimping ears of a crimp terminal, the degree and type of deformation are determined by

the crimp applicator and its terminal-specific parts (tooling), such as crimp die and anvil.

Only tooling that is optimally matched to the crimp terminal to be processed can

assure high crimp quality.Beat Locher, Product Manager for Schleuniger: Our crimp applicators stand for quality

without compromise at an extremely attractive price. He judges the requirements for

quality and precision of the tooling as follows: If the terminal-specific parts are not

precisely made, then even the best crimp machine will not be able to achieve a good

result. At Schleuniger, we design and manufacture not only crimp applicators, but also

crimping machines, StripperCrimpers, fully automatic crimping machines and transfer

systems, so we know only too well the importance of the crimp applicator as the central

element in production.

Therefore, from the very beginning, key factors in Schleuniger crimp applicators have

been designed with the highest precision and to be maintenance-friendly. As proof of

quality for customers, every crimp applicator is tested internally and a ground cross-

sectional view is prepared.

Central Role of the Feed

Next to an optimal, terminal-specific design of the tooling, the basic design of the feed

plays a central role. With banded terminals, the feed is responsible for the exact

positioning of the terminal parts before crimping. At first glance, it appears to be of

secondary importance whether the feed is pneumatic or mechanical. Deviations from the

ideal position with either types of feed can lead to faulty crimping.


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Transport distance = distance between

two crimp terminals on the carrier strip

Mechanical or Pneumatic?

With mechanical feed, the vertical stroke of the crimping press is translated into a

horizontal transport movement of the terminal carrier strip, so that after each crimp, thenext terminal part is brought into the exact pre-defined position between the anvil and

crimp die. As the distance between two terminals on the carrier strip is usually different

between different terminal types, most applicators have user adjustable settings for

setting the terminal feed stroke and terminal position. Pneumatic feed is often used in

automatic operation, in order to achieve the highest level of accuracy for positioning and

precision over large transport distances. The advantage of pneumatic feed is that the

transport movement is not coupled to the press stroke directly. Therefore, the speed and

timing of the feed can be controlled individually.


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Side- or Rear-Feed?

Depending on how the terminal is positioned on the carrier strip, the feed must either take

place from the side (= side-feed applicator) or from behind (= rear feed applicator).

Internationally, the universal crimp applicator with a stroke of 40 mm and a shut height

of 135.788 mm (height of applicator in closed state) predominates, but as far as feed

direction (which is determined ultimately by the terminal manufacturer) is concerned, all

types are still to be found in the global market: feed from the side (left or right possible)

or feed from rear naturally, all with different terminal pitches.

Depending on how the terminal is positioned on the carrier strip, the feed must either

take place from the side from left or right (=side-feed applicator) or from behind

(=rear-feed applicator)

Numerous Settings

In order to achieve optimal crimping, numerous terminal-specific settings can be made on

the crimp applicator: from basic parameters, such as crimp height of the wire and

insulation crimps, to fine-adjustments of the bell mouth, terminal end position,

compensation of play, and adjusting the force of the terminal braking system. It is a

decisive advantage if settings, such as those with the Schleuniger Uni-A, can take place

directly in the crimping press so that any necessary adjustments can be made quickly and

verified directly.


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What is Standard?

At least in Europe, the 40 mm stroke and the 3-point mounting of an applicator in the

press are defined as standard. In general, these applicators are appropriate for wire cross-

sections up to 6 mm (AWG 10). For larger cross-sections or for use with flat foil cables,

there is as yet no international standard.

As a worldwide company, Schleuniger offers, for example, the Uni-A standard crimp

applicator in different designs (mechanical / pneumatic / side-feed / rear-feed), with

special designs for closed barrel terminals, 30 mm stroke or as a double crimp applicator.

Next to the FlexoCrimper (a special standard applicator for high-speed automatic

production), Schleuniger also has special tools for cross-sections up to 50 mm as well as

solutions for crimping of flat foil cables (FFC / FPC) in the product range.

What Influence Does The Crimping Press Have On Crimp

Quality?

In comparison to the crimp applicator (for which the numerous set-up possibilities lead to

numerous influencing factors), a crimping machine's press force, repeatability and cycle

times are important factors. Other important criteria are the seamless interaction of the

press with the crimp applicator and the crimp force monitoring system.

Basic Function

The crimping press moves the crimp applicator into the lower bottom dead center"

position, deforming the crimp terminal with the conductor at the set crimp height and

brings the tool back into the initial position at "top dead center."


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Shut Height & Press Stroke

The basic prerequisite for being able to use a crimp applicator in a crimping press is that

the shut height, press stroke and interlock system are identical for the press and the crimp

applicator. The shut height is the distance between the upper and lower applicator

mounting positions of the press in the closed position (= height of applicator in closed

position). Every crimp applicator to be used on a given press must have an identical shut

height and stroke. In order to be able to use the widest possible spectrum of crimp

applicators, a press with the international standard shut height of 135.788 mm is

recommended. This height has more or less become the norm in both Europe and the

USA.

Example shut height

The distance between the open and closed positions of the crimping press is described as

the press stroke. As the vertical movement of the applicator is carried out exclusively by

the crimping press, the press strokes should concur precisely. Depending on the crimp

applicator manufacturer, this varies as a rule between 39 and 42 mm, but 30 mm is also

common in USA and Asia. Therefore, Schleuniger offers crimping machines with a

stroke of 40 mm as well as 30mm (and adapters for different strokes). An exact stroke of

the press, especially with mechanical crimp tools, is of central importance for the

terminal feed, as here the press stroke is translated directly into a horizontal terminal

transport movement.

Crimp Force & Operation Modes

The force of the press usually given in Kilo-Newton (kN) or tons determines the

cross-sectional area that can be processed. In order to achieve an optimal deformation,


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the required minimum force varies, depending on wire cross-section, the type of wire

(solid or stranded) and the terminal to be processed. The UniCrimp 200 from Schleuniger

has a high press force of 33 kN so that it can be used with a wider variety of wires and

terminals.

As far as crimp drives go, the eccentric crank drive predominates, with the rotational

movement of the drive motor being transformed into a linear movement through a

crankshaft with an eccentric crank arm. The advantage of this design is that the "bottom

dead center" position of the press is precise and repeatable. The maximum force occurs a

few degrees before bottom dead center and continues until dead center. The deformation

of the terminal must therefore be completed upon reaching the bottom dead center

position. A second maximum force, occurring shortly after bottom dead center is

reached, does not contribute to deformation.

UniCrimp 200 programmable crimp machine

A combined knee-lever-crank-drive, such as with the Schleuniger UniCrimp 500, has the

advantage that the closing procedure takes place very quickly, thus favoring short cycle

times. The actual deformation process is carried out more slowly in order to achieve anoptimal result without requiring longer cycle times. There are also crimp machines on the

market with pneumatic linear or knee-lever drives.


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Cycle Time

More and more, short cycle times are determining factors when purchasing a new

crimping press. Especially with mechanical crimp applicators, high press speed

automatically effects the feed / transport velocity of the crimp applicator and thereby

influences the precision of positioning of the terminal. Depending on conductor and

terminal, the material also needs a certain time during the deformation to flow

optimally. Insufficient time can lead to reduction in quality or faulty crimps. Therefore,

the optimal set-up of the press and crimp tool depends on the material (steel, brass) as

well as the coating (gold, silver, pewter). In order to achieve the best possible result,

individual setting of the press velocity is necessary.

Repetitive Precision

The repetitive precision of the press is an important characteristic. Otherwise, the initial

fine-tuning becomes partially lost during operation. If the crimping process doesnt take

place with constant speed and force, it can lead to undesired variations.

If a crimp applicator is used in different presses, it is worthwhile to make sure that the

shut height is re-set to the identical height regularly using a calibration device in order to

achieve the same results independent of which press is in use. The shut height can beadjusted with most crimping presses.

Stability of bearings and precision of the guides are also important points to consider in

regard to achieving long-term high-quality production. The wear and tear on the

mechanical parts of old presses leads to more play and thereby to a reduction in crimp

quality.

Crimp Force Monitoring

Crimp force monitoring is a measuring device used to monitor the crimp quality

during the crimping process. It monitors how the crimp press, crimp applicator and


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terminals are "working together" during the process. During the crimping procedure, a

sensor measures the press force applied and reports this to the electronic control system,

which converts the recorded force into a curve over time. The aim is to find out where the

curves deviate. Known good crimps are used to "teach" the system the characteristics of a

good crimp and to calculate a reference force. Each and every subsequent crimp is

compared with the reference crimp force. Deviations of the crimp force that lie outside of

the pre-set tolerance limit are registered as bad.

Today, two out of three crimp presses have an integrated crimp force monitoring system.

Other crimp quality characteristics include only one parameter such as crimp height,

crimp width and pull-out force. On the other hand, crimp force monitoring includes

forces that are influenced by the entire system. Each of these components can have an

effect on crimp characteristics.

Changeover Time & Flexibility

With changeover and maintenance, it is an advantage if the press is accessible and not too

small. The applicator change should take place simply, and if possible, without additional

tools. If the working area is too small, the use of certain standard applicators may not be

possible.

For maximum flexibility, the crimping machine, such as the UniCrimp 200 from

Schleuniger, should have an adjustable press velocity, a valve for pneumatic crimp

applicators and a split-cycle function for the processing of closed barrel terminals. Only

with the perfect interplay of crimping press, crimp applicator and crimp force monitoring

system can an optimal result be achieved. At first glance, the crimp applicator seems to

be more important because of its complexity. However, upon more careful examination,

the extensive influence of the crimping press on the quality of the product to be processed

becomes evident.


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What Is The Stripper-Crimper Needed For?

Numerous characteristics determine the quality of a crimp connection. The following

essential conditions must be considered and fulfilled before crimping can take place:

The correct assignment of terminal and conductor

The selection of the correct crimp tool for the terminal

The terminal must be positioned correctly in the crimp tool

The conductor must be stripped to the correct length

The stripping must be carried out to perfection

The correct position of the stripped conductor in the crimp barrel

Strip Length and Position of the Conductor in the Crimp

Most crimp connections use stranded wires with an insulating jacket (insulation) in

different designs. The wire must be stripped before it is crimped. The strip length and the position of the wire must be selected so that the individual strands are visible on both

sides of the crimp zone (crimp barrel). The individual wires should not jut into the

plugging or connection area as this can limit the function of, or damage, the terminal.

The exact positioning of the wire is especially difficult with very small terminals with

very short distances both sides of the crimp barrel. High precision is extremely important

during the stripping and the feeding of the cable. The insulation should be visible

between the insulation holding device (insulation crimp) and the crimp zone (wire

crimp). Under no circumstance should it appear inside the crimp barrel (in wire crimp).


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Example of stranded wire in a crimped terminal

Perfect Stripping

Perfect stripping of the wire is a must for a good and durable crimp connection. Faults

that occur during stripping often remain undiscovered and can have fatal consequences

for the crimp connection.

Wire crimp in cross section

For perfect strip quality, the individual strands of the wire must not be damaged or cut off

during the stripping process. The insulation must not be damaged. There must be no

remnants of insulation on the stripped part of the wire. The individual strands must not be

untwisted during the stripping process as this often leads to spreading out of the

individual strands, which can cause some of them to fall outside the crimp area during

crimping. The crimp connection would thereby be faulty, creating the risk to short circuit.

On the other hand, the individual strands must not be over-twisted as this causes an

uneven distribution in the crimp barrel and the wire cross-section becomes larger.

Therefore, it is especially important to use precise and reliable systems for the stripping process.


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Crimp Dimensions with Open Barrel Terminals

One of the most important methods of checking the quality of a crimped terminal is to

measure the key dimensions after crimping. The crimp width and especially the crimp

height, determined by the manufacturer, have an important influence on the quality and

the long-term behavior of a crimp connection. Also for the insulation crimp, crimp

dimensions are defined by the manufacturer (generally as approximate values).

Bellmouth

The conductor entry end of the crimp barrel must have a visible radius (funnel-shaped

expansion). This entry radius prevents the notching or separation of individual wires and

is therefore important for the quality of the crimp connection. A radius on the conductor

exit end is permitted but not essential.

General Condition of the Crimped Terminals

After the crimping process, neither the terminals nor the conductor should show evidence

of damage, which could restrict function or influence long-term behavior. Faults can

occur with crimped terminals through incorrect handling, incorrect set-up or

inappropriate crimp applicators. In practice, the following cases occur frequently:

The terminal is bent: Generally, the limit for the curvature of the terminals is max.

3 to 4 degrees

The terminal is twisted

The plugging area is damaged

The dividing wedges are not correct (too long or too short) or imprecisely cut

There are signs of crack formation in the terminal seams or terminal base

Over-sized ridge formation (flash) in the crimp base: the flash height must be less

than half of the material thickness


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Tolerance ranges for crimp terminals

Quality Assurance with Crimping

The most important instruments for quality assurance are the visual and dimension

checks, optical tests, crimp force monitoring, the measurement of tensile strength and the

preparation of a cross-sectional view.

Visual Check

The human eye is still irreplaceable for quality assurance. Many defects/faults can be

recognized through a visual check carried out by an expert:

Are all individual wires covered?

Are the individual wires, the insulation and the seal of the individual wires

undamaged?

Is the terminal undamaged and not bent?

Is the radius on the crimp barrel correctly formed?

Is the base of the crimp claw visually deformed?

Are the crimping ears closed and do they support each other?

Is there flash, and if so, is it less than half of the material thickness?

Does the conductor lie correctly in the crimping area?

Is the strip length correct?


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Eventually existing flash height should be less than half of the material thickness

Dimension Check

The measurement of crimp height must be very precise and reproducible. For this

measurement, a special micrometer or a special crimp height measuring devices is used.

The crimp height measuring equipment is used mostly in fully automatic processing or

where quality assurance has a high priority. Through their high precision and network interfaces, such devices offer the possibility of direct electronic data recording and

evaluation. In networks with crimping presses, the crimp height can be automatically

adjusted by the press according to the measured values. The crimp width and the crimp

dimensions of the insulation holding device are measured with a measuring gauge.

Crimp height measuring

Optical Test Devices

Some characteristics can only be measured optically (e.g. curvature of the terminals,

length of the dividing wedges, size of the radii on the crimp barrel). For such checks,

measuring or profile projectors or measuring microscopes are used. Also, the


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aforementioned visual tests are often supported by the use of optical instruments, such as

a hand-held or bench-top magnifying glass.

Crimp Force Monitoring

The measurement, recording and evaluation of the crimp force allows crimp faults to be

recognized during the running process. This task, known as crimp force monitoring, is

carried out by crimp force monitors that are either integrated into the crimping press or

connected as optional devices.

The crimp force monitoring system records the crimp force curve at the same time as the

press runs. After each crimp, the actual curve is compared to the saved reference curve.

Deviations of the curves are evaluated according to different criteria. If the deviation

exceeds the defined tolerance limit, the crimp is classed as faulty.

This procedure allows a 100% test of crimp connections without requiring any additional

time. Faults, such as the cut-off of individual strands, wire that is not stripped or fully

stripped, or the incorrect positioning of the conductor in the crimp, are found in real time.

Of particular importance is that the crimped samples used to create the reference curves

are perfect. If, for example, the reference curve was created with divided individual

strands, then divided individual strands will not be recognized as a fault during

production . This fault will probably reveal itself once the first perfect examples are

finished after the correction (because they are then classified as faulty crimps).

Measuring the Pull-Out Force

In contrast to the previously described test procedures, this test and the tests which follow

are destructive tests. The tensile strength of the crimp connections, independent of the

cable cross-section, is not allowed to fall below certain values. These values are

normalized or defined by the terminal part manufacturer. For the measurement of these

values, corresponding pullforce measuring devices are used. These devices come in

different sizes and designs. It is also possible for network access here, direct data

recording, evaluation and archiving. Possibly occurring deviations from the ideal values


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allow faults in the crimp process to be recognized at an early stage and enable the

introduction of corrective measures.

Preparation of Ground Cross-Sectional View

The preparation of the ground cross-sectional view largely serves as the assessment of the

degree of deformation and the symmetry of the crimp. A ground cross-sectional view also

allows any occurring ridges to be measured and to recognize possible cracks in the

material.

To create a ground cross-sectional view, the crimp zone is cut horizontally. After that, the

cut surface is polished and cleaned in an electrolyte staining process. The prepared

samples are then visually checked under a microscope and assessed.

Ground cross-section of wire

A good crimp connection shows the following characteristics:

All individual wires of the strand are pressed in honeycomb form

The rolled-in crimping ears support each other

There are no empty spaces between the individual wires

There are no empty spaces between the individual wires and the terminal walls

The base of the terminal is visually deformed

Marked deviations from this ideal condition often suggest errors in wire and terminal

selection, selection of the proper crimp applicator, incorrectly set crimp height, poor

quality stripping or wear and tear of the crimp tooling. However, the crimp quality also


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depends largely on the specialist competency of the employees, on the material quality

(terminals and wires) and on the quality of the crimp applicators and machines.

WIRE PROCESSING - CRIMP FORCE MONITORING

Wire End Quality Assurance - Crimp Force Monitoring

In modern, high volume wire harness production, automatic wire strippers are used tostrip insulation from the wire prior to the crimping process where a terminal is fixed to

the stripped wire.


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Crimp-on terminals are attached to wires to allow the wires to be easily connected to

electrical component terminals and quick-connect terminals. Crimp-on terminals are

attached by inserting the stripped end of a stranded wire into the tubular portion of the

terminal, which is then compressed tightly around the wire in a crimping die on either a

bench press or automatic crimping machine.

What can a CFM detect?

Missing or bent wire strands

Incorrect insulation strip

Strands outside main crimp

Insulation in main crimp

Insulation crimp faults

Crimp misfeeds

Incorrect wire use

Wire processing involves high speed precision cutting and stripping, and often the

placement of a weather seal onto the wire before the terminal is applied. Failing to

ensure absolute quality through every step of this high speed process can result in

significant penalties, containment, reduced profits, or loss of business. Providing this type

of critical quality assurance at parts per second speed for pennies per part prices poses

a significant challenge.


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To accomplish this, leading wire harness manufacturers employ 2 primary quality

assurance methods to assure the quality expected by their customers. The first is the

crimp force monitor, which can be considered a process variation monitor. The other is

an in-process strip and seal inspection device, such as the LPA56B WireScan. These

are complimenting technologies process variation monitoring, combined with wire strip

and seal inspection that will ensure effective and reliable detection of wire processing

defects for even small gauge wire processing applications.

Crimp force monitors have proven to be essential for in-process monitoring of the crimp

quality for wire processing, and are now mandated by most wire harness manufacturers

globally.

Crimp force monitors, or more appropriately called crimp process variation monitors,

detect process variations that can be directly correlated to crimp defects, tool wear,

incorrect alignment or adjustment, etc. that might result in defective parts, accumulation

of unnecessary scrap, and rework. To date, there have been few technological

innovations in the wire processing industry that have proven to be as effective as crimp

process monitors.

How it Works

The CFM series of crimp force monitors from OES utilize a piezo-strain sensor bolted to

the frame of the crimping press to capture a signature of the relative force of the crimp

stroke over the time of the cycle. On stable equipment, this signature is highly

repeatable, so that any variance in the process will be reflected in a change in the

signature, as in this example of a missing strand.

The patented analysis of each production curve against a learned reference curve of a

known good crimp, allows the monitor to provide a Pass for cycles within tolerance or

a Fail output for cycles outside of tolerance allowing the part to be segregated for quality

assurance.


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Detectable Defects: Missing wire strands, strands out of the core, no strip, high/low

insulation, missing terminals and twisted terminals, changes to crimp height, and scrap in

the tooling.

Key Features and Options of the CFM4000:

One to three channel Crimp Force Monitor utilizing the most current

microprocessor technology.

Unique automatic setup features with user-friendly alpha-numeric and graphic

displays to minimize setup time.

Three display screens available in RUN mode, showing:

1. Graphic display of process relative to compared Control Limits.

2. Engineering data results on each crimp (target, actual, tolerances,

deviation).

3. Graphic display of Force Curve following every crimp.

Option to store multiple force signatures for special applications.

CPK computation and automatic optimization of the control limits based on

process capability.

Two levels of failure detection and ability to interface with advanced wire

processing equipment batch separators, choppers, etc.

A counter that maintains a running total of passes and failure types for each press.

Communication port configurable for a wide range of requirements (computer for

crimp studies using OES CFMView Software, external printer, network link,

etc.)


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Built in self-diagnostics.

WIFI option for remote monitoring, configuration and setup.


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KOMAX GAMMA


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Ultra short conversion times, additional applications and a user-friendly user interface

with multiple-language capability. The Komax Gamma 333 PC makes it all possible!

With its third processing station and state of the art control software, you are assured

maximum flexibility and an even more efficient way of meeting your wire processing

needs. What?s more, the system is a superb value for the money.

Maximum flexibility

With its additional processing station on side 1, the Gamma 333 PC enables you to crimp

both ends of the wire, to create double crimp connections with three different contacts, to

carry out one-ended seal application, tinning or ink-jet marking. In addition, process

monitoring is all integrated to ensure that the wire is cut to length and stripped perfectly

to specification and that quality control is optimized.

Special features

Guide tubes can be changed without tools thanks to the quick-release system.

The contact rolls are positioned in the lower part of the machine and the safety cover

opens upwards to ensure optimum access to the tools. Thanks to the fully programmable

CNC axes plus the stored wire and processing parameters, production is always

economical, even with small batches.

Integrated device

Wire processing today requires cost-optimized, comprehensive solutions. To this end, the

MCI 711 and MCI 761 peripheral stations have been specially adapted for use with these

new machine generations. You benefit from the compact design and standardized

operating concept. Thanks to serial control, the peripheral devices with integrated process

monitoring are also integrated into the TopWin user software.

Here is how you benefit

Exact reproducible settings for processing stations

Optimum accessibility to the processing stations and contact rolls

Drawer for storing the guide parts


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Accessories for crimp module

Height adjustable module elevating table

Contact feed units with paper strip take-up

Contact strip cutter

Wire deposition

Feed belt and extension to deposition system (2m or 4m) for long wires

Process monitoring

Crimp force monitoring

Seal monitoring Splice monitoring

Detection system for wire end and knots

Reference values for piece output on Gamma 333 PC

Wire cross-sections: 0,125mm2 ? 5mm2AWG 26 ? AWG 10

Length range: 60mm ? 50000mm (optional 30mm)

(+/- 1mm bzw. < 0,2% depending on wire length)Stripping lengths: Side1: 0,1 ? 15mm (optional 28mm)

Side2: 0,1 ? 15mm

Wire feed rate: max. 6m/s

Noise level: < 75dB (without crimp modules)

Electrical connections: 3x208 ? 480 V / 50 ? 60Hz6kVA

Pneumatic connection: 5-6 bar

Air consumption weight: 6,5 m3/h

Weight: 840 kg with two crimp modules

Dimensions (W?D): 3137 x 1377mmHeight with cover closed: 1790mm (70.5 in.)Height with cover open: 2670mm (105.1 in.)


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Wire length (mm)

Wire data

Wires FLK-R 0,75 mm2

Pneumatic pressure 6 bar

Speed 6 m/s

Acceleration 40 m/s2

MCI 711 crimp modules

MCI 761 seals module

Quality control OFF


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ULTRASONIC WELDING

When bonding material through ultrasonic welding, the energy required comes in the

form of mechanical vibrations. The welding tool (sonotrode) couples to the part to bewelded and moves it in longitudinal direction. The part to be welded on remains static.

Now the parts to be bonded are simultaneously pressed together. The simultaneous action

of static and dynamic forces causes a fusion of the parts without having to use additional

material. This procedure is used on an industrial scale for linking both plastics and metals

(figure ).

Figure Differences in the process for welding plastics and metals with ultrasonics

Anvil

Parts to be welded

Sonotrode

Ultrasonic oscillation

Ultrasonic welding of plastics

Oscillations are introduced vertically


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Ultrasonic welding of plastics is a state-of-the-art technology that has been in use for

many years. When welding thermoplastics, the thermal rise in the bonding area is

produced by the absorption of mechanical vibrations, the reflection of the vibrations in

the connecting area, and the friction of the surfaces of the parts. The vibrations are

introduced vertically. In the contraction area, frictional heat is produced so that material

plasticizes locally, forging an insoluble connection between both parts within a very short

period of time.

The prerequisite is that both working pieces have a near equivalent melting point. The

joint quality is very uniform because the energy transfer and the released internal heat

remains constant and is limited to the joining area. In order to obtain an optimum result,the joining areas are prepared to make them suitable for ultrasonic bonding. Besides

plastics welding, ultrasonics can also be used to rivet working parts or embed metal parts

into plastic.

Ultrasonic metal welding

Horizontal oscillation direction

Whereas in plastic welding, high-frequency vertical vibrations (20 to 70kHz) are used to

increase the temperature and plastify the material, the joining of metals is an entirely

different process. Unlike in other processes, the parts to be welded are not heated to

melting point, but are connected by applying pressure and high-frequency mechanical

vibrations.

In contrast to plastics welding, the mechanical vibrations used during ultrasonic metal

welding are introduced horizontally.

The mechanisms during ultrasonic metal welding


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The most commonly used frequency of oscillation (working frequency) is 20 kHz. This

frequency is above that audible to the human ear and also permits the best possible use of

energy. For welding processes which require only a small amount of energy, a working

frequency of 35 or 40 kHz may be used.

Figure Ultrasonic metal welding mechanism

Rough surfaces prevents slippage


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The sonotrode and anvil (welding tools) usually feature rough surfaces or have a milled

or ground structure (cross-ribbed or grooved structure, etc.) to grip the parts to be joined

and prevent unwanted slippage.

Locally limited metal deformations

The static pressure is introduced at right angles to the welding interface. Here, the

pressure force is superimposed by the high-frequency oscillating shearing force. As long

as the forces inside the workpieces are below the limit of linear elasticity, the pieces will

not deform. If forces surpass a given threshold value, local material deformation will

soon take place. These shearing forces, at high frequency, break down contamination,

remove it and produce a bond between pure metal interface. The further oscillation makesthe interface deformation grow until a large welding area has been produced. At the same

time, there is an atomic diffusion in the contact area and the metal re-crystallizes into a

fine grain structure having the properties of a cold-worked metal (figure).

Temperature rise in the welding area

No fusion

Ultrasonic metal welding is local and limited to the shear forces and displacement of

intermediate layers. However, a fusion does not take place if the pressure force, the

amplitude and the welding time have been properly adjusted. Microscopic analyses using

optical and electronic microscopes make re-crystallization, diffusion and other

metallurgical phenomena evident. However, they provide no evidence of fusion (melted

interface). The use of highly sensitive thermal sensing devices in the intermediate layers

shows in initial quick rise in temperature with a steady temperature drop afterwards.

The temperature profile can be controlled

The maximum temperature obtained is a function of the process settings at the welding

equipment. An increase in welding energy likewise leads to an increase of possible


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maximum temperature. An increase in the static force also leads to an increase of the

initial temperature, but at the same time limits the possible maximum temperature.

Consequently, the temperature profile can, within certain limits, be influenced by proper

machine adjustments.

The temperature in the intermediate layer is, of course, also a function of the properties of

the material. The basic rule is that the temperature obtained is higher for materials with a

low thermal conductivity such as iron, and lower for metals with a higher thermal

conductivity such as copper and aluminum.

Temperature measurements carried for different materials with widely varying melting

points have shown that the maximum temperature in the welding interface will notexceed some 35 to 50% of the melting temperature of the individual metal, provided that

the proper welding parameters have been selected.

Homogeneous and lasting joints

Diffusion takes place

Ultrasonic metal welding is not characterized by superficial adhesion or glued bonds. It is

proven that the bonds are solid, homogeneous and lasting joints. If, for example, a thin

aluminum sheet is ultrasonically welded to a thin copper sheet, it can easily be

ascertained that after a certain period of weld time, copper particles appear on the back

side of the aluminum sheet. At the same time, aluminum particles appear on the back side

of the copper sheet. This shows that the materials have penetrated each other -- a process

which is called diffusion. This process takes place within fractions of a second.


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OVERVIEW OF TYPES OF WELDINGS

The different processes for joining metal parts can be systematically subdivided into

different categories depending on their action principle. Their bond can be form-closed,

frictional or positive-substance bond (figure). Very often, it is not possible to make a

clear distinction between closing shape and frictional bond, as some processes render a

clear distinction between operating principles impossible.

Figure : classification of weldings by their action principle


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A positive substance bond is mostly inseparable, and the bond takes place only by using

additional material or consumables. The most frequent types of joints in this category are

adhesive, soldered, brazed and welded joints. When welding materials, one has to

distinguish between fusion welding and pressure welding.

Fusion and pressure welding

Strong plastification

Fusion welding leads to a welding of the pieces by applying heat at the point of

connection which fuses the pieces together and even joins a material. After the hardening

of the mixed components, a solid joint occurs. Unlike fusion welding, pressure welding

depends on the application of high pressures and/or high temperatures, resulting in astrong plastification and a local deformation of the pieces to be joined in the welding area

so that a bond between both pieces is made. The energy required for the welding process

is of a different kind for both types of procedure.


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Figure : Process principle of metallic pressure welding based on movement

Proven energy sources here are gas, arc welding, light, electron or plasma beams.

Ultrasonic welding belongs in the category of pressure welding and uses motion and

kinetic energy for welding pieces together.

Depending on the kind of motion, a distinction in metal welding between cold-pressed

welding, friction welding and ultrasonic welding can be made. All three procedures show

a high similarity. Ultrasonic metal welding is a combination of cold-press welding and

friction welding because of its mode of action.

Figure shows the different principles of cold-press, friction and ultrasonic welding. Cold-

press welding takes place at room temperature. By applying high pressures to both pieces

the materials weld together. A strong material deformation at the welding zone accounts

for the bond.

The differences between the various metal welding processes

In the friction welder, one or both pieces rotate while they are pressed together. The

frictional heat which emanates together with the static pressure causes the bond between

the pieces. The back pressure required for joining the pieces in comparison to cold-press-

welding is drastically reduced because of the additional rotational energy. The matching

of the surfaces promotes plastification and local deformation of the pieces being welded.

A considerably lower welding pressure

During ultrasonic metal welding, the rotational motion is replaced by mechanical linear

vipin kumar

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