Tyco Quality Manual 1654241-1CrimpBroGB

GB - Crimp Cover 02.05.
2005 11:41 Uhr Seite 1
Catalog 1654241-1
Issued 04-05.
G L O B A L A P P L I C AT I O N T O O L I N G
AND EQUIPMENT
Crimp Connections
GB - Crimp Cover 02.05.2005 11:41 Uhr Seite 2
Crimp Connections Catalog 1654241-1

Issued 04-05.
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Area of Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Crimp Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Crimp Forms for Open Crimp Barrels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Crimp Forms for Closed Crimp Barrels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Crimp Forms for Insulation Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Crimping Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection of the Conductor Crimp – Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection of the Conductor Crimp – Measurement of Crimping Height . . . . . . . . . . . . . . . 13
Inspection of the Conductor Crimp – Measurement of Extraction Force . . . . . . . . . . . . . . . 14
Inspection of the Insulation Support Crimp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Conductor Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Application Tools and Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Quality Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Product Information Center (PIC) Tyco Electronics Online
Our PIC team are there to help with any further questions.
With our experienced employees in the Product Information Center
(PIC) we can offer you a reliable source of information and
support for your technical queries. Internet Homepage:
Phone: +44 (0) 800 267 666 www.tycoelectronics.com
Fax: +44 (0) 208 420 8383
Electronic Internet Catalog:
E-Mail: PICUK@tycoelectronics.com
http://catalog.tycoelectronics.com
Outside United Kingdom please contact the subsidiary company Processing Equipment:
in your country. www.tooling.tycoelectronics.com/europe
Our website is more than an Internet guide. It is constantly being

added to and is an innovative and interactive source for applications
Product und Machine Literature
tips, product updates and technical information of all types. With our
innovative StepSearch software, which has been perfected over a
Order quickly and easily by fax: period of several years you can conveniently surf your way through
all our products.
Fax: +44 (0) 208 420 8383
A large product range has extensive product literature.

You can request flyers, catalogs and brochures for each of the Part No. for this catalog:
product sectors of relevance to you. 4-523909-4
Only the most recent Tyco Electronics customer drawings and /or product and processing specifications
which you may receive upon request are binding in terms of tolerances for dimensions and technical values.
Issued 04-05.
Introduction
Within industrial manufacturing, The vital prerequisite for this is In the following the characteristic
crimp connections almost com- the correct arrangement of the features of a crimp connection,
pletely took over from soldered following components: the requirements of this, their
connections for connecting leads testing, inspection and process-
The wire with its conductor
to contacts a good number of ing will be examined in more
section and insulation diameters.
years ago. detail.
The contact with its wire- and
Crimp connections prove
insulation barrel.
themselves again and again with
billions of applications and under The crimping tool with its
extreme mechanical, thermal crimp width dimensions and
and environmental conditions. crimp height settings.
Like all connections even a crimp The values given in the visual
connection is only satisfactory inspection tests have been taken
and reliable in the long term if it as extracts from the “General
has been made properly. Specification 114-18022”.
Only the most recent Tyco Electronics customer drawings and /or product and processing specifications 1
Issued 04-05.
Area of Application
There is a differentiation to be
made between a conductor crimp
and a crimp for an insulation
Conductor Crimp
support.
The conductor crimp insures
a good connection between the
wire and the terminal. The
insulation crimp supports the
wire to reduce the affects of
vibrations and movement on the
conductor crimp.
Insulation Crimp
2 Only the most recent Tyco Electronics customer drawings and /or product and processing specifications
Issued 04-05.
Crimp Forms
Crimps with different forms are

used for optimal processing of
different products.
A differentiation is made between
crimp forms for open and closed
crimp barrels.
Open Crimp Barrels
Closed Crimp Barrels
Issued 04-05.
Crimp Forms for Open Crimp Barrels
The F-crimp is the most common

crimp form. It may be calculated
accurately for every application,
easily manufactured and can be
processed in high numbers. The
U-shaped open crimp barrel is
closed during the crimping
process and is pressed tightly
together with the conductor.
The F-crimp can be used as a
conductor crimp as well as an
insulation crimp.
The Tab-Lok crimp is mainly

used when there is only a narrow
space available. When crimping
a tongue at the end of the one-
sided conductor crimp barrel will
be passed through a slit in the
contact base, and then bent into
a U-shape and then fixed in place
with two stopper tappets on the
underside.
Contacts with open crimp barrels

are generally produced in strips
and processed automatically.
The crimp terminals may also be
obtained loose-piece for use in
hand crimping tools.
Issued 04-05.
Crimp Forms for Closed Crimp Barrels
The W-crimp is one of the first

crimp forms which were
designed.
With the metallic closed crimp
barrels solid conductors as well
as stranded conductors or a
combination of both may be
processed.
This crimp form has no insulation
barrel.
The C-crimp is used with crimp

barrels which have a metallic
closure with a plastic barrel
on top of this. With this crimp
barrel, there also is good
support for the insulation.
The bar crimp is a special devel-

opment for aluminium crimp
connections. An inner brass
mesh barrel breaks up oxide
layers during the crimping
process and on the other hand
guarantees safe mechanical
anchoring.
View from below View from above
The indent crimp is used for

screw machined contacts.
Contacts with closed crimp
barrels are generally processed
individually with hand crimping
tools.
Issued 04-05.
Crimp Forms for Insulation Support
The F-crimp is generally used

for leads with thick-walled insu-
lations. The rolled-round crimp
edges are pushed into the insu-
lation by their tips.
The overlap crimp is mainly used

for leads with thin-walled insu-
lation. The crimp edges which lie
on top of one another press flat
down on the lead and hold this
tight.
The wrap-over crimp is used

preferably for individual stopper
components and in the process-
ing of individual seals. The great
overall length is compensated
for by the lead being completely
enclosed.
The O-crimp is predominantly

used for the processing of indi-
vidual seals. The rolled-round
crimp edges ideally enclose the
component in a closed circle or
with a residual gap.
A single wire application is
recommended for all crimp forms
so as to obtain better enclosure.
In the case of double wire appli-
cation the thinner wire lies under-
neath in the bottom of the crimp
barrel.
Issued 04-05.
Crimping Process
Crimping Process
(shown with the example of
an F-crimp)
The application tool is opened. The crimper moves down and presses the lead
A contact is positioned on the anvil. into the crimp barrel and makes contact with the
The lead is inserted by hand or mechanically. crimp edges.
In the next processing stage the crimp edges are The final position at a given crimping height
rolled-round, the conductor is compressed at the guarantees the necessary compression of the
same time, and the crimp is formed. conductor to form a tightly compressed crimp.
Issued 04-05.
Inspection of the Conductor Crimp
The qualitative assessment of

a conductor crimp (using the
example of an F-crimp) is
determined by:
● Visual Inspection
● Measurement of
the Crimp Height
● Conductor Extraction Force
Visual Inspection
The conductor end is flush with
the front edge of the conductor
crimp barrel or this is up to
approx. 1 mm in front.
Correct ✓
The insert and lock function of
the contact may be adversely
affected by any individual wire
strands which may be protruding.
✘ Incorrect
The insulation end lies visibly

in the window between the
conductor crimp barrel and the
insulation crimp.
Correct ✓
Issued 04-05.
Inspection of the Conductor Crimp – Visual Inspection (continued)
The insulation must not enter

the conductor crimp – nor end
inside the insulation crimp.
✘ Incorrect
✘ Incorrect
For a smooth transfer of the

conductor from the compressed
zone into the original cross-
section a bellmouth is prescribed
at the end of the conductor
crimp barrel. A bellmouth is
permissible but not necessary on
the front edge of the conductor
crimp.
Correct ✓
✘ Incorrect
Issued 04-05.
The transition tab, which is used

to join the terminal to the carrier
strips in the case of side-feed
contacts or which is used as a
connection for end-feed contacts
may still leave a visible witness
mark after crimping at the base
or it may protrude up to a max.
as specified in the relevant
application specification.
If this specification is complied
with then damage to the insula-
tion crimp and / or the contract
body is avoided.
Correct ✓
The cut off tab and any burrs
on the sheared edge may not
adversely affect the insertion
function of the contact.
✘
Incorrect
Issued 04-05.
The crimp is closed. The rolled-

round crimp edges provide
mutual support for one another.
All individual strands take on a
honeycombed structure and are
pressed tightly against one an-
other. No cavities are visible. The
tight connection to the conductor
crimp barrel is recognisable by
the slight deformations on the
inside. All the individual wires
strands are within in the crimp
barrel.
Correct
✓
Individual cavities due to
unsymmetrical forming or an
unfavourable tolerance build up
of the material and the crimping
height are still permissible as a
borderline case.
Correct
✓
Issued 04-05.
Defective crimp connection due

to a crimping height which had
been set too high. Individual wires
are not sufficiently compressed,
and their contact with one
another and with the crimping
barrel is insufficient.
Excessive compression leading

Incorrect
✘
to a level of flash which is no
longer permissible on the crimp
base. There is a weakening of the
mechanical retention force of the
crimping barrel and an increase
in the contact resistance as a
result of the reduction in cross-
section of the conductor.
Increased tool wear.
Incorrect
✘
Issued 04-05.
Inspection of the Conductor Crimp – Measurement of the Crimping Height
Measurement of
the Crimping Height
The crimping height is the
decisive quality feature of a crimp
connection. Its measurement
allows non-destructive testing to
take place and also for continu-
ous manufacturing checks to be
carried out.
The crimping heights with their
tolerance range guarantee on the
one hand that the conductors are
compressed tightly and on the
other hand that the extraction
force is sufficient taking into
account the material tolerance of
the crimps and the cross-section
tolerance of the conductor.
The crimping height is measured
with an external micrometer in
accordance with the user
instructions IS 408-7424.
Issued 04-05.
Inspection of the Conductor Crimp – Measurement of Pull Out Force
Measurement Mechanical
of Pull Out Force Characteristics
The measurement of the pull
out force is an additional manu-
facturing check. This is carried
out without an insulation crimp
with a standard tensile testing
machine. The minimum values M
are detailed in DIN EN 60352-2.
The principal correlation between
crimp height and pull out force
and the mechanical and electrical
characteristics resulting from the
crimp connection will be shown
using the graphs.
Decreasing Crimp Height

Increasing Crimp Force
The first graph shows the qualitative change in mechanical characteristics, that is to say the tensile strength
of the connection between the conductor and the crimping barrel depending on the crimping height.
The crimping process corresponds to a movement along a horizontal axis from left to right. The crimping
strength thereby increases and the crimping height is reduced.
If the crimping height is too great then the conductor will only be gripped loosely. With the reduction in
crimping height the tensile strength will quickly increase to up to a maximum of M. After this the pull out
forces are again reduced until finally the individual wires are almost sheared off due to excess pressure.
Electrical
Characteristics

The second graph shows the dependency of the electrical characteristics on the crimping height.
With a reduction in crimping height the conductance slowly rises to a maximum of E.
The conductance then falls abruptly due to the great reduction in the cross-section.
Issued 04-05.
Inspection of the Conductor Crimp – Measurement of Pull Out Force
Mechanical Electrical
Characteristics Characteristics
E
M

When the two graphs are superimposed on one another one can see that the maximum mechanical value
and the maximum electrical value are reached at different crimping heights.
When looking at a cross section it will be recognised that if the crimp height is set to attain the maximum
pull out force then the wires will still not be compressed tightly. It would still be possible to see small
cavities between the individual wires.
On the other hand with the best electrical conductance value the compression would already be very
intensive. Bare surfaces would originate due to the extrusion of the copper which would make for an
excellent contact.
Mechanical Electrical
Characteristics Characteristics
C E
M

The crimp height C established by Tyco Electronics with a tolerance range on both sides represents
a compromise between the mechanical and electrical optimums.
Issued 04-05.
Inspection of the Insulation Crimp
Due to the large degree of

tolerance of the external diameter
of the lead a crimping height is
not specified. BENDING TEST
The correct support of the lead is
established either by means of
■ a bending test in order to
simply realise this during Conductor Crimp without Conductor
manufacture
or by means of
■ a winding test in accordance
to DIN EN 60512-8 (specified
in DIN EN 60352 T2).
In both tests the unstripped lead

is only crimped in the insulation
crimp.
The lead may not spring out
from the insulation crimp due to
bending or winding. On the other
The lead must
hand the insulation may not be
still be gripped after
pierced or cut through. the bending test
WINDING TEST
The lead must The test mandrel

still be gripped after (adjusted according to
the bending test the insulation diameter)
Issued 04-05.
Conductor Structure
Stranded Conductor
It is predominantly leads with Stranded Conductor – 7 Strands
a stranded structure which are
used. Theoretically all structure
types have to be applied at their
specific crimp height so that they
are compressed tightly.
In practice all leads from those
with 7 strands to those with up to
approx. 80 are applied using a
common crimp height.
The crimp heights specified by
Tyco Electronics guarantee a tight
crimp even under unfavourable
tolerance conditions.
The crimp height is determined
separately when applying braided
wire.
The wire size ranges given for
contacts always apply for
stranded conductors unless
Stranded Conductor – with Fine Wire Strands
stated otherwise.
Solid Conductor
Solid conductors can be pro-
cessed with open crimp barrels
using the F-crimp and with
closed crimp barrels using the
W-crimp. Due to other forms of
deformation which may occur
certain criteria have to be com-
plied with:
■ The cross-section of the solid
wire must be in the upper
third of the wire size range Solid Conductor
which applies for the stranded
conductor.
■ The contact may not be
subject to any vibrations or
jarring.
■ The solid wire must be
supported by an insulation
crimp.
■ The special crimp height can
only be determined empirically
via sample crimps and cross
sections.
■ Due to the other deformation
characteristics automatic
application is recommended.
Issued 04-05.
Application Tools and Machines
Hand Crimping Tools ERGOCRIMP Hand Tool
CERTI-LOK Hand Tool
Hydraulic Hand Tool

(12 Tonnes)
You will find other Application Tooling and Machines at: http://tooling.tycoelectronics.com/europe
Issued 04-05.
Application Tools and Machines (continued)
Semi-Automatic HD-I Applicator

Application Equipment
with Applicators
AMP 3K/40 and

AMP 5K/40 Terminator
Stripping Unit for

AMP 3K/40 and AMP 5K/40
Terminators
Issued 04-05.
Semi-Automatic CRIMPMATIC 971

Application Equipment for large conductor
cross-sections
with Applicators
SC 15 Stripper Crimper
FFC Crimping Machine
Issued 04-05.
Fully-Automatic
komax gamma 255
Application Equipment
komax alpha 433 S/L /H
komax gamma 333 PC komax alpha 477
Issued 04-05.
Quality Guidelines
Correct WIRE CRIMP Test

Insulation present Bellmouth must always be present
Conductor
WIRE CRIMP
present
Crimp Height Measurement
Bellmouth permissible
Locking lances and

Cut off tabs present
terminal body not deformed
Crimp Heights and Tolerances

Correct selection of wire,
terminal and applicator For crimp height tolerances for any given
contact, please refer to the relevant
application specification.
Crimp barrel is closed, Sufficient gap between legs

legs support each other and bottom of crimp Digital Crimp Height Micrometer
(0.001 mm increments)
All strands are equally distributed and deformed
acc. to DIN ISO 9001
Part No. 547203-1
INSULATION CRIMP
Correct Insulation Diameter, Applicator and Terminal
F-CRIMP
Insulation is securely held.

Crimp barrel closed
For double wire applications with different size wires always

place wire with smallest outer diameter in the bottom
OVERLAP CRIMP
INSULATION CRIMP
Wire crimp without conductor

30
Insulation is securely held.

°
Legs overlap
°
30
WRAP OVER
CRIMP
Insulation must be
securely held
Insulation securely held. after bend test
Legs must pass each other
Issued 04-05.
Quality Guidelines
Incorrect Terminal twisted
Terminal damaged
Cut off tab too long Crimp barrel distorted Cut off tab deformed
Crimp height too tight Insulation inside the wire crimp
Conductor Brush protruding into terminal body
Bellmouth on wrong end

Terminal bend
INSULATION CRIMP
Insulation is pierced and could damage conductor Insulation material is pierced Insulation is Insulation is
not securely held over crimped
Insulation legs are not closed Insulation is not securely held

Legs do not overlap
WIRE CRIMP
Incorrect applicator adjustment Incorrect terminal/wire selection Incorrect crimp height adjustment
Unacceptable
Asymmetric Crimp height Crimp height
formation excessive Wire size too large Wire size too small
crimp too loose too tight
flash and/or cracks
Terminal feed Anvil and crimper Crimp barrel Legs too close Insufficient Flash at under
incorrectly adjusted not aligned or worn does not close to bottom of crimp. deformation, side of crimp,
Insufficient defor- showing voids due to over crimping
mation of strands,
showing voids
Issued 04-05.
Notes and Supplementary Information
Global Contacts
Detailed Product Information is available at the following Tyco Electronics Companies:
Europe/ Middle East/Africa

Austria – Slovenia – Croatia – Germany North East Hungary Poland
Serbia & Montenegro – Bosnia & Klaus Seiger Budapest Bydgoszcz
Herzegovina – Macedonia: Phone: +49-4206-445-652 Tibor Romány Andrzej Orbik
Vienna Fax: +49-4206-445-653 Phone: +36-1-289-1000 Phone: +48-52-3250-131
Emil Zolnaritsch kseiger@tycoelectronics.com Fax: +36-1-289-1010 Fax: +48-52-3250-277
Phone: +43-1-90560-1235 TRomany@tycoelectronics.com aorbik@tycoelectronics.com
Fax: +43-1-90560-1311 Germany North West
Ernst Haase Italy Product Information Center:
emil-franz.zolnaritsch@
Phone: +49-4921-942-843 Torino Phone: +48-22-4576-704
tycoelectronics.com
Fax: +49-4921-936-661 Mauro Papalini Fax: +48-22-4576-720
Czech – Slovakia ehaase@tycoelectronics.com Phone: +39-011-4012-562 jmatasz@tycoelectronics.com
Brno / Kurim Fax: +39-011-40287-562
Germany South East Sweden
Drahomir Bazant MPapalini@tycoelectronics.com
Manfred Duerr Stockholm / Upplands Väsby
Phone: +420-541-162-150
Phone: +49-9727-8760 Netherlands – Mats Jansson
Fax: +420-541-162-152
Fax: +49-9727-8762 Belgium – Luxembourg: Phone: +46-8-50-72-50-00
dbazant@tycoelectronics.com
mduerr@tycoelectronics.com ’s-Hertogenbosch Fax: +46-8-50-72-50-01
Denmark Henk van Hassel MJansson@tycoelectronics.com
Copenhagen / Glostrup Germany South West Phone: +31-73-6246-108
Manfred Schulz Spain & Portugal
Bent Kristensen Fax: +31-73-6246-931
Phone: +49-241-401-6813 Barcelona
Phone: +45-86-68-4811 HHassel@tycoelectronics.com
Fax: +49-241-401-8664 Jose Luis Baena
Fax: +45-86-68-4811
manfred.schulz@tycoelectronics.com Product Information Center: Phone: +34-93-291-0396
bkristensen@tycoelectronics.com
Phone: +31-73 6246-999 Fax: +34-93-5644-819
Product Information Center: Fax: +31-73-6246-998 JBaena@tycoelectronics.com
Finland
Phone: +49-6251-133-1999 picbenelux@tycoelectronics.com
Helsinki Product Information Center:
Fax: +49-6251-133-1998
Petri Laiho Phone: +34-93-291-0330
germany-pic@tycoelectronics.com Norway
Phone: +35-89-51234-224 Fax: +34-93-200-3779
Oslo / Nesbru
Fax: +35-89-51234-250 pic.spain@tycoelectronics.com
Great Britain Torgeir Mikalsen
plaiho@tycoelectronics.com
Bideford Phone: +47-66-77-88-89
Switzerland
France Paul Stevens Fax: +47-66-77-88-55
Steinach
Pontoise Phone: +44-1237-428-668 tmikalsen@tycoelectronics.com
Marcel Duenner
Dominique Versmée Fax: +44-1237-428-689
Phone: +41-71-447-0244
Phone: +33-(0)1-3420-8770 PStevens@tycoelectronics.com
Fax: +41-71-447-0420
Fax: +33-(0)1-3420-8603 m.duenner@tycoelectronics.com
Great Britain
dversmee@tycoelectronics.com
Bideford
Product Information Center: Bruce Verrall
Phone: +33-(0)1-3420-8943 Phone: +44-1237-428-654
Fax: +33-(0)1-3420-8623 Fax: +44-1237-428-683
b.dubois@tycoelectronics.com bruce.verrall@tycoelectronics.com
Americas
USA Canada Brasil
Harrisburg, PA Troy, MI Toronto Bragança Paulista, São Paulo
Phone: +1-717-564-0100 Phone: +1-248-273-3359 Phone: +1-905-475-6222 Celso C. Lima
Fax: +1-717-986-7575 Fax: +1-248-273-3322 Fax: +1-905-474-5520 Phone: +55-11-4034-6021
Fax: +55-11-4034-6088
Customer Service (USA) Customer Service (USA) Mexico cclima@tycoelectronics.com
Phone: +1-800-522-6752 Phone: +1-800-522-6752 Mexico City
Phone: +52-55-1106-0935
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Kawasaki Sydney Seoul Shanghai
Phone: +81-44-844-8079 Phone: +61-2-9554-2600 Phone: +82-2-3415-4586 Phone: +86-21-5383-8188-1813
Fax: +81-44-844-8733 Fax: +61-2-9502-1753 Fax: +82-2-3486-3595 Fax: +86-21-5383-8018
AMP, CERTI-LOK, ERGOCRIMP and TYCO are registered trademarks. www.tooling.tycoelectronics.com/europe

Tyco Electronics AMP GmbH is ISO 14001 and ISO/TS 16949:2002 certified
© 2005 Tyco Electronics AMP GmbH • AMPèrestr. 12–14, 64625 Bensheim • Phone +49-6251-133-0, Fax +49-6251-133-1600
1654241-1–5M–ST–04-05 Printed in Germany www.tycoelectronics.com

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GB - Crimp Cover 02.05.

2005 11:41 Uhr Seite 1

Crimp Connections Catalog 1654241-1

Crimp Forms for Open Crimp Barrels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Crimp Forms for Closed Crimp Barrels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Crimp Forms for Insulation Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Inspection of the Conductor Crimp – Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Inspection of the Conductor Crimp – Measurement of Crimping Height . . . . . . . . . . . . . . . 13

Inspection of the Conductor Crimp – Measurement of Extraction Force . . . . . . . . . . . . . . . 14

Inspection of the Insulation Support Crimp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Application Tools and Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Product Information Center (PIC) Tyco Electronics Online

Our website is more than an Internet guide. It is constantly being

A large product range has extensive product literature.

Crimps with different forms are

Open Crimp Barrels

Closed Crimp Barrels

Crimp Forms for Open Crimp Barrels

The F-crimp is the most common

The Tab-Lok crimp is mainly

Contacts with open crimp barrels

Crimp Forms for Closed Crimp Barrels

The W-crimp is one of the first

The C-crimp is used with crimp

The bar crimp is a special devel-

View from below View from above

The indent crimp is used for

Crimp Forms for Insulation Support

The F-crimp is generally used

The overlap crimp is mainly used

The wrap-over crimp is used

The O-crimp is predominantly

Inspection of the Conductor Crimp

The qualitative assessment of

The insulation end lies visibly

Inspection of the Conductor Crimp – Visual Inspection (continued)

The insulation must not enter

For a smooth transfer of the

Inspection of the Conductor Crimp – Visual Inspection (continued)

The transition tab, which is used

Inspection of the Conductor Crimp – Visual Inspection (continued)

The crimp is closed. The rolled-

Inspection of the Conductor Crimp – Visual Inspection (continued)

Defective crimp connection due

Excessive compression leading

Inspection of the Conductor Crimp – Measurement of the Crimping Height

Inspection of the Conductor Crimp – Measurement of Pull Out Force

Decreasing Crimp Height

Decreasing Crimp Height

Inspection of the Conductor Crimp – Measurement of Pull Out Force

Decreasing Crimp Height

Decreasing Crimp Height

Inspection of the Insulation Crimp

Due to the large degree of

In both tests the unstripped lead

The lead must The test mandrel

Application Tools and Machines

Hand Crimping Tools ERGOCRIMP Hand Tool

CERTI-LOK Hand Tool

Hydraulic Hand Tool

Application Tools and Machines (continued)

Semi-Automatic HD-I Applicator

AMP 3K/40 and