Connection Systems Training

Global Crimp Technology

Prepared By John Yurtin Revised and Updated 2-3-05 CTIS # 29957

Excellence
Performance Goal: Do it right the first time, every time Method: Innovation and continuous improvement

Having a good technical understanding of crimping can help you properly apply terminals within the vehicle. Crimps are essential to the performance of the wiring system and are often overlooked in troubleshooting electrical problems. This training help you understand the importance of the crimps and the performance requirements so you can better support customers.

Crimp Validation
The purpose of crimp validation is to assure the crimp attachment of a terminal to a wire will function properly in the vehicle application.
Electrical capability is the most important function. The terminal, at its root, is an electrical component. Its functionality must be described in terms of electrical performance. Mechanical capability is also an important function. The terminal crimp must be able to withstand a certain amount of handling and vehicle stress.

Crimp Performance
The quality of a crimp connection is based on many criteria:

good electrical properties

Low and stable electrical resistance
resistant to the growth of insulating films

good mechanical properties

high pull off forces

good physical attributes

good compaction good bell mouth (flare) minimal burrs good CCW/CCH ratio

Crimp Components and Crimp Design

Terminals
Material, Plating, Features, Design Cable Material, Plating, Gauge size, Stranding Crimp Tooling Geometry, Size, Thickness

Determination of Crimp Configuration The best possible crimp configuration is analytically, physically and optically determined.
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Crimp Performance The Optimum Compaction Level

Determined through the combination of terminal, cable(s), core crimp tooling and core crimp dimensions. Crimp performance is verified through testing.

Core Crimp Dimensions ensure the Quality Factor

The crimp validation process will determine the core crimp height and width.
crimp height 6

Crimp Micrographs & Crimp Performance

The optimum compaction level will be determined by the crimp height and tooling
1.0 mm 1.1 mm 1.2 mm 1.3 mm

Excessive compaction - no voids - good electrical properties - poor mechanical properties

Ideal compaction - no voids - good electrical properties - good mechanical properties

Insufficient compaction - includes small voids - poor electrical properties -superior mechanical properties

Insufficient compaction - includes many voids - poor electrical properties -poor mechanical properties

Crimp Performance Curve

200 1.6 1.4 150 Pull 1.2 1.0

100
80 (Min)

0.8 Environmental 0.6 0.4 Power 0.2 0.0 1.00 1.05 1.10 1.15 1.20 1.25

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Validated Crimp Height

Core Crimp Height

Cross Sections not ideal

Conductor crimp attributes considered undesirable Extreme ram-horning Overlapping wings Conductor crimp attributes considered unacceptable One or both wings (grips) penetrate (crash) to the terminal floor or wall Open wings with conductor exposed or folded down into core but not touching (not locked) One or both wing (grip) details do not capture strands No strand compaction

One or both wings folded back Terminal stock cracked / broken

Note: With OEM customer approval, the above attributes listed as unacceptable may be considered acceptable if it can be shown that all other requirements of this specification are met and past production experience has shown them to be functional in the intended application. 9

Ideal Cross Section

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Example of a Really Bad Cross Section

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Crimp Validation Testing - Summary

Determination of Crimp Configuration
The best possible crimp configuration (terminal design, cable, crimp tooling crimp height and crimp width) is analytically, physically and optically determined.

Cross Section Reduction

The reduction of the cross section of the copper (compaction) is estimated using a computer program, then verified using actual cross sections.

Determination of the Mechanical Characteristics of the Crimp Connection

The mechanical capability of a Crimp Connection (cable/crimp/terminal transition metal) is determined by means of the pull force of the crimp connection. The Average-3 sigma pull force must meet the Specification Standards ( min. pull force) across a 3 CCH tolerance range.
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Crimp Validation Testing - Summary

Pull Test: EST460
20 samples (prep 23) X-3 to limits: (Newtons) .22:40, .35:60(annealed); .35:70(hard drawn); .5:80; .8:90; 1.0:120; 2.0:200; 3.0:250; 5.0:300; 8.0:350N

Current Cycle Test: EST913

8.3 days (200 hours + resistance measurement time) 10 samples (prep 12-one end, or 7-both ends) 45 minutes on, 15 minutes off for 200 hours: .35:10; .5:14; .8:18; 1.0:22; 2.0:30; 3.0:40; 5.0:65; 8.0:100 Amps

Accelerated Environmental Test: EST931

7 days (168 hours + resistance measurement time) 10 samples (prep 12) Dry Circuit Resistance test with 4 wire milliOhm meter Maximum resistance change must be less than 0.3m or 9Rc Resistance Thermal Shock 72 hours:(30 min at -40C, 30 min at +125C) Resistance Temp/Humidity 4 Cycles (16 hours at 95-98% R.H., 65C, 2 hours at -40C, 2 hours at +85C, 4 hours at +25C) Resistance

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Component & Systems Validation Lab

Component and Systems Evaluation Laboratories

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Component & Systems Validation Lab

Sample Preparation area at the Engineering Service Center. All of the samples used for validation testing are built by trained technicians.

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Component & Systems Validation Lab

Cross sectioning equipment at the Component and Systems Evaluation Laboratories. There is also a metallurgical lab on site that can be used if the terminal must be potted prior to sectioning.

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USCAR-21 Crimp Specification

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Why a Standard USCAR Crimp Specification?

OEMs and Terminal Manufactures were specifying Different Crimp Performance Tests prior to 2002.
There was a need for common testing to reduce costs and improve Vehicle Life Electrical performance.

OEMs are more and more going to Common Component and Wiring Assembly Suppliers.
Need for Standardization.

Increased need to address the needs of Wiring Harness Suppliers

USCAR-21 Compliments the existing Electrical Performance Specifications now offered by USCAR , which had not previously addressed specific Crimp Technology needs.

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USCAR-21 Requirements
Paragraph 1.2 Crimp applications validated to this specification supercede any crimp information on Ford, GM, or DaimlerChrysler component prints. It is preferred that the terminal supplier do testing and selection of crimp tooling and supply detailed crimp information or make crimp tooling available to the wiring assembly supplier actually doing the production crimping. If the wiring supplier deviates from this information or it is not available, then the responsibility for testing to this specification or getting approval from the customer with appropriate test data showing that the crimp will function in its intended circuit lies with the wiring harness supplier. Paragraph 1.8 Crimp validation testing and design is primarily the responsibility of the terminal supplier. Tooling and/or design for the crimp shall be made available to the full service wiring supplier. Should the wiring supplier choose to deviate in any way from the established and validated design, then the wiring supplier shall be responsible for completing this test procedure using the alternative crimp design.
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Crimp Resistance vs. Time on a Typical Unstable Crimp

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Strand Movement due to Loose Crimp (Low Energy Circuit Intermittency)

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USCAR-21 Ideal Cross Section

Symmetric Compaction of all strands Ends of wings touch only conductor Terminal stock free of cracks / breaks Core wings "Locked" (No Gap) at top of crimp
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Spring-back
Shapes are important for the stability of the crimp.

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USCAR-21 Conductor Crimp Burrs

0.1 mm max.

A major cause of seal failure

An indicator of improper setup or worn tools Can lead to cracks in the terminal material Can be dangerous

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USCAR-21 Insulation Crimp Cross Sections

Insulation Crimp cross sections considered ideal

B Shape

Overlap

Round

Bypass

Symmetric crimp No insulation penetration Wings (grips) embrace insulation to provide strain relief

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USCAR-21 Insulation Crimp Cross Sections

Insulation crimp attributes considered undesirable Insulation wings contact conductor (no damage to conductor) Insulation extruded outward between open insulation wings Insulation crimp attributes considered unacceptable One or both wings (grips) penetrate (crash) to the terminal floor or wall One or both wings (grips) penetrate and damage the conductor

Insulation split behind crimp (away from terminal) Less than 3-point contact

No contact

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