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  • + openCrimp height too small or too large
    • The crimp height is the guiding body cross-section height of the crimp area after the crimp, it is good to crimp the most important features. Connector manufacturer for the terminal design for each wire size crimp height. Given the correct cable crimp height range of 0.002 or tolerances may be small. "In such a stringent specifications, test pressure is too small (Figure 1) or too large (Figure II) crimp height can not provide the required crimp intensity (of the cable and the terminal holding force), will reduce the rated current of the cable pulling force and, under normal circumstances can also cause pressure joints under abnormal operating conditions degrade performance. pick correctly set to get a good press then it is very important.
    • Too small crimp height will press break or broken metal core conductor crimp area.
    • Oversized crimp height can not properly compress the core, causing the crimp area is too large gap invalid, since no sufficient contact between the metal core and the terminal metal.
    • Solution to the problem is simple: adjust the conductor crimping machines crimp height. First Use crimping machine operates using a vernier caliper or micrometer inspection crimp height within a predetermined range, and in the course of their work should be in accordance with the frequency required to re-examine, in order to maintain the correct crimp height.
  • + openInsulation crimp area is too small or too large (Figure 3 and Figure IV)
    • Given the diversity of the insulation type and thickness, connector manufacturers generally do not provide voltage insulation crimp height. Conductor insulation crimp to crimp area to provide stress relief, so that when the cable is bent does not make the core break. Too little insulation crimp area make insulation crimp area of the metal too much stress, weaken the stress release function.
    • Most types of crimp tool can be independent of the conductor crimp height adjusting insulation crimp height. Improper adjustment insulating layer such that the clamp terminals of at least 180 degrees, without piercing the insulating layer. In outer diameter insulated terminals and cable insulation crimper close to the same.
  • + openLoose wire core

    Loose wire core (Figure 5) is another common cause of crimp problems. If all of the core is not completely closed on the conductor crimp area, the crimping member strength and current carrying capacity will be greatly reduced. To get a good crimp, you must meet the connector specified by the manufacturer of the crimp height. If not all cores are on the crimp height and crimp strength play a role, then the crimper performance will not meet the requirements. In general, loose wire core problem is easily solved, just re-folded cable bundles, and then insert the crimping of the terminal. If the insulating layer is peeled off from the cable is a process separate operation, handling or cluster process may inadvertently core separation. Stripping use and maintain process to remove the insulating layer, so that the insulating sleeve is not completely removed from the cable, until ready to use crimping the cable helps minimize the problem of loose core issues.

  • + openStrip length too short

    If the strip length is too short, or cable is not fully inserted into the conductor crimp area, crimping may not achieve the required drawing force, because the intermetallic contact between the cable and the terminal is reduced. Shown in figure VI, cable stripping length is too short (Note that the insulating layer is in the correct position), extending from the front portion of the conductor crimp area unable to obtain a cable outer diameter requirements. The solution is simple: increase the stripping length stripping device to a predetermined value of the terminal.

  • + openCable inserted too deep
    • Another too short strip length crimping related problems occur in the cable into the crimping area is too deep a case. As shown in Figure VII, the insulating layer forward too deeply inserted into the insulation crimp area, conductor extends to the transition area. In practice, this may lead to three kinds of failure modes. Two of which it is due to metal contact between the conductor crimp area reduction, so that the rated current and the cable pulling force is reduced. Contact metal and plastic no metal contact between the firm, and it does not conduct electricity.
    • The third failure mode may occur when the connectors are engaged. If the cable is extended to the transition area is too dark, the tip of the pin terminals collision on the cable, may prevent the connector is fully seated, or may cause bent pins or socket terminals.
    • In extreme cases, even if the terminal is fully seated within the housing, but housing will be pushed back. To resolve this problem, make sure not to use too much force the cable into the crimping machine crimping machine in making it over the cable only the mouth, or adjust the position of the cable so that only the mouth of the correct axial positioning of stripped cable.
  • + open"Bananas" (bent over) terminal

    One of the most vivid crimp problem is called "banana" crimp (Figure 8), because the crimp terminal was a banana shape. This makes it difficult to insert the terminal housing, the terminals may cause a collision. This problem is easily solved, you can adjust the position limit pin crimping machine. This small pin located crimping machine, pressure when connected to the cable landing zone at the contact terminal crimp area. In the crimping process, a large metal terminal end (the crimp area) movement. Such a large force tends to the front of the terminal is forced upwards, unless appropriate "restraint pin" limited.

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