Crimp Height—
Employing the Most Effective Crimp Quality Metric
for Meeting Contemporary Quality Standards
Driven by the requirements of 6-Sigma and other international Comparing Crimp Quality Measurement
quality standards, TE has developed crimp testing technology that Technologies
provides dependable, non-destructive, evaluation of 100% of
It is common to measure pull-out force as a basic criterion for
crimped terminals without impact on production throughput.
crimp quality. Indeed, it checks the mechanical properties of the
Crimp height measurement is a well-established methodology
crimp. However, as discussed above, too tight a crimp can be as
and, in combination with crimp force measurement, is superior to
bad as one that is not tight enough. Pull-out force may not be
destructive methods, sampling methods, or techniques that
sufficiently sensitive to detect over-crimping in cases where the
depend on crimp force alone. Crimp height has been
process has not gone so far as to break the wire or terminal. A
demonstrated to be an effective measure of the quality of the
crimped terminal that passes the pull-out test may nonetheless
crimped-on terminal. Crimp height measurement combined with
have a reduced lifetime or resistance to subsequent damage from
crimp force is a powerful tool that can detect assembly issues as
handling, installation, or vibration. Of course, since it can be a
well as tool wear and other process defects.
destructive test, it may be performed on a sampling basis, only.
Connector Design Factors This sampling still provides an auditable quality record.
When a connector design engineer begins to design a crimp, Crimp force has also been employed. Strain gauges or other force
several things are considered, including the size and composition— sensors appropriately mounted can acquire force data. Specifically,
solid/stranded/aluminum/copper, etc.—of the wires to be crimped, force during the crimp and the peak force are evaluated in relation
and the required electrical and mechanical properties. After to average and standard deviation specifications and, as soon as a
optimizing to obtain the best results in both these properties, the crimp cycle occurs in which the value of either exceeds a preset
engineer determines the best crimp profile and the appropriate multiple of the standard deviation, the termination is evaluated for
crimp height range and width, to achieve the desired reduction in faults. This test does allow 100%, non-destructive testing, but does
the area of the wire. Deviations from crimp height standards can not validate the crimp to the original terminal design intent.
result in degradation of either mechanical or electrical performance. Crimp height, as illustrated in Figure 1, is also a common
A loose crimp will result in poor mechanical qualities, and likely, measurement. Crimp height can be used to validate crimp to
poor or noisy electrical conduction. Too tight a crimp may improve original design intent but by itself, crimp height can not discern
the electrical properties up to a point, but mechanical properties process variables such as wire and terminal variation. As a standard,
may suffer as a result. Individual wire strands may get cut or the this measurement can be performed with a vernier caliper fitted
wire may start to undergo excessive plastic flow, leading to a with appropriate jaw modifications. As such, of course, it is useful
reduction in crimp tensile strength or vibration resistance. Figure 1 for standardizing but is too slow for 100% production inspection.
illustrates the tradeoffs in optimizing crimp design and how crimp The best method to validate crimp quality is to use a combination
height is an accurate measure that combines both electrical and of crimp force and crimp height. This results in being able to
mechanical performance. confirm the achievement of the terminal design intent as well as
discerning wire and terminal variables that can result in poor
terminations.
Practical Measurement of Crimp Height
Clearly, the ideal situation for production is 100% testing without any
impact on throughput. Such an approach avoids any sampling error,
and allows process adjustment as the production run progresses.
Over a decade ago AMP Incorporated (now TE Connectivity)
introduced a patented system (US Patent No. 4,867,186 and others )
that monitors parameters that can be used to calculate crimp height
during the final phase of each crimp cycle.
In this Crimp Quality Monitor (CQM), a solid state position sensor
is installed in the terminator, with a force transducer assembled
into the ram or base plate, with both monitored by a control unit
Figure 1: Correct connection design takes account of materials, attached to the terminator. The resulting signals are transmitted to
dimensions, and terminal characteristics, for the optimum the microcomputer in the CQM system, where the crimp height
electrical and mechanical properties of the crimp.
is calculated. The height is determined as a function of ram
displacement and crimp force through a complex algorithm, which
also takes account of the effects of friction. The critical point of
measure is where the “retreating” ram experiences zero force,
representing the point where the terminal ceases to spring back.
See Figure 2 for a typical force signature, showing the force vs. ram (See Figure 4). On some applicators, sequencing through the run
position during a crimp cycle. The area within the curve represents is also displayed, either for single parts of for components within
the energy in the permanent deformation of wire and terminal. a kit. A simple Good/Bad indicator cues the operator for action.
Measurement data also can guide the operator to correct problems
in wire placement, stripping, or tool wear. Bar graph displays give a
visual indication of crimping quality (See Figure 5). Production and
quality managers have full remote access to the CQM through a
web interface, including statistical data, software and memory
information, and production parameters. Depending on batch
parameters, setup information and data can be stored within
the unit for operational flexibility and subsequent analysis.
Figure 3: A full
alphanumeric keyboard
shows on screen
when needed for data
entry.
Figure 2: The force signature is a real time picture of the
crimping process.
Once the CQM is calibrated, it can display the measured crimp
height with an accuracy of ± 0.013 mm [± 0.0005 in] for base plate
mount or ± 0.005 mm [± 0.0002 in] for ram-mounted sensor).
For compatibility with a fully integrated production environment,
An Accurate, Practical Tool the CQM communicates through an Ethernet connection to the
network. Management functions, including data monitoring and data
The basic technology of crimp height measurement in a working
backup are accessible through a web interface.
environment calls for a convenient, traceable calibration method
and effective data management, display, and communication. The CQM has all the statistical capability to support 6-sigma and
The CQM is designed for operator convenience and operational other standards, including yield, PPM, mean, standard deviation, Cp,
versatility, with a touch screen for control and display. and Cpk.
Display and control languages include English, Spanish, Italian, German,
Chinese, and French, for use in major manufacturing regions.
Figure 4: Detailed display of real time crimp data is readily
available to the operator.
The CQM II is a compact, easy-to-use tool for tracking crimp Crimp Height as a Production Tool
height, monitoring the process, and generating the data necessary
The CQM implements crimp height measurement in a versatile,
for 6-sigma and other statistical compliance measures.
easy-to-use package that allows wire harness manufacturers to
meet contemporary quality standards and improve their
Calibration production yields.
Calibration is performed for each new part type by measuring a Figure 5: On-screen bar
crimp and then by performing a visual inspection for acceptability. graphs quickly reveal
If acceptable, this becomes the nominal value. A subsequent statistical trends, alerting
calibration run of a predetermined number of crimps provides the the operator to impending
statistical limits for the full run. Tolerances, size of calibration run, problems with the process.
run and batch size, and product identification are all entered on
screen, for auditable control of the run.
Data Management, Display, and Communication
All functions are controlled through the touch screen, with an easy-
to use graphical user interface. When numeric or alphanumeric
input is required, an appropriate keypad or full keyboard appears on
©2005 by Tyco Electronics Corporation.
the screen (See Figure 3). AMP and TYCO are trademarks.
During a run, detailed data can be observed on screen, including For information about tooling, call 1-800-522-6752
Need More Information?
or e-mail [email protected].
curves of force vs. position, force vs. time, and position vs. time
