Measuring of Wire Crimp Height

[Ksyuha]

Hello,
We have faced problems during measuring of wire crimp height for small types of terminals. We use crimp micrometers but it is diffiult to position contact in the appropriate position. Destructive cross section control is not suitable for us due to necessity to have SPC and also not to spend a lot of time for this control.
May be somebody has other good measurement systems for crimp height control.
thank you.

 

[wmarhel]

May be somebody has other good measurement systems for crimp height control.

I've used small calipers before. Also, what are the mating heads on the micrometers like? I've seen a couple of different variations:

1. Side A > < Side B

2. Side A > | Side B

Version TWO is more appropriate.

If you are concerned with the results from the calipers due to flashing that may occur on the underside from the crimp tool, just verify the caliper results a pull test.

Regards,

Wayne

 

[Ksyuha]

we use 2nd type micrometer ( > | ) and it is difficult to position contact in the centre to have appropriate result

 

[somashekar]

Hello,
We have faced problems during measuring of wire crimp height for small types of terminals. We use crimp micrometers but it is diffiult to position contact in the appropriate position. Destructive cross section control is not suitable for us due to necessity to have SPC and also not to spend a lot of time for this control.
May be somebody has other good measurement systems for crimp height control.
thank you.

This may be not about wire crimp height measurement.
But your crimping process must be validated and measurement of crimp height alone cannot be an assurance activity.

 

[Ksyuha]

Understand your point, but we have problems with repeatability and reproducibility of measurement not with crimping process itself, therefore we need to improve measurement method

 

[wmarhel]

Understand your point, but we have problems with repeatability and reproducibility of measurement not with crimping process itself

Have you tried crimping a piece of solder, of larger diameter than the crimp height, and taken the measurement off that instead? In cases of small, or difficult terminal geometries, that does work.

Also, is there a pull test specification for the terminal/s in question? If so, then this is what really matters. Assuming you have the ability to perform a pull test of course.

How frequently are you taking the crimp height? What is the type of wire and gauge in question?

Wayne

 

[somashekar]

Understand your point, but we have problems with repeatability and reproducibility of measurement not with crimping process itself, therefore we need to improve measurement method

Here is one for you ... See attachment.
Have you looked at this before ?

 

[Ksyuha]

thank you for datasheet. We have similar micrometer, problem is that terminal is really small and it is difficult to define center to position the micrometer spindle. As a result we have variance between measured values