Mecal GUIDE TO QUALITY CRIMPING The following information is referred to standard crimping Unacceptable Acceptable Checks and evaluations General appearance Insulation crimping Wire crimping Insulation scraps on stripped wire Strands too twisted Strands not twisted Damaged insulation Insulation badly cut Strands damaged by stripping tool Strands crushed by insulation barrel Wire stripping too short Loose strands Wire stripping too long Insulation crimped by wire barrel Wire section too small Insulation pierced by insulation barrel Insulation pierced by insulation barrel Insulation barrel not correctly closed Wire section too big Insulation barrel not correctly shaped and closed Insulation barrel too tight Insulation barrel not correctly closed Crimping not symmetrical Excess of material extrusion Wrong or damaged anvil Crushing not correct, shapeless wire barrel’s bottom Wire section too big Inadequate compacting Wire section too small Stripping length precisely set and cut The wire stripped section must be undamaged The wire stripped section must be clean and free of insulation scraps Gripping marks on insulation are allowed Both wire and insulation must be clearly visible Insulation Wire Insulation barrel correctly closed Insualtion barrel correctly shaped and closed Insulation barrel correctly aligned and closed The crimping is symmetrical. The strands are uniformly compacted, there are no empty spots. There’s no material extrusion and/or terminal deformation. The flat spots are clearly visible and aligned Flat spot Flat spot The flat spots are an important mark of the anvil on the terminal bottom, they help with the strands compacting and keep the terminal aligned with the anvil itself Terminal has been cutted according to Mecal internally approved procedure Measurements Pull test The material estrusion is acceptable when h < _ ? t The tips of the barrel can not touch the terminal bottom Crimping height measurement Crimping width measurement H/L ratio and crimp compacting The crimp compacting is the difference between the cross section of the wire + terminal before and after the crimping itself. It is acceptable when within a min of 17% and a max of 24% Crimp compacting The H/L ratio is acceptable when within a min of 55% and a max of 70% Automotive Electronics/white goods Class 1: Terminals with Ø < _ 2,9 mm/Ampere < _ 5A Class 2: Terminals with Ø > 2,9 mm/Ampere > 5A Class 3: Cylindrical terminals (to be coined) Ref: DIN EN 60352-2 Mecal Specifications Bent left or right (max) 3° A Bent up or down (max) 3° B Torsion (max) 3° C Bellmouth 0,2-0,5 mm D Cut-off (max) 0,5 mm E Wire overlay (min) 0,5 mm F Description Rif. 0,35 0,5 0,75 1 1,27 1,5 2 2,5 3 4 6 10 16 25 35 50 70 95 ----- 60 70 80 ----- 90 ----- 100 ----- ----- ----- ----- ----- ----- ----- ----- ----- ----- 34 80 120 160 160 200 230 250 300 350 450 800 1400 1900 2270 2800 3500 4200 ----- 80 120 160 ----- 200 ----- 250 ----- 350 500 1500 2400 3000 4200 6000 8400 11400 32 30 28 26 24 22 20 18 16 14 0,03 0,05 0,08 0,12 0,2 0,33 0,5 0,75 1,25 2 3 5 10 20 30 34 60 90 130 150 Wire sect mm 2 Min pulling force in Newton Class 1 Class 2 Class 3 Wire section AWG mm 2 Min pulling force in Newton H L H L A C B E D F Specifications subject to change. Consult Mecal s.r.l. for latest specification h t

The following information is referred to standard crimping ......Crimping width H/L ratio and crimp compacting The crimp compacting is the diﬀerence between the cross section of

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Mecal GUIDE TO QUALITY CRIMPINGThe following information is referred to standard crimping

Unacceptable Acceptable Checks and evaluations

Gen

eral app

eara

nce

Insu

lation

crimping

Wire

crim

ping

Insulation scrapson stripped wire

Strands too twisted Strands not twisted

Damaged insulation Insulation badly cut Strands damagedby stripping tool

Strands crushed byinsulation barrel

Wire stripping too short Loose strands

Wire stripping toolong

Insulation crimped bywire barrel

Wire sectiontoo small

Insulation piercedby insulation barrel

Insulation piercedby insulation barrel

Insulation barrelnot correctly closed

Wire section toobig Insulation barrel notcorrectly shaped

and closed

Insulation barreltoo tight

Insulation barrelnot correctly closed

Crimping notsymmetrical

Excess of materialextrusion

Wrong ordamaged anvil

Crushing not correct,shapeless wirebarrel’s bottom

Wire sectiontoo big

Inadequatecompacting

Wire sectiontoo small

Stripping length precisely set and cutThe wire stripped section must be undamaged The wire stripped section must be clean and freeof insulation scrapsGripping marks on insulation are allowed

Both wire and insulation must be clearly visible

Insulation Wire

Insulation barrel correctly closed

Insualtion barrel correctlyshaped and closed

Insulation barrel correctlyaligned and closed

The crimping is symmetrical. The strands areuniformly compacted, there are no empty spots.

There’s no material extrusion and/or terminal deformation.The flat spots are clearly visible and aligned

Flat spot Flat spotThe flat spots are an important mark of the anvil

on the terminal bottom, they help with the strandscompacting and keep the terminal aligned with the

anvil itselfTerminal has been cutted according to Mecal internally approved procedure

Mea

surements

Pull test

The material estrusion isacceptable when

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