What is the machined contact crimping criteria on insulation clearance?
There are some contacts are manufactured by machining, we need to crimp it onto the wire conductor. In the crimping process, the insulation clearance is an important parameter, if it is not controlled correctly, the terminal crimping reliability will be affected. Top-cable still follow IPC-A-620 to control it.
Figure 5-44 defines the parts of a machined crimp contact. See 5.2.2 for machined crimp contacts - insulation support style criteria.
Target - Class 1,2,3
• 50% overall wire diameter (D) clearance (C) between the
insulation and contact barrel.
Acceptable - Class 2,3
• Conductor is visible between the insulation and contact barrel
but no greater than one wire diameter (Figure 5-46).
Acceptable - Class 1
Process Indicator - Class 2,3
• Insulation is flush to the end of the contact barrel (not
shown).
Acceptable - Class 1
Process Indicator - Class 2,3
• Insulation is greater than one but less than two wire diameters
from the end of the contact barrel (Figure 5-47).
Defect - Class 2,3
• Insulation is greater than two wire diameters from the end of
the contact barrel (Figure 5-48).
Defect - Class 1,2,3
• Exposed conductor violates minimum electrical clearance.
• Insulation enters barrel of terminal (Figures 5-49, 5-50).
